Rail: going to even greater lengths

Corus Rail has commissioned Corus Northern Engineering Services to develop a new Rail Weld Test Module capable of testing the integrity of welded joints to destruction.

Corus Rail satisfies the market demand for ever increasing lengths of rail by joining two sections together using a purpose built 70,000-amp flash butt welding machine.At the same time, Corus is making rail from stronger material, and needs to prove the integrity of its welding by testing every fiftieth joint to destruction.

This bespoke self contained unit delivers accurate results, meeting all of the standards expected from testing stronger steels, using state of the art finite element analysis in the design process. The design is housed inside a standard shipping container, providing both easy means of transport and the effective personnel protection from flying debris. Conforming to CE Standards, the test machine is capable of testing weld rails beyond the mandatory standards.

The test module can be adaptable to mobile versions, which will house a self-powered generator for on-site track laying. Controlled by a PC panel that not only provides practical touch screen technology and an interlock system to prevent personnel entering during testing, but also records each test, allowing full traceability for quality management systems.