Railways are one of the most important modes of transport throughout the world, they allow us to pass through varying places with ease. But over time they endure various forms of damage. None more so than corrosion – and our spray coatings can reduce can not only improve the rail lifespan, but reduce downtime.

The components of external environments can also reduce the thickness of the rail components. Lucky for you, you have found a company in Alphatek that can help improve rail lifespan with spray coatings.

How Often Do Railways Need Maintenance?

Railways need maintenance, including the track itself. The Track must be surfaced, too, to restore alignment and ride quality, anywhere from annually to every five years or so depending on traffic volume, speed, type of track components, and subgrade quality.

While rail operations fully understand the need for ongoing preventative maintenance, it’s a time-consuming and expensive process – and due to the challenges, that exist in properly tracking and carrying out maintenance activities, it’s easy to allow these preventative measures to fall by the wayside.

What Is Railway Corrosion?

There are essentially two forms of corrosion-related rail failure. Rail gall and foot fatigue.

Rail gall is a general loss of rail section (usually affecting the foot). This can be a general loss of section but is usually more severe under rail clips/fastenings due to the localised environment.

Foot fatigue results from the combined effect of corrosion and fatigue. A corrosion pit forms on the foot of the rail and under traffic a fatigue crack can grow from this defect, ultimately causing complete rail failure. This is, in my opinion, the most problematic form of corrosion.

Improve The Rail Lifespan With Our Coating Solutions

When Structural engineers design steel railways, consideration is given to how to protect the steel frame against corrosion. Various measures can be employed, but the typical solution is to coat the steel frame with an anti-corrosion coating.

We have been a major supplier of standard and bespoke coating solutions of the highest performance to a variety of industries. This includes the oil and gas industry and transportation sector for over 2 decades.

Anti-corrosion coatings used for offshore structures and components must, by definition, be designed to withstand the onslaught from one of the most inhospitable environments there is.

If we’re supplying for a region with a high movement of sand, the soil composition of desert areas, such as Iran, consists of sand and salt. Due to the movement of sand and the corrosive ions of salt, railway fastening systems can corrode.

Corrosion protection coatings must be efficient and long-lasting under the most destructive of environmental conditions.

Here are our proven Rail Coating benefits:

  • Provides galvanic corrosion protection.
  • Electrically conductive coating.
  • High-durability allows rail installation with standard handling techniques.
  • High-temperature capability minimises heat damage from welding operations.
  • Coating thickness does not impair the fitting of nylon insulators and fastenings.

Using these methods and solutions will greatly increase the lifespan of your railway. Other railway benefits include:

  • Reduced rail lifetime costs through reduced rail maintenance and increased rail life.
  • Reduced rail replacement costs compared to epoxy paint coating systems.
  • Retained S&T capabilities.

Types Of Thermal Spray Coatings

There are five main types of thermal spraying, all of which project small molten or softened particles onto a surface to adhere and form a continuous coating. The temperature increase of the coated part is minimal, meaning heat distortion is rare – a major advantage over hot-dipped galvanising or welding.

Thermal spraying for corrosion control is combatted by Flame and Arc-wire – This method is cost effective and quicker to implement. It is perfect for corrosion protection of larger structures like railways. Plasma and HVOF sprays are used to apply engineering coatings and are of higher quality, density, and bond strength.

Alphatek: Contact Us

Here at Alphatek, we have a combined over 100 years of cumulative coating expertise in house. We have experienced and dealt with a variety of railways, check out our case studies.

Working closely with our customers over the years, we have developed our products and services to deliver the best value, most effective thermal spray coatings solution, first time, every time and with a stress-free service that suits everyone.

For Metal Spraying and Thermal Spray Coating specialists, look no further than us, Alphatek. You can call us directly on 01706 821021, or you can email us at postbox@alphatek.co.uk.

Alternatively, if you’d like to visit us we are located 20 miles north of Manchester. Just be wary of our opening times.