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11/15/2024
Compiled by Bridget Dean, Associate Editor
Traditional flash-butt rail welds have been produced using diesel-powered generators that face ever-stringent emissions standards. This year, Holland deployed its first battery-powered flash-butt welder to provide a more sustainable rail welding solution.
The Hybrid Welder™ can currently perform approximately 20 to 25 welds with a prototype battery system that uses its current AC welding equipment with a DC-to-AC converter and power factor control, Holland officials said in an email.
The system is designed to reduce fuel consumption, emission and noise, making it suitable for applications in denser urban settings and tunnels, they said. When developing and testing the battery-powered welder, Holland’s research and experimentation showed that slow bend testing, voltage control and weld consistency performed well in testing on welds made with the battery system. The hardness, heat affected zone and overall equipment function were equal to current generator-powered welding equipment, Holland officials said.
Another benefit of the Hybrid Welder: its compliance with evolving emission standards. The battery system reduces units from two engines to one, avoiding the potential equipment downtime associated with traditional diesel-powered generators, Holland officials said.
Currently, two mobile flash-butt welders with battery-powered systems are operating throughout North America, and Holland plans more builds. In the future, the company’s “Version 2” Hybrid Welder will allow for faster charging, enabling the unit to perform 40 to 45 welds per shift, Holland officials said.
RailWorks offers an expanding fleet of narrow head flash-butt trucks equipped with a 70-ton weld head to add to its existing fleet of standard mobile welders. The head only requires 8 inches of clearance to perform a weld.
This unique design allows RailWorks to safely make close clearance welds around the frog and switch points, which are usually done with thermite welds, company officials said.
The narrow head flash-butt trucks are equipped with a 25-foot Hiab crane that maximizes the reach, allowing welds to be performed both adjacent to or on track with fewer moves. These units operate with a standard Chemetron Control System and remote monitoring, which allows for observation of real time weld data, RailWorks officials said.
When utilizing right conditions, RailWorks is noting extremely high production rates, which is lowering the capital expenditure for special trackwork, company officials said.
Genesis Rail Services offers expert Thermite welding services, delivering permanent track joints that ensure safety and stability, company officials said.
The Genesis team consists of certified Thermite welders who are skilled in utilizing specialized equipment from Goldschmidt thermite welding kits to perform this critical task with precision and efficiency, they said. Genesis Rail Services offers mechanical, engineering, transportation and equipment services to customers in the rail industry.
Its team is dedicated to designing and constructing reliable railroad infrastructure, supporting maintenance projects, responding to emergencies when necessary and providing the needed specialized equipment, company officials said.
Email questions or comments to bridget.dean@tradepress.com.