Integrated ballast mat
A protective coating system for a railway structure having a waterproof membrane and a ballast mat. The waterproof membrane is disposed on the railway structure. The ballast mat further has a ballast protection coating and a sealing layer. The ballast protection coating is a rubber compound and is disposed on the waterproof membrane. The sealing layer is disposed on the ballast protection layer.
1. A protective coating system for a deck of a railway structure having ballast and a railway track structure in combination with the railway structure comprising:
a railway bridge structure;
a waterproof membrane disposed on the railway bridge structure, wherein the waterproof membrane forms a substantially waterproof seal on the deck of the railway structure;
a ballast protection coating adhered to the waterproof membrane, the ballast protection coating including a filler and a resin, wherein the ballast protection coating is formed from a plurality of layers of coating, wherein the ballast protection coating is compressible; and
wherein the ballast protection coating has a thickness selected to protect the waterproof membrane from damage from the ballast caused by operation of trains on the railway track structure and wherein the ballast protection coating has a substantially isosceles triangle cross-sectional profile.
2. The system of claim 1 , wherein the filler is rubber.
3. The coating of claim 1 , wherein the thickness of the waterproof membrane is less than the thickness of the ballast protection coating.
4. The coating of claim 1 , wherein the ballast protection coating has a variable thickness.
5. The coating of claim 1 , wherein the ballast protection coating forms a substantially seamless waterproof coating over the railway structure.
6. The coating of claim 1 , further comprising a primer layer, wherein the primer layer is disposed on the railway bed and the waterproof membrane is disposed on the railway bed.
7. A protective coating system for a railway structure comprising in combination with a railway structure:
a railway structure;
a waterproof membrane disposed on the railway structure; and
a ballast mat further comprising,
a ballast protection coating disposed on the waterproof membrane, wherein the ballast protection coating is composed of, at least in part, a filler compound wherein the ballast protection coating has a substantially isosceles triangle cross-sectional profile; and
a sealing layer sprayed on the ballast protection coating wherein the ballast protection coating has a thickness selected to protect the waterproof membrane from damage from the ballast caused by operation of trains on the railway track structure.
8. The coating of claim 7 , wherein the railway structure is a bridge structure.
9. The coating of claim 7 , wherein the waterproof membrane and the ballast mat substantially cover an upper surface of the bridge structure.
10. The coating of claim 7 , wherein the filler is a rubber compound.
11. The coating of claim 10 , wherein the rubber compound includes styrene-butadiene rubber.
12. The coating of claim 7 , wherein the ballast protection coating has a plurality of layers.
13. The coating of claim 7 , wherein the thickness of the ballast protection coating is greater than the thickness of the waterproof membrane.
14. The coating of claim 7 , wherein the thickness of the ballast protection coating is less between approximately 200 mils and 300 mils.
15. The coating of claim 7 , wherein the thickness of the waterproof membrane is between approximately 60 mils and 120 mils.
16. The coating of claim 7 , wherein the thickness of the sealing layer is between 20 mils and 60 mils.
17. The coating of claim 7 , wherein the ballast protection coating has a variable thickness.
18. The coating of claim 7 , wherein the ballast protection coating is shaped to create a slope relative to the railway structure.
19. The coating of claim 7 , wherein the waterproof membrane and the ballast mat are substantially parallel.
20. The coating of claim 7 , wherein the ballast mat is a substantially uniform thickness.
21. The coating of claim 7 , wherein the ballast mat has dielectric properties.
22. The coating of claim 7 , wherein the ballast mat forms a substantially seamless waterproof coating over the railway structure.
23. A method of coating a deck of a railway structure with a protective coating, the method comprising:
applying a waterproof membrane on the deck of a railway structure, wherein the waterproof membrane is applied by spraying the waterproof membrane on the bridge structure;
applying a ballast protection layer on the waterproof membrane, wherein the ballast protection layer is applied by distributing the ballast protection layer on top of the waterproof membrane and wherein the ballast protection coating has a substantially isosceles triangle cross-sectional profile; and
applying a seal coat on the ballast protection layer; wherein the seal coat is applied by spraying the seal coat on the ballast protection layer wherein the ballast protection coating has a thickness selected to protect the waterproof membrane from damage from the ballast caused by operation of trains on the railway track structure.
24. The method of claim 23 , further comprising applying additional ballast protection layers to form a ballast protection coating having a non-uniform thickness.
25. The method of claim 23 , further comprising applying a primer layer to the deck of the railway structure.
26. The method of claim 23 , wherein the ballast protection layer substantially covers the waterproof membrane.
27. The method of claim 23 , further comprising positioning a ballast material on the ballast protection layer.