Key Features & Benefits

High Flowability (Self-Leveling): Penetrates densely packed ballast for complete void filling & uniform support.

Non-Shrink: Maintains volume stability after setting, eliminating gaps and ensuring continuous support.

High Early & Ultimate Strength: Rapid strength gain for quick track reopening; exceptional long-term durability under dynamic loads.

Vibration Resistance: Engineered to withstand constant vibration and impact from rail traffic.

Bond Strength: Excellent adhesion to concrete sleepers, steel rails, and ballast stone.

Frost & Weather Resistance: Suitable for all climates.

Corrosion Protection: Creates a stable, non-reactive environment, protecting embedded steel.

Adjustable Setting Time: Formulations available for different temperature conditions and project timelines.

Pumpable: Designed for efficient large-scale application.

 

Technical Parameters

Parameter	Value / Performance	Test Standard
Consistency	Highly Flowable, Self-Leveling	EN 1015-3
Flow Value (Initial)	≥ 550mm	EN 1015-3
Setting Time (Initial)	Adjustable: Typically 60 - 180 minutes (at 20°C)	EN 196-3
Compressive Strength		EN 12190
- 24 hours	≥ 20 MPa
- 7 days	≥ 40 MPa
- 28 days	≥ 55 MPa
Flexural Strength (28d)	≥ 8 MPa	EN 1015-11
Bond Strength (28d)	≥ 2.0 MPa (to concrete)	EN 1542
Shrinkage/Expansion	Non-Shrink, Slight Expansion (Typically +0.02% to +0.04% at 28d)	EN 12617-4
Water Requirement	Approx. 4.0 - 4.5 liters per 25kg bag	Manufacturer Data
Density (Hardened)	Approx. 2200 - 2300 kg/m³	EN 1015-6
Chloride Content	< 0.10% (Corrosion Inhibited)	EN 1015-17 / EN 480-10
Frost Resistance	Excellent (300+ freeze-thaw cycles with scaling < 1000 g/m²)	EN 13687-1 / CDF
Application Temperature	+5°C to +35°C (Special formulations for colder/hotter conditions available)	-
Pot Life (after mixing)	Approx. 30 - 45 minutes (at 20°C)	-
Shelf Life	6 months in original, undamaged packaging, stored dry & cool	-

 

Primary Application Scenarios

Ballasted Track Bedding: Filling voids beneath concrete sleepers on ballast for:

New Track Construction: Creating a stable, uniform foundation.

Track Maintenance & Renewal: Replacing worn ballast, re-leveling sunken sleepers, correcting track geometry.

Spot Repairs: Addressing localised settlement or voids under specific sleepers.

Transition Zones: Stabilising the track where ballast meets bridges, tunnels, or slab track, mitigating differential settlement.

Under Sleeper Pads (USP) Installation: Providing a consistent bedding layer when using USPs for enhanced vibration damping.

Switch & Crossing (S&C) Areas: Providing critical support and stability under complex pointwork and crossings subject to high dynamic loads.

Level Crossing Foundations: Creating a robust and level base for rail sections within road crossings.

Slab Track Transitions: Bedding sleepers at the interface between ballasted track and concrete slab track sections.

 

Packaging & Handling

Standard: 25kg multi-ply paper sacks with inner PE liner.

Bulk: Silo trucks for large projects.

Storage: Keep dry, cool, and off the ground on pallets. Protect from moisture and direct sunlight.

 

Advantages Over Traditional Methods

Faster Installation: Rapid mixing and pouring enables quicker track possession times.

Superior Support: Eliminates voids and point-loading, reducing track maintenance frequency.

Long-Term Track Stability: Prevents sleeper settlement and maintains precise track geometry.

Reduced Ballast Degradation: Minimises particle breakage and fouling by distributing loads evenly.

Improved Safety: Enhances overall track integrity and reduces derailment risk.

Cost-Effective: Lower lifecycle costs due to reduced maintenance needs and extended asset life.

High Flowability (Self-Leveling): Penetrates densely packed ballast for complete void filling & uniform support. Non-Shrink: Maintains volume stability after setting, eliminating gaps and ensuring continuous support. High Early & Ultimate Strength: Rapid strength gain for quick track reopening; exceptional long-term durability under dynamic loads.