Railway ballast bonding
Surface or deep application to bond aggregate particles. Select dosage and delivery method for the required zone and drainage; assess the result on a trial section.
RAILWAYS AND SOIL CONSOLIDATION
GeoTrack
Two-component PU resin for bonding railway ballast and consolidating non-cohesive soils. In dry conditions it sets without foaming; on contact with water it reacts faster and may increase in volume.
| Product / ratio | PU A + B; 1 : 1 by volume |
|---|---|
| Mixture viscosity | 220 ± 50 mPa·s at 23°C |
| Mixture density | Approximately 1.14 g/cm³ at 23°C |
| Setting: dry / wet, 23°C | 40–60 min / 3–4 min |
| Air and substrate temperature | +5 to +40°C |
| Delivery method | 2K pump, 1:1 by volume; pouring/spray lance or injection system |
Technical data
Read values together with the temperature, material state and test conditions.
| Mixture viscosity at 23°C | 220 ± 50 mPa·s |
|---|---|
| Mixture density at 23°C | Approximately 1.14 g/cm³ |
| Setting time in dry conditions, 23°C | 40–60 min; without foaming |
| Setting time in wet conditions, 23°C | 3–4 min; expansion on contact with water |
| Foam expansion on contact with water v/v | 1–2.5 according to the TDS table |
| Relative humidity during spraying | 30–80% |
Setting time in the surrounding medium is not an unconditional time for leaving the mixture in a hose. Penetration extent and preservation of drainage depend on aggregate, moisture, dosage and application method. Component mass conversions based on estimates do not replace 1:1 dosing by volume.
- Storage and shelf life
- +5 to +25°C for unopened components; 6 months in original, closed containers, protected from moisture and sunlight.
Applications and selection criteria
First establish the repair objective, substrate condition, presence of water and joint movement.
Transition zones and embankments
The TDS lists areas around abutments, culverts and embankments at risk of settlement. The method requires assessment of the cause and acceptance criteria for strengthening.
Sands, gravels and voids
Consolidation of loose soils beneath foundations and filling cavities. Water shortens the reaction and changes the filling structure.
Application conditions and limitations
Selection requires assessment of soil, water, voids and loads. Resin specimen parameters are not the capacity of the strengthened soil. Confirm injection extent, quantity and effect through a trial and the adopted monitoring programme; a pressure increase alone does not confirm completion. Do not treat cured resin hardness as a permissible railway traffic load or a guarantee that ballast permeability will be preserved.
How the material behaves
Dry: no foaming. Wet: faster curing and expansion. Rigid grain bonding; not flexible joint sealing.
1. A + B
Reaction after combining
2. Dry conditions
No foaming; setting 40–60 min at 23°C
3. Wet conditions
Expansion; setting 3–4 min at 23°C
Preparation and application
Work sequence after assessing the structure and selecting the method. Full requirements are given in the product instructions.
Assess aggregate, soil and water
Assess grading, compaction, moisture and the required treatment depth. Plan result monitoring and a trial section.
Configure the 2K pump
Deliver A and B at a 1:1 ratio by volume. For ballast, use a suitable spraying or pouring lance; for the ground, use an injection system with lances.
Account for the change in reaction caused by water
On a dry substrate, the material spreads and sets more slowly. Contact with water accelerates setting and causes expansion; the sample must represent actual conditions.
Monitor delivery and flushing
Record quantity and extent. For soil injection, the TDS specifies a head with separate flushing; the flushing circuit is not a third resin component. Clean equipment after work.
Clean the 2K resin system with PI-CLEANER before the material sets, then maintain with PI-SAVER according to the product instructions.
From selection to application
Choose the instructions for your task and calculate material quantities using clearly defined assumptions.
Product documentation
Data, application instructions and safety documents for the supplied material.
Preparing for safe work
Before use, read the current documentation for all supplied components. Select protective equipment, ventilation and cleaning methods appropriate to the material and equipment.
Discuss your project conditions
Prepare a description of the substrate, water, geometry and expected result. Let us select the material and delivery method.