Case Study: Fast-Setting Concrete for Rail Repairs

Infrastructure repairs rely on materials that meet durability standards and reduce downtime. This is important as essential transport routes cannot afford extended closures. Fast-setting concrete has become the go-to solution for such projects.

This case study explores the use of Rapid Set, fast-setting concrete for rail repairs at the Felixstowe Docks. We will explore how the right materials can streamline operations.

Project Overview: Rail Crossing Renewal at Felixstowe Docks

For this rail repair our client Trackwork Ltd needed a solution that would minimise any disruption at Felixstowe Docks. The primary objectives were to:

• Achieve early set and strength development, and re-open the crossing for HGVs.
• Complete the repair fast and outside of standard operational hours for minimal disruption.

After assessing these requirements, we have worked with our client to supply 3.4m³ of Rapid Set concrete via a volumetric mixer. The pour was successfully completed in just one hour.

Rapid Set is composed of BCSA (belitic calcium sulfoaluminate) cement, which offers several benefits. For instance, it is more sustainable compared to traditional Portland cement. BSCA has over 30% less CO2 emissions and does not use chemicals or heat to accelerate the setting process. It also doesn’t shrink, crack or curl and is sulphate-resistant.

Therefore, the product was selected for its quick curing times, durability, and suitability for high-load applications. This enabled the crossing to reopen the same day.

Customer Feedback

Following the installation, Trackwork Ltd praised the quality and efficiency of the concrete, describing it as “brilliant”.

The client also acknowledged the skill and professionalism of Eastern Concrete’s driver and the seamless coordination between teams.

This emphasises the importance of skilled personnel in time-sensitive projects.

Key Takeaways: Fast-Setting Concrete for Time-Critical Rail Repairs

Rapid Set offers transformative benefits for rail repairs and other infrastructure projects, especially in:

• Minimising Operational Downtime: Projects requiring minimal closures can benefit from the quick set and high-strength properties of Rapid Set concrete.
• Streamlining Repair Operations: With the right preparation and a reliable team, installations can proceed smoothly, even on tight schedules.

• Rapid Strength Gain: Setting begins within minutes, achieving high strength in just an hour. This allows transport routes to return to service swiftly, making it ideal for railways, airports, raods and other essential infrastructure.
• Durability Under Heavy Loads: Fast-setting concrete withstands the demands of HGVs and other heavy traffic.
• Reduced Shrinkage and Cracking: Rapid Set concrete demonstrates zero shrinkage, ensuring a robust, long-lasting repair without the risk of early cracking, a common issue in concrete repairs.
• Sustainability Benefits: Lower CO₂ emissions associated with fast-setting formulas contribute to greener construction practices, supporting eco-friendly project initiatives.

Conclusion

Fast-setting concrete like Rapid Set is an effective solution for infrastructure projects. It allows contractors to achieve swift turnaround times and durability.

Essential routes can be operational with minimal disruption, and meet both safety and logistical demands.

Contact us today if you’re considering concrete solutions for critical infrastructure repairs. Our team will help you explore fast-setting options to meet your project requirements.