How are rails manufactured? - Knowledge

Steel rail, we also called the railway track, it is crucial to the steel railing system. As a rail component of the railway system, steel rail guides the train forward and bears the enormous pressure. Meanwhile, the steel rails convey the pressure to the railway sleepers. So steel rails play a big role in the railway system and the quality of the steel rails is much important.

heavy rail

Besides, steel rails have another crucial function. The steel rails provide a smooth and less resistance surface for the vehicles that ensure the safe running.

How are rails manufactured?

Rail manufacturing involves smelting scrap steel into molten steel, casting it into rectangular billets, and then using a hot rolling process with universal mills to shape the steel into the familiar "I" profile, followed by cooling, straightening, cutting, and intensive quality inspection (like ultrasonic testing) to ensure strength and durability for heavy loads.

1. Raw Material & Smelting

Scrap Preparation: Recycled steel scrap is the primary raw material.

Smelting: The scrap is melted in an electric arc furnace, with precise amounts of carbon and other elements added to create specific steel grades (like U71Mn, U75V).

crane rail

Steel Grade	C(%)	Si	Mn	Cr	V	P	S	Tensile Strength (Rm/MPa)
U71Mn	0.65~0.76	0.15~0.58	0.70~1.40	–	–	≤0.035	≤0.030	≥880
U75V	0.71~0.80	0.50~0.80	0.75~1.05	–	0.04~0.12	≤0.035	≤0.030	≥980

Casting: The molten steel is continuously cast into large, rectangular "blooms" (e.g., 280mm x 380mm).

2. Heating & Rolling

Heating: Blooms are heated uniformly in a walking beam furnace to about 1200-1300°C.

Rolling: The hot bloom is passed through a series of roughing, intermediate, and finally universal rolling mills.

Shaping: These mills progressively deform the bloom into the final "I-shape," forming the head, web, and base, often in a single continuous pass.

light rail

3. Finishing & Inspection

Cooling & Straightening: Rails are carefully cooled and then straightened to remove stress and ensure dimensional accuracy, with processes like slow quenching for specific properties.

Cutting: They are cut to standard lengths (e.g., 25m, or longer for continuous welded rail).

Inspection: Rigorous quality checks, including ultrasonic flaw detection, verify the rail's internal and surface integrity for strength, wear resistance, and fatigue life.

heavy rail

4. Installation (Not Manufacturing, but Related)

Rails are joined using techniques like thermite welding and secured to ties with clips or spikes, with precise spacing measured by track gauges.

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GB standard steel rail

gb rail

Classification		Height(mm)	Head (mm)	Bottom (mm)	Thick(mm)	Weight (kg/m)
Light Rail	8 KG/M	65	25	54	7	8.42
	9 KG/M	63.5	32.1	63.5	5.9	8.94
	12 KG/M	69.85	38.1	69.85	7.54	12.2
	15 KG/M	79.37	42.86	79.37	8.33	15.2
	18 KG/M	80	40	80	10	18.06
	22 KG/M	93.66	50.8	93.66	10.72	22.3
	24 KG/M	107	51	90	10.9	24.46
	30 KG/M	107.95	60.33	107.95	12.3	30.1
Heavy Rail	38 KG/M	134	68	114	13	38.733
	43 KG/M	140	70	114	14.5	44.653
	45 KG/M	145	67	126	14.5	45.546
	50 KG/M	152	70	132	15.5	51.514
	60 KG/M	176	73	150	16.5	60.64
Crane Rail	QU 70	120	70	120	28	52.8
	QU 80	130	80	130	32	63.69
	QU 100	150	100	150	38	88.96
	QU 120	170	120	170	44	118.1

Japanese industrial standard steel rail

Size	A	B	C	t	Weight (kg/m)
JIS 15kg	42.86	79.37	79.37	8.33	15.2
JIS 22kg	50.8	93.66	93.66	10.72	22.3
JIS 30A	60.33	107.95	107.95	12.3	30.1
JIS 37A	62.71	122.24	122.24	13.49	37.2
JIS 50N	65	153	127	15	50.4
CR 73	100	135	140	32	73.3
CR 100	120	150	155	39	100.2

Britain standard

Size	A	B	C	t	Weight (kg/m)
50O	52.39	100.01	100.01	10.32	24.833
60A	57.15	114.3	109.54	11.11	30.618
60R	57.15	114.3	109.54	11.11	29.822
70A	60.32	123.82	111.12	12.3	34.807
75A	61.91	128.59	114.3	12.7	37.455
75R	61.91	128.59	122.24	13.1	37.041
80A	63.5	133.35	117.47	13.1	39.761
80R	63.5	133.35	127	13.49	39.674
90A	66.67	142.88	127	13.98	45.099
100A	69.85	152.4	133.35	15.08	50.182
113A	69.85	158.75	139.7	20	56.398

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