Evaluating Different Track Sub-Ballast Solutions Considering Traffic Loads and Sustainability

The railway industry is seeking high-performance and sustainable solutions for sub-ballast materials, particularly in light of increasing cargo transport demands and climate events. The meticulous design and construction of track bed geomaterials play a crucial role in ensuring an extended track service life. The global push for sustainability has prompted the evaluation of recycling ballast waste within the railway sector, aiming to mitigate environmental contamination, reduce the consumption of natural resources, and lower costs. This study explores materials for application and compaction using a formation rehabilitation machine equipped with an integrated ballast recycling system designed for heavy haul railways. Two recycled ballast-stabilised soil materials underwent investigation, meeting the necessary grain size distribution for the proper compaction and structural conditions. One utilised a low-bearing-capacity silty sand soil stabilised with recycled ballast fouled waste (RFBW) with iron ore at a 3:7 weight ratio, while the second was stabilised with 3% cement. Laboratory tests were conducted to assess their physical, chemical, and mechanical properties, and a non-linear elastic finite element numerical model was developed to evaluate the potential of these alternative solutions for railway sub-ballast. The findings indicate the significant potential of using soils stabilised with recycled fouled ballast as sub-ballast for heavy haul tracks, underscoring the advantages of adopting sustainable sub-ballast solutions through the reuse of crushed deteriorated ballast material.