A twist on ties: An array of concrete, composite and steel ties are available to support, stabilize track

Compiled by Michael Popke

PCM RAILONE AG

PCM RAILONE AG designs and produces concrete ties, which provide a reliable and sustainable alternative to traditional wooden ties, company officials said in an email.

RAILONE focuses on the engineering of high-performance ties designed for high-speed rail lines, heavy freight corridors, urban transit systems and track structures, such as turnouts and bridges. The ties offer high stability in high-speed and heavy-load situations, up to 50 years of service life with reduced maintenance needs and resistance to moisture and temperature changes, company officials said.

The ties have been tested to withstand Arabian deserts and Siberian cold, in temperatures ranging from -4 to 149 F, company officials said. RAILONE’s products also can be adapted to meet specific needs of various track systems, construction clients and designing companies on ballasted or ballast-free tracks.

“By offering advanced concrete tie technology and engineering expertise, RAILONE supports the development of modern, sustainable railway networks worldwide,” company officials said, adding that RAILONE’s North American railroad customers include Union Pacific Railroad and CN.

voestalpine Railway Systems Nortrak

Shown: LVT blocks in production by voestalpine Railway Systems Nortrak at the company’s Cheyenne, Wyoming, plant.

voestalpine Railway Systems Nortrak

The company is continuously investing in the development and support of fixation systems — including concrete crossties and rail fasteners — to expand its turnout offerings, voestalpine Railway Systems Nortrak officials said.

Recently, Nortrak announced a partnership with Switzerland-based Sonneville for the sale and manufacturing of low vibration track (LVT) for slab track applications. Nortrak produces LVT blocks at its plants in Spokane, Washington, and Cheyenne, Wyoming. The expanded range of concrete-tie products enables the company to offer a wider selection of system options for customers, Nortrak officials said.

Nortrak also recently supplied concrete ties and turnouts for transit projects in San Francisco and St. Louis, with construction and commissioning ongoing for both projects.

There are opportunities to expand demand through products such as the Keyway Tie, which can be interspersed with wood ties, Nortrak officials said. The Keyway Tie offers the same track modulus as wood ties but provides greater gauge-holding capability compared with traditional wood-tie fastening systems, they said.

The tie has been successfully installed on several Class I tracks and multiple passenger railroad lines to enhance gauge holding, extend the service life of remaining wood ties and reduce maintenance intervals, according to Nortrak.

Additionally, collaborating with Sonneville on the LVT System enables Nortrak to deliver comprehensive fixation solutions for passenger- rail customers. That includes concrete mainline and turnout ties for ballasted track, LVT blocks and vulcanized rubber-bonded direct-fixation fasteners for slab track sections, all of which are manufactured in-house at Nortrak facilities, company officials said.

WVCO Railroad Solutions

SpikeFast® CTR-100 is designed for fast repair of damaged concrete ties.

WVCO Railroad Solutions

WVCO offers a range of products for repairing wood, composite and concrete ties.

To address the railroad industry’s need for concrete tie repairs, SpikeFast® CTR-100 is a solution that meets railroad specifications and allows for rapid repair of damaged concrete ties, sealing and protecting them from abrasion while restoring original geometry for proper cant and gauge, company officials said.

CTR-100 also reduces head deflection and cures quickly, minimizing train downtime. Additionally, WVCO offers fast-curing solutions for concrete tie insert and shoulder repairs.

Meanwhile, SpikeFast® is designed to restore wood and composite ties, securely anchoring spikes with strength comparable to unspiked hardwood ties. The patented dual-component, non-foaming polyurethane is engineered to effectively hold cut-spikes or screw-spikes.

ES-50 is dispensed from handheld canisters or 200-gallon returnable steel totes via a pressure- and temperature-controlled meter. It is easy to apply, requires minimal equipment maintenance and cures quickly, allowing for a high production rate, company officials said.

NARSTCO

NARSTCO’s steel ties in track.

NARSTCO

NARSTCO provides steel ties, precision-engineered turnouts and “e” Clip fasteners to freight- and transit-rail operators, and industrial rail yards across North America.

The company utilizes recycled, high-strength U.S. steel that significantly enhances track performance, NARSTCO officials said. The steel ties are designed to be resistant in harsh environmental and operating conditions, addressing increasing maintenance concerns and prioritizing the safety of track crews.

NARSTCO steel ties and turnouts are durable under extreme load conditions; they offer extended service life and maintain precise track geometry, company officials said.

Current projects include port facility expansions in such states as Alabama, Georgia, South Carolina and North Carolina, as well as in points in Canada. NARSTCO also is supplying steel ties and turnouts to large-scale private industrial storage-in-transit yards and transload operations.

NARSTCO officials anticipate continued growth in 2025 and beyond “based on many shippers shifting to rail service,” they said.

Triton Ties

Triton’s composite ties are engineered using recycled plastics reinforced with virgin glass fibers, resulting in a tie that is impervious to moisture, decay and insect damage, company officials said.

Triton Ties

Triton Ties brings “a materials science approach to railroad infrastructure,” leveraging its expertise in composite engineering and a patent-pending extrusion process to deliver a tie that meets and exceeds the needs of modern rail systems, company officials said.

Triton’s composite ties are engineered using recycled plastics reinforced with virgin glass fibers, resulting in a tie that is impervious to moisture, decay and insect damage. The advanced formulation contributes to a longer service life than traditional materials and requires no changes to existing installation equipment, company officials said.

Triton uses a proprietary materials feeding process to ensure consistent material quality and performance throughout every tie — critical attributes for high-volume installations across varied climates, they said.

The company has direct access to post-consumer plastics through its own recycling operations, which allows it to maintain a stable and consistent supply chain and predictable pricing in volatile markets, Triton officials said. This end-to-end control enhances product availability and reduces procurement risk for railroads and contractors, they added.

Advanced Carpet Recycling

Advanced Carpet Recycling’s synthetic product is designed to extend crosstie life and eliminate the need for harmful preservation chemicals, company officials said.

Advanced Carpet Recycling

In September 2024, the National Science Foundation (NSF) awarded Advanced Carpet Recycling a Phase I Small Business Innovation Research (SBIR) grant to enhance the company’s ability to convert used carpet into railroad ties and test to ensure compliance with AREMA standards for hardwoods. Additionally, NSF requires the company to engage in customer discovery to validate market demand for its railroad ties, Advanced Carpet Recycling officials said.

The company’s synthetic product “extends the crossties’ life and eliminates the need for harmful preservation chemicals,” according to a project abstract on NSF/SBIR’s website. “By sourcing whole, used carpets to produce a synthetic rail crosstie, this project removes some of the annual 4 billion pounds of carpet waste; thus, saving landfill space from both future carpet and wooden crosstie disposal.”

The project’s aim is to first supply ties to short lines “while waiting on needed certifications” from Class Is, according to SBIR.

During Phase I, research will investigate the chemistry risks involved in upscaling the technology to produce larger, more complex pieces while minimizing waste, eliminating hazardous waste and optimizing process time.

“Validating chemical reactions in a hot fuse environment is critical,” according to SBIR. “The project must also identify the correct resins needed to ensure the variable insource material does not hinder the final product. Scientists from two nationally known laboratories will assist in identifying and mitigating these chemical risks, identifying needed resins, and running necessary tests to meet AREMA standards.”

Vossloh Tie Technologies

Vossloh Tie Technologies/Rocla Concrete Tie Inc. has been supplying ties across North America for more than 35 years.

Vossloh Tie Technologies

For Vossloh Tie Technologies/Rocla Concrete Tie Inc. — which has been supplying ties across North America for more than 35 years — product demand remains consistent this year, with a slight uptick in orders from Class Is and major commuter lines, company officials said.

One of the company’s latest products is the 102 Yard tie, a tie and fastener combination designed with less reinforcement and material for yards and a variety of transit applications.

“We believe the cost efficiencies we have driven into this new tie and fastener design make it extremely competitive to plated wood ties, coupled with a much longer lifespan as compared to traditional ties, thus driving a compelling return on investment for both new yard construction as well as total yard rehabs,” company officials said.

Michael Popke is a Madison, Wisconsin-based freelance writer. Email comments or questions to prograil@tradepress.com.