oSIST prEN 15594:2025

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

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.

Bahnanwendungen - Infrastruktur - Aufarbeitung von Schienen durch elektrisches Lichtbogenschweißen

Dieses Dokument behandelt elektrische Reparaturschweißungen, die sich nur auf den Schienenkopfbereich beziehen.
Dieses Dokument beschreibt ein Zulassungssystem für Schweißzusatzwerkstoffe und Verfahren bei der Ausführung von Reparaturschweißungen an Schienen mit Metall-Lichtbogenhandschweißung und Schmelz-Fülldrahtschweißungen. Dieses Dokument schließt die qualitätsbezogenen Aufgaben und Verantwortlichkeiten des Personals, das sich mit der elektrischen Lichtbogenreparaturschweißung an Schienen befasst, ein. Dieses Dokument ist anzuwenden für Bauteile des Hauptgleises und der Weichen und Kreuzungen für Stahlsorten R200, R220, R260, R260Mn und R350HT mit einer längenbezogenen Masse ab 27 kg/m in Übereinstimmung mit EN 13674-1, EN 13674-2 und EN 13674-4.
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: SMAW (Metall-Schutzgasschweißen, en: shielded metal arc welding) und der Verfahrens Nr. 114: FCAW (Metall-Lichtbogenschweißen mit Fülldrahtelektrode ohne Schutzgas, en: flux cored arc welding).
Dieses Dokument kann an Baustellen im Gleis oder außerhalb des Gleises angewendet werden. Die abbrennstumpfgeschweißten Schienenenden von Kreuzungen aus austenitischem Manganstahl werden in diesem Dokument berücksichtigt, es sei denn, sie befinden sich innerhalb von 500 mm von Mangan-Herzstücken. Wenn Reparaturen innerhalb von 500 mm erforderlich sind, wird auf EN 16725 verwiesen.

Applications ferroviaires - Infrastructure - Réparation des rails par soudage à l’arc électrique

Le présent document spécifie les exigences de la réparation de rails par soudage à l’arc électrique strictement limitée au champignon du rail.
Le présent document 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. Le présent document 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 27 kg/m conformément à l’EN 13674-1, l’EN 13674-2 et l’EN 13674-4, et de nuances d’acier R200, R220, R260, R260Mn et R350HT.
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 : soudage à l’électrode enrobée et par le Procédé n° 114 : soudage au fil fourré.
Le présent document 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 le présent document, à l’exception des zones situées à moins de 500 mm de l’acier au manganèse. Si des réparations sont nécessaires dans un rayon de 500 mm, se référer à l’EN16725.

Železniške naprave - Infrastruktura - Obnova tirnic z električnim obločnim varjenjem

General Information

• Status: Not Published
• Public Enquiry End Date: 30-Apr-2025
• ICS: 25.160.10 - Welding processes
• ICS: 93.100 - Construction of railways
• Technical Committee: IŽNP - Reilway applications
• Current Stage: 4020 - Public enquire (PE) (Adopted Project)
• Start Date: 26-Feb-2025
• Due Date: 16-Jul-2025
• Completion Date: 22-Apr-2025
• Directive: 2016/797/EU - Directive (EU) 2016/797 of the European Parliament and of the Council of 11 May 2016 on the interoperability of the rail system within the European Union (Text with EEA relevance)
• Mandate: M/483 - Mandate for programming and standardisation addressed to the European standardisation bodies under directive 2008/57/EC in the field of the interoperability of the rail system within the European Union
• Mandate: M/591 - Standardisation request to the European Committee for Standardisation and the European Committee for Electrotechnical Standardisation as regards railway products in support of Directive (EU) 2016/797
• Ref Project: prEN 15594 - Railway applications - Infrastructure - Restoration of rails by electric arc welding

Relations

• Revised: SIST EN 15594:2009 - Railway applications - Track - Restoration of rails by electric arc welding
• Effective Date: 18-Jan-2023

Overview

prEN 15594 - Railway applications: Restoration of rails by electric arc welding (CEN) defines a Europe‑wide control system for repairing the head of rails using electric arc welding. The standard covers approval and validation of welding consumables, welding procedures (WPS), contractor and personnel qualification, quality tasks and responsibilities, and tests required to place welds back into service. It applies to plain rails, switches and crossings manufactured from Vignole rail grades R200, R220, R260, R260Mn and R350HT of 27 kg/m and above (see EN 13674 series).

Key topics and technical requirements

• Scope limit: Repairs are limited to the rail head only; flash‑welded leg ends of austenitic manganese crossings are included except when within 500 mm of manganese crossings (see EN 16725 for those cases).
• Permitted processes: Electric Arc (EA) processes only - Process No. 111 SMAW (Shielded Metal Arc Welding) and Process No. 114 FCAW (Flux Cored Arc Welding) in accordance with EN ISO 4063.
• Consumable & WPS approval: Structured model including laboratory tests (single bead, single layer, multi‑layer deposits), batch testing and track trials to validate weld performance and general weldability.
• Testing & inspection: Macro/microstructure, hardness (Brinell/Vickers references), non‑destructive testing (penetrant, magnetic particle), and acceptance criteria for both lab and in‑track samples.
• Personnel & organisation: Requirements for contractor quality management (EN ISO 3834‑2), welder diplomas/permits, training, supervision, traceability, documentation, audits and welding procedure specifications.
• Application settings: Procedures can be applied in situ, at line side or off‑track locations, with controls for pre‑heating, storage/handling of consumables, and care of infrastructure during welding.

Practical applications and who uses it

• Railway authorities, infrastructure owners and custodians (RAs) for establishing approved repair regimes and accepting contractors.
• Heavy maintenance and rail welding contractors for qualifying consumables, welders and WPS before in‑track work.
• Welding engineers, quality managers and inspectors responsible for procedure approval, track trials and audit evidence.
• Maintenance planners and asset managers for safe, standardized repair of rails and switches & crossings to minimize downtime and risk.

Related standards

• EN 13674‑1, EN 13674‑2, EN 13674‑4 (Vignole rails)
• EN ISO 4063 (welding process classification)
• EN ISO 15609‑1 / EN ISO 15613 (WPS and qualification)
• EN ISO 9606‑1 (welder qualification)
• EN 16725 (manganese crossing repairs)
• EN ISO 3452‑1, EN ISO 17638 (NDT methods)

Keywords: rail welding standard, electric arc welding, rail restoration, SMAW, FCAW, welding consumables, welding procedure specification, track repair, rail maintenance.

Standards Content (Sample)

SLOVENSKI STANDARD
01-april-2025
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: prEN 15594
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.

DRAFT
EUROPEAN STANDARD
NORME EUROPÉENNE
EUROPÄISCHE NORM
February 2025
ICS 25.160.10; 93.100 Will supersede 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 draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee
CEN/TC 256.
If this draft becomes a European Standard, 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.

This draft European Standard was established by CEN 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.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2025 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 15594:2025 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
4.5.1 List of tests . 10
4.5.2 Information to be confirmed . 11
4.5.3 Statement on the general weldability . 11
4.6 Laboratory tests . 11
4.6.1 Purpose . 11
4.6.2 General requirements for laboratory tests . 11
4.6.3 Description of the sample for laboratory test . 12
4.6.4 Single bead on rail tests . 12
4.6.5 Single layer deposit on rail tests . 13
4.6.6 Multi-layer deposit on rail tests . 13
4.6.7 Welder’s report from trials . 14
4.6.8 Preparation, examination and testing of samples . 14
4.6.9 Acceptance criteria. 16
4.7 Track trial tests . 17
4.7.1 General. 17
4.7.2 Excavation detail for track trials . 17
4.7.3 Track trial test categories . 17
4.7.4 Test methods . 18
4.7.5 Requirements for in-track test samples . 18
4.7.6 Acceptance criteria for track trial restoration . 18
4.7.7 Inspection frequency . 18
4.8 Evaluation, reporting and decision following track trials . 18
4.8.1 List of general information . 18
4.8.2 Track trial tests inspection records . 19
4.8.3 Decision by approving RA on consumable and WPS . 19
4.9 Validation of consumables . 19
5 Approval of contractors . 19
5.1 Quality management systems . 19
5.2 Inspection and testing . 19
5.3 Subcontracting . 19
5.4 Equipment . 19
5.5 Welding activities . 19
5.6 Storage and handling of welding consumables . 20
5.7 Care of the infrastructure . 20
5.8 Welding procedure specifications . 20
5.9 Pre-heating of rails . 20
5.10 Welders . 20
5.11 Welder records . 20
5.12 Supervision . 20
5.13 Traceability . 21
5.14 Audits . 21
5.15 Training . 21
5.16 Documentation . 21
6 Personnel and qualification requirements . 21
6.1 Training and qualification requirements . 21
6.2 Diploma in electric arc welding of rails . 22
6.3 Permit to restore rails by electric arc welding . 22
6.3.1 RA requirements for permit application . 22
6.3.2 Mandatory information required . 23
6.3.3 Change or withdrawal of the permit . 23
7 Repair applications . 24
Annex A (normative) Track trials supplementary information . 25
Annex B (informative) Welding Procedure Specification (WPS) . 26
Annex C (informative) Diploma in electric arc restoration welding of rails . 28
Annex D (normative) Permit to restore rail by electric arc welding . 29
Annex E (informative) Track components. 30
Annex ZA (informative) Relationship between this European Standard and the essential
requirements of EU Directive (EU) 2016/797 aimed to be covered . 31
Bibliography . 32
European foreword
This document (prEN 15594:2025) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
This document is currently submitted to the CEN Enquiry.
This document will supersede 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.
Introduction
Restoration of rails by electric arc welding is a special process requiring the co-ordination of welding and
grinding activities to establish confidence and reliability of the weld deposit and safety of the line.
Controls must 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 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.
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 14700:2022, Welding consumables — Welding consumables for hard-facing
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)
EN ISO 3452-1:2021, Non-destructive testing — Penetrant testing — Part 1: General principles (ISO 3452-
1:2021)
EN ISO 3580:2017, Welding consumables — Covered electrodes for manual metal arc welding of creep-
resisting steels — Classification (ISO 3580:2017)
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 15613:2004, Specification and qualification of welding procedures for metallic materials —
Qualification based on pre-production welding test (ISO 15613:2004)
EN ISO 17638:2016, Non-destructive testing of welds — Magnetic particle testing (ISO 17638:2016)
EN ISO 18276:2024, Welding consumables — Tubular cored electrodes for gas-shielded and non-gas-
shielded metal arc welding of high strength steels — Classification (ISO 18276:2024)
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
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 15613:2004.
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 describes how a consumable and its related WPS shall be approved. WPS
approval shall follow the principle of EN ISO 15613:2004 approval by a pre-production test.
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
— 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/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 magnetic particle inspection (MT) in accordance with EN ISO 17638:2016
or dye penetrant inspection (PT) in accordance with EN ISO 3452-1:2021.
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.

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.
Figure 2 — 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 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.
4.6.5 Single layer deposit on rail tests
4.6.
...