Method for applying weather-resistant asphalt film composition to wooden railroad sleeper

Abstract

A method of applying a weather resistant asphalt film composition to a wooden railroad sleeper having cracks and / or voids on a surface, the method comprising: applying the composition to a surface of a wooden railroad sleeper wherein the application of the composition permeates at least some of the cracks and / or voids present on the surface, and allowing the composition to cool; wherein the composition comprises an asphalt binder and at least one additive. The asphalt film composition is formulated to reduce the water permeability of the sleepers and protect the sleepers from degradation due to moisture, UV radiation and extreme temperature, thereby extending the service life of wooden railway sleepers.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of US Provisional Application No. 63 / 508,004, filed June 14, 2023, which is incorporated herein by reference in its entirety. This application also claims the benefit of US Provisional Application No. 63 / 508,006, filed June 14, 2023, which is incorporated herein by reference in its entirety. Background Technology

[0003] Railway sleepers are primarily made of wood (usually hardwood, such as oak). These wooden railway sleepers have long been treated with materials such as creosote, copper naphthenate, and / or boric acid to impart rot resistance. The main mechanism for delaying decay is through treatments of a fungicide and insecticide nature. These treatments protect the wood only to the depth to which the agent can penetrate during the treatment. These treatments are not intended to make the wood waterproof, but rather to delay biodegradation. If the outer surface of the sleeper experiences splitting or cracking, spores and / or insects can enter the wood and begin the sleeper's degradation, thus reducing its lifespan.

[0004] Checking, cracking, and / or splitting in wooden railway sleepers in use are the result of weathering of the woody components within the sleepers. Exposure to moisture, ultraviolet radiation, and extreme temperatures all affect the structural stability of the wood. For example, UV radiation causes the degradation of lignin in the wood, leading to material loss and ultimately initiating microcracks on the outer surface of the sleepers. These microcracks then propagate into the wood structure, creating sites susceptible to decay or insect infestation. Once cracks form, more water and air penetrate into the underlying layers of the sleeper, causing further damage to the structure. This accelerates both mechanical and biological decay processes, which, if left untreated, can lead to eventual structural failure.

[0005] Therefore, there is still a need for a treatment system for railway sleepers that protects the wooden sleepers from moisture, UV radiation, and the effects of hot and cold temperatures. Summary of the Invention

[0006] In some aspects, methods for applying a weather-proofing asphalt film composition to wooden railway sleepers are disclosed. In some embodiments, the weather-proofing asphalt film typically comprises a mixture of an asphalt binder and at least one additive. In some embodiments, the additive includes at least one of an elastic polymer or a thickener. In one embodiment, the weather-proofing asphalt film composition is sprayed onto the surface of the wooden railway sleeper in the form of a hot liquid. The asphalt film composition then cools and adheres to the surface of the sleeper. After application, the asphalt film composition protects the wooden railway sleeper from exposure to moisture, UV radiation, and extreme temperatures. Furthermore, the application of the asphalt film composition reduces the permeability of the sleeper by penetrating at least one crack or void within the sleeper. Therefore, the service life of the wooden railway sleeper is extended.

[0007] In another embodiment, the weather-resistant bitumen film composition is poured into a mold shaped to the size of a wooden railway sleeper. After cooling, the bitumen film composition comprises a pre-formed pad. In another embodiment, the pad can be formed by extruding the bitumen film composition to a width and thickness covering the surface of the railway sleeper. The extrusion can be cut to the length of the sleeper. The pre-formed pad can then be adhered to the surface of the railway sleeper by heating the underside of the pre-formed pad or heating the surface of the sleeper. As the pre-formed pad and / or the sleeper cool, the pre-formed pad will adhere to the surface of the sleeper.

[0008] In some embodiments, the weather-resistant asphalt film composition incorporates aggregate. The aggregate is configured to provide increased friction on the surface of the asphalt film strip. Furthermore, the aggregate provides additional UV protection for the railway sleepers. In other embodiments, the aggregate is added to the weather-resistant asphalt film composition before the composition cools.

[0009] The weather-resistant bitumen film is configured to be applied to wooden railway sleepers, regardless of their treatment status. For example, the bitumen film can be applied to untreated railway sleepers or railway sleepers that have been treated with common treatment chemicals, including, for example, boric acid, sodium borate, creosote, copper naphthenate, or dichlorooctylisothiazolinone, or combinations of such treatment chemicals. Attached Figure Description

[0010] Figure 1 This is a digital image of a prefabricated mat according to one embodiment of the present invention.

[0011] Figure 2 This is a digital image of a prefabricated mat according to another embodiment of the present invention. Detailed Implementation

[0012] For the purpose of facilitating an understanding of the principles of the invention, reference will now be made to certain embodiments, and these embodiments will be described using specific language. However, it should be understood that this is not intended to limit the scope of the invention, and such changes and other modifications, as well as other applications of the principles of the invention as described herein, are considered to be commonly apparent to those skilled in the art to which this invention pertains. Furthermore, in the detailed description below, numerous alternatives to various features are given. It will be understood that each such disclosed alternative or combination of such alternatives may be combined with more generalized features discussed in the above summary or set forth in the embodiments described below to provide other embodiments disclosed herein.

[0013] A weather-resistant bitumen film composition is configured to fill and seal pre-existing fine cracks, fissures, and fissures (microscopic and macroscopic, as well as other surface defects) in wooden railway sleepers, and to provide a protective layer to the outer surface of the sleepers. The bitumen film composition is formulated to protect wooden railway sleepers from exposure to moisture, UV radiation, and extreme temperatures. This is achieved by covering the surface of the railway sleepers with a sufficiently thick layer of the weather-resistant bitumen film composition, allowing the flexible protective layer of the composition to adhere to the outer surface of the sleepers. Simultaneously, the composition is formulated to resist lateral flow, which allows the composition to remain on the surface of the railway sleepers. Therefore, the service life of wooden railway sleepers is effectively increased. A method for applying the aforementioned weather-resistant bitumen film composition is disclosed herein.

[0014] Weather-resistant bitumen films are configured to be applied to wooden railway sleepers, regardless of their treatment status. For example, bitumen films can be applied to untreated railway sleepers or railway sleepers that have been treated with common treatment chemicals, such as boric acid, sodium borate, creosote, copper naphthenate, or dichlorooctylisothiazolinone, or combinations of such treatment chemicals.

[0015] Weather-resistant asphalt film compositions typically comprise a mixture of asphalt binder and at least one additive. In some embodiments, the additive may be selected from one or more elastic polymers and a thickener. In some embodiments, the composition comprises an asphalt binder, at least one elastic polymer, and a thickener. In some embodiments, the thickener comprises a wax modifier. However, other compositions may comprise an asphalt binder, an elastic polymer, a thickener, and fillers (e.g., fumed silica and / or fumed alumina). Further compositions may comprise an asphalt binder, an elastic polymer, a thickener, a wax modifier, and saponified fatty acids and resin acid gelling compounds. Even further, the composition may comprise an asphalt binder, an elastic polymer, a thickener, fumed silica and / or fumed alumina, and saponified fatty acids and resin acid gelling compounds.

[0016] In some embodiments, the bitumen binder is the major component of the composition and provides material strength or a foundation for covering railway sleepers and providing weather resistance. The bitumen binder may comprise 85 to 97 wt.% of the composition, and in some embodiments 90 to 93 wt.% of the composition. Suitable bitumen binders include paving-grade bitumen, which includes performance grading, viscosity grading, and / or penetration grading.

[0017] The asphalt film composition may include an elastic polymer component. The elastic polymer component allows the weather-resistant asphalt film to expand and contract elastically. This allows the asphalt film composition to move synchronously with the movement of railway sleepers (e.g., due to wood expansion and contraction caused by changes in temperature and moisture content within the wood). The polymer component is combined with an asphalt binder component to produce a polymer-modified asphalt binder. Suitable examples of such polymer components include styrene-butadiene-styrene (SBS), styrene-butadiene rubber (SBR), ethylene-styrene copolymer (ESI), Evaloy (an ethylene terpolymer available from DuPont), and other elastic polymers for use in polymer-modified asphalt compositions. This polymer component may comprise 1 to 6 wt.% of the composition, more preferably 2 to 5 wt.%.

[0018] The asphalt film may include thickeners, such as wax modifiers. Wax modifiers can reduce the viscosity of the composition at the application temperature, allowing the composition to migrate into the wooden sleepers during application, thereby filling and sealing cracks, fissures, and fissures (and other surface defects) and reducing permeability. Furthermore, at ambient temperature, wax modifiers provide stiffness to the weather-resistant asphalt film, which reduces tackiness issues. Suitable wax modifiers include, but are not limited to, plant waxes (e.g., but not limited to carnauba wax), animal waxes (e.g., but not limited to beeswax), mineral waxes (e.g., but not limited to Montan™ wax from coal and / or Fischer-Tropsch wax from coal), or petroleum waxes (e.g., but not limited to paraffin wax, polyethylene wax, and / or Fischer-Tropsch wax from natural gas), including oxidized waxes; amide waxes (e.g., but not limited to ethylene bis-stearamide, stearamide, stearyl stearamide); and / or fatty acids and soaps with waxy properties (e.g., but not limited to aluminum stearate, calcium stearate, fatty acids). Wax modifiers can also improve the cohesive properties of the composition. In some embodiments, the wax modifier may account for 1 to 5 wt.% of the composition, more preferably 2 to 4 wt.% of the composition.

[0019] Fumed silica and / or fumed alumina can be used as fillers and can immediately impart resistance to lateral flowability to the composition after application, and impart non-sticky characteristics to the composition, thereby preventing adhesion before aggregate application. Fumed silica and fumed alumina can be used alone or together in any desired proportion. The total amount of filler (e.g., fumed silica and / or fumed alumina) can be 1 to 10 wt.% of the composition, more preferably 1 to 4 wt.% of the weather-resistant asphalt film composition.

[0020] In some embodiments, the weather-resistant asphalt film composition may further include saponified fatty acids and resin-acid gelling compounds. The saponified fatty acids and resin-acid gelling compounds can be used to control the rate of solidification or curing of the composition. Suitable saponified fatty acids and resin-acid gelling compounds include, but are not limited to, crude tall oil or distilled tall oil. The total amount of saponified fatty acids and resin-acid gelling compounds may be 0 to 3 wt.% of the composition, more preferably 1 to 2 wt.% of the composition.

[0021] An exemplary formulation of a weather-resistant asphalt film composition can be prepared by adding an elastic polymer component to a heated asphalt binder while shearing the mixture. A wax modifier can be added while shearing the mixture, either after or before the polymer component and asphalt binder are thoroughly mixed, followed by the addition of fumed silica and / or fumed alumina, as well as saponified fatty acids and resin acid gelling compounds.

[0022] In some embodiments, the inventors have surprisingly discovered that when the final composition contains fumed silica and / or fumed alumina fillers, the resulting composition exhibits improved thermal stability. Furthermore, in some embodiments, the polymeric properties imparted to the composition remain more consistent over time at high temperatures compared to similar compositions that do not contain fumed silica and / or fumed alumina.

[0023] Weather-resistant bitumen film compositions can be applied to wooden railway sleepers in a variety of suitable ways. The disclosed methods apply the weather-resistant bitumen film composition to the top surface of the wooden railway sleepers. Importantly, regardless of the application method, the bitumen film composition can be applied to the sleepers, regardless of location. Specifically, the bitumen film composition can be applied to the sleepers (including previously installed old sleepers) at a treatment facility, on-site before the sleepers are installed on the railway, or on-site after the sleepers are installed on the railway.

[0024] In some embodiments, regardless of the application method, the weather-resistant bitumen film composition has a thickness of approximately 1 / 8 inch after being applied to the sleepers. At this thickness, any movement of the sleepers during their lifespan (e.g., due to railway shrinkage / expansion and / or movement) or any cracks in the timber will not cause the weather-resistant bitumen film to break. Furthermore, this thickness includes a sufficient amount of bitumen film composition to retain the aggregate cover.

[0025] In some implementations, an aggregate cover (also called aggregate) is added to the weather-resistant bitumen film composition. The aggregate acts as an anti-slip agent to ensure that the railway sleepers treated with the bitumen film composition are not slippery or dangerous to walk on. The aggregate also acts as a physical barrier between the bitumen film composition and the underlying railway sleepers to protect them from exposure to sunlight and UV radiation. Furthermore, the aggregate is used to resist fires caused by hot metal sparks or embers generated during rail grinding operations.

[0026] Suitable aggregates include, but are not limited to, natural materials (e.g., unwashed and washed sand, gravel, crushed stone), recycled building materials (e.g., recycled asphalt pavement, recycled asphalt shingles, or recycled crushed concrete), and / or post-industrial waste (e.g., boiler slag, steel slag, crushed PVC pellets, or crushed solar panels). In some embodiments, the aggregate gradation should be between 1 / 16 and 1 / 8 inch in maximum width. In other embodiments, other gradation sizes may be used, as those skilled in the art should understand. Furthermore, the gradation size should be used to determine the aggregate thickness applied to the weather-resistant asphalt membrane. In one embodiment, the weather-resistant asphalt membrane is covered with aggregate of a thickness equal to the nominal width of the aggregate (i.e., the nominal gradation size). In another embodiment, aggregate of other thicknesses may be applied to the asphalt membrane.

[0027] In one method, a weather-resistant bitumen film composition is sprayed as a hot liquid onto the surface of a wooden railway sleeper. This can be achieved by heating the bitumen film composition to a temperature of approximately 300 to approximately 350°F. In one embodiment, a spraying system is mounted on a manually driven or mechanically driven mobile device, such as a vehicle or device mounted on the track, which applies the composition from a position above the railway sleeper. In other embodiments, a handheld spraying device (e.g., a wand) is used to spray the bitumen film composition onto the sleeper. In some embodiments, the composition is sprayed onto the sleeper until a strip of composition approximately 1 / 8 inch thick is applied. Furthermore, in some embodiments, the spraying should be performed uniformly and carefully to ensure that the composition does not run or overflow from the sleeper surface. During application, the composition fills and seals at least some cracks, fissures, and / or fissures present in the sleeper. As the composition cools, it adheres to the sleeper, thus forming a flexible protective layer as it fills the cracks, fissures, and / or fissures present in the sleeper.

[0028] In some embodiments, the aggregate cover is applied to the sprayed asphalt film composition before it cools. Specifically, in some embodiments, finely dried aggregate is placed in the weather-resistant asphalt composition while the composition is still at at least 250℉. In other embodiments, the aggregate is added to the composition after it has cooled and adhered to the sleepers. Here, the aggregate is heated to at least 200℉ and placed on the surface of the cooled asphalt film composition strip. The heat allows the aggregate to partially liquefy the outer surface of the composition, and then, as the composition cools again, the aggregate is embedded into the strip. The aggregate cover can be applied using a drip spreader or a crusher spreader. Furthermore, for typical natural aggregates, the aggregate application rate is 2.5 to 5.5 lbs. / square yard. For lightweight aggregates or heavy aggregates (e.g., slag), this application rate can be higher or lower.

[0029] In another method, the weather-resistant asphalt film composition is formed into a precast pad 10, such as... Figure 1 As shown. The precast pad 10 is then placed and adhered to the surface of the railway sleeper. Specifically, a hot liquid asphalt film composition is poured into a mold 15. As the composition is poured, it takes the shape of the mold 15. As the composition cools, the precast pad 10 is formed. Furthermore, the mold 15 is sized such that the precast pad 10 is suitable for covering the surface of the railway sleeper. The precast pad 10 is then applied to the railway sleeper. This is achieved by heating the underside of the precast pad 10, the surface of the railway sleeper, or both, using an external heat source. After one or both surfaces are heated, the precast pad 10 is placed on the surface of the sleeper and cooled, which adheres the precast pad 10 to the sleeper and allows some of the composition to fill and seal any surface defects present in the sleeper.

[0030] Similar to a spraying method, the precast pad 10 can be embedded with a layer of aggregate 20, such as Figure 2 As shown. In some embodiments, aggregate 20 is placed on the hot bitumen film composition before the composition cools in mold 15. In other embodiments, aggregate 20 is heated and then placed on the cooled precast pad 10. In another method, the composition can be extruded to the applied width and thickness and then cut to the length required to cover the sleepers. Similar to spraying or molding methods, aggregate can be placed on the extruded composition while the composition is hot, or the aggregate can be heated and placed on the cooled extrusion pad.

[0031] In some embodiments, the aggregate can be pressed or rolled into the composition, which embeds the aggregate within the cooled composition. For example, a tamper or roller can be used after the aggregate has been spread / applied to the composition.

[0032] Regardless of the application method, approximately thirty (30) minutes after the weather-resistant bitumen film composition is applied to the surface of the wooden railway sleepers, the composition is formulated to be substantially non-sticky. In other words, a person can walk on the treated surface of the railway sleepers after 30 minutes, and the composition will not stick to the soles of the person's shoes.

[0033] In some embodiments, the precast mat can be reinforced with a base material such as a fabric, textile, or polymer base. In some embodiments, the fabric can be a geotextile or geogrid. The geotextile can consist of flax, polyester, polypropylene, or glass fiber, or a composite material of more than one fiber. The fibers can be woven or nonwoven. The fabric can be lightweight or medium weight. In some embodiments, the fabric is nonwoven glass fiber or a composite material having a predominantly glass fiber composition. In some embodiments, the nonwoven glass fiber will have openings that allow the composition to penetrate the fabric. The nonwoven glass fiber fabric is coated with a composition at a rate of 0.5 gallons / square yard to 1.5 gallons / square yard, for example, about 0.7 to 1.0 gallons / square yard. The precast composite mat may have aggregate embedded on one side of the reinforcing mat. In some embodiments, the aggregate can be placed on the hot composition before the composition cools. In other embodiments, the aggregate is heated and then placed on the cooled composite mat. The other side of the precast mat may be sprinkled with fumed silica to allow the mats to not stick together during handling. The composite prefabricated pad can be applied to railway sleepers by heating the fumed silica side of the composite pad and placing it on the sleeper. In another embodiment, the railway sleeper can be heated, and the fumed silica-treated side of the composite prefabricated pad can be placed on the sleeper.

[0034] In the context of this disclosure (especially in the context of the preceding claims), the use of the terms “a” and “an” and “the,” as well as similar references, should be interpreted to cover both singular and plural forms, unless otherwise stated herein or obviously contradicted by the context. Unless otherwise stated herein, the description of numerical ranges herein is intended only as a shorthand method for individually referring to each individual value falling within that range, and each individual value is incorporated into this specification as if it were individually described herein. All methods described herein may be performed in any suitable order, unless otherwise stated herein or obviously contradicted by the context. The use of any and all instances or exemplary language (e.g., “such as”) provided herein is merely intended to better illustrate the invention and not to limit the scope of the invention, unless otherwise stated. The language in this specification should not be construed as indicating that any unstated element is essential to the practice of the invention.

[0035] Although the invention has been described in detail above, these descriptions are intended to be illustrative rather than restrictive, and it should be understood that all changes and modifications within the spirit and scope of the invention are intended to be protected. Furthermore, all references cited herein indicate the level of expertise in the art and are incorporated herein by reference in their entirety.

[0036] Implementation Plan

[0037] The following provides a list of some embodiments disclosed herein. It will be understood that this list is non-limiting, and that individual features or combinations of features (e.g., 2, 3, or 4 features) described in the specific embodiments above may be combined with the embodiments listed below to provide further embodiments disclosed herein.

[0038] 1. A method for applying a weather-resistant bitumen film composition to wooden railway sleepers with cracks and / or voids on their surface, the method comprising:

[0039] The weather-resistant asphalt film composition is sprayed onto the surface of the wooden railway sleepers, wherein the application of the composition penetrates at least some cracks and / or voids present on the surface; and

[0040] Cool the composition.

[0041] The composition contains asphalt binder and at least one additive.

[0042] 2. The method according to embodiment 1, wherein the at least one additive is selected from elastic polymers, wax modifiers, or fillers.

[0043] 3. The method according to embodiment 2, wherein the filler comprises fumed silica or fumed alumina.

[0044] 4. The method according to embodiment 1, wherein the composition comprises an asphalt binder, an elastic polymer, and a filler.

[0045] 5. The method according to embodiment 4, wherein the composition further comprises at least one wax modifier.

[0046] 6. The method according to any one of embodiments 1-5, wherein the bitumen binder accounts for 85 to 97 wt.% of the composition.

[0047] 7. The method according to any one of embodiments 2-6, wherein the elastic polymer accounts for 1 to 6 wt.% of the composition.

[0048] 8. The method according to any one of embodiments 2-7, wherein the wax modifier accounts for 1 to 5 wt.% of the composition.

[0049] 9. The method according to any one of embodiments 2-4, wherein the total amount of the filler accounts for 1 to 10 wt.% of the composition.

[0050] 10. The method according to any one of embodiments 1-9, wherein applying the composition to the wooden sleeper reduces the water permeability of the wooden sleeper.

[0051] 11. The method according to embodiment 1, wherein the composition is formulated to become substantially non-sticky after being applied to the surface of a wooden sleeper for about 30 minutes.

[0052] 12. The method according to embodiment 8, wherein the wax modifier comprises amide wax.

[0053] 13. The method according to any one of embodiments 2-12, wherein the elastic polymer comprises a styrene-butadiene-styrene compound.

[0054] 14. The method according to any one of embodiments 1-13, wherein the composition is sprayed onto the surface of the wooden sleepers using a handheld sprayer.

[0055] 15. The method according to any one of embodiments 1-13, wherein the composition is sprayed onto the surface of the wooden sleeper using a spraying system mounted on a mechanically driven mobile device.

[0056] 16. The method according to any one of embodiments 1-13, wherein the composition is sprayed onto the surface of the wooden sleeper using a spraying system mounted on a manually driven mobile device.

[0057] 17. The method according to any one of claims 14-16, wherein the composition is applied from a position above the surface of the railway sleepers using a vehicle or device mounted on the track.

[0058] 18. The method according to any one of embodiments 1-17, wherein the composition is sprayed onto the surface of the wooden sleeper at a thickness of about 1 / 8 inch.

[0059] 19. The method according to any one of embodiments 1-18, wherein the composition does not flow or run off the surface of the wooden sleeper.

[0060] 20. The method according to any one of embodiments 1-19, wherein the composition is applied to the wooden sleeper at a temperature of 300℉ to 350℉.

[0061] 21. The method according to any one of embodiments 1-20, the method further comprising applying aggregate to the composition.

[0062] 22. The method according to embodiment 21, wherein the aggregate is applied to the composition at a ratio of 2.5 to 5.5 lbs. / square yard.

[0063] 23. The method according to embodiment 21, wherein the aggregate is applied to the composition when the composition has a temperature above 250℉.

[0064] 24. The method according to embodiment 21, wherein the aggregate is applied to the composition after the composition has been cooled.

[0065] 25. The method according to embodiment 24, wherein the aggregate is heated to at least 200℉ and then applied to the composition.

[0066] 26. A method for applying a weather-resistant bitumen film composition to a wooden railway sleeper having a surface, wherein the surface of the railway sleeper has cracks and / or voids, the method comprising:

[0067] Choose a prefabricated pad that includes both the surface and the bottom;

[0068] Heating the surface of the wooden sleeper or the bottom surface of the prefabricated pad, and,

[0069] The prefabricated pad is applied to the surface of the wooden railway sleeper, wherein the application of the prefabricated pad to the surface of the wooden sleeper fills and / or seals at least some cracks and / or voids present in the surface of the sleeper;

[0070] The composition contains asphalt binder and at least one additive.

[0071] 27. The method according to embodiment 26, wherein the at least one additive is selected from elastic polymers, wax modifiers, and fillers.

[0072] 28. The method according to embodiment 27, wherein the filler comprises fumed silica or fumed alumina.

[0073] 29. The method according to embodiment 26, wherein the composition comprises an asphalt binder, an elastic polymer, and a filler.

[0074] 30. The method according to embodiment 29, wherein the composition further comprises at least one wax modifier.

[0075] 31. The method according to any one of embodiments 26-30, wherein the bitumen binder accounts for 85 to 97 wt.% of the composition.

[0076] 32. The method according to any one of embodiments 27-31, wherein the elastic polymer accounts for 1 to 6 wt.% of the composition.

[0077] 33. The method according to any one of embodiments 2-7, wherein the wax modifier accounts for 1 to 5 wt.% of the composition.

[0078] 34. The method according to any one of embodiments 2-4, wherein the total amount of said filler accounts for 1 to 10 wt.% of the composition.

[0079] 35. The method according to embodiment 26, wherein applying the composition to a wooden sleeper reduces the water permeability of the wooden sleeper.

[0080] 36. The method according to embodiment 26, wherein the composition is formulated to become substantially non-sticky after being applied to the surface of a wooden sleeper for about 30 minutes.

[0081] 37. The method according to embodiment 30, wherein the wax modifier comprises amide wax.

[0082] 38. The method according to embodiment 29, wherein the elastic polymer comprises a styrene-butadiene-styrene compound.

[0083] 39. The method according to embodiment 26, wherein the mold is sized such that the prefabricated pad has the same surface dimensions as the wooden railway sleeper.

[0084] 40. The method according to embodiment 26, wherein the surface of the railway sleeper is covered by one or more prefabricated pads.

[0085] 41. The method according to embodiment 26, wherein the precast pad is applied to wooden railway sleepers already installed on the railway.

[0086] 42. The method according to embodiment 26, wherein the precast pad is applied to a wooden railway sleeper and then the wooden railway sleeper is installed on the railway.

[0087] 43. The method according to embodiment 26, wherein the thickness of the prefabricated pad is approximately 3 / 16 inch.

[0088] 44. The method according to embodiment 26, the method further comprising applying aggregate to the composition.

[0089] 45. The method according to embodiment 44, wherein the aggregate is applied to the composition at a ratio of 1.5 to 3 lbs. / square yard.

[0090] 46. ​​The method according to embodiment 44, wherein the aggregate is applied to the composition while the composition is still hot in the mold.

[0091] 47. The method according to embodiment 44, wherein the aggregate is applied to the composition after the composition has been cooled to form the preformed pad.

[0092] 48. The method according to embodiment 47, wherein the aggregate is heated to at least 200℉ and then applied to the precast mat.

[0093] 49. The method according to any one of embodiments 26-48, wherein the prefabricated pad further comprises a base material, wherein the base material is selected from woven fabrics or polymer materials.

[0094] 50. A weather-resistant bitumen film composition comprising:

[0095] Asphalt adhesives;

[0096] Elastic polymers;

[0097] Wax modifier;

[0098] Fillers selected from fumed silica and / or fumed alumina,

[0099] The composition is formulated to contain 85 to 97 wt.% of the bitumen binder;

[0100] 1 to 6 wt.% of the elastic polymer;

[0101] 1 to 5 wt.% of the wax modifier;

[0102] The filler is selected from fumed silica and / or fumed alumina in a total amount of 1 to 10 wt.%; and

[0103] The composition is applied to the surface of wooden railway sleepers.

[0104] 51. The bitumen composition according to embodiment 50, wherein applying the composition to the wooden railway sleeper reduces the permeability of the wooden railway sleeper.

[0105] 52. The asphalt composition according to embodiment 50, wherein the asphalt composition is formulated to become substantially non-sticky after being applied to the surface of the railway sleeper for about 30 minutes, thereby preventing sticking when walking.

[0106] 53. The asphalt composition according to embodiment 50, wherein the asphalt composition is a sprayable composition.

[0107] 54. The bitumen composition according to embodiment 50, wherein the wax modifier comprises amide wax.

[0108] 55. The bitumen composition according to embodiment 50, wherein the elastomeric polymer comprises a styrene-butadiene-styrene compound.

[0109] 56. The bitumen composition according to embodiment 50, wherein the bitumen composition is formulated to adhere to the surface of the wooden railway sleeper and fill surface defects.

[0110] 57. The bitumen composition according to embodiment 50, wherein the filler comprises fumed silica.

[0111] 58. The bitumen composition according to embodiment 57, wherein the bitumen composition is formulated to adhere to the surface of the wooden railway sleeper and fill surface defects.

[0112] 59. The bitumen composition according to embodiment 57, wherein applying the composition to the wooden railway sleeper reduces the permeability of the wooden railway sleeper.

[0113] 60. The asphalt composition according to embodiment 57, wherein the asphalt composition is formulated to become substantially non-sticky after being applied to the surface of the railway sleeper for about 30 minutes, thereby preventing sticking when walking.

[0114] 61. The bitumen composition according to embodiment 57, wherein the bitumen composition is a sprayable composition.

[0115] 62. The bitumen composition according to embodiment 57, wherein the wax modifier comprises amide wax.

[0116] 63. The bitumen composition according to embodiment 57, wherein the elastomeric polymer comprises a styrene-butadiene-styrene compound.

[0117] 64. The bitumen composition according to embodiment 50, wherein the filler comprises fumed alumina.

[0118] 65. The bitumen composition according to embodiment 64, wherein the bitumen composition is formulated to adhere to the surface of the wooden railway sleeper and fill surface defects.

[0119] 66. The bitumen composition according to embodiment 64, wherein applying the composition to the wooden railway sleeper reduces the permeability of the wooden railway sleeper.

[0120] 67. The asphalt composition according to embodiment 64, wherein the asphalt composition is formulated to become substantially non-sticky after being applied to the surface of the railway sleeper for about 30 minutes, thereby preventing sticking when walking.

[0121] 68. The asphalt composition according to embodiment 64, wherein the asphalt composition is a sprayable composition.

[0122] 69. The bitumen composition according to embodiment 64, wherein the wax modifier comprises amide wax.

[0123] 70. The bitumen composition according to embodiment 64, wherein the elastomeric polymer comprises a styrene-butadiene-styrene compound.

[0124] 71. The bitumen composition according to embodiment 50, wherein the composition is applied to the wooden railway sleeper to protect the railway sleeper from UV radiation, moisture and extreme temperatures.

[0125] 72. The bitumen composition according to embodiment 50, wherein after the composition is cured onto the wooden railway sleeper, the composition is sufficiently flexible to move as the railway sleeper moves.

[0126] 73. The bitumen composition according to embodiment 50, wherein aggregate is applied to the composition after the composition is applied to the wooden railway sleeper.

[0127] 74. The asphalt composition according to embodiment 73, wherein the aggregate contributes to friction and UV protection.

[0128] 75. The asphalt composition according to embodiment 73, wherein after the aggregate is applied to the composition, the aggregate is further embedded in the composition.

[0129] 76. The asphalt composition according to embodiment 73, wherein the aggregate is embedded into the composition using a counterweight roller.

[0130] 77. The asphalt composition according to embodiment 75, wherein the aggregate is embedded into the composition using a rammer.

[0131] 78. The bitumen composition according to embodiment 73, wherein the aggregate comprises natural materials, recycled building materials and / or post-industrial waste.

[0132] 79. The bitumen composition according to embodiment 78, wherein the aggregate size gradation is from 1 / 8 to 5 / 16 inch at the maximum width.

[0133] 80. The asphalt composition according to embodiment 79, wherein the aggregate is applied to the composition with a thickness approximately equal to the gradation size of the aggregate width.

[0134] 81. The bitumen composition according to embodiment 50, wherein the composition is applied to the wooden railway sleepers in strip form.

[0135] 82. The bitumen composition according to embodiment 81, wherein the width of the composition applied to the wooden railway sleeper is approximately 8 to 10 inches.

[0136] 83. The asphalt composition according to embodiment 50, wherein the composition further comprises saponified fatty acids and resin acid gelling compounds.

[0137] 84. The asphalt composition according to embodiment 83, wherein the composition comprises 0 to 3 wt.% of saponified fatty acids and resin acid gelling compounds.

[0138] 85. The method according to any one of claims 26-49, further comprising producing a prefabricated mat, the method comprising:

[0139] The asphalt film composition is heated to form a heated liquid composition;

[0140] The heated composition is poured into a mold, wherein the composition takes the shape of the mold; and

[0141] The composition is cooled, and the cooling of the composition forms the preformed pad.

Claims

1. A method for applying a weather-resistant bitumen film composition to wooden railway sleepers with cracks and / or voids on their surface, the method comprising: The composition is applied to the surface of the wooden railway sleeper, wherein the application of the composition penetrates at least some cracks and / or voids present on the surface, and Cool the composition; The composition contains asphalt binder and at least one additive.

2. The method of claim 1, further comprising mixing and heating the composition before applying it to the surface of the wooden railway sleeper.

3. The method according to any one of the preceding claims, wherein the at least one additive is selected from elastic polymers, wax modifiers, or fillers.

4. The method according to claim 2, wherein the filler comprises fumed silica or fumed alumina.

5. The method according to any one of the preceding claims, wherein the composition comprises an asphalt binder, an elastic polymer, and a filler.

6. The method according to any one of the preceding claims, wherein the composition further comprises at least one wax modifier.

7. The method according to any one of the preceding claims, wherein the asphalt binder accounts for 85 to 97 wt.% of the composition.

8. The method according to any one of claims 2-7, wherein the elastic polymer comprises 1 to 6 wt.% of the composition.

9. The method according to any one of claims 2-7, wherein the wax modifier accounts for 1 to 5 wt.% of the composition.

10. The method according to any one of claims 2-4, wherein the total amount of said filler accounts for 1 to 10 wt.% of the composition.

11. The method according to any one of the preceding claims, wherein applying the composition to the wooden sleeper reduces the water permeability of the wooden sleeper.

12. The method according to any one of the preceding claims, wherein the composition is formulated to become substantially non-sticky after being applied to the surface of the wooden sleeper for about 30 minutes.

13. The method of claim 9, wherein the wax modifier comprises amide wax.

14. The method according to any one of claims 2-13, wherein the elastic polymer comprises a styrene-butadiene-styrene compound.

15. The method according to any one of the preceding claims, wherein the composition is applied by spraying.

16. The method of claim 15, wherein the composition is sprayed onto the surface of the wooden sleeper using a spraying system mounted on a mechanically driven mobile device.

17. The method of claim 15, wherein the composition is sprayed onto the surface of the wooden sleeper using a spraying system mounted on a manually driven mobile device.

18. The method according to any one of claims 15-17, wherein the composition is applied from a position above the surface of the railway sleepers using a vehicle or device mounted on the track.

19. The method according to any one of the preceding claims, wherein the composition is applied to the surface of the wooden sleeper at a thickness of about 1 / 8 inch.

20. The method according to any one of the preceding claims, wherein the composition is applied to the wooden sleeper at a temperature of 300℉ to 350℉.

21. The method according to any one of the preceding claims, further comprising applying aggregate to the composition.

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