Innovative polyurethane material rail system: Rail vehicles use part of the foam-filled track bed to reduce noise pollution for nearby residents Leverkusen – A groundbreaking new technology is set to revolutionize the future of railway construction. The Frenzel-Bau Group, a leading company in railway infrastructure, has developed an innovative rail system called Durflex® in collaboration with Bayer MaterialScience AG and its subsidiary Hennecke GmbH. This system uses polyurethane foam to fill the gaps between gravel ballast, significantly reducing noise and extending the lifespan of the tracks. By stabilizing the ballast, it prevents displacement caused by train traffic, which often leads to rail wear and maintenance issues. In the town of Uelzen, Lower Saxony, a 300-meter test section of the Durflex® system is currently undergoing trial operations, with regular rail services expected to start soon. Partners involved in the project hope that this innovation will have wide-reaching benefits in terms of noise reduction and long-term durability. The project was funded by several German federal ministries, including those responsible for railways, transport, urban development, and economic affairs. Many residents near rail lines are often disturbed by the noise from freight trains. Traditionally, noise barriers have been used to mitigate this issue, but these can be expensive and visually unappealing. The Durflex® system eliminates many of these problems. Dr. Andreas Hoffmann, a polyurethane expert at Bayer MaterialScience, explained, “The polyurethane foam stabilizes the ballast, preventing movement and reducing noise in areas where it typically occurs.†Rail transport is considered more eco-friendly than road transport, but heavy trains can cause damage to the track bed, leading to costly repairs. Jürgen Frenzel from Frenzel-Bau noted, “With Durflex®, we can extend the maintenance cycle significantly. It’s suitable for both new and existing railway lines.†The 300-meter test track in Uelzen was constructed using the same method that will be used in future rail projects. Hennecke developed a specialized rail vehicle that injects liquid polyurethane directly into the gaps between the ballast, filling them completely. Once the foam sets, the rails can be reused quickly. Similar polyurethane systems have already proven successful in reinforcing rock and in construction equipment applications. Hoffmann added, “This project showcases our strong partnership with customers in the polyurethane materials industry.†Bayer MaterialScience operates under the brand BaySystems® globally, offering advanced polymer solutions across various industries. About Bayer MaterialScience: Drymix Mortar admixtures has wide range of products, including HPMC, MHEC, RDP, HPS, PVA. Drymix Mortar Admixtures,Calcium Formate,Lignocellulose,Potassium Formate Santo Chemical Limited , https://www.santchem.com
Bayer MaterialScience is one of the world's largest producers of polymers, with sales reaching €10.2 billion in 2006. The company focuses on developing high-tech polymer materials and innovative solutions for everyday life. Its clients include the automotive, electronics, construction, and sports industries. As of the end of 2006, the company had 30 production sites and approximately 14,900 employees worldwide. Bayer MaterialScience is part of the larger Bayer Group.
Innovative polyurethane material rail system