Railroad ties, also known as crossties, are the backbone of any enduring track or landscape edging project. These hefty blocks of wood or concrete provide the essential stability required to keep rails or borders aligned, but their true strength is realized only when they are securely united. Attaching railroad ties together is not merely a matter of stacking them; it is a precise engineering process that ensures the integrity of the entire structure. Whether you are building a robust retaining wall or laying a section of permanent track, understanding the correct methods for connecting these components is critical for safety and longevity.
Preparation and Planning
Before any hardware touches the wood, meticulous preparation is the key to a successful assembly. You must first determine the specific application, as the method for securing a railway segment differs significantly from that of a garden retaining wall. For track work, the joint bar is the industry standard, designed to bridge the gap between ties and transmit the immense weight of locomotives across the connection. For landscaping, heavy-duty lag screws or robust connector plates are often sufficient. Regardless of the project, the surface of the tie where the connection will be made must be clean, flat, and free of splinters or debris to ensure maximum contact and load distribution.
Gathering the Right Tools and Materials
Having the correct tools is as important as selecting the right tie. For metal joint bars, you will need a powerful drill capable of driving large anchor bolts, a wrench set for tightening the nuts, and a heavy-duty hammer to seat the bar precisely into the pre-drilled holes. If you are using concrete ties, specialized diamond drilling bits are required to create the anchor points. For wooden ties in landscaping, a high-torque impact driver and galvanized lag screws are the most efficient tools. Skipping the right tool for the job will result in loose connections, damaged materials, and potential safety hazards down the line.
Method One: Using Joint Bars for Track Applications
The most common and methodical way to attach railroad ties together in a rail line is via joint bars. These steel plates feature a central gap that sits directly over the rail joint, while the holes on either end align with the anchors in the ties below. The process begins by lifting the rail into place so that the joint aligns perfectly with the gap in the bar. Once the rail is seated, the bar is carefully positioned over it, ensuring it is parallel to the track. The alignment is critical; any misstep will cause stress on the rail or tie, leading to premature failure.
Once aligned, the holes in the joint bar are used as guides to drill through the railroad tie. After drilling, high-strength anchor bolts are inserted into the tie, and the bar is secured with heavy nuts and washers. This creates a rigid, vibration-resistant bond that allows the load to flow seamlessly from the rail into the tie and subsequently into the ballast or ground. This method is essential for maintaining the precise gauge required for safe rail operations.
Method Two: Securing with Lag Screws and Plates
For applications involving retaining walls or stacked landscape borders, the joint bar is unnecessary, and a more straightforward mechanical fastening is appropriate. Here, the goal is to create a tight bond that resists lateral pressure from the retained soil. The process involves drilling a pilot hole through the connecting face of two adjacent ties to prevent the wood from splitting. A thick, flat connector plate or a long lag screw is then used to pull the ties tightly together.
The lag screw acts like a massive bolt, drawing the wood tight against the grain, which is the strongest direction for wood integrity. When using plates, you typically drill through the plate and the tie with a socket wrench, securing it with a nut on the opposite side. This method ensures that the wall remains square and does not bow under pressure, providing years of stable service.
Addressing Gaps and Ensuring Stability
No matter the technique you employ, achieving a tight connection is the ultimate goal. In some cases, natural wood shrinkage or manufacturing tolerances can result in slight gaps between the ends of the ties. These gaps compromise the transfer of force and should not be ignored. The preferred solution involves using custom-cut hardwood shims. These tapered pieces of wood are hammered tightly into the gap before the lag screw or joint bar bolt is tightened. By eliminating the air space, you ensure that the load is transferred directly through the wood fibers rather than crushing air pockets, significantly increasing the connection's strength.
Maintenance and Long-Term Considerations
Once the railroad ties are attached, the work is not necessarily complete. The durability of the connection depends heavily on regular inspection and maintenance. For outdoor installations, the metal bolts and joint bars are constantly exposed to the elements. Rust expansion can occur, applying outward pressure that can crack the concrete or surrounding wood. Inspecting the tightness of the nuts and the integrity of the wood annually is recommended. Tightening hardware or replacing damaged shims can extend the life of the structure significantly, ensuring that the ties remain firmly attached for the long haul.