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6/13/2024
Compiled by Michael Popke
Arva Industries Inc. offers a new diesel-powered, bi-directional vehicle designed to collect track ballast during maintenance and repair operations. The vehicle features a hydrostatic drivetrain and has two primary functions: collecting ballast from around ties and storm drain cleaning, Arva officials said in an email.
Equipped with a vacuum system and hydraulically actuated boom, the vehicle also has an eight-inch suction hose that can extend to 48 inches. The boom and vacuum functions are remotely controlled via radio to provide safer and more efficient operations, company officials said. The vehicle’s storage capacity is 20 cubic yards for wet or dry products.
A high-pressure water system provides 2,500 pounds per square inch of power at 10 gallons per minute with a clean water-tank capacity of 1,325 gallons. The vehicle also has provisions for winter freeze prevention to ensure reliable operation in harsh weather conditions. With a maximum travel speed of 32 mph and a 450-horsepower diesel engine, the vehicle can efficiently and effectively collect ballast while minimizing the time required for maintenance and repair projects, company officials said.
Herzog has introduced the Track Lifter, which is designed to accelerate track rehabilitation and construction efforts with greater efficiency.
The Track Lifter streamlines track restoration efforts by minimizing the need for supplementary off-track equipment. Positioned strategically within a train consist, it gains access to traditionally inaccessible areas, offering greater assistance for restoration projects, company officials said.
Featuring a lifting capability of 40,000 pounds and a Rated Capacity Indicator for operational steadiness, the Track Lifter reduces the need for downtime caused by relocating conventional off-track equipment. This efficiency accelerates equipment mobilization between job sites, facilitating faster deployment, company officials said.
Partnered with Herzog’s Automated Conveyor TrainSM, the Track Lifter “showcases its capabilities,” they said: The machine’s precision-engineered excavator arm securely grasps the rail, elevating track sections for ballast unloading via its integrated conveyor system, helping stabilize the trackbed.
Its vibration unit and automated plow work in tandem to clear material away from the front of the machine and off the track. Engineered to Plate F specifications, the machine offers precise envelope control, which mitigates the risk of interference with operations on adjacent tracks, company officials said.
A number of attachments are available, including an undercutter, grapple, shear, brush cutter and rotary ditcher.
This year, Knox Kershaw Inc. is rolling out a hybrid version of its KBR 925 Ballast Regulator. The company recently converted straddle-lift cranes to hybrid versions. The hybrid KBR 925 will offer a smaller engine package for quieter operation, greater visibility, battery-powered motors, longer engine life and less wear-and-tear on pumps, company officials said.
The KBR 925 is designed for ballast work on all track types. Its plow and wing work together to transfer ballast from shoulder to shoulder in one pass while leaving one shoulder profiled. The standard reversing valve allows ballast to be swept away from switches and grade crossings, company officials said.
The upgraded KBR 925’s hydraulic tank has been moved to the front for better weight distribution and features a 130-gallon capacity. The machine features sloped fuel tanks with integral steps to improve cab entry and exit, and a ballast wing that uses the same grader blade throughout.
The KBR 925 includes the Plus+1® System Op/on that automates key functions for smoother operations, company officials said. It features a touch screen for monitoring system functions. The Plus+1 system is available as an option for the KSF 940 machine and is standard on the KKA 1050, KTC 1250 and KPB 200 models.
Loram Maintenance of Way’s full fleet of ballast maintenance equipment can undercut, clean shoulder ballast, excavate ditches and safely vacuum material away from special trackwork. When paired with Loram’s MHC60 material handling cars, rail customers can realize improved work block efficiencies and reduced unit costs, company officials said.
Railroads continue to find new uses for Loram Maintenance of Way’s LRV vacuum excavators, they added. By pairing vacuum power with a manipulator that can apply 5,000 pounds of force at the nozzle’s tip, the LRV can excavate the most fouled and cemented ballast in hard-to-reach locations.
In addition to excavating in tight clearances on ballast deck bridges, in tunnels and around switches and crossings, the LRV can perform mud spot undercutting and removal, cross drain or trench digging and drain cleaning. Because there are no moving parts associated with vacuum excavation, ballast can be removed from critical components without any damage, company officials said.
Designed for high-speed ditch clearing and creation, the Badger and DC Max Ditchers can excavate material at up to 800 tons per hour to quickly improve drainage and direct water away from track.
Loram also offers shoulder ballast cleaning services, equipment and technologies. By consistently excavating at 8 inches below the tie and restoring the ballast shoulder structure, fines can migrate through the shoulder with dramatically improved seepage time. The equipment is designed to break open mud pockets, compacted fines, and ballast voids in the cribs and under the ties to release damaging trapped water.
Loram Technologies Inc.’s ballast maintenance solutions are designed to enable operators to complete work efficiently and reliably, minimizing the impact on track time.
The company’s GateSync uses two potential data streams that allow it to deliver ballast. Cars can be unloaded using manual surveys or data fed from ballast profiling equipment. Once a survey is in place, the GateSync software synchronizes the opening and closing of gates on ballast cars to place ballast exactly where it’s needed — all done while avoiding crossings, switches and other “no dump” zones, company officials said. GateSync provides continuous ballast unloading at up to 10 mph.
Meanwhile, the company’s Solaris is designed to improve the productivity and safety of existing ballast cars by converting their gates to remote operation. The conversion uses a rugged 24-volt electric hydraulic pump and hydraulic cylinders to produce the force needed to open and close the gates.
Solar panels recharge the system when not in operation, creating a low-maintenance solution. Solaris-converted ballast cars can be unloaded by either operating joysticks on the sides of the cars or by using a handheld radio remote control that has a range of up to 300 feet.
Solaris is particularly beneficial when combined with GateSync technology to automate ballast delivery; for manually operated cars, Solaris provides a quick and easy upgrade to make them GateSync-compatible, company officials said.
Miner AggreGate® ballast/MOW outlet gates are available in electric, air-powered and manual operating models, and all are suitable for both retrofit and new car systems. The solar-powered stand-alone electric AggreGate enables independent operation of the car from anywhere within the ballast train, eliminating the need for grouping manual and automatic cars.
It also can be operated without connection to another car for power. Solar-powered and battery-operated systems provide stand-alone operation. An optional remote control with push-button override also is available, designed to allow for individual car and gate selection.
The AggreGate effectively ballasts inside, outside or both sides of rail simultaneously; large guillotine door openings are designed to stop ballast flow with minimum effort. It features easy ballast shutoff at switches, crossovers and bridge, and single- or double-door control options.
The dual cylinder air-powered AggreGate is available in either push-button or remote-control operation. The remote-control system enables an operator to select a specific car and gate, as well as control ballast flow — ensuring more accurate ballast discharge from distances up to 300 feet, company officials said. The standard transmitter can select up to 999 cars for remote control and features an override air valve to continue ballasting if power is lost.
The manual AggreGate is available with transition sheets designed to enable new or retrofit application to any open-top hopper car. It features a three-position handle for easy opening and closing of doors. Spring tension holds the door in position at any opening for controlled flow of ballast.
Nordco offers a suite of ballast management systems, including the M7 Ballast Regulator. The M7 is equipped with a single-pass ballast transfer system, allowing for efficient ballast distribution and profiling, company officials said.
It features a one-inch thick, hydraulically adjustable front plow to meet the specific needs of different rail environments. The M7’s design includes various wing types — fixed, rotational and articulating rotational — which provide precision in ballast sculpting and profiling across diverse track conditions, company officials said. The M7 also can be converted into a snow-fighting machine during winter.
The dual-use capability of the M7 reduces the need for multiple machines, which lowers both initial acquisition and ongoing maintenance costs. Compatibility with other Nordco machines allows for streamlined maintenance operations and parts inventory management.
Pettibone’s Speed Swing 445F2 is a rail crane designed to accept more than a dozen attachments for rail maintenance tasks, including three attachments that assist with ballast management.
A track-cleaning bucket is available to efficiently clear excess ballast from tracks while the machine travels along a stretch of rail, company officials said. The Speed Swing also can be equipped with a switch broom to clean switches and clear unwanted ballast and other debris. When maintaining the area around a crossing, the Speed Swing can be used with rail mat tongs to set mats. That attachment is then swapped out for a general purpose bucket, which allows the machine to scoop up ballast and lay it down where required.
Additionally, a Speed Swing equipped with an AAR car coupler can be used to pull heavy rail cars loaded with ballast.
The Speed Swing 445F2 is powered by a 163-horsepower Cummins Tier 4 diesel engine and includes a 49-gallon fuel tank, representing a 29% increase over the previous model’s tank capacity for extended working intervals, company officials said. The Speed Swing can travel at 25 mph on hi-rail and 20 mph with all-terrain rubber tires.
Plasser American’s ballast machines serve a variety of railroad maintenance needs. For routine projects on plain track and turnouts, the RM80 features a single excavating chain and screening unit, along with a 50-mph travel speed and rapid setup/breakdown times to maximize track availability.
For heavier maintenance, the RM80-800 is a high-performance machine built to conquer extremely fouled or encrusted ballast. Its powerful cutting chain tackles tough jobs, while a high-capacity screening system ensures optimal cleaning, company officials said. The RM80-800 also features a track lifting and shifting device for navigating obstacles with minimal disruption.
For large-scale projects requiring the highest production rates, the RM802 is designed to work with pre-dumped ballast or post-dump ballast scenarios, and it achieves cleaning speeds of up to 2,000 feet per hour.
Meanwhile, Plasser Shoulder Ballast Cleaners — including the FRM85 and FRM802 machines — are designed to cut the entire shoulder width and full depth in one single pass to provide more productive and efficient operation. Offered with a single shaker box or, for higher performance, a double shaker box configuration, the units maintain clean ballast shoulders, promoting proper drainage and reducing the frequency of maintenance cycles, company officials said.
Presto Geosystems’ Geoweb® Soil Stabilization System is a powerful tool for reinforcing ballast and sub-ballast layers, company officials said. When trains encounter soft soil, railroads institute speed reductions or halt operations altogether, which can lead to costly downtime. The Geoweb system’s 3D honeycomb structure is designed to confine and stabilize cohesionless soils, delivering strength and higher performance, company officials said.
Presto Geosystems is researching and developing cellular confinement technology for soil stabilization challenges. The Geoweb system has been tested by the Association of American Railroads at the Transportation Technology Center in Pueblo, Colorado. It also has been tested using SmartRock concrete sensor technology at the University of Kansas. Testing found minimal ballast movement and rotation, company officials said.
The Geoweb system’s ability to stabilize and control ballast results in cost savings by requiring less cross-section and virtually eliminating maintenance, they added. The system is designed to perform well on mainline track and in heavy-stress areas, such as crossings, bridge approaches and diamonds.
Presto Geosystems offers free project evaluations, accredited research and testing, and project recommendations.
RELAM (Railway Equipment Leasing and Maintenance) offers several repair facilities strategically located throughout the United States. This enables the company to provide access to affordable, late-model equipment while minimizing the cost of transportation to and from job sites, REALM officials said.
The company has more than 1,000 pieces of railway maintenance equipment, as well as 350 hi-rail vehicles available to lease.
For ballast management, RELAM offers Knox Kershaw and Progress Rail Kershaw ballast regulators that can double as snow fighters to keep tracks clear. Knox Kershaw regulator series 860, 925 and 940, and Kershaw 4600 regulators are “readily available all year long,” company officials said.
RELAM also offers new, rebuilt/remanufactured and late-model Harsco 6700 and Mark IV Production Tampers, as well as Harsco TS-30 HD and Plasser PTS 90C Track Stabilizers. The company also provides turn-key operations for track cleaning along with the Mineral Products Inc. multipurpose 6260 Yard Cleaner, which can accomplish several tasks, from clearing snow to grinding ice to track/yard brooming.
Michael Popke is a Madison, Wisconsin-based freelance writer. Email comments or questions to prograil@tradepress.com.