Thermoset composite material and structural component and method of making the same from engineered recycled rubber powder

A composite railroad crosstie, comprising:

• about 30% to about 50% by weight of vulcanized recycled rubber particles;
• about 12% to about 20% by weight of a polyurea binding agent added to the vulcanized rubber particles;
• about 5% to about 15% by weight of a granulated silica material;
• about 15% to about 20% by weight of urea melamine and,
• wherein the blend, including the vulcanized recycled rubber, the polyurea binding agent, the granulated silica and urea melamine, is subjected to a compression molding force of about 300 psi to about 1,000 psi and heat at one or temperatures of about 230° F. to about 270° F. for a resident time period forming the thermoset composite railroad crosstie.

A method of assembling a railroad crosstie, comprising:

• developing a thermoset composite material by mixing of blend of vulcanized recycled rubber particles, a polyurea binding agent, a granulated silica material and urea melamine;
• introducing the blend into a compression mold;
• subjecting the blend to a compressive molding force and heat for a resident time;
• allowing the blend to cool and harden after the resident time has elapsed;
• and,
• removing the hardened blend from the mold.