Composite rail tie apparatus and method

An apparatus, shaped as a rail tie and comprising:

• a shell formed of materials resistant to bending and to environmental damage;
• a first fill as a solid within the shell;
• a second fill, pourable and distinct from the first fill, supporting the first fill by filling spaces inside the shell left by the first fill;
• and
• The first and second fill being configured to receive fasteners penetrating thereinto.

An apparatus, functional as a rail tie and comprising:

• a shell capable of resisting bending and compression;
• a first fill inside the shell and capable of resisting compression and bending of the apparatus;
• a second fill inside the shell supporting the first fill by backfilling spaces located in at least one of spaces between the first fill and cavities within the first fill;
• the shell, first fill, and second fill being configured together to receive a fastener penetrating through the shell and into the first and second fills.

A method of supporting a rail as a track in a railroad, the method comprising:

• providing an apparatus capable of operating as a rail tie and including a shell defining a length and containing a first fill and a second fill dispersed throughout the shell;
• positioning the apparatus on a ballast;
• positioning a rail on the apparatus;
• securing the apparatus to the rail by penetrating the shell, the first fill, and the second fill onsite with fasteners securing the rail onto the apparatus.