The Future of Composite Railroad Crosstie
America’s railroad industry is built on wood. The other less popular alternative is concrete ties. But concrete ties are not structurally flexible or as economically viable compared to hardwood. In addition, treated hardwood can last up to 40 years, depending on the climate, with those in warm, moist environments needing replacing in as often as five years. This means up to 25 million wood ties need replacing every year.
The increase in axle loading (carriage width) across the United States has also exerted more pressure on wood crossties, causing frequent wear and tear. Additionally, wood ties are prone to splitting, rotting, and plate-cutting. These shortcomings have led the railroad industry to explore other durable options.
A tie, also known as crosstie, is the horizontal block that supports the rail track. In the race for sustainability, the railroad industry is exploring composite ties as a replacement for hardwood crossties. Composite ties are made of recycled plastic and rubber. If adopted countrywide, composite ties would ease the pressure on hardwood, all reducing plastic pollution.
Plastics are naturally water and insect-resistant and non-biodegradable. Therefore, the resultant composite ties would require minimal maintenance. In addition to not requiring treatment (which uses hazardous chemicals), composite ties are just as effective as wood ties but last many times longer. Unlike other alternatives, namely concrete and steel, composite ties weigh almost the same as hardwood ties. This, coupled with the nearly similar installation requirements of wood and composite ties, means they are interchangeable. So, phasing in composite ties during renewal projects would be relatively easier than if concrete or steel were to be used.
Cut spikes used to hold wood ties tend to loosen with time, requiring frequent, ongoing maintenance. This may not be needed with composite ties, given they hold screws tighter than hardwood. Unfortunately, wood is the cheapest of the crosstie alternatives, at least initially.
Cost is one of the major factors holding the railroad sector back from adopting composite ties. However, initial cost considerations pale in comparison to the lifetime value of wood ties, not to mention the cost of medium-to high-rates of replacement. A relatively shorter wood tie cycle is where composite crosstie value is.
The initial cost of composite tie installation is higher than that of wood ties, favorable spread over the product’s lifespan. With a lifetime of up to 50 years, regardless of the weather conditions, composite ties offer a relatively cheaper alternative in the long term.
As the composite tie technology picks up, more companies are lining up for a piece of the composite tie market size, projected to hit $9.7 billion by 2032. Among them is IntergriCo, which promises composite crosstie that lasts up to four times longer than concrete and wood ties.
Up to 95 percent of America’s railroad still runs on hardwood more than three centuries later. The industry has welcomed numerous new technologies. Tie construction has remained relatively unchanged until now. Although composite ties use has yet to go mainstream, the potential is there, and it’s only a matter of time until wood ties become a thing of the past.
