Everything for rails Factory services: Long rail manufacturing Rail transition points and insulated joints Profile processing Logistics
we care for rails
Rail profiles
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We have all the relevant rail profiles – just in time
From primary product to long rail
Vossloh Rail Services‘ factories have the most common rail profiles in stock: head-hardened and of standard quality. We can thus react to our customers‘ needs immediately. In the railway industry, in particular, construction times have to be short and track possession times kept to a minimum. Our customer-specific pre-assembly to the precise centimetre reduces cutting scrap at the construction site to a bare minimum. Our web-based materials management system also optimises production and delivery phases.
We are able to execute all the common methods of sawing, welding, straightening, re-profiling, compressing and drilling rails. In the process, we produce about 200,000 tons, i.e., about 3,200 kilometres of long rails, every year. We manufacture long rails with lengths up to 180 m using flash welding. We deliver the highest quality geometry, metallurgy and durability thanks to our state-of-the-art measuring, straightening and milling technology.
The long rail is cut precisely to achieve the exact length.
we care for rails
Rails are the lifeline of modern infrastructures. Building and maintaining them is a challenging task during which safety always has top priority, and these tasks are the realm of experienced specialists. Vossloh Rail Services is your partner in rail care and we can offer you a complete range of rail services worldwide. Your Vossloh Rail Services-Team After welding comes straightening and refining
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The welding procedure on the inspection monitor
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We refine rails
Rail transition points and glued insulated joints
Perfect profile processing: Because time is money
In our factories, we manufacture profile transition points for all common rail profiles. Using controlled compression and flash welding, we create a transition point between rails with different profiles or quality. These are integrated into the rail string or as a customised length. Glued insulated joints are indispensable for reliable signalling. We manufacture them in a long rail, as classic S joints, and as angular joints of 30°. Using the full adhesion principle in this process allows us to achieve optimum power transmission and a longer service life than would be possible with MT joints manufactured on the track. During manufacturing, we work according to customer specifications. Other angular positions are also available, as well as prefabricated rail contacts, such as Cembre.
Profile transition point
Cross-section of angular joint IVB 30°
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Insulated joint S, 4-hole, reinforced
Completely glued angular joint IVB 30°
The so-called edge-decarburised zone is removed from the new rail milled at our factory, thus delaying the later formation of corrugations. Time-consuming grinding at the construction site is also no longer necessary. Compared to the rolling product, this results in increased transverse and longitudinal profile precision. Operation-relation wear develops considerably later. After installation, the rail can be used immediately and without any limitations, and track possessions become unnecessary. Using state-of-the-art measuring, aligning, and milling technology, we manufacture geometrically inconspicuous welded long rails in a longitudinal profile. This kind of processing no longer produces the typical conspicuous areas on the rail joints that result from bent rail ends. This „invisible welding“ is the world‘s highest-quality manufacturing technology for long rails on high-speed routes.
Longitudinal profile precision up to 0.01 mm
Transverse profile tolerance of less than 0.2 mm
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Our just-in-time logistics
In the right place at the right time
Our customers can rely on our just-in-time delivery right to the construction site. Vossloh Rail Services employs special transport systems and unloading equipment. High loading capacities guarantee fast processing at the construction site. Further advantages: less shunting and considerably more efficient unloading compared to the unloading of short rails. We also deliver rails by lorry, or customers can pick them up at the factory. So our logistics experts have the right solution for every construction site situation. Emergency deliveries in the event of loss or damage naturally have highest priority.
Recycling, refining, reusing
We make the best use of used rails Environmentally friendly, sustainable, and up to 50% cheaper than purchasing new rails: Normally, rails typically only wear on one edge. The non-running edge retains enough material for a new running edge. Vossloh Rail Services therefore doubles the service life of rails through what we call “second configuration use”. We can manufacture these re-processed rails to a length of up to 180 m, which then can be used in track sections classified for speeds of up to 160 km/h. Ultimately, old rails that can no longer be used are sent to scrap metal recycling. We market the rail scraps on the best possible terms. Numerical identification for tracking each weld joint
Here’s how we reprocess a rail
old running edge
new
new running edge
used
reprocessed
The rail is turned over and the unused side ground. This is what we call ”second configuration use”
1. First, the ultrasonic and eddy current tests are performed to determine the inner and outer, vertical and horizontal points where material is missing. 2. The points where material is missing are subsequently cut out. 3. The next station is the rail straightening machine. 4. A brushing machine then cleans the surface of the rail. 5. Now the rails are welded using the flash welding process. This process is fully automated and digitally monitored. 6. The offset of the rails is measured and they are then sawn to delivery length. 7. The straightening and grinding plant optimises the geometrical result of the weld joint. 8. The last workstation is milling and grinding. 9. After the final ultrasonic check, the rail is ready for use.
Fast and efficient securing of load on the Robel special transport units
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Overview of the factory services 2
Complete range of all common rail profiles
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From primary product to long rail
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Rail transition points and glued insulated joints
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Perfect surface processing
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Our just-in-time logistics
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Recycling, refining, reusing
Find out about our other services
Learn about our other services
Learn about our other services
Co-ordinated perfectly
Examining rails in detail
Loading & Logistics: Transporting and loading rails Railway car leasing Construction site logistics Rail replacement
Rail inspection: Rail testing Rail measurement Welding monitoring and vehicle testing Consulting
we care for rails
we care for rails
From 1946 to the future In order to rebuild the railway infrastructure, usable pieces of rail had to be removed, processed, and welded into „long rails“ again. In order to be involved in this project, a welding factory was built in 1946 at the current location in Hamburg-Harburg. The number of employees rose from 40 in 1950 to over 230 in the 1960s, at an annual delivery volume of more than 200,000 m of rails. In close co-operation with Deutsche Bahn, the services and products were constantly expanded and further developed. In addition to that, the company increasingly took on rail processing projects from abroad. After rapid growth and the opening up of new service areas (see the back page), the company and its three Rail Centers in Nuremberg, Leipzig, and Hamburg were taken over by Vossloh in 2010 and became the origin and main business branch of Vossloh Rail Services GmbH.
Today, Vossloh Rail Services guarantees the retention in value and safety of modern railways with about 400 employees – also with its own companies in the United States, China, Sweden, Austria, and Turkey. The range of services covers the entire life cycle of the rails – from the manufacture and transport of welded long rails and their maintenance and preventive care to the reconditioning of old rails. In the process, our development department has created numerous innovations that decisively shape today‘s market – including high-speed rail grinding vehicles, transport and loading systems, measuring devices and a crane rail processing system.
Perfectly connected on the move
Rail care at full speed
Mobile welding: Welding on the route Mobile welding factory
Grinding & milling: High Speed Grinding High Performance Milling Switch maintenance Crane and factory rail grinding
Vossloh Rail Services – we care for rails. we care for rails
Vossloh Rail Services GmbH Hannoversche Straße 10 · 21079 Hamburg · Tel. 0049 (0)40 430931-0
[email protected] · www.vossloh-rail-services.com
we care for rails
we care for rails
