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Coated Insulated Block Joints

IBJs with a protective coating, designed to extend the life expectancy to over 15 years.

The Coated Insulated Block Joint was developed when a European client asked HRS to supply a new Insulated Block Joint (IBJ) design. This design included a hard-wearing protective coating which is durable, electrically resistant, waterproof, and capable of extending IBJ life expectancy to over 15 years.

The protective coating was subject to a rigorous programme of testing, including life cycle testing at the manufacturer’s laboratory and sample testing at the state-of-the-art purpose-built coating facility in Doncaster. This was followed by in-track testing on the European customer’s rail infrastructure.

Coated Insulated Block Joints now have full product acceptance from Network Rail (PA05/07408).


HRS were successful in manufacturing coated IBJs capable of improving reliability, adding value and reducing whole life costs for their customers. Made using cutting-edge science, the coated IBJs have been approved for use in two European rail networks with thousands supplied to date and no justifiable faults reported.

The coated IBJs are designed to combat track issues caused by harsh conditions. These conditions occur on coastal routes exposed to saltwater, level crossings subjected to salt and grit spreading, locations with high humidity, and in tunnels where metal filing debris often accumulates.

Key benefits include:

  • Wear protection against erosion and abrasion
  • Corrosion protection against water and saltwater, acid and alkaline, oil and grease
  • Specially developed two-part epoxy coating which contains ceramic powder which provides excellent protection against abrasion and impact 
  • Gloss finish with a film thickness of ~250-300μm

For information on how we can support your business with coated IBJs, please get in touch and we will be happy to help.

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