Polyurethane-Solidified Ballast Under Unconfined and Confined Conditions: Laboratory Load Testing and Mesoscopic Analysis

The prefabricated polyurethane-solidified track bed (PPSTB) combines the adjustability of ballasted tracks with the low maintenance requirements of slab tracks, offering a promising solution for railway sections on deformable foundations. This study investigates the interaction and mechanical behaviors of the polyurethane-solidified ballast (PSB) modules and bulk ballast under laboratory loading. A series of unconfined uniaxial tests, confined ballast box tests, and cyclic loading tests were conducted, complemented by discrete element method (DEM) simulations to analyze mesoscopic particle evolution. Under monotonic compression, the stress–strain curve exhibits three distinct stages with an average elastic modulus of 19.66 MPa, where the central aggregate framework acts as the primary load-bearing structure. Confinement increases the modulus by 33.57% and yields a nearly linear stress–strain relationship, attributed to a more compact and uniform contact distribution. Furthermore, under cyclic loading, the PSB shows enhanced energy dissipation and deformation resistance compared to conventional ballast. These findings provide a theoretical basis for the structural design and long-term performance assessment of the PPSTB.