Polymer Grout Technology Enhances Tram Track Renewal

VolkerRail has completed embedded track renewal works on the Croydon tram network in south London, introducing a new polymer-based rail grout solution developed by Sika. The project included the replacement of a key crossover and 500 metres of embedded track, delivered within a 15-day blockade.

The works were carried out in a busy urban environment and aligned with school holidays to minimize disruption to passengers.

First UK Use of Polymer Rail Grout
The project marked the first use in the UK of Sika’s Icosit^® KC 350/45 polymer rail grout. The two-part polyurethane material is already used in European light rail systems and is designed to improve durability and performance of embedded track.

The grout offers enhanced vibration absorption, contributing to improved ride quality and reduced long-term maintenance requirements.

Faster Installation and Reduced Closures
One of the key advantages of the polymer grout is its rapid curing time, which is up to six times faster than traditional materials. This enables shorter track possession periods and faster return to service.

The material was also applied using a newly developed machine, marking the first time globally that this product has been installed using a mechanized process rather than manual methods.

Automated Application Improves Efficiency
The use of the new application machine allowed for more controlled and consistent installation, reducing the need for labor-intensive processes. This approach helped improve construction efficiency while lowering costs and environmental impact.

Mechanized application also supports better quality control during installation, contributing to longer-lasting track infrastructure.

Supporting Long-Term Asset Performance
The elastic properties of the polymer grout help absorb dynamic loads and vibrations generated by tram operations. This reduces wear on track components and extends asset life.

By improving both installation efficiency and long-term performance, the solution supports more sustainable maintenance strategies for urban rail networks.

Ongoing Croydon Tram Network Upgrades
The works were carried out on the East Croydon to Wimbledon line, part of a broader embedded track replacement program delivered by VolkerRail for London Trams since 2012.

Croydon’s tram network spans approximately 28 kilometers with 39 stops and carries around 18 million passengers annually. The latest upgrade forms part of an ongoing framework to modernize infrastructure while maintaining reliable service in a high-demand urban transport system.

Edited by Industrial Journalist, Romila DSilva, with AI assistance.