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Rail ballast binding - targeted geopolymer injection

Challenge

Loose railway ballast reduced track stability and increased maintenance requirements, creating a need to improve stiffness and load distribution without major track possession.

Solution

Geobear delivered targeted geopolymer injection to bind and strengthen ballast, improving track support and stiffness with minimal disruption to rail operations.

Improved track stability

Ballast bound and strengthened

Reduced maintenance need

Enhanced load distribution

Minimal possession time

Rapid, targeted installation

Background

Railway ballast plays a critical role in distributing loads and maintaining track geometry. Over time, ballast degradation and loosening can reduce stiffness, leading to track movement and increased maintenance interventions.

The asset required stabilisation to maintain performance and extend service life.



Challenge

Traditional ballast replacement would have required significant track possession, material removal and programme time.

A faster and less disruptive method was required to improve ballast integrity while maintaining operational continuity.

Solutions

Geobear implemented a precision geopolymer injection programme directly into the ballast layer.

Expanding geopolymer resin permeated and bound the aggregate, increasing stiffness and improving load transfer without the need for excavation or full ballast renewal

Injection was carefully controlled to ensure targeted treatment and consistent performance.

Results

Track stability was enhanced, and ballast performance improved without lengthy closures or disruptive works.

The solution reduced maintenance requirements and extended the operational life of the track structure.

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