Track Measurement and Analysis

Ultrasonic Rail Testing

Ultrasonic rail testing is a full-track inspection solution that uses high-pitched waves to scan rails and identify internal flaws in need of repair. Pandrol teams are experts in the application of ultrasonic rail inspection, and our certified inspectors can provide comprehensive training tailored to your infrastructure, setting, and use case.

Ultrasonic Rail Testing product overview

Ultrasonic rail testing is a full-track inspection solution that uses high-pitched waves to scan rails and identify internal flaws in need of repair. Pandrol teams are experts in the application of ultrasonic rail inspection, and our certified inspectors can provide comprehensive training tailored to your infrastructure, setting, and use case.

Our range of ultrasonic equipment includes both manual and motorised inspection tools, which can be operated at up to 20 km per hour. Learn more about our equipment, processes, and training on this page.

Ultrasonic rail testing companies have a responsibility to provide reliable equipment, fully-trained operators, and optimal results. Trust Pandrol’s track record for safety, accuracy, and upholding industry-leading standards.

  • Prevent failures and accidents – reduce the risk of non-detection
  • Check small or large sections of rail – choose the equipment to suit your project
  • Rely on ultrasonic for comprehensive testing – check rails vertically and from many other angles for a full picture
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Advantages of Ultrasonic Rail Testing

01

Predictive maintenance

Pandrol ultrasonic rail inspection detects rail defects earlier than manual methods thanks to its increased sensitivity. This allows for preventative maintenance to be planned as far ahead as possible, reducing disruptions to the rail system including speed restrictions.

02

Reduced costs

Earlier and more efficient management of track defects cuts repair and replacement costs in the long run. Fewer breakages and anticipated replacements lead to fewer losses and cheaper repairs to maintain rail performance.

03

Improve safety

Ultrasonic methods of rail monitoring reduce the need for manual verification thanks to their proven accuracy and reliability. This decreases the need for on-track workers, promoting safety and reducing the risk of accidents. The effectiveness of ultrasonic detection protects workers, rail staff, and passengers from potential accidents caused by undetected defects.

04

Future-proof your track

Extend the life span of your railway system’s assets, with a testing method that detects faults early enough for repair to be an option. Ultrasonic rail inspection also allows maintenance teams to adapt to increasing traffic demands on the rail network. More frequent trains have reduced opportunities to inspect – the speed of ultrasonic testing circumvents this challenge without compromising safety.

05

Improve defect knowledge

Rely on ultrasonic rail testing to gather a detailed analysis of all essential elements relating to track safety, strength, and integrity. From rails to bonded insulating seals, switches to crossings, ultrasonic testing gathers and stores an accurate data record of track condition. This is ideal for learning and analysing track degradation or durability over time.

06

Increase efficiency

Ultrasonic testing of railway track can be carried out much faster than manual methods, while also being far more sensitive to minute defects and flaws in the rail. It reduces the risk of human error impacting the testing process, and can even be completed on areas of the rail where worker and equipment access is limited. The result is a more efficient means to monitor rail conditions.

Technical features of Ultrasonic Rail Testing

01

Work with ultrasonic experts

Our team of experts is comprised of level I, II and III NDT certified inspectors with more than 30 years of experience in Non-Destructive Testing. We offer our Ultrasonic Testing services to
customers worldwide to enhance the quality and lifetime of their infrastructure.

02

Inspect 100% of the weld

Our ultrasonic testing stick uses five angled probes positioned at -70° / -40° / 0° / +40° / +70° to get a fully detailed ultrasonic analysis of the rail.

03

Multiple options available

Pandrol offer their customers three methods of ultrasonic testing: a handheld walking stick with 10 hours of battery life, a trolley that can analyse both track simultaneously, and a motorized solution that can inspect both rails at a speed of up to 20 km/h.

04

Versatile design

Our Ultrasonic Testing solutions detects a variety of defects including blowholes, insufficient fusion, and shrinkage. We offer both conventional probes and newer phase array technology.

05

Realtime data

The information collected by the transducers are transmitted to the displays in realtime for instant data viewing and analysis.

Tell us about your track project

Walking stick

  • Anti-derailment wheel
  • Height-adjustable telescopic handle
  • Single man operation
  • Simple connection to UT flaw detector
  • Inspects all track components, including rail, welds, switches, crossing, and insulated joints
  • Characterisation of defects after detection passage

Watch the video to see the Pandrol ultrasonic testing walking stick in action.

Ultrasonic trolley

  • Capable of ultrasonic inspection of the two parallel rails simultaneously
  • On the track and ready to go in less than 5 mins
  • 23kg lightweight machinery for single-man operation
  • Operation speeds up to 5kmph
  • Suitable for rail temperatures from -10 to 55°C
  • Adaptable to rail gauges from 1000 to 1674mm
  • Multiangle detection of rail and weld defects
  • Officially approved by French railways
  • A-scan display
  • Dead man’s breaking system
  • Available with smart capabilities including B-scan display, encoder, recording and GPS localisation

Watch the video to see the Pandrol ultrasonic rail testing trolley in action.

Ultrasonic rail testing explained

Ultrasonic testing of railway tracks can produce a fully exhaustive report of the location, characteristics, and urgency of any defects detected. The method is ideal for taking dimensional and thickness measurements, characterising material and detecting damage. It is also sometimes referred to as ‘non-destructive testing’ thanks to its non-invasive nature.

The ultrasonic test procedure operates via a pulse-echo technique. This describes the process of passing short ultrasonic pulses from the equipment into the component, where they are then reflected by obstacles. The reflected pulses are then displayed on the screen for reading by the operator. Water or oil is applied to the probe to ensure no air interrupts the pulses, which could impact results.

This comprehensive process can be carried out on both rails and welds. Testing the head, web, and foot to provide a detailed picture of weld health allows engineers to confirm that rail welds meet the specifications set out by the rail network for quality and safety.