Composite Railroad Tie Production Facility

CLIENT: TieTek (Purchased by another company)

Location: Marshall, Texas

Fee: $2 Million 

Project Schedule: 1 Year

PSE provided turnkey services for a new composite railroad tie production facility in Marshall, Texas.  The process was the first of its kind, using an automated machine to manufacture polymer railroad ties in a continuous process, producing 20 ties per hour. This exciting project included structural, electrical, mechanical and civil elements.   

The composite railroad crosstie manufacturing facility was designed to produce synthetic composite ties with nearly identical physical and mechanical properties and characteristics as conventional treated timber ties. This included: size, weight, texture, appearance, and constructability. The synthetic ties needed to accept standard rail mounting methods and hardwares including rail spikes and screws.The ties were made from recycled materials, mostly rubber tires, and common mineral components. PSE provided engineering for pneumatic conveyors, mixers, an extruder, tie molds, cooling baths, automated cranes, a cooling conveyor, a tie rotator, and stacker.

Not only did PSE engineer, design and oversee fabrication and installation of the actual tie manufacturing machine, every element in the facility was also designed and engineered by PSE, including the mold filling system, cooling system, transport systems, and process controls. The complex molding system included interconnection piping, system valving, hoists, molds, and pressure cylinders.  The cooling system consisted of three cooling pools that maximized heat transfer from the hot molds, maintaining temperature and level with temperature elements and level instrumentation.  Air cooling was provided by a conveyor, two tie-rotating arms, and a storage unit at the end of the conveyor.

During construction, PSE supervised the installation and commissioning of the entire facility and even oversaw the initial operation. All equipment and fabricated items were trial assembled and rotated as needed prior to shipping.