EN 15594:2026
(Main)Railway applications - Infrastructure - Restoration of rails by electric arc welding
- Abstract
This document specifies restoration by electric arc welding and is limited to the head of the rails only.
This document describes the approval systems for consumables and procedures used in manual metal arc and flux cored metal deposit rail repair welding. This document includes the quality-related tasks and responsibilities of personnel involved in the electric arc repair welding of rails. This document applies to plain rail and switches and crossings manufactured from new Vignole railway rails R200, R220, R260, R260Mn, and R350HT grades rails of 27 kg/m and above as contained in EN 13674-1, EN 13674-2 and EN 13674-4.
The permitted welding processes are limited to Electric Arc (EA) in accordance with EN ISO 4063 and are by description Process No 111: SMAW (Shielded Metal Arc Welding) and Process No 114: FCAW (Flux Cored Arc Welding).
This document can be applied in situ, at line side or at out of track locations. The flash welded leg ends of austenitic manganese steel crossings are included in this document, except when located within 500 mm of manganese crossings. Where repairs are required within 500 mm, refer to EN 16725.
- Status
- Published
- Publication Date
- 20-Oct-2026
- Technical Committee
- CEN/TC 256 - Railway applications
- Drafting Committee
- CEN/TC 256/SC 1/WG 4 - Rails
- Current Stage
- 6060 - Definitive text made available (DAV) - Publishing
- Start Date
- 21-Oct-2026
- Due Date
- 13-Sep-2024
- Completion Date
- 21-Oct-2026
EN 15594:2026 is a CEN standard for railway applications covering restoration of rail heads by electric arc welding. It specifies how consumables, welding procedures, contractors, welders, and track trials are approved for repair welding on listed Vignole rail grades. In practice, it tells railway authorities and contractors what must be checked before a rail repair weld is accepted for service.
What does EN 15594:2026 specify?
EN 15594:2026 applies to restoration by electric arc welding of the rail head only. It covers approval systems for consumables and procedures used in manual metal arc welding and flux cored arc welding, and it can be used in situ, at line side, or off track. The scope also includes the flash welded leg ends of austenitic manganese steel crossings, except where repairs are within 500 mm of manganese crossings, where EN 16725 applies.
The document is organized into clauses on scope, normative references, terms, consumable and WPS approval, contractor approval, personnel and qualification requirements, and repair applications.
| Annex | What it covers |
|---|---|
| Annex A | Supplementary information for track trials |
| Annex B | Example Welding Procedure Specification (WPS) |
| Annex C | Example diploma in electric arc restoration welding of rails |
| Annex D | Permit to restore rail by electric arc welding |
| Annex E | Track component names |
| Annex ZA | Relationship with EU Directive (EU) 2016/797 |
What are the key requirements of EN 15594:2026?
EN 15594:2026 is built around four controls: approval of consumables and WPS, approval of contractors, qualification of people, and limits on the repairs that may be carried out. The practical point is that a repair weld is only acceptable when the process, the materials, the people, and the site conditions are all under RA control.
Consumable and WPS approval
Clause 4 requires consumable and WPS approval to follow EN ISO 15613, using a pre-production test approach. The approving RA issues the approval certificate after a successful track trial, and it may require extra tests for special operating conditions. That means the consumable and the procedure are not just selected from a catalogue - they must be proven on rail.
Clause 4 also requires laboratory and track trial checks on single bead, single layer, and multi-layer deposits. These checks cover bead shape, spatter, cratering, porosity, cracks, hardness, weld integrity, and welding parameters, with MT or PT inspection and, for some samples, macro and micro examination. In practice, the standard is checking whether a consumable can make sound rail deposits before it is used in service.
Acceptance of weld deposits
EN 15594:2026 sets acceptance criteria by rail grade and deposit type. Table 1 gives separate hardness limits for R200, R220, R260, R260Mn, and R350HT, and multi-layer deposits also have a sub-surface hardness limit. Table 2 rejects cracks, lack of fusion, shrinkage, linear porosity, elongated cavities or wormholes, and un-tempered martensite at the specified magnification.
This matters because rail welding failures are service-critical and cyclic loading is severe. If the deposit does not meet the hardness and defect limits, it is not suitable for track use.
Track trials
Clause 4.7 and Annex A require track trials under RA requirements, using the approved WPS. The trials check surface cracking, flatness over 1 m, rail head profile compliance with EN 13674-1 or EN 13674-4, and weld integrity, with visual, MT or PT, straightedge or electronic straightedge, and UT methods as specified. Trials run for 12 months with inspections after 1 day, 1 month, 6 months, and 12 months.
For a user, this means the process must work not only in the workshop but also in real track conditions. The approving RA records the site, welds, conditions, and inspection results before deciding whether the consumable and WPS are accepted.
Contractor control and site practice
Clause 5 requires a quality management system in accordance with EN ISO 3834-2. It also requires compatible equipment, approved subcontracting arrangements, controlled storage and handling of consumables, protection of the infrastructure, traceability for each weld, audits, training, and documentation. Clause 4.1 also requires welding fumes to be removed by local exhaust ventilation, or, if that is not possible, approved respiratory protective equipment.
In practice, the contractor must be able to show who did the work, with what equipment, under which WPS, and with what records. That is what supports traceability when a weld later has to be investigated.
Personnel, diploma, and permit
Clause 6 requires training and qualification in a training establishment approved by the RA, and welder approval follows EN ISO 9606-1. A welder first receives a Diploma in Electric Arc Welding of Rails, then applies for a Permit to restore rails by electric arc welding; the permit can have a maximum validity of 4 years. The RA controls issue, renewal, withdrawal, and the approved processes, line categories, and components.
Repair applications
Clause 7 applies the standard to repair welding for wheel burns, squats, headwear, sidewear, welding-zone defects, and rail damage, on plain rail and switch and crossing components. The RA defines the permitted repair types, excavation limits, repair dimensions, and special conditions. That means the standard gives the method, while the railway authority sets the local repair policy.
What terms does EN 15594:2026 define?
- RA - the railway authority, meaning the regulator, the infrastructure owner, or a custodian with delegated responsibility.
- Contractor - a company approved by the RA to carry out rail restoration by electric arc welding.
- SMAW - shielded metal arc welding, one of the permitted Electric Arc processes.
- FCAW - flux cored arc welding, the other permitted Electric Arc process.
- Pwps - a preliminary welding procedure specification, used for trial welding before approval.
- WPS - a welding procedure specification approved to European standards and agreed by the RA.
- Training establishment - an RA-approved training organization or centre for welders.
Who uses EN 15594:2026?
Railway authorities use EN 15594:2026 to approve processes, set repair limits, and issue or withdraw permits. Contractors and welding supervisors use it to prepare WPSs, organize work, control consumables, and keep weld traceability. Welders, training establishments, inspection bodies, and quality managers use it for qualification, testing, records, and acceptance of repair welds in track.
What changed in EN 15594:2026 from the previous edition?
EN 15594:2026 supersedes EN 15594:2009. The stated technical changes are updated normative references, inclusion of additional rail steel grades, updated microstructure and macrostructure requirements, and the addition of Annex ZA.
Which standards are used with EN 15594:2026?
| Standard | What it contributes |
|---|---|
| EN 13674-1 | Rail grades and profile requirements for 46 kg/m and above |
| EN 13674-2 | Switch and crossing rails used with Vignole railway rails |
| EN 13674-4 | Rail grades from 27 kg/m to below 46 kg/m |
| EN ISO 4063 | Process numbering for Electric Arc welding, including 111 and 114 |
| EN ISO 15613 | Procedure approval by pre-production welding test |
| EN ISO 15607 / EN ISO 15609-1 | General rules and WPS content for welding procedures |
| EN ISO 3834-2 | Quality management requirements for fusion welding |
| EN ISO 9606-1 | Welder qualification testing for steels |
| EN ISO 17638 / EN ISO 3452-1 | Magnetic particle testing and penetrant testing |
| EN ISO 6506-1 / EN ISO 6507-1 | Brinell and Vickers hardness testing |
| EN ISO 544 | Delivery, marking, and handling of filler materials and fluxes |
| EN ISO 3580 / EN 14700 / EN ISO 18276 | Consumable classification references |
| EN 16725 | Restoration and repair of manganese crossings near the 500 mm limit |
What does the EN 15594:2026 document contain?
EN 15594:2026 contains laboratory test methods for single bead, single layer, and multi-layer rail deposits, including sample geometry, excavation dimensions, preheat positions, MT or PT examination, hardness testing, and macro/micro preparation. It also contains track trial methods, inspection timing, and reporting requirements for approving RA decisions.
The document includes Figure 1 to Figure 4 for sample size, excavation, sectioning, and hardness locations. Table 1 and Table 2 set hardness and defect acceptance criteria. Annex B gives a WPS template, Annex C gives a diploma specimen, and Annex D gives a permit specimen for rail welding control.
Relations
- Effective Date
- 22-Jul-2020
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 04-Nov-2026
- Effective Date
- 28-Jan-2026
Get Certified
Connect with accredited certification bodies for this standard
DVS-ZERT GmbH
German welding certification society.
CARES (UK Certification Authority for Reinforcing Steels)
UK certification for reinforcing steels and construction.
EWF/IIW (European/International Welding Federation)
International welding personnel certification.
Sponsored listings
Frequently Asked Questions
EN 15594:2026 is a standard published by the European Committee for Standardization (CEN). Its full title is "Railway applications - Infrastructure - Restoration of rails by electric arc welding". This standard covers: This document specifies restoration by electric arc welding and is limited to the head of the rails only. This document describes the approval systems for consumables and procedures used in manual metal arc and flux cored metal deposit rail repair welding. This document includes the quality-related tasks and responsibilities of personnel involved in the electric arc repair welding of rails. This document applies to plain rail and switches and crossings manufactured from new Vignole railway rails R200, R220, R260, R260Mn, and R350HT grades rails of 27 kg/m and above as contained in EN 13674-1, EN 13674-2 and EN 13674-4. The permitted welding processes are limited to Electric Arc (EA) in accordance with EN ISO 4063 and are by description Process No 111: SMAW (Shielded Metal Arc Welding) and Process No 114: FCAW (Flux Cored Arc Welding). This document can be applied in situ, at line side or at out of track locations. The flash welded leg ends of austenitic manganese steel crossings are included in this document, except when located within 500 mm of manganese crossings. Where repairs are required within 500 mm, refer to EN 16725.
This document specifies restoration by electric arc welding and is limited to the head of the rails only. This document describes the approval systems for consumables and procedures used in manual metal arc and flux cored metal deposit rail repair welding. This document includes the quality-related tasks and responsibilities of personnel involved in the electric arc repair welding of rails. This document applies to plain rail and switches and crossings manufactured from new Vignole railway rails R200, R220, R260, R260Mn, and R350HT grades rails of 27 kg/m and above as contained in EN 13674-1, EN 13674-2 and EN 13674-4. The permitted welding processes are limited to Electric Arc (EA) in accordance with EN ISO 4063 and are by description Process No 111: SMAW (Shielded Metal Arc Welding) and Process No 114: FCAW (Flux Cored Arc Welding). This document can be applied in situ, at line side or at out of track locations. The flash welded leg ends of austenitic manganese steel crossings are included in this document, except when located within 500 mm of manganese crossings. Where repairs are required within 500 mm, refer to EN 16725.
EN 15594:2026 is classified under the following ICS (International Classification for Standards) categories: 25.160.10 - Welding processes; 93.100 - Construction of railways. The ICS classification helps identify the subject area and facilitates finding related standards.
EN 15594:2026 has the following relationships with other standards: It is inter standard links to EN 15594:2009, EN ISO 6507-1:2023, EN ISO 15609-1:2019, EN ISO 9606-1:2017, EN ISO 6506-1:2014, EN 13674-1:2011+A1:2017, EN ISO 15613:2025, EN ISO 544:2024, EN ISO 3834-2:2021, EN ISO 3452-1:2021, EN 13674-4:2019, EN 17343:2023, EN ISO 15607:2019, EN ISO/IEC 30111:2020. Understanding these relationships helps ensure you are using the most current and applicable version of the standard.
EN 15594:2026 is associated with the following European legislation: EU Directives/Regulations: 2016/797/EU, 2016/797/EU, 2016/797/EU, 2016/797/EU, 2016/797/EU, 2016/797/EU, 2016/797/EU, 2016/797/EU, 2016/797/EU, 2016/797/EU, 2016/797/EU, 2016/797/EU, 2016/797/EU; Standardization Mandates: M/483, M/591. When a standard is cited in the Official Journal of the European Union, products manufactured in conformity with it benefit from a presumption of conformity with the essential requirements of the corresponding EU directive or regulation.
EN 15594:2026 is available in PDF format for immediate download after purchase. The document can be added to your cart and obtained through the secure checkout process. Digital delivery ensures instant access to the complete standard document.
Standards Content (Sample)
SLOVENSKI STANDARD
01-december-2026
Nadomešča:
SIST EN 15594:2009
Železniške naprave - Infrastruktura - Obnova tirnic z električnim obločnim
varjenjem
Railway applications - Infrastructure - Restoration of rails by electric arc welding
Bahnanwendungen - Infrastruktur - Aufarbeitung von Schienen durch elektrisches
Lichtbogenschweißen
Applications ferroviaires - Infrastructure - Réparation des rails par soudage à l’arc
électrique
Ta slovenski standard je istoveten z: EN 15594:2026
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
93.100 Gradnja železnic Construction of railways
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
EN 15594
EUROPEAN STANDARD
NORME EUROPÉENNE
October 2026
EUROPÄISCHE NORM
ICS 25.160.10 Supersedes EN 15594:2009
English Version
Railway applications - Infrastructure - Restoration of rails
by electric arc welding
Applications ferroviaires - Infrastructure - Réparation Bahnanwendungen - Infrastruktur - Aufarbeitung von
des rails par soudage à l'arc électrique Schienen durch elektrisches Lichtbogenschweißen
This European Standard was approved by CEN on 3 August 2026.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this
European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references
concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN
member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by
translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2026 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 15594:2026 E
worldwide for CEN national Members.
Contents Page
European foreword . 4
Introduction . 5
1 Scope . 6
2 Normative references . 6
3 Terms, definitions and abbreviated terms . 7
4 Consumable and WPS approval tests for SMAW electrodes and FCAW wires . 8
4.1 General. 8
4.2 Consumable and WPS approval model . 8
4.3 Information for the test . 9
4.4 Batch testing . 10
4.5 Test requirements . 10
4.6 Laboratory tests . 11
4.7 Track trial tests . 16
4.8 Evaluation, reporting and decision following track trials . 17
4.9 Validation of consumables . 18
5 Approval of contractors . 18
5.1 Quality management systems . 18
5.2 Inspection and testing . 18
5.3 Subcontracting . 18
5.4 Equipment . 18
5.5 Welding activities . 19
5.6 Storage and handling of welding consumables . 19
5.7 Care of the infrastructure . 19
5.8 Welding procedure specifications . 19
5.9 Pre-heating of rails . 19
5.10 Welders. 19
5.11 Welder records . 19
5.12 Supervision . 20
5.13 Traceability . 20
5.14 Audits . 20
5.15 Training . 20
5.16 Documentation . 20
6 Personnel and qualification requirements . 20
6.1 Training and qualification requirements . 20
6.2 Diploma in electric arc welding of rails . 21
6.3 Permit to restore rails by electric arc welding . 21
7 Repair applications . 23
Annex A (normative) Track trials supplementary information . 24
Annex B (informative) Welding Procedure Specification (WPS) . 25
Annex C (informative) Diploma in electric arc restoration welding of rails . 27
Annex D (normative) Permit to restore rail by electric arc welding . 28
Annex E (informative) Track components. 29
Annex ZA (informative) Relationship between this European Standard and the essential
requirements of EU Directive (EU) 2016/797 aimed to be covered . 30
Bibliography . 31
European foreword
This document (EN 15594:2026) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
This European Standard shall be given the status of a national standard, either by publication of an
identical text or by endorsement, at the latest by April 2027, and conflicting national standards shall be
withdrawn at the latest by April 2027.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
This document supersedes EN 15594:2009.
This document includes the following significant technical changes with respect to EN 15594:2009:
— normative references have been updated;
— additional rail steel grades have been included;
— microstructure and macrostructure requirements have been updated;
— an Annex ZA has been included.
The purpose of this document is to unify the restoration of rail electric arc welding across Europe. The
document provides control systems for the approval and qualification of welding processes, welding
procedures, welding consumables, contractors and welders for the successful delivery of welds into track.
This document has been prepared under a standardization request addressed to CEN by the European
Commission. The Standing Committee of the EFTA States subsequently approves these requests for its
Member States.
For the relationship with EU Legislation, see informative Annex ZA, which is an integral part of this
document.
Any feedback and questions on this document should be directed to the users’ national standards body.
A complete listing of these bodies can be found on the CEN website.
According to the CEN-CENELEC Internal Regulations, the national standards organisations of the
following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia,
Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland,
Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North
Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and the United
Kingdom.
Introduction
Restoration of rails by electric arc welding is a special process requiring the coordination of welding and
grinding activities to establish confidence and reliability of the weld deposit and safety of the line.
Controls are to be in place from the design phase through to inspection. Incorrect selection of materials,
consumables or procedure can result in serious track welding failure.
It is important to strictly adhere to the correct application of the approved processes and the types of
repairs permitted to be carried out on various rail components. Only consumables approved by the
method described in this document should be used. The tasks and responsibilities of personnel involved
in restoration, e.g. planning, executing, supervising and inspection should be clearly defined.
1 Scope
This document specifies restoration by electric arc welding and is limited to the head of the rails only.
This document describes the approval systems for consumables and procedures used in manual metal
arc and flux cored metal deposit rail repair welding. This document includes the quality-related tasks and
responsibilities of personnel involved in the electric arc repair welding of rails. This document applies to
plain rail and switches and crossings manufactured from new Vignole railway rails R200, R220, R260,
R260Mn, and R350HT grades rails of 27 kg/m and above as contained in EN 13674-1, EN 13674-2 and
EN 13674-4.
The permitted welding processes are limited to Electric Arc (EA) in accordance with EN ISO 4063 and are
by description Process No 111: SMAW (Shielded Metal Arc Welding) and Process No 114: FCAW (Flux
Cored Arc Welding).
This document is applicable in situ, at line side or at out of track locations. The flash welded leg ends of
austenitic manganese steel crossings are included in this document, except when located within 500 mm
of manganese crossings. Where repairs are required within 500 mm, refer to EN 16725.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
EN 13674-1:2011+A1:2017, Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and
above
EN 13674-4:2019, Railway applications - Track - Rail - Part 4: Vignole railway rails from 27 kg/m to, but
excluding 46 kg/m
EN 17343:2023, Railway applications - General terms and definitions
EN ISO 544:2024, Welding consumables - Technical delivery conditions for filler materials and fluxes - Type
of product, dimensions, tolerances and markings (ISO 544:2024, Corrected version 2026-02)
EN ISO 3452-1:2021, Non-destructive testing - Penetrant testing - Part 1: General principles (ISO 3452-
1:2021)
EN ISO 3834-2:2021, Quality requirements for fusion welding of metallic materials - Part 2: Comprehensive
quality requirements (ISO 3834-2:2021)
EN ISO 6506-1:2014, Metallic materials - Brinell hardness test - Part 1: Test method (ISO 6506-1:2014)
EN ISO 6507-1:2023, Metallic materials - Vickers hardness test - Part 1: Test method (ISO 6507-1:2023)
EN ISO 9606-1:2017, Qualification testing of welders - Fusion welding - Part 1: Steels (ISO 9606-1:2012
including Cor 1:2012 and Cor 2:2013)
EN ISO 15607:2019, Specification and qualification of welding procedures for metallic materials - General
rules (ISO 15607:2019)
EN ISO 15609-1:2019, Specification and qualification of welding procedures for metallic materials -
Welding procedure specification - Part 1: Arc welding (ISO 15609-1:2019)
EN ISO 15613:2025, Specification and qualification of welding procedures for metallic materials -
Qualification based on a pre-production welding test (ISO 15613:2025)
3 Terms, definitions and abbreviated terms
For the purposes of this document, the terms and definitions given in EN 17343:2023 and the following
apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https://www.iso.org/obp
— IEC Electropedia: available at https://www.electropedia.org/
3.1
railway authority
RA
either the railway regulator or the owner of a railway infrastructure or the custodian with a delegated
responsibility for a railway infrastructure
3.2
contractor
company approved by a railway authority to carry out the restoration of rails by electric arc welding on
that infrastructure
3.3
FCAW
flux cored arc welding
3.4
SMAW
shielded metal arc welding
3.5
preliminary welding procedure specification
Pwps
tentative welding procedure specification, which is assumed to be adequate by the manufacturer, but
which has not been approved
Note 1 to entry: Welding of test pieces needed for approval of a welding procedure specification shall be carried
out based on a preliminary welding procedure specification.
3.6
weld procedure specification
WPS
procedure approved to European standards and agreed by the RA for use on the railway infrastructure
3.7
training establishment
welder training organisation or centre approved by the railway authority or alternatively a welder
training organisation or centre approved by and belonging to a railway authority
3.8
running surface
curved surface defined by the longitudinal displacement of a straight line perpendicular to the centre-
line of the track and tangential to both running tables
3.9
PT
dye penetrant inspection
4 Consumable and WPS approval tests for SMAW electrodes and FCAW wires
4.1 General
The approval of consumables and the related WPS shall follow the requirements of EN ISO 15613:2025.
Welding fume shall be removed from the welding environment by the means of local exhaust ventilation,
where this is not possible approved respiratory protective equipment shall be used.
4.2 Consumable and WPS approval model
The following flow chart Figure 1 describes how a consumable and its related WPS shall be approved.
WPS approval shall follow the principle of EN ISO 15613:2025 approval by a pre-production test.
Figure 1 — Approval process for a consumable and its related WPS
NOTE These track trials are undertaken by the approving RA.
The approving RA shall issue an approval certificate upon successful outcome of track trial.
Other railway authorities may require further tests to verify suitability for special service/operational
conditions or deposition techniques.
4.3 Information for the test
The standards quoted below are given for information only:
— toxicity threshold levels;
— SMAW electrode classification in accordance with EN ISO 3580:2017;
— wire electrodes classification in accordance with EN 14700:2022;
— tubular covered electrodes in accordance with EN ISO 18276:2024;
— chemical analysis and batch analysis;
— storage requirements with manufacturers recommendations;
— current range/voltage range/polarity;
— availability of vacuum sealed SMAW electrodes;
— dimensions, length and diameter;
— FCAW spool size/weight availability;
— drying requirements;
— description of marking system;
— optimum deposition technique.
4.4 Batch testing
The batch testing criteria are:
— concentricity and dimensions;
— chemical composition;
— consumable performance, e.g. wire behaviour.
4.5 Test requirements
4.5.1 List of tests
— mechanical tests;
— chemical analysis of undiluted weld metal with batch verification;
— hardness;
— weld integrity (laboratory conditions);
— crack free;
— defect level;
— porosity;
— craters;
— Open Circuit Voltage (OCV) requirements;
— welding parameters.
4.5.2 Information to be confirmed
Marking and branding shall be carried out before and after drying.
4.5.3 Statement on the general weldability
The statement on the general weldability shall include the following information:
— bead shape;
— cratering;
— spatter;
— slag characteristics;
— strike and re-strike capability;
— other relevant information.
These checks are carried out on one bead, one layer and five layers.
The one bead test checks for cracking after grinding.
The single layer test checks the behaviour of weld deposit on rail steel.
The five-layer test checks the behaviour of weld metal on weld metal.
In single and five-layer deposits macro, micro and hardness HV tests are employed.
The five-layer test is finish ground and ultrasonic testing applied.
4.6 Laboratory tests
4.6.1 Purpose
The purpose of the laboratory tests is to prove the suitability of the consumable to successfully repair
appropriate grades of rail steel.
4.6.2 General requirements for laboratory tests
The following deposits are required for laboratory tests:
— single bead on rail: one sample required;
— single layer on rail: one sample required;
— multi-layers on rail: one sample required.
Deposits shall be subjected to PT in accordance with EN ISO 3452-1:2021.
4.6.3 Description of the sample for laboratory test
Figures 2 and 3 describe the requirements of sample size, excavation details and preheat measurement
positions.
Pre-heat point A shall be 75 mm from the end of the excavation on the running surface.
Pre-heat point B shall be at the full railhead flange height.
Length of the sample C shall be 600 mm minimum.
Figure 2 — Position of preheat measurement and sample size
The transverse excavation for trials shall be 100 % of the railhead width.
Key
D depth of excavation
S slope (S ≥ 5D)
L length (L + 2S ≥ 200 mm)
The dimension D shall be such that the surface of the final layer is level with the surface of the parent rail
after grinding.
Figure 3 — Excavation dimensions
4.6.4 Single bead on rail tests
4.6.4.1 Purpose
This test is used to demonstrate the consumable’s compatibility with welding of rail steel before carrying
out further detailed tests. This deposition is without any excavation and provides information regarding
the bead shape, slag detachability, spatter, strike and re-strike capability.
4.6.4.2 Description
The sample shall be a minimum length of 600 mm in an appropriate grade of rail steel. The sample shall
be lightly ground on the running surface to give a clean oxide-free finish. The sample shall be preheated
in accordance with the Pwps and the position of pre-heat measurement in accordance with 4.6.3. For
SMAW only the deposit shall be made to maximum electrode recovery using the manufacturer’s
parameters.
4.6.4.3 Deposit examination and assessment
The deposit shall be cleaned removing all slag and spatter. Initially, the deposit shall be examined visually
in the as-welded condition.
Following visual examination, the bead shall be ground until 0,5 mm - 0,8 mm remains above the rail
surface. Following grinding the deposit shall be examined using visual and PT methods. The deposit shall
be assessed in accordance with 4.6.9.
If the weld deposit fails PT examination, the test shall be terminated. The approval of this consumable for
welding this grade shall be declined.
4.6.5 Single layer deposit on rail tests
4.6.5.1 Purpose
The purpose of this test is to establish the effects of dilution on a single layer and to check the integrity of
the weld deposit.
4.6.5.2 Description
The sample shall be a minimum length of 600 mm long in an appropriate grade of steel. The rail shall be
prepared in accordance with 4.6.3.
For SMAW only the length of the preparation shall be designed to use the full length of the electrode
minus 80 mm. This length can be derived from the single bead deposit on rail.
4.6.5.3 Deposit examination and assessment
The deposit shall be cleaned removing all slag and spatter and the surface checked using PT methods.
The deposit shall be sectioned, prepared and subjected to hardness testing and metallography in
accordance with 4.6.8. All results shall be assessed in accordance with 4.6.9.
If the weld deposit fails PT examination, the test shall be terminated.
4.6.6 Multi-layer deposit on rail tests
4.6.6.1 Purpose
The purpose of this test is to determine the integrity of the multi-layer weld metal on rail.
4.6.6.2 Description
The sample shall be a minimum length of 600 mm long in an appropriate grade of steel. The rail shall be
prepared in accordance with 4.6.3.
For SMAW the length of the preparation shall be designed to use the full length of the electrode minus
80 mm. This length can be derived from the single bead deposit on rail. On completion, the rail shall be
ground to rail head profile and shall contain a minimum of five layers and will facilitate a surface finish
suitable for Brinell hardness testing.
4.6.6.3 Deposit examination and assessment
The deposit shall be cleaned removing all slag and spatter and the surface checked using PT methods.
The deposit s
...