Content Notice

The following articles are taken from the MC aktiv publication and curated by Buidling Chemical Supplies Ltd. Content contained is therefore the property of MC-Bauchemie Müller GmbH & Co. KG.

Track-setting – MC-Ballastbond

Worldwide rail networks are being extended, new lines installed and existing ones are constantly being upgraded. To continuously maintain the performance of the line a reliable and stable track superstructure is necessary.

The use of ballast to support the track line is widespread. However, this method has drawbacks in areas that experience high stress, such as bends, switching points and high speed section. For this reason, “rigid track ways” are preferred for railway sections prone to high stresses. The transition from ballast super-structure to a “rigid track way”, however, poses the danger of displacement of the track and even the formation of a step or ridge. The performance and behaviour of the ballast under these conditions can be significantly improved by the technique of ballast bonding. Stabilising the ballast shoulders to prevent deformation and displacement is especially important when track works are carried out without disruption to rail services.

Track-setting with MC-Ballastbond

In order to fulfil these particular requirements, MC has developed an innovative solutions known as MC-Ballastbond systems. They can be controlled to meet the different innovative job specifications. In contrast to the usual systems, MC-Ballastbond 70 takes advantage of the benefits that the latest in duromer resin technology has to offer. The bonding agent is sprayed onto the surface, seeps in and forms a bond at the constact points of the individual aggregate particles. As a result water can still drain through the ballast layer. The stablisiation of the loose track bed significantly increases the performance of the rail tracks and exceed maintenance intervals – an important contribution to the safe and economic operation of rail ways.

Stabilisation of Aggregate and Ballast

Ballast and aggregate are used in a broad range of applications in rail track systems and bearing surfaces where they are used for stabilisation. Repair and maintenance works are frequently accompanied by the undesired erosion of the ballast surfaces.

The main areas affected are transitions between carriageway and ballast superstructure, for example near bridges, crossings and bends which are prone to heavy stress and the areas of points and junctions. The necessary ballast renewal and maintenance works at track installations are performed during normal rail operations due to the permanently high level of rail traffic. This necessitates the use of static safety easures, whereby MC-Injekt 2700 SK provides a reliable and cost-effective alternative for the bonding of the ballast.

MC-Injekt 2700 SK secures ballast surfaces

The binder, based on ultramodern duromer resin technology, is sprayed onto the surface. The resin thereby flows around the aggregate and penetrates to the base. At the contact points between individual particles a secure and permanent bond is formed after Y2 hour to 3 hours, which is elastically stable. The significant advantage of this system lies in this exceptionally fast reaction time. The ballast is only bonded at the contact points, so that the water can continue to drain off through the ballast layer. Concerns in terms of environmental friendliness and disposal do not exist.

The first experiences with this new system for ballast bonding were gained in 2004 along the high-speed rail track Brussels- Cologne. Then the ballast shoulders of a bridge had to be secured. Initially viewed with scepticism by some of the engineers involved, the new technology soon convinced through its definite time and cost savings.

Track-setting with MC-Ballastbond

In the meantime numerous reference projects not just in Belgium, but also in Germany and Hungary attest to the success of MC-Injekt 2700 SK. Especially in railway traffic, where higher travelling speeds and rising demands on travel comfort put great demands on tracks and ballast superstructure, this system provides a reliable solution. Track systems can be durably stabilised, so that they can meet the requirements of modern railway traffic.

Stable bearing surfaces with MC-DUR 1260 SK

In inner-city railroad structures especially the areas of stops, pedestrian crossings and bearing surfaces are subject to heavy contamination and usage. The cleaning and replacement of the aggregate or ballast material is frequently difficult. With MC-DUR 1260 SK, a special duromer resin, a durably firm surface with chemical resistance can be created, which is not just water-permeable and easy to clean, but also allows a range of different designs due to the diverse colour range on offer.

Track-setting with MC-Ballastbond

A current example is the project "Zeche Zolltverein" in Essen. Here the aggregate of the bearing surfaces has been strengthened with this type of resin. The combination of functionality and aesthetics is of great importance for the project Veltins Arena. The ballast at the Bogestra Stop had to be stabilised so that the cleaning vehicle was able to work unhindered.

With the innovative systems for bonding and stabilising ballast and grit surfaces MC is setting new standards in terms of performance capability and cost-effectiveness.