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The rapid-hardening method employing the injection of calcium sulfoaluminate (CSA) cement mortar into voids between preplaced ballast aggregates has recently emerged as a promising approach for the renovation of existing ballasted railway tracks to concrete tracks. This method typically involves the use of a redispersible polymer powder to enhance the durability of the resulting recycled aggregate concrete. However, the effects of the amount of polymer on the mechanical and durability properties of recycled ballast aggregate concrete were not clearly understood. In addition, the effects of the cleanness condition of ballast aggregates were never examined. This study aimed at investigating these two aspects through compression and flexure tests, shrinkage tests, freezing–thawing resistance tests, and optical microscopy. The results revealed that an increase in the amount of polymer generally decreased the compressive strength at the curing age of 28 days. However, the use of a higher polymer ratio enhanced the modulus of rupture, freezing–thawing resistance, and shrinkage resistance, likely because it improved the microstructure of the interfacial transition zones between recycled ballast aggregates and injected mortar. In addition, a higher cleanness level of ballast aggregates generally improved the mechanical and durability qualities of concrete.

Effects of Redispersible Polymer Powder on Mechanical and Durability Properties of Preplaced Aggregate Concrete with Recycled Railway Ballast