Rail Welding
Continuous rail tracks
Modern handling equipment requires smooth, continuous rail tracks that must be butt-welded to avoid shocks at joints and damage to wheels and other mechanical parts. The geometry of DIN 536/1 type rails is such that it does not allow for any other technique to join rails.
Welding techniques
Gantrex specialises in all three major welding methods, on the ground or at height:
The chosen technique will depend on site constraints, size of the job or local possibilities and contingencies.
- The enclosed arc (puddle arc)
- The alumino-thermic (thermite)
- The flash butt welding.
The chosen technique will depend on site constraints, size of the job or local possibilities and contingencies.
Global coverage, local presence
Here again, Gantrex 300-strong team of in-house experts is available to organise and manage the various welding processes to maximise your productivity. We will help you select the most appropriate method for your situation. Regardless of your location, our own welding specialists’ teams are always on track, with you.
Options Discover our range of products
Enclosed arc welding (Puddle Arc)
Technology
The void between the ends of the rail is filled with a continuous layer of fillet welds.
Equipment
- Permanent basic equipment : material for adjustment and preheating, set of electrolytic copper blocks, power transformer, grinding equipment.
- Consumables : specially adapted electrodes, heat insulation plates to protect the pad.
- The technique requires qualified rail welders.
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Aluminothermic welding
Technology
The steel obtained by combining iron oxide with aluminum is cast at over 2000°C in a refractory mould matching the rail profile.
Equipment
- Permanent basic equipment for thermite welding : material for adjustment, mould fixing, preheating, casting and finishing off.
- Consumables : mould adapted to the rail profile, welding charge and igniter.
- This technique gives excellent results, and is independent of atmospheric and operational conditions.
- The implementation of this thermite welding technique requires qualified welders. Gantrex can provide you with the necessary training and qualification of your welders, or carry out the welding operation.
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Flash Butt Welding
Technology
The flash butt welding process entails bringing the rail ends together and generating an arc which heats the metal. Once the metal reaches the appropriate temperature the rail ends are forged together using hydraulic pressure and the excess upset material at the weld interface is sheared away to produce a near perfect rail profile with minimal secondary profile grinding required. The entire process is automated with the rail ends encapsulated and manipulated by a portable weld head
Equipment
The support equipment which provides power and control to the flash butt weld head is truck-mounted and connects to the weld head with umbilical cables and hoses. The support vehicle must be able to get close to the welded site. For overhead welding at least two mobile cranes are required to support the welding operations. One to support the weld head and the second to lift and place the rails.
Implementation
The process lends itself to very high weld production rates but only if the supporting labor force is well organized to take full advantage of the equipment capabilities. The process is most productive when the rail is fed to the weld head at a fixed location, welded then pulled down the runway on rollers. Gantrex can offer organization and management of the flash butt welding process to maximise your productivity.
The flash butt welding process entails bringing the rail ends together and generating an arc which heats the metal. Once the metal reaches the appropriate temperature the rail ends are forged together using hydraulic pressure and the excess upset material at the weld interface is sheared away to produce a near perfect rail profile with minimal secondary profile grinding required. The entire process is automated with the rail ends encapsulated and manipulated by a portable weld head
Equipment
The support equipment which provides power and control to the flash butt weld head is truck-mounted and connects to the weld head with umbilical cables and hoses. The support vehicle must be able to get close to the welded site. For overhead welding at least two mobile cranes are required to support the welding operations. One to support the weld head and the second to lift and place the rails.
Implementation
The process lends itself to very high weld production rates but only if the supporting labor force is well organized to take full advantage of the equipment capabilities. The process is most productive when the rail is fed to the weld head at a fixed location, welded then pulled down the runway on rollers. Gantrex can offer organization and management of the flash butt welding process to maximise your productivity.
Contact us for more info about our products and services
Contact us