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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 rail, for example, does not allow for any other technique to join rails.
Gantrex has proven expertsie in all three major welding methods, on the ground or at height:
Enclosed arc (puddle arc) welding
Alumino-thermic (thermite) welding
Flash butt welding
The chosen technique will depend on site constraints, size of the job or local possibilities and contingencies.
ENCLOSED ARC WELDING (PUDDLE ARC)
ALUMINOTHERMIC WELDING
FLASH BUTT WELDING
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, a set of electrolytic copper blocks, power transformer and grinding equipment.
Consumables: specially adapted electrodes and heat insulation plates to protect the pad.
Implementation
The technique requires qualified rail welders.
Contact us for more information about our welding solutions and services
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 an igniter.
Implementation
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 for your welders, or we can carry out the welding operation on your behalf.
Contact us for more information about our welding solutions and services
Technology
The flash butt welding process involves 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. We are able to provide guidance and management of the flash butt welding process to maximize your productivity.
Contact us for more information about our welding solutions and services
In 2013, Gantrex supplied and supervised the installation and welding works for 2,400 meter of rais including fulll accessories in this APM Terminal in Aqaba, Jordan.
Application : bulk unloading crane.
Gantrex supplied 91 m A75-90 rail with sole plates, clips, pads, grout, welding kits and installation.
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