Method of applying a weather proofing asphalt membrane composition to a wooden railroad tie

Abstract

A method of applying a weather-proofing asphalt membrane composition to a wooden railroad tie having cracks and... or air voids on its surface, the method comprising: applying the composition onto the

Description

[0001] 0 0ETHOD OF APPLYING A WEATHER-PROOFING ASPHALT MEMBRANE COMPOSITION TO A WOODEN RAILROAD TIE

[0002] Cross Reference to Related Applications

[0003] 5 This application claims the benefit of US Provisional Application No. 63 / 508,004 filed June 14, 2023, which is hereby incorporated herein by reference in its entirety. This application claims the benefit of US Provisional Application No. 63 / 508,006 filed June 14, 2023, which is hereby incorporated herein by reference in its entirety.

[0004] 10 Background

[0005] Railroad ties are mainly made from wood, usually hardwoods, such as oak. These wooden railroad ties have long been treated with materials such as creosote, copper naphthenate, and or boric acid to give the wood a resistance to decay. The primary mode of action for delaying decay is by the fungicidal and insecticidal nature of the treatments. These treatments protect 15 the wood only as deep as the agent can penetrate into the wood during treatment. The treatments are not intended to waterproof the wood, but to delay biological degradation. If the exterior surface of the tie is subject to splitting or cracking, spores and / or insects can enter the wood and begin degradat ion of the tie, thereby reducing the functional lifespan of the railroad tie.

[0006] 20 Checking, splitting, and / or cracking of wooden railroad ties in service are a function of the weathering of the wood components present in the tie. Ties are subject to exposure to moisture, ultraviolet radiation, and hot and cold temperatures, which all have an effect on the structural stability of the wood. For example, UV radiation leads to the degradation of lignin within the wood, which leads to loss of material and the eventual initiation of micro-cracking in the 25 exterior surface of the tie. T hese micro-cracks can then expand and propagate into the wood structure, giving rise to sites available for decay or insecticidal infestation to begin. Once cracks form they allow more water and air to penetrate into the underlying layers of the tie, causing more damage to the tie structure. This accelerates the mechanical and biological decay processes and leads to eventual structural failure if left untreated.

[0007] 30 Therefore, there remains a need for a treatment system for rai Iroad ties that protects the wooden ties from exposure to moisture, UV7radiations, and the effects of hot and cold temperatures. Summary of the Invention

[0008] In certain aspects, methods of applying a weather-proofing asphalt membrane composi tion to a wooden railroad tie are disclosed. In certain embodiments, the weather-proofing asphalt membrane generally comprises a mixture of asphaltic binder and at least one additive. In some 5 embodiments, the additive comprises at least one of? an elastomeric polymer or a thickener. In one embodiment, the weather-proofing asphalt membrane composition is sprayed, as a hot liquid, onto the surface of the wooden railroad tie. The asphalt membrane composition then cools and adheres to the surface of the tie. Once applied, the asphalt membrane composition protects the wooden railroad tie from exposure to moisture, IJV radiation, and the effects of? 10 extreme temperatures. Further, the application of the asphalt membrane composition reduces the water permeability of the tie by penetrating at least one crack or void within the tie. Thus, the usable lifespan of the wooden railroad tie is prolonged.

[0009] In another embodiment, the weather-proofing asphalt membrane composition is poured into a mold shaped to the dimensions of the wooden railroad tie. Once cooled, the asphalt membrane 15 composition comprises a preformed pad of the asphalt membrane composition. In another embodiment, the pad may be formed by extruding the asphalt membrane composition to the width and thickness to cover the surface of? a railroad tie. The extrusions may be cut to the length of? a tie. The preformed pad can then be adhered to the surface of a railroad tie by either heating the underside of the preformed pad or heating the surface of the tie. As the preformed 20 pad and / or tie cool, the preformed pad will adhere to the surface of? the tie.

[0010] In some embodiments, the weather-proofing asphalt membrane composition is imbedded with an aggregate. The aggregate is configured to provide increased friction on the surface of the asphalt membrane band. Further, the aggregate provides additional UV protection io the railroad tie. In further embodiments, the aggregate is added to the weather-proofing asphalt 25 membrane composition before the composition cools.

[0011] The weather-proofing asphalt membrane is configured to be applied to wooden railroad ties regardless of their treatment status. For example, the asphalt membrane may be applied to an untreated railroad tie or to a railroad tie that has already been treated with common treatment chemicals including, for example, boric acid, sodium borate, creosote, copper naphthenate, or 30 Diehl oro-octyl-isothiazoli none or combinations of such treatment chemicals. Brief Description of the Drawings

[0012] FIG. 1 is a digital image of a preformed, pad according to one embodiment of the present invention.

[0013] FIG. 2 is a digital image of a preformed pad according to another embodiment of the present invention.

[0014] Detailed Description of the Invention

[0015] For the purposes of promot ing an understanding of the principles of the invention, reference will now be made to certain embodiments and specific language wifi be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is 5 thereby intended, such alterations and further modifications, and such further applications of the principles of the invention as described herein being contemplated as would normally occur to one skilled in the art to which the invention relates. Additionally, in the detailed description below, numerous alternatives are given for various features. It will be understood that each such disclosed alternative, or combinations of such alternatives, can be combined with the more 10 generalized features discussed in the Summary above, or set forth in the embodiments described below to provide additional disclosed embodiments herein.

[0016] The weather-proofing asphalt membrane compositions are configured to both fill and seal checks, cracks, and splits (micro and macro, and other surface imperfections) already present in wooden railroad ties and to provide a protective layer to the outer surface of the railroad fie. 15 The asphalt membrane compositions are formulated to protect the wooden railroad ties from exposure to moisture, UV radiation, and the effects of low and high temperatures, and the like. This is accomplished by covering the surface of the railroad tie in a sufficient thickness of weather-proofing asphalt membrane composition such that a flexible, protective layer of composition adheres to the outer surface of the tie. At the same time, the compositions are 20 formulated to be resistant to lateral flow, which allows the compositions to remain on the surface of the railroad tie. As such, the usable lifespan of wooden railroad ties is effectively increased. Methods of applying said weather-proofing asphalt membrane composition are disclosed herein.

[0017] The weather-proofing asphalt membrane is configured to be applied to wooden railroad ties 25 regardless of their treatment status. For example, the asphalt membrane may be applied to an untreated railroad tie or to a railroad tie that has already been treated with common treatment chemicals including, for example, boric acid, sodium borate, creosote, copper naphthenate, or Dichloro-octyl-isothiazolinone or combinations of such treatment chemicals.

[0018] Weather-proofing asphalt membrane compositions generally comprise a mixture of an asphalt 30 binder and at least one additive. In certain embodiments, the additive can be selected from one or more elastomeric polymers and thickeners. In some embodiments, the composition comprises an asphalt binder, at least one elastomeric polymer, and a thickener. In some embodiments, the thickener comprises a wax modifier. Yet, other compositions may comprise an asphalt binder, elastomeric polymers, a thickener, and a filler such as fumed silica and / or fumed alumina. Further compositions may include an asphalt binder, elastomeric polymers, a thickener, a wax modifier and a saponified fatty acid and resin acid gelling compound. Still further, compositions may comprise an asphalt binder, elastomeric polymers, a thickener, 5 finned silica and or fumed alumina and a saponified fatty acid and resin aeid gelling compound.

[0019] In some embodiments, the asphalt binder is the primary component of the composition and provides the material strength or foundation to cover and weather-proof the railroad tie. The asphalt binder may comprise 85 to 97 wt. % of the composition and in some embodiments 90 to 93 wt. % of the composition. Suitable asphalt binders include paving grade asphalts 10 including: performance graded, viscosity graded, and / or penetration graded.

[0020] The asphalt membrane compositions may include an elastomeric polymer component. The elastomeric polymer component allows the weather-proof asphalt membrane to expand and contract elastically. This allows the band of asphalt membrane composition to move in conjunction with movement of the railroad tie (e.g., due to expansion and contraction of the 15 wood as a result of changing temperatures and moisture content in the wood). The polymer component creates a polymer modified asphalt binder in combination with the asphalt binder component. Suitable examples of this polymer component include Styrene-Butadene-Styrene (SBS), Styrene-Butadene Rubber (SBR), Ethylene-Styrene-lnteipolymers (ESI), Evaloy (an ethylene terpolymer available from Dupont), and other elastomeric polymers that are used in 20 polymer modified asphalt compositions. This polymer component may comprise 1. to 6 wt. % of the composition and more preferably 2 to 5 wt. % of the composition.

[0021] The asphalt membrane may include a thickener such as a wax modifier. The wax modifier may reduce the viscosity of the composition at the application temperature so that during application the composition may migrate into the wooden tie, thus filling and sealing cracks, checks, and 25 splits (and other surface imperfections) and reducing water permeability. Furthermore, at ambient temperature, the wax modifier provides stiffness to the weather-proofing asphalt membrane which reduces issues with tackiness. Suitable wax modifiers include, but are not limited to, waxes of vegetable (for example, but not limited to, carnauba wax), animal (for example, but not limited to beeswax) mineral (for example, but not limited to, Montan™ wax 30 from coal, and / or Fischer Tropseh wax from coal) or petroleum (for example, but not limited to, paraffin wax, polyethylene w ax, and / or Fischer-Tropsch wax from gas) origin, including oxidized waxes; amide waxes (for example, but not limited to, ethylene bis stearamide, stearyl amide, stearylstearamide); and / or fatty acids and soaps of waxy nature (for example, but not limited to, aluminum stearate, calcium stearate, fatty acids). The wax modifier may also improve cohesion properties of the composition. In certain embodiments, the wax modifier may comprise 1 to 5 wt. % of the composition and more preferably 2 to 4 wt. % of the composition,

[0022] 5 Fumed silica and; or fumed alumina may function as fillers and may impart resistance to lateral flow immediately after application and give a non-tacky character to the composition that prevents pick-up before an aggregate has been applied. The 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) may comprise 1 to 10 wt. % of the composition and more 10 preferably 1 to 4 wt. % of the weather-proofing asphalt membrane composition.

[0023] In some embodiments, the weather-proofing asphalt membrane composition may further include a saponified fatty acid and resin acid gelling compound. The saponified fatty acid and resin acid gelling compound may function to control the rate at which the composition sets or cures. Suitable saponified fatty and resin acid gelling compounds include but are not limited to 15 crude tall or distilled tall oil. The total amount of saponified fatty acid and resin acid gelling compound may comprise 0 to 3 wt. % of the composition and more preferably 1 to 2 wt. % of the composition.

[0024] An exemplary formulation of the weather-proofing asphalt membrane composition may be made by adding the elastomeric polymer component to the heated asphalt binder while shearing 20 the mixture. After or before the polymer component and asphalt binder are thoroughly mixed, the wax modifier may be added while shearing the mixture followed by the addition of the fumed silica and / or fumed alumina and saponified fatty acid and resin acid gelling compound. In certain embodiments, the inventors have surprisingly discovered that when the final composition includes the filler of fumed silica and / or fumed alumina, the resulting composition 25 demonstrated improved heat stability. Furthermore, in certain embodiments, the polymeric properties imparted to the composition remained more consistent over time while at an elevated temperature as compared to a similar composition that did not include fumed silica and or fumed alumina.

[0025] The weather-proofing asphalt membrane composition may be applied to wooden railroad ties 30 in several suitable ways. The methods disclosed apply the weather-proofing asphalt membrane composition to the top surface of the wooden railroad tie. Importantly, the asphalt membrane composition, regardless of the methods of application, can be applied to the tie regardless of location. Specifically, the asphalt membrane composition can be applied to the tie at a treatment facility, in the field prior to installation of the tie on the railroad, or in the field after installation of the tie on the railroad, including old ties previously installed.

[0026] In some embodiments, the weather-proofing asphalt membrane composition, regardless of method of application, has a thickness of approximately 1 / 8 of an inch after application to the 5 tie. At this thickness, any movement of the tie during its lifetime (e.g., from contraction / expansion and / or movement of the railroad) or any crack openings in the wood would not rupture the weather-proofing asphalt membrane. Further, this thickness includes a sufficient amount of asphalt membrane composition to hold an aggregate cover.

[0027] In some embodiments, an aggregate cover, also called an aggregate, is added to the weather- 10 proofing asphalt membrane composition. The aggregate functions as a slip-resistant aid to ensure that the railroad ties treated with the asphalt membrane composition are not slippery or hazardous to walk on. The aggregate further functions as a physical barrier for the asphalt membrane composition and the underlying railroad tie, protecting both from exposure to sunlight and UV radiation. Further, the aggregate functions to resist fire from hot metal sparks 15 or hot embers generated from rail grinding operations.

[0028] Suitable aggregate incudes, but is not limited to, natural materials (e.g., unwashed and washed sand, gravel, crushed stone), recycled construction materials (e.g., recycled asphalt pavement, recycled asphalt shingles, or recycled crushed concrete), and / or post-industrial waste materials (e.g., boiler slag, steel slag, shredded polyvinyl chloride granules or crushed solar panels). In 20 some embodiments, the aggregate should be sized to a gradation between 1 16 to 1 / 8 of an inch in maximum width. In other embodiments, other sizes of gradation may be used, as should be appreciated by one of skill in the art. Additionally, the size of the gradation should be used to determine the thickness of aggregate to apply to the weather-proofing asphalt membrane. In one embodiment, the weather-proofing asphalt membrane is covered in aggregate at a thickness 25 equal to the nominal width of the aggregate (i.e., the nominal size of gradation). In another embodiment, other thicknesses of aggregate may be applied to the asphalt membrane.

[0029] In one method, the weather-proofing asphalt membrane composition is sprayed onto the surface of the wooden railroad tie as a hot liquid. This may be accomplished by heating the asphalt membrane composition to temperatures between about 300 to about 350 °F. In one 30 embodiment, a spraying system is mounted to either manually driven or mechanically driven mobile equipment, such as a rail-mounted vehicle or device that applies the composition from a position above the railroad tie. In other embodiments, the asphalt membrane composition is sprayed onto the tie using a handheld spraying device, such as a wand. In some embodiments. the composition is sprayed on the tie until an approximately 1 '8 of? an inch-thick band of? composition is applied to the tie. Additionally, in some embodiments, spraying should be uniform and performed carefully, to ensure the composition does not flow or drain down from the surface of the tie. During application, the composition fills and seals at least some of the 5 cracks, checks, and / or splits present in the tie. As the composition cools, it adheres to the tie thus forming a flexible, protective layer as it fills cracks, checks, and / or splits present in the tie.

[0030] In some embodiments, an aggregate cover is applied to the sprayed asphalt membrane composition before it cools. Specifically, in some embodiments, the fine, dry aggregate is 10 placed in the weather-proofing asphalt composition while the composition is still at least 250 °F. In other embodiments, the aggregate is added to the composition after the composition has cooled and adhered to the tie. Here, the aggregate is heated to at least 200 °F and placed on the surface of? the cooled band of asphalt membrane composition. The heat allows the aggregate to partially liquify the outer surface of the composition and then, as the composition re-cools, the 15 aggregate is imbedded into the band. The aggregate cover can be applied using a drop spreader or a chip spreader. Further, the application rate of? the aggregate is between 2.5 to 5.5 Ibs. / square yard for typical natural aggregates. The rates may be higher or lower for lightweight aggregates or heavier aggregates, such as a slag.

[0031] In another method, the weather-proofing asphalt membrane composition is formed into 20 preformed pad 1.0, as shown in FIG. 1 . The preformed pad 10 is then placed on and adhered to the surface of the railroad tie. Specifically, hot, liquid asphalt membrane composition is poured into a mold 15. As the composition is poured, the composition takes the shape of the mold 15. As the composition cools, the preformed pad 10 is formed. Further, the mold 15 is dimensioned such that the size of the preformed pad 10 is suitable to cover the surface of the railroad tie. 25 Then, the preformed pad 10 is applied to the rai lroad tie. This is accomplished by heating either the underside of the preformed pad 10, the surface of the railroad tie, or both, using an external heat source. Once one or both surfaces are hot, the preformed pad 10 is placed on the surface of the tie and allowed to cool, which adheres the preformed pad 10 to the tie and allows some composition to fill and seal any surface imperfections present in the tie.

[0032] 30 Similar to the spray method, the preformed pad 10 may be imbedded with a layer of aggregate 20, as show n in FIG. 2. In some embodiments, the aggregate 20 is placed on the hot asphalt membrane composition before the composition cools in the mold 15. In other embodiments, the aggregate 20 is heated and then placed onto the cooled preformed pad 10. In yet another method, the composition may be extruded to the width and thickness for the application and then cut to the length needed to cover a tie. Similar to the spray or mold method, aggregate may be placed on the extruded composition, either while the composition is hot or heat the aggregate and place on the cooled extruded pad.

[0033] 5 In some embodiments, the aggregate may be pressed or rolled into the composition, which imbeds 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.

[0034] Regardless of the application method, the composition is formulated to be substantially tack- free approximately thirty (30) minutes after application of the weather-proofing asphalt 10 membrane composition to the surface of the wooden railroad tie. Said differently, a person could walk on the treated surface of the railroad tie after 30 minutes and the composition would not stick to the sole of the person’s shoes.

[0035] In certain embodiments, the preformed pad may be reinforced with a substrate material, such as a fabric, textile, or polymeric substrate. In certain embodiments, the fabrics may be 15 geotextiles or geogrid. The geotextiles may be comprised of linen, polyester, polypropylene or fiberglass or a composite of more than one fiber. The fibers may be woven or nonwoven. The fabric may be lightweight or medium weight. In certain embodiments, the fabric is a nonwoven fiberglass or a composite with a predominant fiberglass composition. In certain embodiments, the nonwoven fiberglass would have an opening size that allows the composition to penetrate 20 the fabric. The nonwoven fiberglass fabric is coated w ith 0.5 gallon per square yard to 1.5 gallon per square yard of the composition, such as about 0.7 to 1.0 gallon per square yard of the composition. The preformed composite pad may be imbedded with aggregate on one side of the reinforced pad. In some embodiments, the aggregate may be placed on the hot composition before the composition cools. In other embodiments, the aggregate is heated and 25 then placed on the cooled composite pad. The other side of the preformed pad may be dusted with fumed silica to allow the pads to be handled without sticking to each other. The composite preformed pad may be applied to the railroad tie by heating the fumed silica side of the composite pad and placing on the tie. In another embodiment, the railroad tie may be heated and fumed silica treated side of the composite preformed pad placed on the tie.

[0036] 30 The uses of the terms “a” and “an" and “the” and similar references in the context of the disclosure (especially in the context of the following claims) are to be construed to cover both the singular and the plural unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and ail examples, or exemplary language (e,g., ‘‘such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any nonclaimed element as essential to the practice of the invention.

[0037] While the invention has been described in detail in the foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that all changes and modifications that come within the spirit of the invention are desired to be protected. In addition, all references cited herein are indicative of the level of skill in the art and are hereby incorporated by reference in their entirety.

[0038] Embodiments

[0039] The following provides an enumerated listing of some of the embodiments disclosed herein. It will be understood that this listing is non-limiting, and that individual features or combinations of features (e.g, 2, 3, or 4 features) as described in the Detailed Description above can be incoiporated with the below-listed Embodiments to provide additional disclosed embodiments herein.

[0040] 1. A method of applying a weather-proofing asphalt membrane composition to a wooden railroad tie having cracks and / or air voids on its surface, the method comprising: spraying a weather-proofing asphalt membrane composition onto the surface of the wooden railroad tie, wherein application of the composition penetrates at least some of the cracks and / or air voids that exist on the surface; and allowing the composition to cool, wherein the composition comprises an asphalt binder and at least one additive.

[0041] The method of embodiment 1. wherein the at least one additive is selected from an elastomeric polymer, a wax modifier, or a filler,

[0042] 3. The method of embodiment 2, wherein the filler comprises fumed silica or turned alumina,

[0043] 4. The method of embodiment 1 , wherein the composition comprises an asphalt binder, an elastomeric polymer, and a filler. 5. The method of embodiment 4, wherein the composition further comprises at least one wax modifier.

[0044] 6. The method of any one of embodiments 1 -5, wherein the asphalt binder comprises 85 to 97 wt. % of the composition,

[0045] 5 7, The method of any one of embodiments 2-6, wherein the elastomeric polymer comprises 1 to 6 wt. % of the composition.

[0046] 8. The method of any one of embodiments 2-7, wherein the wax modifier comprises 1 to 5 wt. % of the composition,

[0047] 9. The method of any one of embodiments 2-4, wherein the filler comprises I to 10 total

[0048] 19 wt. % of the composition.

[0049] 10. The method of any one of embodiments 1 -9, wherein application of the composition to the wooden tie reduces the water permeability of the wooden tie.

[0050] 11. The method of embodiment I , wherein the composition is formulated to become substantially tack-free about 30 minutes after being applied to the surface of the wooden tie.

[0051] 15 12. The method of embodiment 8, wherein the wax modifier comprises an amide wax.

[0052] 13. The method of any one of embodiments 2-12, wherein the elastomeric polymer comprises a styrene-butadiene-styrene compound.

[0053] 14. The method of any one of embodiments 1-13, wherein the composition is sprayed onto the surface of the wooden tie using a handheld sprayer,

[0054] ?.o 15. The method of any one of embodiments 1-13, wherein the composition is sprayed onto the surface of the wooden tie using a spraying system mounted to mechanically driven mobile equipment,

[0055] 16. The method of any one of embodiments 1-13, wherein the composition is sprayed onto the surface of the wooden tie using a spraying system mounted to a manually driven mobile

[0056] 25 equipment.

[0057] 17. The method of any one of embodiments 14-16, wherein the composition is applied using a rail-mounted vehicle or device from a position above the surface of the railroad tie.

[0058] 18. The method of any one of embodiments 1-17, wherein the composition is sprayed onto the surface of the wooden tie at a thickness of approximately 1 / 8 of an inch. so 19. The method of any one of embodiments 1-18, wherein the composition does not (low or drain down from the surface of the wooden tie.

[0059] 20. The method of any one of embodiments 1-19, wherein the composition is applied to the wooden tie at a temperature between 300 °F and 350 °F. 1 01 . The method of any one of embodiments 1 -20, the method further comprising applying aggregate to the composition.

[0060] 22. The method of embodiment 21, wherein the aggregate is applied to the composition at a rate between 2,5 to 5,5 Ibs. / square yard,

[0061] 5 23, The method of embodiment 21 , wherein the aggregate is applied to the composition while the composition has a temperature greater than 250 "F.

[0062] 24. The method of embodiment 21, wherein the aggregate is applied to the composition after the composition has cooled.

[0063] 25. The method of embod imen t 24, v. herein the aggregate is heated to at least 200 / F before 10 being applied to the composition.

[0064] 26. A method of applying a weather-proofing asphalt membrane composition to a wooden railroad tie having a surface, wherein the surface of the railroad tie has cracks and / or air voids, the method comprising: selecting a preformed pad comprising a surface and an underside; 15 heating either the surface of the wooden tie or the underside of the preformed pad, and. applying the preformed pad to the surface of the wooden railroad tie, wherein application of the preformed pad to the surface of the wooden tie fills and / or seals at least some of the cracks and / or air voids that exist in the surface of the tie; wherein the composition comprises an asphalt binder and at least one additive.

[0065] 20 27, The method of embodiment 26, wherein the at least one additive is selected from an elastomeric polymer, a wax modifier, and a filler.

[0066] 28. The method of embodiment 27, wherein the filler comprises filmed silica or finned alumina.

[0067] 29. The method of embodiment 26, wherein the composition comprises an asphalt binder, 25 an elastomeric polymer, and a filler.

[0068] 30. The method of embodiment 29, wherein the composition further comprises at least one wax modifier,,

[0069] 31. The method of any one of embodiments 26-30, wherein the asphalt binder comprises 85 to 97 wt. % of the composition.

[0070] 30 32, The method of any one of embodiments 27-31, wherein the elastomeric polymer comprises 1. to 6 wt, % of the composition,

[0071] 33. The method of any one of embodiments 2-7, wherein the wax modifier comprises 1 to 5 wt. % of the composition. 34. The method of any one of embodiments 2-4, wherein the filler comprises I to 10 total wt. % of the composition,

[0072] 35. The method of embodiment 26, wherein application of the composition to the wooden tie reduces the water permeability of the wooden tie.

[0073] 5 36. The method of embodiment 26, wherein the composition is formulated to become substantially tack- free about 30 minutes after being applied to the surface of the wooden tie.

[0074] 37. The method of embodiment 30, wherein the wax modifier comprises an amide wax.

[0075] 38, The method of embodiment 29, wherein the elastomeric polymer comprises a styrene- butadiene-styrene compound, 1 0 39. The method of embodiment 26, wherein the mold has dimensions such that the preformed pad is the same size as the surface of the wooden railroad tie,

[0076] 40. The method of embodiment 26, wherein the surface of the railroad tie is covered by one or more preformed pads,

[0077] 41 . The method of embodiment 26, wherein the preformed pad is applied to a wooden 15 railroad tie already installed on a railroad,

[0078] 42. The method of embodiment 26, wherein the preformed pad is applied to a wooden railroad tie before installation on a railroad.

[0079] 43. The method of embodiment 26, wherein the preformed pad has a thickness of approximately 3 16 of an inch.

[0080] 20 44. The method of embodiment 26, the method further comprising applying aggregate to the composition,

[0081] 45. The method of embodiment 44, wherein the aggregate is applied to the composition at a rate between 1.5 to 3 lbs. square yard.

[0082] 46. The method of embodiment 44, wherein the aggregate is applied to the composition 25 while the composition is still hot in the mold.

[0083] 47. The method of embodiment 44, wherein the aggregate is applied to the composition after the composition has cooled to form the preformed pad.

[0084] 48. The method of embodiment 47, wherein the aggregate is heated to at least 200 °F before being applied to the preformed pad.

[0085] 30 49, The method of any one of embodiments 26-48, wherein the preformed pad further comprises a substrate material, wherein the substrate material is selected from w’oven fabric or polymeric materials.

[0086] 50. A weather-proofing asphalt membrane composition, comprising: s an asphalt binder; an elastomeric polymer; a wax modifier; a filler selected from filmed silica and / or fumed alumina,

[0087] 5 wherein the composition is formulated to include 85 to 97 wt. % of the asphalt binder;

[0088] 1 to 6 wt. % of the elastomeric polymer;

[0089] 1 to 5 wt, % of the wax modifier;

[0090] 1 to 10 total wt, % of the filler selected from fumed silica and / or fumed alumina; and wherein the composition is applied to a surface of a wooden railroad tie. 10 5 1 The asphalt composition of embodiment 50, wherei n application of the composition to the wooden railroad tie reduces water permeability into the wooden railroad tie,

[0091] 52, The asphalt composition of embodiment 50, wherein the asphalt composition is formulated to become substantially tack-free to pick-up by walking about 30 minutes after being applied to the surface of the railroad tie,

[0092] 15 53, The asphalt composition of embodiment 50, wherein the asphalt composition is a sprayable composition,

[0093] 54. The asphalt composition of embodiment 50, wherein the wax modifier comprises an amide wax.

[0094] 55. The asphalt composition of embodiment 50, wherein the elastomer polymer comprises ?,o a styrene-butadiene-styrene compound,

[0095] 56. The asphalt composition of embodiment 50, wherein the asphalt composition is formulated to adhere to the surface of the wooden railroad tie and fill in surface imperfections.

[0096] 57. The asphalt composition of embodiment 50, wherein the filler comprises fumed silica.

[0097] 58. The asphalt composition of embodiment 57, wherein the asphalt composition is 25 formulated to adhere to the surface of the wooden railroad tie and fill in surface imperfections,

[0098] 59. The asphalt composition of embodiment 57, wherein application of the composition to the wooden railroad tie reduces water permeability into the wooden railroad tie.

[0099] 60. The asphalt composition of embodiment 57, wherein the asphalt composition is formulated to become substantially tack-free to pick-up by walking about 30 minutes after

[0100] 30 being applied to the surface of the railroad tie,

[0101] 61. The asphalt composition of embodiment 57, wherein the asphalt composition is a spray able compositi on , 62. The asphalt composition of embodiment 57, wherein the wax modifier comprises an amide wax.

[0102] 63. The asphalt composition of embodiment 57, wherein the elastomer polymer comprises a styrene-buladiene-styrene compound.

[0103] 5 64. The asphalt composition of embodiment 50, wherein the filler comprises fumed alumina.

[0104] 65. The asphalt composition of embodiment 64, wherein the asphalt composition is formulated to adhere to the surface of the wooden railroad tie and fill in surface imperfections.

[0105] 66. The asphalt composition of embodiment 64, wherein application of the composition to m the wooden railroad tie reduces water permeability into the wooden railroad tie.

[0106] 67. The asphalt composition of embodiment 64, wherein the asphalt composition is formulated to become substantially tack-free to pick-up by walking about 30 minutes after being applied to the surface of the railroad tie.

[0107] 68. The asphalt composition of embodiment 64, wherein the asphalt composition is a 15 spray able composition.

[0108] 69. The asphalt composition of embodiment 64, wherein the wax modifier comprises an amide wax.

[0109] 70. The asphalt composition of embodiment 64, wherein the elastomer polymer comprises a styrene-buladiene-styrene compound.

[0110] 20 71. The asphalt composition of embodiment 50, wherein application of the composition to the wooden railroad tie protects the railroad tie from UV radiation, moisture, and extreme temperatures.

[0111] 72. The asphalt composition of embodiment 50, wherein after curing of the composition io the wooden railroad tie, the composition is sufficiently flexible to move with the movement of

[0112] 25 the railroad tie.

[0113] 73. The asphalt composition of embodiment 50, wherein after application of the composition to the wooden railroad tie, aggregate is applied to the composition.

[0114] 74. The asphalt composition of embodiment 73, wherein the aggregate aids in friction and I V protection.

[0115] 30 75. The asphalt composition of embodiment 73, wherein after application of the aggregate to the composition, the aggregate is further Imbedded into the composition.

[0116] 76. The asphalt composition of embodiment 73, wherein the aggregate is imbedded into the composition using a weighted roller. 77. The asphalt composition of embodiment 75, wherein the aggregate is imbedded into the composition using a tamper.

[0117] 78. The asphalt composition of embodiment 73, wherein the aggregate comprises natural materials, recycled construction materials, and / or post-industrial waste materials.

[0118] 5 79. The asphalt composition of embodiment 78, wherein the aggregate is sized to a gradation between 1 / 8 to 5 / 16 of an inch in maximum width.

[0119] 80. The asphalt composition of embodiment 79, wherein the aggregate is applied to the composition in a thickness approximately equal to the size of gradation of the width of the aggregate.

[0120] 10 81. The asphalt composition of embodiment 50, wherein the composition is applied to the wooden railroad tie in a band.

[0121] 82. The asphalt composition of embodiment 81, wherein the band of composition applied to the wooden railroad tie is approximately 8 to 10 inches wide.

[0122] 83. The asphalt composition of embodiment 50, wherein the composition further includes 15 a saponified fatty acid and resin acid gelling compound.

[0123] 84. The asphalt composition of embodiment 83, wherein the composition includes 0 to 3 wt. % of the saponified fatty acid and resin acid gelling compound.

[0124] 85. The method of any one of claims 26-49, further comprising producing the preformed pad comprising:

[0125] 20 heating the asphalt membrane composition to form a heated liquid composition; pouring the heated composition into a mold, wherein the composition takes the shape of the mold; and allowing the composition to cool, wherein cooling of the composition forms the preformed pad.

Claims

Claims1 . A method of applying a wea ther-proofing asphalt membrane composi tion to a wooden railroad tie having cracks and. or air voids on its surface, the method comprising: applying the composition onto the surface of the wooden railroad tie, wherein 5 application of the composition penetrates at least some of the cracks and / or air voids that exist on the surface, and allowing the composition to cool; wherein the composition comprises an asphalt binder and at least one additive.

2. The method of claim 1 , further comprising mixing and heating the composition prior 10 to applying it to the surface of the wooden railroad tie.

3. The method of any one of the preceding claims, wherein the at least one additive is selected from an elastomeric polymer, a wax modifier, or a filler.

4. The method of claim 2, wherein the filler comprises fumed silica or fumed alumina,1 5 5. The method of any one of the preceding claims, wherein the composition comprises an asphalt binder, an elastomeric polymer, and a filler,6. The method any one of the preceding claims, wherein the composition further comprises at least one wax modifier,7. The method of any one of the preceding claims, wherein the asphalt binder comprises20 85 to 97 wt. % of the composition.

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

9. The method of any one of claims 2-7, wherein the wax modifier comprises 1 to 5 wt. % of the composition.25 10. The method of any one of claims 2-4, wherein the filler comprises 1 to 10 total wt. % of the composition,1 1 . The method of any one of the preceding claims, wherein application of the composition to the wooden tie reduces the water permeability of t he wooden tie.

12. The method of any one of the preceding claims, wherein the composition is formulated 30 to become substantially tack-free about 30 minutes after being applied to the surface of the wooden tie.

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

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

15. The method of 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 tie using a spraying system mounted to mechanically driven mobile equipment, 17. The method of claim 15, w herein the composition is sprayed onto the surface of the wooden tie using a spraying system mounted to a manually driven mobile equipment.

18. The method of any one of claims 15-17, wherein the composition is applied using a rail-mounted vehicle or device from a position above the surface of the railroad tie.

19. The method of any one of the preceding claims, wherein the composition is applied onto the surface of the wooden tie at a thickness of approximately 1 / 8 of an inch.

20. The method of any one the preceding clai ms, wherein the composition is applied to the wooden tie at a temperature between 300 °F and 350 / F.

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

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