System 1

Born of countless hours of research and development, our two-component polyurethene formulas have excellent memory and density, and can be applied in virtually any weather conditions. System 1 will perform well in either production gangs with a machine/ operator or with section crews to handle smaller jobs with hand gun systems.

  • Specially formulated two-component polyurethane with excellent memory.
  • Insensitive to moisture and can be applied in extreme heat or cold.
  • Excellent for filling all tie cavities, especially spike holes and it will not shrink after curing.
  • Designed to be flexible in its application.
  • Performs well in either production gangs with a machine/operator or with the handguns for emergencies and with section crews to handle smaller jobs.


System 1 Specifications

Basic Use
Railroad Solutions System 1 is time tested two-component polyurethane designed with excellent memory, and moisture insensitive properties. The new densities of System 1 will allow for better performance and versatility in harsh climate conditions. System 1 is used for filling tie holes and spike anchoring, as well as helping prevent spike kill.

Railroad Solutions System 1 polyurethane is especially designed in the repairs of wood ties on the railroad tracks in a production gang or hand gun application. System 1 can be used in extreme heat, and extreme cold conditions. Product can accept the spike by hand and be driven by hand without splitting the tie.

Composition and Material

  • System 1 polyurethane is a two-component, 1:1 ratio.
  • System 1 will not shrink after curing and provides dense wood like compound.

System 1 is packaged in hand cartridge, 5 gallon (U.S.) and 275 gallon tote units. Each container is clearly marked with the component designation. The label includes complete application instructions.

Applicable Standards
System 1 reference testing ( TD-96-010 ) and AAR/UI study and the TTCI-FAST-HAL STUDY.

Contact Railroad Solutions.

Technical Data


Each component should be examined for settling of contents and stirred separately. Be careful not to inadvertently mix the two components.The components are premeasured to the correct ratio and are designed to react completely. Never deviate from the specified mixing ratio.

Physical Properties
The physical properties of fully cured Railroad Solutions polyurethane include:

  • Tie condition: good to poor
  • Insertion strength: 9,000 psi
  • Extraction strength: 7,640 psi
  • Set Times: (in tie) 5 min
  • Density: 42 lbs/cuft
  • Shelf Life: Shelf life of properly stored containers is two years.

Component A - Clear
Component B - Brown
Mixed - Tan

Pot Life
200 grams 77°F
3 minutes

Machine Set Time In Cold Weather
Material @ 110°F with a substrate and ambient temperature of 10°F.
Plugged hole 1-3 min

Material @ 90°F with a substrate 
and ambient temperature of 10°F.
Plugged hole 3-5 min

Material @ 75°F with a substrate 
and ambient temperature of 10°F.
Plugged hole 5-7 min

Material @ 60°F with a substrate 
and ambient temperature of 10°F.
Plugged hole 7-10 min

When the substrate is a normal ambient Temperature of 73°F, an increase of 50% can be expected in set times above.

Shelf Life
Component A - 2 years
Component B - 2 years

Specific Gravity
Component A - 1.25 ± .02 gr/cc

Component B - 1.28 ± .02 gr/cc
Mixed - 1.26 ± .02 gr/cc

Tack Free Time
75°F: 5 hole application
10 minutes

Component A - 500-780 cps
Component B - 500-780 cps
Mixed - 600 cps

Weight Per Gallon
Component A - 10.4 ± .2 lbs
Component B - 8.65 ± .2 lbs
Mixed - 9.53 ± .2 lbs


Containers should be tightly closed and properly stored. Protect from temperature extremes, moisture, and water.

Preparatory Work
For maximum product performance, System 2 polyurethane should be applied to a wood tie. Recommendations include: should be applied to properly prepared wood tie.

System 1 Polyurethane should be applied as follows:
1. Specifically formulated to be applied with railroad equipment that is designed for this type of application.
2. Caution: if mixed manually, unusual applications or extreme weather conditions may require the technical assistance of a Railroad Solutions Technical Representative.

It is mandatory that the user take the following precautionary actions to protect worker and the public.
2. Avoid inhalation of vapors. Ensure adequate ventilation.
3. Avoid contact with skin. Protective clothing is recommended. Contact areas should be washed with soap and water.
4. Avoid contact with eyes. Protective goggles are recommended in case of splashing. Flush eyes with water if contact occurs.
5. Avoid ingestion of material. If ingestion occurs, contact a poison center or physician.
Additional precautions, safety information and first aid treatments are contained in the Material Data Safety Sheet.

Railroad Solutions warrants that this product will be free from defects and will perform as represented in writing provided application of product is in accordance with manufactures recommendations and application recommendations. Railroad Solutions will refund the purchase price of any product proven defective, but shall in no way be liable for indirect, consequential, special or resultant damages, whether due to breach of warranty or negligence. Railroad Solutions makes no guarantee or warranty, express or implied. Including, without limitation, warranties of fitness or merchantability, with respect to this product.

Independent Laboratory Testing

AAR Research Report. In-Track Performance Testing of Synthetic Tie-Plugging Materials at FAST and in Revenue Service.
Performed by TTCI (Transportation Technology Center, Inc. a subsidiary of the Association of American Railroads)

RailroadSolutions System 1 Test

100 South Santa Fe Drive
Denver, Colorado 80223
303.777.9692 Phone
303.733.2851 Fax