Rail
Composite Ballast Boards
A durable GRP retaining system engineered by CCS as a safer, lighter and longer-lasting replacement for traditional concrete ballast boards.
Overview
Composite ballast boards offer a lighter, easier-to-handle alternative to traditional concrete while providing the strength needed to retain ballast and protect trackside assets. Each board weighs approximately 12.5 kg, significantly less than concrete equivalents – helping reduce manual-handling demands and allowing faster installation on site. The tongue-and-groove design ensures that once stacked, the boards act together as a continuous retaining wall.
The boards are manufactured from pultruded GRP using UV-inhibited polyester resins and glass-fibre reinforcement, protected by a tough surface veil to improve weathering performance. They maintain their structural properties in temperatures from –40°C to +80°C. Because they contain no steel, the boards can be cut cleanly to length on site without exposing reinforcement that might corrode.
Composite ballast boards are used on embankments, around drainage assets, at the base of slopes and in locations where concrete boards would be difficult to transport or install. Their low weight means far more boards can be delivered per load, reducing vehicle movements and associated emissions. With a service life of more than 50 years, they provide a durable, low-maintenance solution for retaining ballast on challenging routes.
Key features
- Approximately 12.5 kg per board, significantly lighter than concrete alternatives
- Interlocking tongue-and-groove design forms a continuous retaining wall
- Pultruded GRP construction with UV protection and corrosion-resistant reinforcement
- Performs consistently from –40°C to +80°C
- Easy to cut to length on site without exposing metal
Additional Documentation
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