The world’s longest coated rails can now be produced in Hilversum, the Netherlands. Rail rolling lengths of 120 meters are coated and then connected by two flash butt welds of up to a maximum of 360 meters.
Unprotected rails are a hazard to safe train operation. Rails are often exposed to influences like salt, water, moisture, faeces and stray currents, which can cause severe damage, e.g. corrosion. Coated rails provide an excellent method for preventing corrosion and securing the rail infrastructure for a longer life span. voestalpine Track Solutions Netherlands, a subsidiary of voestalpine Railway Systems, upgraded their coating line to offer a better service towards our customers.
The coating line has been completely upgraded for durable operation and improved adhesion. The relocation and its upgrade was a complex project, which included adjusting the hoisting height of our gantry cranes and taking up part of the cable park.
With the upgraded line, numerous enhancements have been made, such as special heating elements as well as the blasting process. This led to incredibly improved adhesion of the coating. Previously, we measured values of 8,5 - 9,5 N/mm2 in our laboratory. Whereas now, we measure values of 14 N/mm2.
The polyurea Rubbercoat® is applied with the utmost precision, in order for the rails to become completely isolated and protected from corrosion, as a result of stray currents, salt influences along coast lines, and in tunnels. A huge improvement of the adhesion and even better protection of the rails - The Rubbercoat® coating now offers a life extension of five to ten times
We can coat different profiles in lengths up to 360m. In addition, delivering rails longer than 120 meters directly to the work site not only accelerates installation, it also reduces the number of welds in track, known as potential weak spots. Our coating has an insulating effect and protects not only against weather influences but also against stray currents at level crossings. Logistics solutions are available and safe welding in the track is possible. In the event of the coating being accidentally welded, no toxic fumes are released. However, to avoid entrapment of the coating in a thermite weld, the coating must be completely removed before the welding process. For the after-treatment of thermite welds and recovery of small damages, we sell an easy-to-use recovery kit.