Can deformed rail pads be reused?

A rail pad, also called rail rubber plate, is designed between the rail tie plate and foot of the rail, made by an elastic polyurethane mat, which is interposed between steel rails and tie sleepers to protect the sleeper top from wearing and impacting. Its defined stiffness is used to increase the elasticity of the superstructure of the ballast and reduce shock and vibration in the rail system. With such upgraded load distribution, it will lead to greater passenger comfort and less wearing onto the superstructure.

 

Can deformed rail pads be reused?

 

Deformed rail pads generally should not be reused in critical track applications because deformation compromises their ability to provide proper support, insulation, and vibration damping, affecting track stability and safety; For direct track use, if deformed (cracked, hardened, flattened), replacement is key for safety and performance.

 

 

Why Reuse is Risky for Track?

 

 

• Loss of Function: Deformation (flattening, hardening, cracking) reduces the pad's ability to absorb shock, provide electrical insulation, and maintain consistent track support.

 

• Safety Hazard: Degraded pads can lead to increased rail/sleeper stress, noise, and dynamic instability, posing a safety risk.

 

• Performance Impact: In slab tracks, pad stiffness changes affect overall track stiffness and dynamic behavior, so performance is key.

 

What materials are used to manufacture rail pads?

 

Rail pads are made from durable, elastic materials like rubber (natural, EPDM, SBR), polyurethane, and plastics such as HDPE (High-Density Polyethylene) and EVA (Ethylene-Vinyl Acetate), often combined with fibers for reinforced elastomeric pads, all chosen for shock absorption, vibration dampening, electrical insulation, and wear resistance under heavy loads.

 

 

• Rubber: Natural rubber, Styrene-Butadiene Rubber (SBR), and EPDM are popular for their elasticity and resistance to harsh conditions.

 

Rubber Rail Pad
Technical Parameter	Unit	Value
Stiffness	KN	90-130
Hardness Shore A	℃	72-80 degree
Electronic Resistance	Ω	≥ 106
Tensile Strength before Aging	Mpa	≥12.5
Elongation before Aging	%	≥250

 

• Polyurethane (PU): Offers excellent load distribution, durability, and vibration dampening.

 

• Plastics: HDPE and EVA provide good stiffness and durability, often used in blends or as alternatives to rubber.

 

HDPE Rail Pad
Technical Parameter	Unit	Technical Requirement	Value
Density	g/cm3	0.95-0.98	0.95
Tensile Strength	Mpa	≥19	19
Elongation	%	>80	150
Melting Point	℃	170-190	190
Insulation Resistance	Ω	≥1×1010	3.5 ×1010
Hardness	A	≥98	98(A)

 

EVA: Polyethylene 80%, Vinyl Acetate 20%.
Technical Parameter	Unit	Technical Requirement	Value
Density	g/cm3	0.95-0.98	0.95
Tensile Strength	Mpa	≥15	16
Elongation	%	>500	550
Melting Point	℃	170-190	170
Insulation Resistance	Ω	≥1×1010	5.0 ×1010
Hardness	A	≥90	92(A)

 

• Thermoplastic Elastomers (TPE/TPEE): Blend rubber-like flexibility with plastic processability.

 

• Fiber-Reinforced Composites: Combine elastomeric materials with fibers (like 30% fiber content) for enhanced strength and stability.

 

GNEE RAIL equips 130sets machines' rail pad production line, for processing, injection, refining rubber, sulfuration , moulding and inspection etc.Our EVA/HDPE/rubber rail pads are with high elasticity, applying to types for rails such as rail UIC54, UIC60, BS80lbs,BS100lbs, and sizes as ordered. The pads can be customized with or without grooves, in various possible designs, depending on customers' requirements.

 

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