UltraCrete, part of the multi award-winning Instarmac Group plc, is home to a portfolio of contractor-friendly repair and maintenance products for the rail sector. UltraCrete’s product offering is ideal for a range of applications including the installation of signals, signposts and street furniture, the maintenance of kerbs and sleepers as well as repairs to car parks, concourses and crossings. The materials in their Rail Refurbishment Solutions range have all been independently tested and are proven to provide fast setting and time savings advantages.
UltraCrete’s list of repair products is extensive with a number approved for use on the London Underground and Overground. Their products have been used all around the world for over 40 years with many achieving the HAPAS seal of approval – an independent, nationally recognised, third party system of approval supported by the Highways Technical Advisory Committee. The scheme provides the supply chain with the confidence and peace of mind that they are using products from a trusted, reliable and expert source.
For the fast, efficient installation of heavy duty posts and for repairs to concrete sleepers, choose UltraCrete’s HAPAS approved QC10 F flowable fast set rapid strength concrete. Fibre modified for added strength, QC10 F achieves a 20N/mm² compressive strength after just 90 minutes, is easy to mix and literally pour from the bucket facilitating a speedy application.
These were just some of the reasons why QC10 F flowable concrete was used to carry out track repairs to sections of the LUAS Tram Line in Dublin. LUAS is a state-of-the-art Light Rail transport system that provides passengers with a high-capacity service that is fast, frequent and reliable. Opened in 2004, the LUAS Tram Line transports 30 million passengers every year across 54 stations and 23.7 miles of track.
A section of the embedded track concrete shoulder, adjacent to the road surface, had become damaged after the installation material had failed. Maintenance engineers, Civic Group Ltd, used QC10 F to complete the reinstatement overnight during a window of just 4 hours – ensuring minimal disruption to the tram line and its commuters. Existing material was broken out before QC10 F was poured into the void around the girder rails. The site was re-opened within the allotted window thanks to the material’s rapid setting properties.
UltraCrete’s Rail Refurbishment range also includes Instant Road Repair. Ideal for first time reinstatements around access covers in station car parks and other bituminous areas, Instant Road Repair has been independently tested and is proven to provide a permanent repair in all weathers – even in wet and freezing temperatures. Instantly trafficable, with no special preparation, Instant Road Repair is the ideal repair product for sites where disruption is not an option!
This was ideal for Premier Rail who used Instant Road Repair to install and repair level crossing systems for key clients such as Babcock Rail and Amey Sersa. The project was part of ongoing maintenance and included the installation of signs, signals, track and access platforms as well as reinstating safety lines.
UltraCrete Instant Road Repair® cold lay asphalt 10mm grade was used for surface repairs around a number of rail tracks. The easy work formula enables patches to be filled with ease with effortless compaction once in-situ. What’s more, Instant Road Repair is available in 25kg resealable buckets, meaning the lid can be popped back on and remaining material used another day, eliminating any waste and helping budgets stretch further.
The project also involved the installation of signals and signposts. This was carried out using Post Fix rapid hardening concrete – another London Underground and Overground approved product in UltraCrete’s Rail Refurbishment Solutions range. Post Fix is a 10mm concrete formulated for sub-surface use and fast installation. Combining strength and durability, Post Fix significantly reduces the likelihood of movement damage – eliminating costly repeat visits – sets in 15 minutes and achieves a final compressive strength of 41N/mm².
On completion of the project, David Claridge, Director at Premier Rail, commented: “UltraCrete products are easy to work with, convenient to store, with a great shelf life!”
The range also includes a selection of high performance bedding mortars. UltraCrete’s M45 rapid strength bedding mortar is the ideal choice for bedding platform coping and kerbs. Opened to traffic in just 45 minutes, M45 helps you keep downtime to an absolute minimum.
For the reinstatement of linear drainage and ironwork in areas exposed to extreme trafficking, use UltraCrete Envirobed HA104® bedding mortar. An environmentally friendly alternative to resin based materials, Envirobed HA104® can be used in the wet weather and in temperatures as low as 1°C – no more delays due to poor weather conditions!
Eliminate vandalism to concrete repairs with UltraCrete QC6 rapid set surfacing concrete. Ideal for the surface reinstatement of ‘picture frames’ and around access covers, QC6 sets in just 15 minutes, so by the time your tools and any traffic management have been packed away, the concrete will have set meaning there’s no time for anyone to walk over it and cause any damage.
Some may be surprised to discover that UltraCrete’s Rail Refurbishment Solutions range also includes BS 7533 compliant eco-bed fine bedding mortar and Flowpoint rapid set flowable grout.
Projects incorporating BS 7533 compliant materials benefit from a reduction in failures and considerable whole life cost savings. UltraScape’s eco-bed and Flowpoint have been independently and rigorously tested by UKAS accredited laboratories to access their performance capabilities. This removes the uncertainty of site batched mortars and offers a minimum construction life of 40 years – all appealing features for UK’s premier concrete frame contractors, MPB Structures Ltd. who used eco-bed and Flowpoint as part of the redevelopment of Birmingham New Street Station.
The long awaited renovation of Birmingham New Street station was transformed what was previously a dark, overcrowded site with poor access for passengers, into a prestigious gateway to the UK’s second city. Highlights include more space and better facilities for commuters, brighter and clearer platforms, a stunning new station facade and a grand concourse enclosed by a light filled atrium.
The project included reinstating existing station platforms as well as installing new structures, hardscaping around the station perimeter and creating Birmingham’s ‘Spanish Steps’ – the latter of which was installed using eco-bed fine bedding mortar and Flowpoint rapid set flowable grout.
Construction was carried out in difficult circumstances as the station was fully operational throughout the project. Flowpoint grout was the ideal choice as its rapid setting properties enable areas to be open to foot traffic in just 1 hour, keeping downtime and disruption to a minimum. Simple to use, requiring only the addition of water on-site, it is poured over the entire area and washed clean, filling all joints evenly, without staining.
UltraScape eco-bed provided a perfect bound base for the pavers. It can be laid up to 75mm in one pass, with greater achievable using successive layers. The fast strength gain of eco-bed allows pedestrian areas to be trafficked in as little as 12 hours.
With all these products on offer, choose UltraCrete for cost-effective, fast track, rail approved materials that are proven to minimise your possession time. For further information on UltraCrete’s rail compliant products, or to book a free product demonstration, please contact UltraCrete’s team of experts by email or by calling 01827 254402.
Download a free copy of UltraCrete’s Rail Refurbishment Solutions brochure.
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