Milled and step rails

The design of the new milling machine in the Netherlands is unique compared to existing variations. This prototype is the only machine in the world that mills symmetrically in one operation. The rails are milled on both sides, It therefore does not matter from which direction the rail arrives at the construction site. This greatly increases flexibility of transportation and storage.

First of all, the decarburised on the surface of the rail is removed, before the train goes into operation,  to prevent damage during use and to extend the service life. If not, it will be ground into the rails and cause damage.  Often, this removal isn’t performed before new tracks are installed. Or it is carried out too late which results in unnecessary rail damage. All of which can be prevented by installing pre-milled rails.

The milling process not only extends the rail life span but is also essential and contributes essentially to the overall sustainability and quality of railway networks.

• No downtime by grinding activities in track
• Longer lifespan of rails
• A longer crack-free period after installation
• Process is carried out under controlled conditions
• Quality control
• Production and deliveries on call

The outer layer, the so-called ‘carbon reduced zone’ is a fine layer of ignition formed during the production process of rail. It covers the entire rail surface and consists of a depth of approximately 0.7 mm. If this layer is not removed before the train goes into operation it will inevitably cause damage.  The hard scale particles will be ground into the head of the vignol rails which can be the initiator of cracks.

It is a continuous process, and the machine is equipped with a fully automatic handling system for loading and offloading finished rails. A new production hall has been built to house the milling machine. The milling machine is certified by an authorized body (KIWA) and meets the official Dutch specifications ‘Prefab milled, ground or planed rails’.

The standard rail type profiles that can be milled are UIC54 and UIC60 rails with a standard length of 60, 90 and 120 meter and with standard depths of ≥ 0,7 mm ≤1 mm; 2 mm, 4 mm, 6 mm, and deeper. Other rail profiles and depths are milled on request.

This high productivity can be achieved without producing sparks, dust or dirt. In comparison to mobile grinding, stationary milling technology not only protects the environment, but also prevents pollution of the track bed. All metal chips produced during milling are removed by a suction device and can be resold as high-grade steel scrap.