Examining rails in detail. Rail inspection: Rail testing Rail measurement Welding monitoring and vehicle testing Consulting

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1 Examining rails in detail Rail inspection: Rail testing Rail measurement Welding monitoring and vehicle testing

2 Rail inspection Value retention and safety for your rails Our tests Geometrical testing of the track 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 Rails undergo a great deal of stress. Precise analysis of their condition is absolutely necessary for their proper care. Vossloh Rail Services relies on our comprehensive knowledge regarding all phases of the life cycle of the rail. We offer you all relevant tests and inspections, combining them with our expert consulting for the best possible servicing. For these tasks, we make available to you our state-of-the art testing and measuring technology, along with our highly specialised employees. Our comprehensive tests and inspections guarantee the best possible diagnosis of the condition of the rail. Rail testing: Visual inspection (VT) Eddy current testing (ET) Ultrasonic testing (UT) Magnet particle testing (MT) Rail measurement: Measurement of the longitudinal waviness Measurement of the transverse profile Height measurement Abrasion measurement Surface roughness What we would like to do for you: test, measure, advise The most comprehensive solution is always the best one when it comes to rail servicing. Tests and measurements of the rail section at regular intervals, and the resulting visualisation and documentation of data are the basis for the best possible servicing strategy. This long-term approach guarantees our customers minimum disruptions to their rail traffic, thus providing maximum efficiency. References Animated maps show you exactly where there is need to take action We have won over large rail network operators like Deutsche Bahn AG, Österreichische Bundesbahnen, Dresdener Verkehrsbetriebe AG, Münchner Verkehrsbetriebe, Berliner Verkehrsbetriebe (BVG), SBB Schweiz, BaneDanmark, Trafikverket Schweden, and many others. Typical rail damage: Head checks, squats, slip waves, and shelling 2 3

3 Fault checking We examine your section in detail Rail measurement How your perfect service strategy arises Our non-destructive rail testing procedure usually starts with a visual inspection: With the naked eye and supported with mirrors, magnifying glasses, and artificial light sources, our experts can recognise exactly which testing methods should be used. Eddy current testing The depth of damage in surface cracks on rails, generally caused by rolling contact fatigue, can be determined using eddy currents. Our eddy current testing systems test the riding surfaces and running edges of the rails and, in addition to the fault frequency, measure the depth of damage per metre of rail (up to 2.7 mm). We also check the spring points of switch blades. Ultrasonic testing Irregularities in material and internal faults can be detected by the ultrasonic testing method. In the process, areas of the rail that are subject to faults can be checked through the various angles of incidence and probe heads. Magnetic particle test Surface faults on magnetisable components can be determined using magnetic particle testing. In particular, the quality of welding procedures is tested using this method. Eddy current testing Test of the weld joint geometry Geometrical measurement Using geometrical measurements, the condition of superstructure installations (such as tracks, switches, crossings, rail expansion devices) is determined and compared with standards, sets of regulations, or company-specific set-points. In the process, devices for the measuring of the transverse profile, longitudinal waviness, track gauge, switch opening, torsion, and elevation are used. Transverse profile measurement The rail head is measured using many co-ordinates, the rail type is recognised, and its condition is compared with the original shape from the rail library. This provides important information on rail wear. The rail height, head width, rail cant, and channel lip are measured, including wear from various angles. The rail shape in the wheel/rail contact area is particularly relevant. Measurement of the longitudinal waviness The system for detecting short-wave rail head faults measures all corrugations between 10 mm and 1 m. With up to four configurable wavelength bandwidths, various corrugation types can be detected in a single pass. The results and inclusion of historical data provide exact data for the best possible grinding plan. Height measurement In this case, the material abrasion on the rail is measured by determining the delta at the reference points. Magnetic particle testing 4 5

4 Welding monitoring and vehicle inspection Always the right application strategy Monitoring Welding monitoring/specialised construction site management: For the manufacturing of a gap-free track and welding repair work, an approved supervisor must monitor the proper performance of the welding work and stress equalisation. The rail technology quality monitor is the customer s representative for grinding and milling work on the track who aims for the best possible, economical elimination of faults. Wheel set shaft testing Dynamic stress can cause surface damage like notches or even corrosion that can turn into cracks. This can lead to spontaneous breakage with far-reaching consequences. We use testing systems that enable a precise display of faults and guarantee comprehensible documentation. The magnetic particle test is mainly used when the wheel set shaft is dismantled and cleaned. When it is installed or if attachment parts or protective layers remain, usually only the ultrasonic test is possible. Wheel set shaft testing Assessment of a milled section The right consulting for a long-term servicing solution: Every section has its own characteristics, even in regard to wear and damage. The best possible testing and measuring instruments are required to determine the precise rail condition and to make the right conclusions from all the data. Thanks to their training, targeted further education, and extensive expertise, the experts of Vossloh Rail Services can make safe analyses and point out solutions. This well-founded consulting shows optimisation potentials in rail servicing and sketches the best application strategy to minimise shutdown periods and costs permanently. In addition, we provide solutions for a efficient elimination of individual faults. We do everything to achieve the best condition of your rails Measurement and inspection of a section on foot 6 7

5 Overview of our services Rail inspection Rail testing and rail measurement Welding monitoring and vehicle inspection Find out about our other services 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. Vossloh Rail Services we care for rails. Vossloh Rail Services GmbH Hannoversche Straße Hamburg Germany Tel: info@vrs.vossloh.com