EN 15594:2009

Railway applications - Track - Restoration of rails by electric arc welding

This European Standard specifies restoration by electric arc welding and is limited to the head of the rails only.
This European Standard describes the approval systems for consumables and procedures used in manual metal arc and flux cored metal deposit rail repair welding. The standard includes the quality-related tasks and responsibilities of personnel involved in the electric arc repair welding of rails. The standard applies to plain rail and switches and crossings manufactured from new vignole railway rails R200, R220, R260, R260Mn and R350HT grade rails of 46 kg/m and above as contained in EN 13674-1.
The permitted welding processes are limited to Electric Arc (EA) in accordance with EN ISO 4063 and are by description Process No 111: MMA (Manual Metal Arc) and Process No 114: FCAW (Flux Cored Arc Welding). Their applications are described.
This European Standard may 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 standard, except when located within 500 mm of manganese crossings.

Bahnanwendungen - Oberbau - Aufarbeiten von Schienen durch elektrisches Lichtbogenauftragschweißen

Diese Europäische Norm behandelt elektrische Reparaturschweißungen, die sich nur auf den
Schienenkopfbereich beziehen.
Diese Norm beschreibt ein Zulassungssystem für Schweißzusatzwerkstoffe und Verfahren bei der Ausführung
von Reparaturschweißungen an Schienen mit Metall-Lichtbogenhandschweißung und Schmelz-Fülldrahtschweißungen.
Diese Norm schließt die qualitätsbezogenen Aufgaben und Verantwortlichkeiten des
Personals, die sich mit der elektrischen Lichtbogenreparaturschweißung an Schienen befassen, ein. Diese
Norm ist anzuwenden für Bauteile des Hauptgleises und der Weichen und Kreuzungen für Stahlsorten R200,
R220, R260, R260Mn und R350HT mit einer längenbezogenen Masse ab 46 kg/m in Übereinstimmung mit
EN 13674-1.
Die zugelassenen Schweißverfahren und ihre Anwendungen sind begrenzt auf das elektrische
Lichtbogenschweißen (EA) in Übereinstimmung mit EN ISO 4063 und der dort beschriebenen Verfahrens-
Nr 111: MMA (Lichtbogenhandschweißen, en: manual metal arc) und der Verfahrens-Nr 114: FCAW (Metall-
Lichtbogenschweißen mit Fülldrahtelektrode ohne Schutzgas, en: flux cored arc welding).
Diese Europäische Norm kann an Baustellen im Gleis oder außerhalb des Gleises angewendet werden. Mit
Ausnahme von Schweißungen an austenitischen Mangan-Herzstückspitzen in einem Bereich von 500 mm,
beinhaltet diese Norm auch das Lichtbogenschweißen als Verbindungen zwischen austenitischen Mangan-
Herzstücken.

Applications ferroviaires - Voie - Réparation des rails par soudage à l'arc électrique

La présente Norme européenne spécifie les exigences de la réparation de rails par soudage à l’arc électrique
strictement limitée au champignon du rail.
La présente Norme européenne décrit, les procédures d’approbation relatives aux consommables et aux
modes opératoires, que la réparation des rails soit réalisée au moyen d’une électrode enrobée ou d’un fil
fourré. La norme définit également les missions et responsabilités du personnel impliqué dans la qualité des
réparations de rail par soudage à l’arc électrique. La norme s’applique aux rails de voie courante, aiguillages
et coeurs d’appareils de voie fabriqués à partir de rails Vignole neufs de masse supérieure ou égale à 46 kg/m
conformément à l’EN 13674-1 et de nuances d’acier R200, R220, R260, R260Mn et R350HT. Leurs
applications sont décrites.
Les procédés de soudage autorisés sont limités aux procédés de soudage à l’arc électrique conformément à
l’EN ISO 4063 et décrits par le Procédé n° 111 pour l’électrode enrobée et le Procédé n° 114 pour le fil fourré.
La présente norme peut être applicable in situ, en ou hors voie. Les antennes soudées par étincelage aux
coeurs d’appareils de voie en acier austénitique au manganèse sont incluses dans la présente norme, à
l’exception des zones situées à moins de 500 mm de l’acier au manganèse.

Železniške naprave - Zgornji ustroj - Obnova tirnic z električnim obločnim varjenjem

General Information

• Status: Published
• Publication Date: 31-Mar-2009
• Withdrawal Date: 30-Oct-2009
• ICS: 25.160.10 - Welding processes
• ICS: 93.100 - Construction of railways
• Technical Committee: CEN/TC 256 - Railway applications
• Drafting Committee: CEN/TC 256/SC 1/WG 4 - Rails
• Current Stage: 9093 - Decision to confirm - Review Enquiry
• Start Date: 27-Jul-2016
• Completion Date: 14-Apr-2025
• Directive: 2001/16/EC - Directive 2001/16/EC of the European Parliament and of the Council of 19 March 2001 on the interoperability of the trans-European conventional rail system
• Directive: 2008/57/EC - Directive 2008/57/EC of the European Parliament and of the Council of 17 June 2008 on the interoperability of the rail system within the Community (Recast)
• Directive: 93/38/EEC - Procurement procedures of entities operating in the water, energy, transport and telecommunications sectors
• Mandate: M/275 - Mandate to CEN/CENELEC/ETSI for standardization in the field of railway equipment on the interoperability of the Trans-European high-speed rail system
• Mandate: M/334 - Mandate for programming and standardisation addressed to CEN, CENELEC and ETSI in the field of the Interoperability of the trans-european conventional rail system
• Ref Project: SIST EN 15594:2009 - Railway applications - Track - Restoration of rails by electric arc welding

Relations

• Revised: prEN 15594 - Railway applications - Infrastructure - Restoration of rails by electric arc welding
• Effective Date: 22-Jul-2020

Overview

EN 15594:2009 - "Railway applications - Track - Restoration of rails by electric arc welding" is a CEN European Standard that defines how to perform and control repair welding of the rail head using electric arc processes. The standard is limited to the head of vignole rails (46 kg/m and above) and associated switches and crossings of grades R200, R220, R260, R260Mn, R260Cr and R350HT. It standardizes approval systems for consumables, welding procedures and personnel responsibilities to ensure safe, repeatable rail restoration in situ or off-track.

Key topics and requirements

• Scope limitation: Restoration restricted to the rail head; includes flash-welded leg ends of austenitic manganese crossings except where within 500 mm of manganese crossings.
• Permitted processes: Electric Arc (EA) per EN ISO 4063 - Process No. 111 (MMA / Manual Metal Arc) and No. 114 (FCAW / Flux Cored Arc Welding).
• Consumables and WPS approval: Defines certification flows for MMA electrodes and FCAW wires, including laboratory tests, pre-production tests and track trials. Approval follows principles compatible with EN ISO 15613 but with rail-specific requirements.
• Testing and trials: Laboratory sample builds, single/multi-layer deposits, and on-track trial procedures to verify performance under rolling contact conditions.
• Personnel and qualifications: Requirements for welder qualification, permits, diplomas, supervision, training establishments and documented welder records.
• Contractor control & QA: Requirements for contractor approval, quality management systems, traceability, storage/handling of consumables, equipment, audits and documentation.
• Safety & procedures: WPS preparation, pre-heating guidance, inspection regimes, and acceptance criteria to reduce risk of weld failure and rolling contact fatigue.

Applications and practical value

• Standardizes rail repair welding for infrastructure owners, maintenance contractors and certifying bodies to deliver consistent, safe restorations.
• Used to approve welding consumables (electrodes, wires) and to develop and validate Welding Procedure Specifications (WPS) for track repairs.
• Guides planning and execution of in situ emergency repairs, planned maintenance on plain line, switches and crossings, and off-track restoration at depots.
• Provides a framework for welder training, permits and audits, improving traceability and regulatory compliance for railway track maintenance programs.

Who should use this standard

• Railway Authorities and infrastructure managers
• Track maintenance contractors and welding teams
• Welding procedure certifying bodies and laboratories
• Training establishments and safety auditors

Related standards (examples)

• EN 13674-1 / EN 13674-2 (rail grades & switches)
• EN ISO 4063 (welding process nomenclature)
• EN ISO 15613 (qualification of welding procedures)
• EN 287-1, EN 571-1, EN 1290 (welding and NDT qualifications)

Keywords: EN 15594:2009, rail restoration, electric arc welding, rail repair welding, MMA electrodes, FCAW wires, WPS approval, railway track maintenance, welder qualification, track trials.

Standards Content (Sample)

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.YDUMHQMHPBahnanwendungen - Oberbau - Aufarbeitung von Schienen durch elektrisches LichtbogenauftragsschweißenApplications ferroviaires - Voie - Réparation des rails par soudure a l'arc électriqueRailway applications - Track - Restoration of rails by electric arc welding45.080Rails and railway components25.160.01Varjenje, trdo in mehko spajkanje na splošnoWelding, brazing and soldering in generalICS:Ta slovenski standard je istoveten z:EN 15594:2009SIST EN 15594:2009en,fr,de01-junij-2009SIST EN 15594:2009SLOVENSKI
STANDARD
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 15594April 2009ICS 25.160.10; 93.100 English VersionRailway applications - Track - Restoration of rails by electric arcweldingApplications ferroviaires - Voie - Réparation des rails parsoudure à l'arc électriqueBahnanwendungen - Oberbau - Aufarbeiten von Schienendurch elektrisches LichtbogenauftragschweißenThis European Standard was approved by CEN on 5 March 2009.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the CEN 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 translationunder the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as theofficial versions.CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre:
Avenue Marnix 17,
B-1000 Brussels© 2009 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 15594:2009: ESIST EN 15594:2009

Track trials supplementary information . 25Annex B (informative)
Welding Procedure Specification (WPS) . 26Annex C (informative)
Diploma in electric arc restoration welding of rails . 28Annex D (normative)
Permit to restore rail by electric arc welding. 29Annex E (informative)
Track components . 30Annex ZA (informative)
Relationship between this European Standard and the Essential Requirements of EU Directive 2008/57/EC . 31WARNING — Other requirements and other EC Directives may be applicable to the product(s) falling within the scope of this standard. . 33Bibliography . 34 SIST EN 15594:2009

(ISO 4063:1998) EN ISO 6506-1, Metallic materials – Brinell hardness test – Part 1: Test method (ISO 6506-1:2005) EN ISO 6507-1, Metallic materials – Vickers hardness test – Part 1: Test method (ISO 6507-1:2005) EN ISO 14341, Welding consumables – Wire electrodes and deposits for gas shielded metal arc welding of non alloy and fine grain steels – Classification (ISO 14341:2002) EN ISO 15613, Specification and qualification of welding procedures for metallic materials – Qualification based on pre-production welding test (ISO 15613:2004) UIC 714, Classification of lines for the purpose of track maintenance SIST EN 15594:2009

NOTE This may include staff from within the RA. 3.3 preliminary welding procedure specification (pWPS) tentative welding procedure specification, which is assumed to be adequate by the manufacturer, but which has not been approved. Welding of test pieces needed for approval of a welding procedure specification has to be carried out on the basis of a preliminary welding procedure specification 3.4 weld procedure specification (WPS) procedure approved to European standards and agreed by the RA for use on the railway infrastructure 3.5 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 4 Consumable and WPS approval tests for MMA electrodes and FCAW wires 4.1 General The approval of consumables and the related WPS is broadly in line with the requirements of EN ISO 15613, but owing to the special nature of the repair weld in terms of rail steel grade and use, e.g. rolling contact fatigue, the approval process shall follow this standard. 4.2 Consumable and WPS approval model The following flow chart describes how a consumable and its related WPS shall be approved. WPS approval shall follow the principle of EN ISO 15613 approval by a pre-production test. SIST EN 15594:2009

Consumable Certification body Classification according to EN ISO 3580/EN ISO 14341 EN 15594 pWPS (checked by the approving RA)
pWPS becomes WPS Track trials (see note 1) Decision
(see note 2) Other RAs (see note 3) Results Preliminary acceptance by the approving RA
Trial terminated No Yes
NOTE 1 These track trials are undertaken by the approving RA. NOTE 2 The approving RA shall issue an approval certificate upon successful outcome of track trial. NOTE 3 Other RAs may require further tests to verify suitability for special service/operational conditions or deposition techniques. 4.3 Information supplied by the manufacturer to the certifying body  Toxicity threshold levels; SIST EN 15594:2009

Deposits shall be subjected to magnetic particle inspection (MT) in accordance with EN 1290 or dye penetrant inspection (PT) in accordance with EN 571-1. 4.6.3 Description of the sample for laboratory test Figures 1 and 2 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 1 — Position of preheat measurement and sample size The transverse excavation for trials shall be 100 % of the railhead width. SIST EN 15594:2009

Key D depth of excavation S ≥ 5D L + 2S ≥ 200 mm Figure 2 — Excavation The dimension D shall be such that the surface of the final layer is level with the surface of the parent rail. 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. 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 MMA 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 MT or PT methods. The deposit shall be assessed in accordance with 4.6.9. If the weld deposit fails MT or PT examination the test shall be terminated. The approval of this consumable for welding this grade shall be declined. SIST EN 15594:2009

Key 1 Length 100 mm minimum (there shall be 10 mm minimum of unwelded rail before bead start point). Depth shall be
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