Aluminothermic Welding

Head Wash Repair (HWR) Process

The Head Wash Repair (HWR) process provides a cost-effective and efficient solution to repair railhead defects and significantly decreases the maintenance cost of modern rail networks. The latest improvement on HWR expands the possibilities by allowing the repair of flash butt welds, which often suffer from squats.

The process is an effective solution for repairing defects with a width between 25 mm and 90 mm, and a depth of 25 mm (depending on the rail profile). It is suitable for both the parent rail and on EFB welds.

Technical Features

  • Aluminothermic weld process with specially designed molds
  • The HWR process is well established and has been used in the USA and Canada since 2008, in the UK since 2013, and has been approved in France from 2015
  • The HWR process is available for each rail grade


  • HWR process is used on parent rails and on Flashbutt welds for reparation
  • A familiar mould design allows the welding crew to install the HWR weld quickly and easily
  • An efficient process when compared to using plug rail, reducing the number of welds from two to one and offering a significant reduction in time and maintenance costs
Aluminothermic Welding

Head Wash Repair (HWR) Process

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