Welding services

BTW Grupa Trakcja performs bonded joints in tracks, turnouts and track crossings using thermite mixes and prefabricated dry forms. Our company offers high quality rail autogenous welding in a jointless track. The staff we have at our disposal has the appropriate authorisations to perform and accept welding works performed on the tracks of PKP PLK S.A. and tramways.

The rails are welded with two-way welding machines:
- Vaia Car Spark Rail type with K335A1 head
- KCM005 with head K 922-1
Overlay welding of rails and turnout parts
Production of thermite welds 49E1 or 60E1 using the SoWoS/SoWoS-P method
Production of 3-part thermite welds
Production of transition thermite welds 49E1/60E1
Production of 3-part thermite welds

Production of thermite welds L-70, wide clearance
Production of thermite welds 60R2
Production of electrical welds 60R2
Production of thermite welds with the use of tensioners
Production of glued insulated rail joints 49E1 or 60E1
Heating the rails with the SH 12S two-pipe heating bogie

Welding high quality railway rails in a non-contact track.
Mobile, two-way transport system.
Welding of short and long rails up to 340 m.

Welding of rails with UIC60, S49 profiles.
High machine performance: from 2 to 4 welds per hour.
Control of the welding process documented on the record from the welding process recorder.

Vaia Car Spark Rail type welding machine with K335A1 head

The Vaia Car Spark Rail type welding machine with K335A1 head is designed to weld rails directly in the track. The welding head is mounted on a truck with a wheel-rail chassis. It is possible to put the vehicle on the rails at a level crossing or by means of an auxiliary ramp. On the railway track, the machine moves independently as a rail vehicle. Transport from one construction site to another is carried out on a low-loading platform. The welding head used in this autogenous welding machine is a typical head produced at the plant in Kakhovka (Ukraine). The autogenous welding process is controlled and monitored by the on-board computer. The measuring system measures three autogenous welding parameters: distance, working pressure and electric current, all as a function of time.

KCM005 welding machine with K 922-1 head

The KCM005 two-way autogenous welding machine with K 922-1 head is designed for welding of rails in the track. The head, together with the unit and auxiliaries, is mounted on a truck with a chassis enabling driving on the road and on the railway track. The head allows autogenous welding of rails with basic profiles. The autogenous welding process is controlled by a computer system, ensuring repeatability of the process and appropriate quality of joints. The control system monitors and records welding parameters such as autogenous welding current (I), transformer voltage (U), travel distance (S), pressure (P) as a function of time. The autogenous welding program allows for presparking, sparking with increasing speed, swelling, cutting off the bead of molten material and, if necessary, heat treatment.

Using the thermite welding method, we produce joints intended for making inseparable rail joints, including the cycle of preparation, execution and acceptance of rail joints (Vignole) with profiles 60E1, 49E1 manufactured from steel grades R260 and R350HT.

Our services include thermite welding of rails and turnouts using the following methods: SoWoS, SoWoS-P, SoWoS-P 350, SoWoS 120

Our range of products and services includes:

Autogenous welding of rails

Vaia Car Spark Rail type welding machine with K335A1 head

KCM005 welding machine with K 922-1 head

Welding of rails and turnouts