MC-Ballastbond Engl 21-05-08 X

Bonding Systems for the Track Superstructure

• High penetration properties

• Controllable penetration depth

• Short curing

• Adjustable reaction time

MC-Bauchemie • Am Kruppwald 1-8 • 46238 Bottrop • GermanyPhone: +49 (0) 2041-101 10 • Fax: +49 (0) 2041-101 188

[email protected] • www.mc-bauchemie.com

Bonding Systems for theTrack Superstructure

Mont_Ballastbond_engl 21_05-08.qxd 21.05.2008 18:15 Uhr Seite 1

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 ballastchipping and sealed surface-near with MC-Ballastbond 60.As a special effect the MC-Ballastbond 60 was dyed in theclub colours of the local soccer club – thus a perfect combi-nation of aesthetics and practical benefit.

Hollow spaces or cavities under tram railway tracks reducethe stability of the railway track in the sound lane. Injectionwith the damp-proof MC-Ballastbond 80 stabilises railwaytracks reliably and durably. The rapid strength developmentof the injection resin allows for injection during short railwaytraffic interruptions, as in Essen (Germany). Furthermore, thefire protection class B1 provides additional protection forpossible future welding works.

MC-Ballastbond 60

MC-Ballastbond 80

Sealing of surfaces

Stabilisation of hollow spaces

Year Project

2006 Walcourt 1, Belgium

2006 Zeche Zollverein Essen, Germany

2007 Brussels (Metro), Belgium

2007 Brussel-Zuid 4, Belgium

2007 Hoeilaart, Belgium

2007 Kessel-Lo, Belgium

2007 Lake Balaton, Hungary

2007 Leuven, Belgium

2007 Manage, Belgium

2007 Ottignies 2, Belgium

2007 Ottignies 3, Belgium

2007 Rákosrendezö Budapest, Hungary

2007 Tapolca, Hungary

2007 tram Lille, France

2007 Walcourt 2, Belgium

2007 Waremme, Belgium

2007 Wetzlar-Aßlar, Germany

2007 Zichlinek, Czech Republic

Page 11Page 2

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 infra-

structure 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.

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.

Track systems consisting of rails and railway sleepers rest loose-

ly 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.

In conversions and track repairs on multi-track lines special mea-

sures 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.

Bonding Systems for the Track Superstructure


Referencesexcerpts

Near the railroad bridge Chenée (Belgium) the old bridgeplate 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-intensiveshuttering measures could be economized by bonding the gravel roadbed with MC-Ballastbond 70. The rapidstrength development of MC-Ballastbond 70 also reducedinterruptions.

Ballast replacement and railway track renewals in Essen-Kray (Germany) required a protection of the neighbourrailway track against ballast deformation. The ballastshoulder of the neighbour railway track was stabilised withMC-Ballastbond 70 on a length of 2.5 km. Minimum inter-ruptions of the train operation and saving of time- andcost-intensive shuttering were decisive for using MC-Ballast-bond 70.

MC-Ballastbond 70Deep bonding and securing of ballast courses

Securing of ballast shoulders

Project Year

Bridge Chenee, Belgium 2004

Railway station Freiberg, Germany 2004

Römertalbrücke Werdau / Steingleis,Germany 2004

Brussel-Zuid 1, Belgium 2005

Verviers, Belgium 2005

BOGESTRA station “Veltins Arena”, Gelsenkirchen, Germany 2006

Braunschweig, Germany 2006



Dortmund Aplerbeck, Germany 2006

Essen-Kray, Germany 2006

EVAG tram Essen, Germany 2006

Leuven-Wilsel, Belgium 2006

Lohr, Germany 2006

Millenium metro, Hungary 2006

Ottignies 1, Belgium 2006

Vilvoorde, Belgium 2006

Page 10 Page 3

A particularly difficult area in railway lines is the integration of

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

resins also provide efficient solutions for specific scenarios in

terms of stabilisation, sealing and track design.

This brochure gives you an overview of the application possibi-

lities of bonding systems based on duromer resins. Every single

system has its own advantages. Make best use of the

specialist knowledge of our project advisors for your speci-

fic problem. Experienced application technologists will be

pleased to instruct you on the particular application

technology.

Area of Application MC-Ballastbond 60 MC-Ballastbond 70 MC-Ballastbond 80

Bonding, stabilising, securing of positionof ballast superstructures

Bonding, stabilising, securing of positionof ballast superstructures with rapid load capacity

Sealing and colouring of ballast courses

Graded ballast bonding in the transition fromrigid trackways to ballast tracks

Securing ballast courses during track construction works

Stabilisation of grit areas

Boundary setting for lawn tracks

Stabilisation of rigid trackways in presence of water

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Page 9

MC-Ballastbond 80 consists of two components that shortlyafter mixing fully cure to form a viscoplastic resin. A visco-plastic reaction material is created.

Due to the rapid reaction rate the mixing of the two compo-nents is done directly in the mixhead of the injection pump.

MC-Ballastbond 80 is delivered with the two-componentinjection pump MC-I 700. A compressor with sufficient powermust be available to operate the pump. This pump is auto-matically 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 weigheddown in such a way that they cannot slip out. The fill level ofthe single components must be checked continuously toensure an equal material flow.

Prior to installation the structure must be checked in terms oftechnological conditions and regulations. The ballast can bedry 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 alance held at a certain spray angle. The material requirementper m2 is dependent on the project definition.

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 cleaningagents. For resins on an organic mineral basis MC-Verdün-nung U (thinner) is available.

During longer interruptions of the working process the injec-tion pump must be rinsed thoroughly. To clean the componentside A water must be used. To clean the component side BMC-Reinigungsmittel U must be used. The cleaning agentsmust not be mixed. The separate cleaning of the pump mustbe observed at all times; otherwise the cleaning agent maycause a reaction of the components.

When using solvents the pump’s instruction manual must beobserved. In particular, gaskets must be able to withstandsolvents.

The handling of reaction resins requires special safety measures. The instructions in the safety data sheets must befollowed.

� Stabilising ballast courses� Securing ballast areas� Securing ballast courses during

track construction works

� Graded ballast bonding in thetransition from rigid trackways toballast tracks

Alternatively MC-Ballastbond 70 or MC-Ballastbond 60 canbe used, taking into account the product core values.

Area of Application

Application Instructions

System Variations

Page 4

Sealing and Stabilising of Ballast

MC-Ballastbond 60

Product CharacteristicsMC-Ballastbond 60 penetrates ballast and grit. This bondsthe ballast grains at the contact points and improves the loadbearing characteristics. In the case of ballast bonding forlawn tracks MC-Ballastbond 60 prevents the undesirablegrowth of plants near the tracks, which is detrimental to thebraking action of trains.

The duromer resin is also suitable for sealing ballast areasand thus facilitates their cleaning.

For special applications requiring a coloured design, MC-Ballastbond 60 can be pigmented with individual colours.

Ballast condition:

Application objective:

dry

Bonding and sealing ofballast and grit

Component Product Required Quantity

MC-Ballastbond 60

MC-Spritzlanze

MC-I 700

MC-Verdünnung EP

depending on scenario

1 piece/construction site


at least 1 pot

Injection material

Spray lance

Injection pump

Cleaning agent

Recommended System Components


Page 8

Stabilisation of Ballast

MC-Ballastbond 80

MC-Ballastbond 80 penetrates the ballast bed withoutobstructing the drainage capability of the ballast. The ballastis stabilised by bonding it with the environmentally-friendlyMC-Ballastbond 80.

The duromer resin cures within a short time. Stoppages to therail operations are minimised compared with other measures.

The reaction material offers high resistance to fire.

Ballast condition:


dry to dampish

Ballast bonding


MC-Ballastbond 80

MC-Spritzlanze

MC-I 700

water andMC-Reinigungsmittel U




at least 1 pot

Injection material

Spray lance

Injection pump

Cleaning agent

Product Characteristics


Page 5

Area of Application

Application InstructionsMC-Ballastbond 60 consists of two components. To mix theresin the hardener is emptied into the main component andeverything 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 thenpoured into the storage tank of the injection pump.

MC-Ballastbond 60 is applied using the injection pump MC-I700. The MC-I 700 is operated the same way as a 2-c injectionpump. The premixed resin is delivered via both sides of thecomponents simultaneously. This ensures the optimal use of MC-I 700 pump’s 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 oftechnological conditions and regulations. The ballast has tobe dry to dampish. Wet ballast should be surface-dried priorto application of MC-Ballastbond 60 by running a flame overthe ballast surface with a standard construction site flametorch.


Tools and machinery can be cleaned with special cleaningagents. For duromer resins on an epoxy resin basis MC-Verdünnung EP (thinner) is available.

During longer interruptions of the working process, beyondthe pot life of the resin, the injection pump must be rinsedthoroughly with MC-Verdünnung EP. Partly cured or curedmaterial can only be removed mechanically.


The handling of reaction resins requires special safety measures. The instructions in the safety data sheets must be followed.

� Bonding of ballast areas� Boundary setting for lawn tracks� Sealing and colouring of ballast

areas at stops� Stabilisation of grit areas

System VariationsThe demand for a faster reaction rate that can be controlledif necessary, is met by MC-Ballastbond 70.


Page 7

MC-Ballastbond 70 consists of two components that shortlyafter mixing fully cure to form a viscoplastic resin. A visco-plastic reaction material is created.

Due to the rapid reaction rate the mixing of the two compo-nents is done directly in the mixhead of the injection pump.

MC-Ballastbond 70 is delivered with the two-componentinjection pump MC-I 700. A compressor with sufficient powermust be available to operate the pump. This pump is auto-matically sucking in both resin components. To this end thesuction pipes must be inserted deep into the separately positioned single components and must be fixed or weigheddown in such a way that they cannot slip out. The fill level ofthe single components must be checked continuously toensure an equal material flow.

Prior to installation the structure must be checked in terms oftechnological conditions and regulations. The ballast shouldbe dry and only slightly damp at most.

Wet ballast should be surface-dried prior to applicationof MC-Ballastbond 70 by running a flame over the ballast surface with a standard construction site flame torch.


In contact with water MC-Ballastbond 70 forms a firm, flexible closed-celled foam. A little foam formation does notharm the effectiveness of the bonding.

Opened containers should be used up within 24 hours.

Tools and machinery can be cleaned with special cleaningagents. For resins on a polyurethane basis MC-VerdünnungPU (thinner) is available.

During longer interruptions of the working process, beyondthe pot life of the resin, the injection pump must be rinsedthoroughly with MC-Verdünnung PU. Partly cured or curedmaterial can only be removed mechanically.


The handling of reaction resins requires special safety measures. The instructions in the safety data sheets must be followed.

� Stabilising ballast courses� Securing ballast surfaces� Securing ballast courses during

track construction works

� Graded ballast bonding in thetransition from rigid trackways toballast tracks

Alternatively MC-Ballastbond 80 or MC-Ballastbond 60 canbe used, taking into account the product core values.

Area of Application

Application Instructions

System Variations

Page 6

Stabilisation of Ballast

MC-Ballastbond 70

MC-Ballastbond 70 penetrates the ballast bed withoutobstructing the drainage capability of the ballast. The ballastis stabilised by bonding it with the environmentally-friendlyMC-Ballastbond 70.

The duromer resin cures within a short time. Ballast bondedwith MC-Injekt 2700 is able to withstand stress/loads after

just a few hours. Stoppages to the rail operations are mini-mised compared with other measures.

For conversions in track construction only short lead timesare required to secure ballast shoulders.

Ballast condition:


dry to dampish

Ballast bonding


MC-Ballastbond 70

MC-Spritzlanze

MC-I 700

MC-Reinigungsmittel PU




at least 1 pot

Injection material

Spray lance

Injection pump

Cleaning agent

Product Characteristics



Documents

MC-Ballastbond Engl 21-05-08 X