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Ballast stabilization
Ballast bonding for rail, tram and metro systems
The increasing stress on railway networks due to higher speeds and heavier axle loads leads to more intensive maintenance requirements. Certain locations, such as transition zones near bridges, level crossings, insulated joints and switch mechanisms, are particularly sensitive to instability and wear. Ballast bonding offers an effective solution to these challenges. In addition, it is highly suitable for reducing vandalism, minimising noise pollution and preventing ballast displacement caused by high train speeds. With Heatpoint’s advanced ballast bonding, we address these challenges at their core. By fixing the upper layer of the ballast bed using an environmentally friendly resin, we create a robust foundation that remains both flexible and permeable to water. This offers immediate results:
- maximum stability: The track remains firmly in place, even under the heaviest loads
- cost-efficient: Maintenance requirements in vulnerable areas are significantly reduced
- environmentally friendly & functional: The resin is sustainable and preserves essential track drainage
- increased comfort: A more stable track ensures a smoother and safer train journey
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Where is ballast bonding most commonly used?
We typically apply this technique at strategic and high-risk locations within railway infrastructure. This includes:
- existing and new high-speed lines (HSL)
- around switches and level crossings
- at platforms and stations (for passenger protection)
- transition zones where the track changes from a fixed structure (such as a bridge or tunnel) to a conventional ballasted track
- temporary applications to stabilise the track during civil excavation works under or directly adjacent to the railway
- to prevent vandalism. A bonded ballast surface helps prevent stone throwing
Practical characteristics
- applied in liquid form
- beige in colour
- application temperature: between +5°C and +30°C
- preferably not applied during rainfall; however, application on damp ballast is possible.
- long service life: approximately 20 years, provided the bonded ballast is not broken up by a tamping machine.
- no performance impact at ambient temperatures ranging from –20°C to +80°C.
- consumption varies depending on the application.
- electrical conductivity: equivalent to that of damp ballast.
- bonded ballast can be recycled or disposed of in the same way as conventional ballast.
- tamping machines are not affected by bonded ballast.
- the curing time varies depending on the application and may range from a few minutes to several days.
- bonded ballast significantly reduces noise levels caused by rail traffic.
Functionel characteristics
Bonded ballast:
- is permeable to water, as the adhesive is applied only at the contact points between the ballast stones.
- provides excellent load-bearing capacity while maintaining elasticity.
- provides very high bonding strength.
- is environmentally friendly (non-toxic)
- can be cleaned easily
- creates a stable base that distributes loads, thereby reducing maintenance requirements.
- tamping machines and other railway machinery do not require cleaning after working on ballast.
- if the adhesive layer is broken by a tamping machine, it can be easily re-applied afterwards.
- reduces noise by altering disturbing frequency patterns.
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