September/October 2023 - 15
S P O N S O RE D B Y
Future Rail Treatment - NOW
shielding, fire-suppression equipment,
a dust collection system). The resultant
surface quality (roughness) can be adjusted
through the process parameters.
Rail grinding machines are available in
various sizes, ranging from a small eightstone
high-rail vehicle to a 120-stone
production grinder. Rail grinding can
achieve passing speeds of up to 20 mph.
Rail milling is a dry, spark- and dustPhoto:
Plasser American
What is the significance of the rail
for wheel-rail system behavior?
The rail is a central component of the
wheel-rail system, as it defines the wheelrail
contact patch together with the wheel.
Although the rail sits at a central point of
the system, it cannot be classified as the
most important component. Every component
of the system (subgrade, ballast,
ties, fastenings, etc.) has an impact on
system behavior and thus has a direct or
indirect impact on the other components
of the system, as well. Only by choosing
a holistic approach that considers these
components and their interactions, the
whole system can be optimized.
What can be done to extend the
life of the rail (and the system)?
The term " rail treatment " is used to summarize
strategies, measures and technologies
to extend the life of the rail and
the system. The infrastructure owner can
choose from several tools in the rail treatment
toolbox, so to speak. First, measurement
technology is a requirement, or
even a precondition, for using any other
tool, as you can only manage what you
can measure. Measurement technology
includes transversal and longitudinal
profile measurement, surface crack detection
systems and ultrasound systems.
Next, the most suitable rail grade needs
to be selected for the application scenario
in question and these rail grades need to be
joined with a reliable, high-quality joining
technology, such as flash butt welding,
so the rail and rail connection have the
same service life. Optimized rail (and
wheel profiles) reduce contact stresses and
improve vehicle steering, thereby extending
the life of both components. A track
in very good condition has low dynamic
forces, which delays the formation of rail
damage. Conversely, a damage free rail in
very good condition delays track degradation.
Friction management, the combined
application of gauge face lubrication and
top of rail friction control, reduces contact
and steering forces between the wheel and
rail, which delays the formation of rail
damage.
Finally, rail maintenance (rail grinding,
rail milling) is the only tool in the
toolbox that does not delay the formation
of damage. Instead, it can counter rail
degradation by removing surface damage
and restoring the rail profile. It is important
to highlight these rail treatment tools
must not be seen as stand-alone solutions.
Instead, they need to be applied considering
their direct or indirect interaction.
Rail grinding and rail milling -
competitive or complimentary
technologies?
Rail grinding and rail milling are the two
main technologies for rail maintenance.
Rail grinding is an abrasive process that
allows for low to medium metal removal
per machine pass, creating the desired
rail profile as a slightly polygonised
shape. The process allows for " on the
fly " profile adaptation by adjusting the
grinding stone angle and pressure. The
bi-directional process results in sparks
and dust that can be adequately controlled
through various measures (spark
free, rotational cutting process in which
the rail material is removed from the rail
surface in the form of milling chips. The
chips are collected and stored on the machine
for later recycling. The resultant rail
profile is defined by the negative shape
of the cutting head. A different profile
requires changing the cutter head. Rail
milling has a wide range of metal removal
capabilities, ranging from 0.3 mm to several
millimeters per pass, depending on
the machine size. Due to the integrated
polishing process, rail milling creates
a high-quality surface finish with low
roughness. The directional process can
achieve up to 1.85 mph per pass.
Considering the properties of both
technologies, it is evident that grinding
and milling are mostly complimentary
technologies. Rail grinding has the highest
productivity in preventive, low metal
removal scenarios, whereas rail milling
has the advantage in regenerative or
heavy corrective scenarios that require
high metal removal. There is a limited
competitive overlap in corrective applications
requiring medium to high metal
removal. Of course, specific customer requirements
and technological properties
may shift the application window toward
one maintenance technology or the other.
What is the future of rail treatment?
The future of rail treatment has already
begun today, with Plasser American offering
a wide variety of innovative technologies
and services as a full-service
provider in the areas of rail measurement
technology, rail welding and rail maintenance,
as well as track maintenance
machinery / technologies.
About the author
Richard Stock is global head of rail solutions at
Plasser American.
SEPTEMBER/OCTOBER 2023 | MassTransitmag.com 15
http://www.MassTransitmag.com
September/October 2023
Table of Contents for the Digital Edition of September/October 2023
Editor’s Notebook
People & Places
MCTS’ CONNECT 1 BRT Bringing Public Transportation Usage Up in Milwaukee Area
Transit Agency Consortium Applies for FTA Waiver for Minibuses
APTA Awards BART the 2023 APTA Rail Safety Gold Award
APTA’s Big Show Returns to Orlando
Improve Fare Revenues and the Passenger Experience by Upgrading to a Future- Proofed Ticketing Infrastructure
Industry Insights: The Intersection of Diverse Leadership
Products
September/October 2023 - 1
September/October 2023 - 2
September/October 2023 - 3
September/October 2023 - 4
September/October 2023 - 5
September/October 2023 - Editor’s Notebook
September/October 2023 - 7
September/October 2023 - 8
September/October 2023 - 9
September/October 2023 - People & Places
September/October 2023 - 11
September/October 2023 - 12
September/October 2023 - 13
September/October 2023 - 14
September/October 2023 - 15
September/October 2023 - 16
September/October 2023 - 17
September/October 2023 - MCTS’ CONNECT 1 BRT Bringing Public Transportation Usage Up in Milwaukee Area
September/October 2023 - 19
September/October 2023 - 20
September/October 2023 - 21
September/October 2023 - 22
September/October 2023 - 23
September/October 2023 - Transit Agency Consortium Applies for FTA Waiver for Minibuses
September/October 2023 - 25
September/October 2023 - 26
September/October 2023 - 27
September/October 2023 - 28
September/October 2023 - 29
September/October 2023 - APTA Awards BART the 2023 APTA Rail Safety Gold Award
September/October 2023 - 31
September/October 2023 - 32
September/October 2023 - 33
September/October 2023 - APTA’s Big Show Returns to Orlando
September/October 2023 - 35
September/October 2023 - 36
September/October 2023 - 37
September/October 2023 - 38
September/October 2023 - 39
September/October 2023 - 40
September/October 2023 - 41
September/October 2023 - Improve Fare Revenues and the Passenger Experience by Upgrading to a Future- Proofed Ticketing Infrastructure
September/October 2023 - 43
September/October 2023 - 44
September/October 2023 - 45
September/October 2023 - Industry Insights: The Intersection of Diverse Leadership
September/October 2023 - 47
September/October 2023 - 48
September/October 2023 - 49
September/October 2023 - Products
September/October 2023 - 51
September/October 2023 - 52
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