Types of Rail Welding Methods for Ordinary Rail and Crane Rails: Agico Rail

When flash butt rail welding method is used to weld a rail, the first step is to place the two rail heads opposite each other. Connect the power supply to make the cross sections of the rails close to each other and reach local contact. And these contact points are heated by resistance heat (to produce a flash), so that the end faces are all melted. When a predetermined temperature is reached within a certain depth range, then quickly apply the forging force to complete the rail welding.

Advantages of flash butt rail welding

Flash butt rail welding has the characteristics of high automation, stable process and excellent welding quality. The welded joint of the rail is compact forged structure, the joint toughness is good, the mechanical properties are close to the steel base metal, and the production efficiency is high. It is mainly used for factory rail welding or base rail welding, and partly for unit steel rail welding.

Disadvantages of flash butt rail welding

The flash butt rail welding machine is expensive, the one-time investment is large, the equipment is complicated, and it needs to be equipped with high-power power supply and diesel generator set. The welding process parameters are more and the adjustment is cumbersome. At the same time, the rail burns bad seriously during the flash welding process, and single rail is consumed 25.1-50mm by each joint part.

Gas Pressure Welding Rail Method

Gas pressure welding rail is to use the heat energy generated by the gaseous fuel to heat the end of the rail to be in a molten state or a plastic state, and then apply a certain upsetting pressure to complete the rail welding.

Advantages of gas pressure welding rail

The one-time investment is lower for gas pressure welding rail, the welding time is shorter, the welding quality is better, and the welded joints are also compact forged structures. It mainly used for on-site joint welding. The steel rail burning loss is less, about 30mm shorter on average.

Disadvantages of gas pressure welding rail

The gas pressure welding requirements of the joint section are very strict during welding. The welding process is affected by many human factors, and the joint quality fluctuates greatly and is difficult to control.

Thermite Rail Welding for Rail Connection

Thermite rail welding is to use aluminum and iron oxide (including additives) to arise redox reaction at a certain temperature. The high-temperature liquid metal forms and is sent into a special mold, the two welded rail ends will get melted to achieve the connection.

Advantages of the thermite welding railroad

The thermite welding railroad has the characteristics of simple equipment, convenient operation, low production cost, no upsetting process, good appearance of joints and short lock-up time. The thermite welding railroad method is especially suitable for broken steel rail repair, on-site joint welding on railway frog section of seamless railway line ball and heavy transportation tasks.

Disadvantages of the thermite welding railroad

The thermite welding railroad has low strength, low quality, high breakage rate, poor overall performance. The welding part of the thermite welding railroad is the weakest link in seamless lines.

Electric Arc Welding Railroad

Electric arc welding railroad is to use welding rod or welding wire to melt steel rail by the arc heat generated on end faces and fill the joint gap and forced their ends to get the needed form with copper stopper. After cooling, it will form to be a welded joint. It is a melting welding method.

Advantages of electric arc welding railroad

With suitable welding rod and wire composition, the electric arc welding railroad joint part can obtain bainite structure with excellent performance. The comprehensive performance of welded rail joint part can reach the level of base metal, and the tensile strength and wear resistance sometimes exceed steel base material.

Disadvantages of electric arc welding railroad

At present, the electric arc welding railroad method has been less widely used, and the welding process and technical level are strict.

AGICO Railway can provide you with reasonable rail welding solutions, rail welding technical support and a variety of rail welding equipment. In addition to rail welding machine, we also produce various standard types of steel rails and rail fasteners. Welcome to send enquiry to us for details.

Here’s a reliable reference guide based on information from Agico Rail and related industry sources, detailing common rail welding methods used for ordinary rails and crane (gantry) rails:

🔧 Main Welding Methods for Ordinary Track Rails

According to Agico Rail, the following 4 methods are commonly used for ordinary rails:

1. Flash Butt Welding

Uses high-voltage, high-current resistance heating to create arcs (“flashes”) at rail ends, which are then forged together under pressure.
Produces strong joints with properties close to base steel and is widely used in factory-based or controlled environments.
Drawbacks include high equipment cost, complexity, and rail-end wastage of 25–50 mm per joint.

2. Gas Pressure Welding

Employs oxygen–acetylene flame to heat rails until plastic; pressure is then applied to bond the ends.
Offers quick and cost-effective onsite welding with minimal rail loss (~30 mm) and compact joint structure.
Joint quality depends heavily on preparation and operator skill, leading to variability.

3. Aluminothermic (Thermite) Welding

A chemical exothermic reaction (aluminum + iron oxide) produces molten steel poured into a mold at the rail gap.
Simple setup, rapid execution (one weld in ~30–40 min), and low equipment needs make it ideal for field use.
However, welds can be weaker than flash-butt joints and more prone to defects if slag is not removed properly.

4. Electric Arc Welding

Uses arc heat and filler rods/wires to melt and fill the rail joint manually.
With appropriate electrode chemistry and post-weld treatment, it can achieve mechanical strength comparable to base metal.
Less commonly used in rail applications due to stringent skill requirements and quality variability.

🏗 Crane Rail (Gantry Rail) Welding Methods

Crane rails require tailored techniques due to high-carbon steel and unique load demands. Agico Rail references the following:

A. Puddle Arc (Enclosed Arc) Welding

Also known as manual stick welding, with preheated ends, copper backing strips, and layered welding to fill the gap.
Suitable for crane rails thanks to flexibility, lower consumable cost than thermite, and acceptable fatigue resistance.
Requires skilled welders and controlled conditions.

B. Aluminothermic (Thermite) Welding

Used with molds and thermite charges similarly to railway rails.
Particularly appropriate for onsite welding of crane rails due to portability, short welding time (~1 hour per joint), and ease of operation.
Requires careful process control to manage slag and ensure metallurgical consistency.

C. Flash Butt Welding (Limited Use)

Occasionally used in workshop settings for crane rails, especially in the U.S., when high-quality factory joints are needed.
Requires heavy mobile flash welders and is less common for field installation due to cost and equipment needs.

D. Electric Arc Welding for Crane Rails

Manual arc welding (e.g. MIG/TIG) may be used for small-scale repairs or finishing.
Can offer high wear resistance and tailored metallurgical properties, but requires strict control for consistency.
Less widely used for full-length crane rail welding.

📋 Summary Table

Rail Type	Welding Method	Advantages	Drawbacks
Ordinary Rails	Flash Butt Welding	Highest strength; smooth joints	Expensive, high rail loss
	Gas Pressure Welding	On-site flexibility; low loss	Manual complexity, variable quality
	Aluminothermic Welding	Fast, low-equipment, field-ready	Joint is often weakest in seamless line
	Electric Arc Welding	Controlled metallurgy, high strength	Rare usage; technical skill required
Crane Rails	Puddle/Enclosed Arc	Adaptable, cost-effective, flexible	Slag, layered welding limitations
	Aluminothermic Welding	Quick, portable, minimal consumables	Quality control needed; possible defects
	Flash Butt Welding	Seamless high-fidelity joint (factory)	Heavy equipment; not field-friendly
	Electric Arc Welding	High hardness/wear resistance	Less common; operator-dependent

💡 Why Multiple Methods Exist

Ordinary rails: continuous welded tracks (using flash butt in factory, thermite in field) offer smooth, high-speed routes and reduced maintenance. Flash butt provides consistency; thermite offers flexibility onsite.
Crane rails: heavy-duty rails with high carbon content require controlled heat, minimal distortion, and layered welding practices. Puddle arc and thermite welding are favored due to portability and adaptability.

🧠 Community Insight

From industry forums and engineering discussions:

“Thermite welding… a skilled team can complete a weld from start to finish in about 30 minutes… most field track repairs are done with aluminothermic welds.”
“Puddle arc welding is often used with electrodes to produce a flexible joint with durable rail head wear surface in crane rails.”

✅ Final Notes

Ordinary rails predominantly use flash butt welding (factory), with thermite welding for field joints; gas pressure and arc welding are supplementary.
Crane rails rely on puddle arc welding and thermite welding for fieldwork; flash butt shielding is occasionally used in controlled settings; arc welding is limited to repair/fine-tuning.
Agico Rail supports and supplies equipment/materials for thermite welding across both rail types, including grooved rails and crane rail profiles.

Would you like detailed procedure steps for any method, specs for rail grade-specific welding, or guidance on selecting the right technique for a project?