Orbital Rail Welding Process for Reliable Track Construction

01Welding process

Many different welding methods exist in the world today. SINCHOLD will recommend a better welding method based on various factors such as the geographic location of the project, available personnel, equipment and consumables.

02Crane rail welding

The crane can only run on continuous welding rails. The reasons why the track is difficult to weld are as follows:

The high carbon content makes the track wear-resistant.
For high carbon equivalent, a special process must be used for welding.
It is considered that the welding area is large and the cross section is poor.

Steel grades for cranes and railway tracks are not easy to weld with traditional methods. The most commonly used welding methods for crane rails are arc welding, thermite welding and flash butt welding. SINCHOLD is a world-recognized leader in the field of crane rail welding.

03Orbital welding method

Ideally, the orbital welding method requires:

The track is cut into squares (rather than beveled like structural welding)
High temperature preheating to deal with the composition of steel
High deposition rate of weld metal
Acceptable defect level for the fracture resistance of steel

Ideally, the rail welding method requires：

The composition of steel should be determined by high temperature preheating
High deposition rate of weld metal
Acceptable defect level of steel fracture resistance
Closed arc and thermite welding methods meet these standards
Operating procedures should be followed by skilled operators

Closed arc and thermite welding methods meet these standards. Flash butt welding is not suitable for most European rails with large cross-sections. The thermite and closed arc welding methods need to be carefully followed by the following operating procedures by skilled operators:

PUDDLE ARC WELDING
Arc welding is widely used in orbital welding of cranes all over the world. SINCHOLD hires skilled technicians to do this work or train other personnel. This method requires cutting the ends of the rails to be welded into squares with an interval of 20 mm, and welding them with special manual metal electrodes after preheating.
ALUMINOTHERMIC WELDING
The two ends of the square rail are thermite welded with refractory molds. After the rail ends are preheated, due to the chemical heating in the crucible, the 20mm space at the rail ends is filled with electric charges in the molten steel.
FLASH BUTT WELDING
The rails are usually flash welded before shipment from the steel plant. Sometimes used to weld crane rails on site. It requires several thousand amperes of current, so the equipment is expensive. The rail end is heated by high-power current. When the heat reaches a certain level, it will be welded together.

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04Crane rail welding and installation

SINCHOLD has a professional technical team capable of completing the installation of various projects in many countries. This provides great flexibility, allowing operations to continue even when project schedules are tight or when the power supply of important power plants is interrupted, thereby ensuring construction progress. During the preliminary on-site inspection, strict planning must be carried out, and the team will hold a meeting for discussion before the project commences. Materials and equipment must be prepared on site, and appropriate protective measures suited to the environmental conditions must be taken. In addition, the team will develop detailed construction plans and contingency measures based on the actual conditions of the project site, ensuring that the installation process is carried out efficiently and in an orderly manner. At the same time, we place great emphasis on close communication with clients, responding promptly to on-site needs, and striving for excellence in every aspect to provide reliable installation service assurance for our clients.

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