Aluminothermic Welding

Head Wash Repair Rail Welding

Provide a cost-effective and efficient alternative to plug rail repairs with Pandrol’s head wash rail repair process. We’ve been adding value to US and Canadian rail networks with this process since 2008, in the UK since 2013, and in France since 2015. Join the global rail pioneers who are already leading the way to improved rail weld repairs with Pandrol.

Pandrol’s Head Wash Repair Welding Process Explained

The aluminothermic head wash repair weld process is carried out using specially designed moulds. After unmoulding, the weld is trimmed and ground in accordance with the network specifications. It is capable of repairing railhead defects between 25mm and 90mm wide and 25mm deep (depending on the rail profile).

The head wash process can be used on both the parent rail and on electric flash butt welds, which often suffer from squats. It is also suitable for repairing transversal defects, shelling and corner gauges, and complies with the quality and safety requirements of all modern rail networks.

  • Fast-track rail defect repairs with no need for destressing
  • Comply with the quality and safety standards of your global rail network
  • Choose a repair process that’s compatible with many weld types
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Advantages of the Pandrol Head Wash Repair Rail Welds

01

Simplicity

Repair head wash welds with just one weld and no need for rail destressing. The Pandrol head wash rail repair process is simple and efficient, bypassing the need for rail section replacement involved in the plug rail repair process.

02

Time savings

Save time compared to plug rail repair. The familiar mould design enables the welding crew to do the repair weld quickly and easily. Head wash repair welding takes just one hour rather than three or four, reducing rail system downtime and labour costs.

03

Safety

Promote a safer rail environment by choosing head wash repair rail welding. The process uses the same parameters and hardware as Pandrol’s signature aluminothermic welding process, which is known for its safety.

04

Equipment cost savings

Save the money you’d otherwise invest in training and hardware for alternative weld repair processes. The head wash weld repair process uses standard hardware and a one-shot crucible, making it easy for any welding expert to complete.

05

Compliance

Easily meet the compliance requirements of modern railway networks. Pandrol head wash repair welding is available for all rail grades and suitable for all environments.

Technical Capabilities of Head Wash Repair Rail Welding

01

Cutting and grinding

Adapt the head wash repair rail welding process to your project and equipment requirements. The slot can be created by oxy-propane cutting or grinding, as per your preference.

02

Optimum fusion area

Ensure total removal of the rail defect with head wash rail repair welding’s optimum size fusion area. The width is approximately 120mm with the oxy-propane cutting method, and 80mm with the grinding method. Fusion depth reaches 30mm below the slot.

03

Tensile stress management

Strengthen fatigue resistance while also avoiding flashing under the rail head for a cleaner weld. When using head wash repair rail welding, the felt protects this crucial location of the highest tensile stress.

04

Hardware

Choose a weld repair process that welding crews are already familiar with. The Pandrol head wash rail repair process uses standard hardware and a one-shot crucible, and its specially designed moulds are based on products that crews use often.

05

Versatility

Repair squats, transversal defects, shelling and corner gauge defects between 25mm and 90mm wide and 25 mm deep with the same process. Head wash repair is even compatible with the parent rail and electric flash butt welds.

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