Efficient and sustainable transport systems are a major factor in reducing our carbon footprint. Embedded grooved rails in tram systems become worn and need to be replaced or refurbished by weld rebuilding to maintain the safety of the track.

Weld rebuilding vs. replacement

• Extend the lifetime of the track
• Rebuild in-situ without the need to uproot the track
• Save on replacement costs with less disruption to traffic and less environmental impact

Welding Alloys products and solutions: TRACKWELD 910W & WS, RAILBUILD 545W & WS, TRACKWELD 910WS, CORUS TRAMWAY*, GCR machine.

*Licensed and approved product developed by Welding Alloys and TATA Rail Technologies

Crossings/frogs - are subjected to daily metal-to-metal wear, abrasion and impact.  This leads the crossing to become worn and subject to damage or potential breakages. In order to maintain a safe track the crossing must be replaced or refurbished by weld rebuilding.

Weld rebuilding vs. replacement

• Quickly restore and repair the crossing in-situ
• Recycle used crossings in the workshop
• Reduce maintenance downtime and track closures
• Achieve cost savings of 80% compared with replacement costs

WA products and solutions: FROGBUILD 478W & WG, FROGBUILD 575W, FROGBUILD 476W & WG, FROGBUILD 570W, TRACKWELD 910W & WG & WS, RAILBUILD 540W, RAILBUILD 545W.

Weld rebuilding vs. replacement

• Quickly restore the switchblade and stock rail in-situ
• Carry out maintenance in the workshop if required
• Reduce rail maintenance downtime
• Achieve cost savings of around 60% compared to replacement costs

WA products and solutions: TRACKWELD 910W & WG, RAILBUILD 545 W.  

Rail heads - The rail heads can become damaged after a relatively short period of time due to the wheel spinning under load. The metal-to-metal wear leaves surface and sub-surface defects which, left untreated, can lead to further damage of the rail - resulting in premature failure. 

Weld rebuilding vs. replacement

• Quicky restore the rail in-situ
• Recycle used rails in the workshop
• Reduce maintenance downtime
• An automatic or semi-automated process offers a cost effective alternative to replacement of the rail

WA products and solutions: RAILBUILD 540W, RAILBUILD 545W,

Rail surfacer.

Tamping - Tamping is an essential part of track maintenance, used to pack the ballast under sleepers, to correct track alignment and ensure the track is parallel and level. The service life of the tamping tines/tools has a fundamental influence on the economic efficiency of this maintenance work; in general, tines are rejected after 15%-20% wear in their thickness/width. 

Weld rebuilding vs. replacement

• Ensure a consistent quality of tamping
• Reduce labour costs required for replacing the tines
• Usage of the right materials can lead to a major extension in lifetime

WA products and solutions: RAILHARD 567W, RAILHARD 660W.