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Bonding Systems for the Track Superstructure

High penetration properties Controllable penetration depth Short curing Adjustable reaction time

Bonding Systems for the Track Superstructure

MC-Bauchemie Am Kruppwald 1-8 46238 Bottrop Germany Phone: +49 (0) 2041-101 10 Fax: +49 (0) 2041-101 188 protection-technologies@ mc-bauchemie.com www.mc-bauchemie.com

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Bonding Systems for the Track Superstructure

Since the construction of the first railroad line in Europe (1825, England, 18 km between Darlington and Stockton) rail traffic has become a vital economic factor. Railways form an important infrastructure component for both short and long-distance transports. The track superstructure is not always capable of meeting the growing traffic loads. Under increasing speeds, higher traffic loads or more intense usage weaknesses in the various building structures become apparent. In addition to regular maintenance track renewal is a necessary measure.

MC-Ballastbond 60
Sealing of surfaces

Long-distance tracks generally have a ballast superstructure. By contrast, rigid trackways are the rule in urban short-distance traffic, on fixed bridges or in tunnels. For both building structures, and in connection with diverse driving surfaces, bonding systems from MC offer efficient solutions for specific particulars. 2006 2006 Walcourt 1, Belgium Zeche Zollverein Essen, Germany Year Project The cleaning ability of the gravel roadbed of the tram stop Veltins Arena auf Schalke" (Germany) should be improved. Therefore the ballast substructure was filled with ballast chipping and sealed surface-near with MC-Ballastbond 60. As a special effect the MC-Ballastbond 60 was dyed in the club colours of the local soccer club thus a perfect combination of aesthetics and practical benefit.

2007 2007 2007 2007 2007 2007 2007 Track systems consisting of rails and railway sleepers rest loosely inside a loose, compacted ballast roadbed without any fixation to the sides. The roadbed can withstand significant compressive forces, but can get marginally out of line under tensile loading. MC bonding systems secure critical areas at rail joints or points for instance quickly and with lasting effect. 2007 2007 2007 In conversions and track repairs on multi-track lines special measures to secure track positioning must be taken. The bonding of the ballast shoulders with duromer resins is a proven effective method. In comparison with conventional installation measures application of this rather fast-curing bonding system saves a lot of time and money.
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Brussels (Metro), Belgium Brussel-Zuid 4, Belgium Hoeilaart, Belgium Kessel-Lo, Belgium Lake Balaton, Hungary Leuven, Belgium Manage, Belgium Ottignies 2, Belgium Ottignies 3, Belgium Rkosrendez Budapest, Hungary Tapolca, Hungary tram Lille, France Walcourt 2, Belgium Waremme, Belgium Wetzlar-Alar, Germany Zichlinek, Czech Republic Hollow spaces or cavities under tram railway tracks reduce the stability of the railway track in the sound lane. Injection with the damp-proof MC-Ballastbond 80 stabilises railway tracks reliably and durably. The rapid strength development of the injection resin allows for injection during short railway traffic interruptions, as in Essen (Germany). Furthermore, the fire protection class B1 provides additional protection for possible future welding works.

MC-Ballastbond 80
Stabilisation of hollow spaces

2007 2007 2007

2007 2007 2007

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References excerpts

A particularly difficult area in railway lines is the integration of

system has its own advantages. Make best use of the specialist knowledge of our project advisors for your specific problem. Experienced application technologists will be pleased to instruct you on the particular application technology.

MC-Ballastbond 70
Deep bonding and securing of ballast courses

different building structures. Transitions between ballast and rigid tracks pose a problem because of the different settlement characteristics. In this area the graded bonding of the ballast has proven successful in adjusting the different elastic forces. Here too, bonding systems from MC offer special advantages through short waiting periods until load capacity can resume and an excellent environmental friendliness.

In short-distance inner-city transport primarily rigid tracks and lawn tracks dominate the railway line scene. In this area duromer Near the railroad bridge Chene (Belgium) the old bridge plate was replaced by a new broader bridge plate. In order to be able to maintain the railway traffic after bridge division, the residual railway track had to be protected on the bridge against ballast deformation. Time- and cost-intensive shuttering measures could be economized by bonding the gravel roadbed with MC-Ballastbond 70. The rapid strength development of MC-Ballastbond 70 also reduced interruptions. Project Bridge Chenee, Belgium Railway station Freiberg, Germany Rmertalbrcke Werdau / Steingleis, Germany Year 2004 2004 2004 This brochure gives you an overview of the application possibilities of bonding systems based on duromer resins. Every single resins also provide efficient solutions for specific scenarios in terms of stabilisation, sealing and track design.

Brussel-Zuid 1, Belgium Verviers, Belgium Securing of ballast shoulders BOGESTRA station Veltins Arena, Gelsenkirchen, Germany Braunschweig, Germany Brussel-Zuid 2, Belgium Brussel-Zuid 3, Belgium Dortmund Aplerbeck, Germany Essen-Kray, Germany Ballast replacement and railway track renewals in EssenKray (Germany) required a protection of the neighbour railway track against ballast deformation. The ballast shoulder of the neighbour railway track was stabilised with MC-Ballastbond 70 on a length of 2.5 km. Minimum interruptions of the train operation and saving of time- and cost-intensive shuttering were decisive for using MC-Ballastbond 70. EVAG tram Essen, Germany Leuven-Wilsel, Belgium Lohr, Germany Millenium metro, Hungary Ottignies 1, Belgium Vilvoorde, Belgium

2005 2005

2006 2006 2006 2006 2006 2006 2006 2006 2006 2006 2006 2006 Boundary setting for lawn tracks Stabilisation of rigid trackways in presence of water G G
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Area of Application Bonding, stabilising, securing of position of ballast superstructures Bonding, stabilising, securing of position of ballast superstructures with rapid load capacity Sealing and colouring of ballast courses Graded ballast bonding in the transition from rigid trackways to ballast tracks Securing ballast courses during track construction works Stabilisation of grit areas

MC-Ballastbond 60 MC-Ballastbond 70 MC-Ballastbond 80 G G G G G G G G G G G G

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Sealing and Stabilising of Ballast

MC-Ballastbond 60

Area of Application
Stabilising ballast courses Securing ballast areas I Securing ballast courses during track construction works
I I I

Graded ballast bonding in the transition from rigid trackways to ballast tracks

Ballast condition:

dry

Application objective:

Bonding and sealing of ballast and grit

Application Instructions
MC-Ballastbond 80 consists of two components that shortly after mixing fully cure to form a viscoplastic resin. A viscoplastic reaction material is created. Due to the rapid reaction rate the mixing of the two components is done directly in the mixhead of the injection pump. At low temperatures the resin components should be heated up with a suitable heating tool in order to achieve the optimum mixing viscosity. Opened containers should be used up within 24 hours. Tools and machinery can be cleaned with special cleaning agents. For resins on an organic mineral basis MC-Verdnnung U (thinner) is available. During longer interruptions of the working process the injection pump must be rinsed thoroughly. To clean the component side A water must be used. To clean the component side B MC-Reinigungsmittel U must be used. The cleaning agents must not be mixed. The separate cleaning of the pump must be observed at all times; otherwise the cleaning agent may cause a reaction of the components. When using solvents the pumps instruction manual must be observed. In particular, gaskets must be able to withstand solvents. The handling of reaction resins requires special safety measures. The instructions in the safety data sheets must be followed.

Recommended System Components

Component Injection material Product MC-Ballastbond 60 Required Quantity depending on scenario

Spray lance

MC-Spritzlanze

1 piece/construction site

MC-Ballastbond 80 is delivered with the two-component injection pump MC-I 700. A compressor with sufficient power must be available to operate the pump. This pump is automatically sucking in both resin components. To this end the suction pipes must be inserted deep into the separately positioned single components and must be fixed or weighed down in such a way that they cannot slip out. The fill level of the single components must be checked continuously to ensure an equal material flow. Prior to installation the structure must be checked in terms of technological conditions and regulations. The ballast can be dry or damp. Wet ballast can be surface-dried prior to application of MC-Ballastbond 80 by running a flame over the ballast surface with a standard construction site flame torch. The material is distributed across the ballast surface with a lance held at a certain spray angle. The material requirement per m2 is dependent on the project definition.

Injection pump

MC-I 700

1 piece/construction site

Cleaning agent

MC-Verdnnung EP

at least 1 pot

Product Characteristics
MC-Ballastbond 60 penetrates ballast and grit. This bonds the ballast grains at the contact points and improves the load bearing characteristics. In the case of ballast bonding for lawn tracks MC-Ballastbond 60 prevents the undesirable growth of plants near the tracks, which is detrimental to the braking action of trains. The duromer resin is also suitable for sealing ballast areas and thus facilitates their cleaning. For special applications requiring a coloured design, MCBallastbond 60 can be pigmented with individual colours.

System Variations
Alternatively MC-Ballastbond 70 or MC-Ballastbond 60 can be used, taking into account the product core values.

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Stabilisation of Ballast

MC-Ballastbond 80

Area of Application
Bonding of ballast areas Boundary setting for lawn tracks I Sealing and colouring of ballast areas at stops I Stabilisation of grit areas
I I

Ballast condition:

dry to dampish

Application objective:

Ballast bonding

Application Instructions
MC-Ballastbond 60 consists of two components. To mix the resin the hardener is emptied into the main component and everything is mixed up into a streak-free homogenous mass. Suitable mixing devices are slow rotating mixers with a maximum of 200 rotations/minute. The mixed resin is then poured into the storage tank of the injection pump. Required Quantity depending on scenario MC-Ballastbond 60 is applied using the injection pump MC-I 700. The MC-I 700 is operated the same way as a 2-c injection pump. The premixed resin is delivered via both sides of the components simultaneously. This ensures the optimal use of MC-I 700 pumps volume capacity. A compressor with sufficient power must be at hand to operate the pump. Prior to installation the structure must be checked in terms of technological conditions and regulations. The ballast has to be dry to dampish. Wet ballast should be surface-dried prior to application of MC-Ballastbond 60 by running a flame over the ballast surface with a standard construction site flame torch. The material is distributed across the ballast surface with a lance held at a certain spray angle. The material requirement per m2 is dependent on the project definition. Tools and machinery can be cleaned with special cleaning agents. For duromer resins on an epoxy resin basis MCVerdnnung EP (thinner) is available. During longer interruptions of the working process, beyond the pot life of the resin, the injection pump must be rinsed thoroughly with MC-Verdnnung EP. Partly cured or cured material can only be removed mechanically. When using solvents the pumps instruction manual must be observed. In particular, gaskets must be able to withstand solvents. The handling of reaction resins requires special safety measures. The instructions in the safety data sheets must be followed.

Recommended System Components

Component Injection material Product MC-Ballastbond 80

Spray lance

MC-Spritzlanze

1 piece/construction site

Injection pump

MC-I 700

1 piece/construction site

Cleaning agent

water and MC-Reinigungsmittel U

at least 1 pot

Product Characteristics
MC-Ballastbond 80 penetrates the ballast bed without obstructing the drainage capability of the ballast. The ballast is stabilised by bonding it with the environmentally-friendly MC-Ballastbond 80. The duromer resin cures within a short time. Stoppages to the rail operations are minimised compared with other measures. The reaction material offers high resistance to fire.

System Variations
The demand for a faster reaction rate that can be controlled if necessary, is met by MC-Ballastbond 70.

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Stabilisation of Ballast

MC-Ballastbond 70

Area of Application
Stabilising ballast courses Securing ballast surfaces I Securing ballast courses during track construction works
I I I

Graded ballast bonding in the transition from rigid trackways to ballast tracks

Ballast condition:

dry to dampish

Application objective:

Ballast bonding

Application Instructions
MC-Ballastbond 70 consists of two components that shortly after mixing fully cure to form a viscoplastic resin. A viscoplastic reaction material is created. Due to the rapid reaction rate the mixing of the two components is done directly in the mixhead of the injection pump. In contact with water MC-Ballastbond 70 forms a firm, flexible closed-celled foam. A little foam formation does not harm the effectiveness of the bonding. Opened containers should be used up within 24 hours. Tools and machinery can be cleaned with special cleaning agents. For resins on a polyurethane basis MC-Verdnnung PU (thinner) is available. During longer interruptions of the working process, beyond the pot life of the resin, the injection pump must be rinsed thoroughly with MC-Verdnnung PU. Partly cured or cured material can only be removed mechanically. When using solvents the pumps instruction manual must be observed. In particular, gaskets must be able to withstand solvents. The handling of reaction resins requires special safety measures. The instructions in the safety data sheets must be followed.

Recommended System Components

Component Injection material Product MC-Ballastbond 70 Required Quantity depending on scenario

Spray lance

MC-Spritzlanze

1 piece/construction site

MC-Ballastbond 70 is delivered with the two-component injection pump MC-I 700. A compressor with sufficient power must be available to operate the pump. This pump is automatically sucking in both resin components. To this end the suction pipes must be inserted deep into the separately positioned single components and must be fixed or weighed down in such a way that they cannot slip out. The fill level of the single components must be checked continuously to ensure an equal material flow. Prior to installation the structure must be checked in terms of technological conditions and regulations. The ballast should be dry and only slightly damp at most. Wet ballast should be surface-dried prior to application of MC-Ballastbond 70 by running a flame over the ballast surface with a standard construction site flame torch. The material is distributed across the ballast surface with a lance held at a certain spray angle. The material requirement per m2 is dependent on the project definition.

Injection pump

MC-I 700

1 piece/construction site

Cleaning agent

MC-Reinigungsmittel PU

at least 1 pot

Product Characteristics
MC-Ballastbond 70 penetrates the ballast bed without obstructing the drainage capability of the ballast. The ballast is stabilised by bonding it with the environmentally-friendly MC-Ballastbond 70. The duromer resin cures within a short time. Ballast bonded with MC-Injekt 2700 is able to withstand stress/loads after just a few hours. Stoppages to the rail operations are minimised compared with other measures. For conversions in track construction only short lead times are required to secure ballast shoulders.

System Variations
Alternatively MC-Ballastbond 80 or MC-Ballastbond 60 can be used, taking into account the product core values.

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