UK: In what supplier Sika says is a world first, contractor VolkerRail has installed polymer rail grout on a section of embedded track on the London Trams network in Croydon using a machine instead of manual application.
The product’s fast curing time and the improved accuracy of machine application enabled a rapid return to operation and significantly reduced material losses compared to conventional labour-intensive hand-poured methods. These typically involve pouring material from small 12 litre tins into the rail channel and can result in material losses of 10% to 20%.
For the Croydon project, the grout was supplied in 200 litre lined drums and mixed and pumped directly into place using a machine, with material loss below 5% and greater consistency of application.
The material cures up to six times faster than more traditional systems, helping to reduce track closure time. It is largely maintenance-free, absorbing movement rather than pushing stress back into the surrounding concrete and helping to maintain track alignment, reduce vibration and limit mechanical wear on both rail and rolling stock. It also helps to dampen the noise generated by passing trams.
When rail replacement is required in the future, the material can be removed using hydro-blasting, in contrast to traditional grout removal methods that require machine sawing into concrete.
‘We were looking for a system that would allow us to work within tight access windows, reduce environmental waste and also maintain superior durability during the track’s service life’, said Jamie Kelly, Programme Manager at VolkerRail. ‘It’s a real game changer for light rail embedment, giving us far greater control to place the material accurately and sustainably.’
