oSIST prEN 14587-3:2025

Railway applications - Infrastructure - Flash butt welding of rails - Part 3: Welding in association with crossing construction

This document specifies requirements for the approval of a welding process in a fixed plant, together with the requirements for subsequent welding production.
This document applies to new Vignole rails manufactured in accordance to EN 13674-1 and welded by flash butt welding to crossing components in a fixed plant, and intended for use on railway infrastructures.
This document applies to cast Manganese crossings manufactured to EN 15689, fabricated crossings manufactured from rail and crossings manufactured from forged/rolled premium steels.
NOTE   EN 14587-1 is also used for the flashed butt welding of switches.
Sometimes special profiles exist in crossing construction, which are not rail profiles as defined in EN 13674 series (example: profile with machined off rail foot). In these cases, tests are defined by the railway authority in participation with the manufacturer.

Bahnanwendungen - Infrastruktur - Abbrennstumpfschweißen von Schienen – Teil 3: Schweißen im Zusammenhang mit Herzstückkonstruktionen

Diese Europäische Norm legt die Anforderungen für die Zulassung eines Schweißverfahrens in einem Schweißwerk fest, gemeinsam mit den Anforderungen für die spätere Schweißung.
Diese Europäische Norm ist anwendbar für neue, nach EN 13674-1 hergestellte Vignol-Schienen mit in einer stationären Anlage abbrennstumpfgeschweißten Herzstückkomponenten, die für den Einsatz in der Eisenbahn-Infrastruktur vorgesehen sind.
Diese Norm gilt für nach EN 15689 hergestellte Manganguss-Herzstücke sowie für aus Schienen und aus geschmiedeten und gewälzten Edelstählen hergestellte Herzstücke.
ANMERKUNG   EN 14587-1 ist auch zum Abbrennstumpfschweißen von Weichen zu verwenden.
In Kreuzungskonstruktionen können Sonderprofile vorliegen, die keine Schienenprofile nach den Definitionen in der Normenreihe EN 13674 sind (Beispiel: Profile mit maschinell bearbeitetem, außerhalb der Schiene liegendem Fuß). In solchen Fällen dürfen die Eisenbahnunternehmen zusammen mit dem Hersteller die Prüfungen vorgeben.

Applications ferroviaires - Voie - Soudage des rails par étincelage - Partie 3 : Soudure en association avec la construction des appareils de voie

Le présent document spécifie les exigences pour l'homologation d'un procédé de soudage dans une installation fixe, ainsi que les exigences pour les soudures de production.
Le présent document s’applique aux rails Vignole neufs fabriqués conformément à l’EN 13674 1 soudés par étincelage à des composants d’appareil de voie dans une installation fixe et destinés à des infrastructures ferroviaires.
Le présent document s'applique aux cœurs de voie en manganèse coulé fabriqués conformément à l’EN15689, aux cœurs fabriqués à partir de rails et aux cœurs fabriqués à partir d'aciers premium forgés/laminés.
NOTE   L’EN 14587 1 est également utilisée pour le soudage par étincelage des interrupteurs.
Dans la construction de cœurs de voie, on peut trouver des profils spéciaux qui ne sont pas des profils de rail tels que définis dans la série de normes EN 13674  (exemple : profil avec patin usiné). Dans ces cas, les essais sont définis par l'autorité ferroviaire en collaboration avec le fabricant.

Železniške naprave - Infrastruktura - Elektrouporovno varjenje tirnic - 3. del: Varjenje pri izdelavi kretnic

General Information

• Status: Not Published
• Public Enquiry End Date: 31-Mar-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: 15-Jan-2025
• Due Date: 04-Jun-2025
• Completion Date: 31-Mar-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/024 - Mandate to CEN/CENELEC/ETSI for programming and standardization in the field of railway equipment
• 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
• Ref Project: prEN 14587-3 - Railway applications - Infrastructure - Flash butt welding of rails - Part 3: Welding in association with crossing construction

Relations

• Replaces: SIST EN 14587-3:2012 - Railway applications - Track - Flash butt welding of rails - Part 3: Welding in association with crossing construction
• Effective Date: 22-Jul-2020

Overview

prEN 14587-3 (CEN) - Railway applications - Infrastructure - Flash butt welding of rails - Part 3 - sets out requirements for the approval and production use of flash butt welding in a fixed plant specifically when welding rails to crossing components. The standard applies to new Vignole rails (EN 13674‑1) welded to cast manganese crossings (EN 15689), fabricated crossings from rail, and crossings made from forged/rolled premium steels. It complements EN 14587‑1 (used for switches) and notes that special crossing profiles may require bespoke testing agreed by the railway authority and manufacturer.

Key topics and technical requirements

The document covers the full approval and production lifecycle for welding in crossing construction, including:

• Information for procedure approval: data to be supplied by purchaser and manufacturer for qualification.
• Manufacturer and process approval: welding procedure, operator qualification, supervision, equipment and quality assurance.
• Welding parameters and process steps: requirements for workpiece preparation, clamping force, initial burn‑off, preheating, final flashing, upsetting and post‑weld treatment.
• Profile finishing and weld geometry: alignment, flatness, foot dimensions and acceptable dimensional limits.
• Inspection and testing: visual inspection, surface finish, liquid penetrant and magnetic particle testing, ultrasonic/internal soundness checks, macro/micro‑examination and hardness testing.
• Mechanical and durability testing: bend tests, fatigue testing procedures (including staircase and past‑the‑post methods) and interpretation.
• Production control: weld parameter monitoring, routine NDT, rejection/retesting and documentation.
• Track trials and validity: requirements for in‑track testing and conditions for maintaining approval.

Practical applications and users

This standard is intended for organizations involved in railway crossing fabrication and installation:

• Crossing manufacturers (cast, fabricated, forged/rolled)
• Rail welding contractors and fixed‑plant operators performing flash butt welding
• Railway infrastructure owners/operators specifying procurement and acceptance criteria
• Quality assurance and inspection bodies conducting NDT, mechanical testing and audits
• Design and maintenance engineers ensuring welded crossings meet operational safety and fatigue requirements

Using prEN 14587‑3 helps ensure consistent weld quality, traceability, and long‑term performance of critical track components at crossings and turnouts.

Related standards

• EN 13674‑1 - Vignole rail specifications (new rails)
• EN 15689 - Cast manganese crossings
• EN 14587‑1 - Flash butt welding of switches (related welding procedures)

Keywords: flash butt welding, rails, crossings, prEN 14587‑3, CEN, welding procedure approval, Vignole rails, manganese crossings, weld inspection, fatigue testing, ultrasonic testing.

Standards Content (Sample)

SLOVENSKI STANDARD
01-marec-2025
Nadomešča:
SIST EN 14587-3:2012
Železniške naprave - Infrastruktura - Elektrouporovno varjenje tirnic - 3. del:
Varjenje pri izdelavi kretnic
Railway applications - Infrastructure - Flash butt welding of rails - Part 3: Welding in
association with crossing construction
Bahnanwendungen - Infrastruktur - Abbrennstumpfschweißen von Schienen – Teil 3:
Schweißen im Zusammenhang mit Herzstückkonstruktionen
Applications ferroviaires - Voie - Soudage des rails par étincelage - Partie 3 : Soudure en
association avec la construction des appareils de voie
Ta slovenski standard je istoveten z: prEN 14587-3
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
January 2025
ICS 25.160.10; 93.100 Will supersede EN 14587-3:2012
English Version
Railway applications - Infrastructure - Flash butt welding
of rails - Part 3: Welding in association with crossing
construction
Applications ferroviaires - Voie - Soudage des rails par Bahnanwendungen - Infrastruktur -
étincelage - Partie 3 : Soudure en association avec la Abbrennstumpfschweißen von Schienen - Teil 3:
construction des appareils de voie Schweißen im Zusammenhang mit
Herzstückkonstruktionen
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 14587-3:2025 E
worldwide for CEN national Members.

Contents Page
European foreword . 5
Introduction . 6
1 Scope . 7
2 Normative references . 7
3 Terms and definitions . 8
4 Information to be supplied for approval of procedure . 10
4.1 By the purchaser . 10
4.2 By the manufacturer . 10
5 Approval of the manufacturer . 10
5.1 General. 10
5.2 Welding procedure . 11
5.3 Operators . 11
5.4 Supervision . 11
5.5 Weld inspection . 11
5.6 Equipment . 11
5.7 Quality assurance . 11
6 Requirements for the welding . 11
6.1 General. 11
6.2 Workpiece preparation . 11
6.3 Clamping force . 12
6.4 Initial burn-off . 12
6.5 Preheating . 12
6.6 Final flashing . 12
6.7 Upsetting . 12
6.8 Post-weld treatment . 12
6.8.1 Before unclamping . 12
6.8.2 After removal from machine. 13
6.9 Welding parameters . 13
6.10 Removal of upset and correction of weld alignment . 13
7 Profile finishing of the weld . 13
8 Weld geometry and dimensions . 14
8.1 General. 14
8.2 Alignment and flatness across the weld . 15
8.3 Foot dimensions . 15
9 Weld identification . 17
10 Procedure approval . 17
10.1 General. 17
10.2 Test weld specimen preparation . 18
10.3 Number of specimens . 18
10.4 Approval tests . 18
10.4.1 General. 18
10.4.2 Weld geometry and dimensions . 19
10.4.3 Visual inspection . 19
10.4.4 Surface finish . 19
10.4.5 Liquid penetrant testing and magnetic particle testing . 19
10.4.6 Internal soundness . 20
10.4.7 Bend test . 20
10.4.8 Fatigue testing . 21
10.4.9 Macro-examination . 21
10.4.10 Micro-examination . 21
10.4.11 Hardness testing . 22
10.5 Test result report . 23
10.6 Validity of approval. 23
11 Approval of other rail profiles or grades . 23
11.1 General . 23
11.2 Sample preparation . 24
11.3 Test result report . 24
12 Track trials . 24
12.1 General . 24
12.2 Track trial test result report . 24
13 Weld production following procedure approval . 25
13.1 Weld production . 25
13.2 Weld parameter monitoring. 25
13.3 Visual inspections . 25
13.4 Weld geometry and dimensions . 25
13.5 Liquid penetrant testing and magnetic particle testing . 25
13.6 Internal soundness . 25
13.7 Bend testing . 25
13.7.1 General . 25
13.7.2 Additional test requirements . 26
13.7.3 Bend test procedure . 26
13.7.4 Interpretation of results . 26
13.7.5 Retesting . 27
13.7.6 Documentation . 27
Annex A (informative) Example of flat spots: lenticular type and grey spot . 28
Annex B (normative) Bend test requirements . 30
Annex C (normative) Test weld fracture faces – Recording of defects . 33
Annex D (normative) Fatigue test method for flash butt welds . 35
D.1 Scope . 35
D.2 Test equipment. 35
D.3 Calibration procedure. 37
D.3.1 General . 37
D.3.2 Test piece . 37
D.3.3 Test piece preparation . 37
D.3.4 Instrumentation . 37
D.3.5 Procedure . 37
D.4 Fatigue test method . 42
D.4.1 General. 42
D.4.2 Staircase testing method . 42
D.4.3 Example of the data analysis of a fatigue strength determination by the staircase
method . 45
D.4.4 Past-the-post testing method . 45
Annex E (normative) Macro-examination and micro-examination . 47
E.1 Macro-examination . 47
E.2 Micro-examination . 47
Annex F (normative) Hardness testing . 50
Annex G (normative) Ultrasonic testing non-austenitic materials . 51
G.1 Reference line (DAC) generation – Reference block . 51
G.2 Reference line (DAC) generation and acceptance criteria . 51
Annex H (informative) Measurement of alignment and flatness . 53
H.1 General. 53
H.2 Vertical alignment . 53
H.3 Horizontal alignment . 54
H.4 Flatness . 55
Biography . 57

European foreword
This document (prEN 14587-3:2025) 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 14587-3:2012.
In comparison with the previous edition EN 14587-3:2012, mainly the following technical modifications
have been made:
— clarification in how foot dimensions have to be measured, introducing a gauge and table for
reference;
— introducing cleaner instruction for the testing sequence, more details for visual inspection;
— a better description of flat spots and clearer criteria for micro structure examination;
— criteria for cross acceptance of materials;
— added bend test requirements for high strength steels;
— a new annex as guidance for geometrical inspection of welded joints.
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 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.
This document is one of three parts in the EN 14587 series of standard “Railway applications – Track –
Flash butt welding of rails”. The list of parts is as follows:
— Part 1: New R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails
in a fixed plant;
— Part 2: New R200, R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade
rails by mobile welding machines at sites other than a fixed plant;
— Part 3: Welding in association with crossing construction (the present standard).

Introduction
This part three of EN 14587 standard has four main topics:
— procedure approval for a fixed plant;
— requirements of a welding process;
— weld production following approval;
— approval of other rail profile or grades.
The European standard satisfies the needs of the railway authority. The manufacturer should achieve the
specified requirements of this European standard.

1 Scope
This document specifies requirements for the approval of a welding process in a fixed plant, together
with the requirements for subsequent welding production.
This document applies to new Vignole rails manufactured in accordance to EN 13674-1 and welded by
flash butt welding to crossing components in a fixed plant, and intended for use on railway
infrastructures.
This document applies to cast Manganese crossings manufactured to EN 15689, fabricated crossings
manufactured from rail and crossings manufactured from forged/rolled premium steels.
NOTE EN 14587-1 is also used for the flashed butt welding of switches.
Sometimes special profiles exist in crossing construction, which are not rail profiles as defined in
EN 13674 series (example: profile with machined off rail foot). In these cases, tests are defined by the
railway authority in participation with the manufacturer.
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 13018, Non-destructive testing — Visual testing — General principles
EN ISO 3452-1, Non-destructive testing — Penetrant testing — Part 1: General principles (ISO 3452-1)
EN ISO 9712, Non-destructive testing — Qualification and certification of NDT personnel (ISO 9712)
EN 1371-1, Founding — Liquid penetrant testing — Part 1: Sand, gravity die and low pressure die casting
EN 13674-1, Railway applications — Track — Rail — Part 1: Vignole railway rails 46 kg/m and above
EN 13674-2, Railway applications — Track — Rail — Part 2: Switch and crossing rails used in conjunction
with Vignole railway rails 46 kg/m and above
EN 13674-4, Railway applications — Track — Rail — Part 4: Vignole railway rails from 27 kg/m to, but
excluding 46 kg/m
EN 14587-1:2018, Railway applications — Infrastructure — Flash butt welding of rails — Part 1: R220,
R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails in a fixed plant
EN 17343, Railway applications — General terms and definitions
EN ISO 6507-1, Metallic materials — Vickers hardness test — Part 1: Test method (ISO 6507-1)
EN ISO 7500-1:2018, Metallic materials — Calibration and verification of static uniaxial testing machines
— Part 1: Tension/compression testing machines — Calibration and verification of the force-measuring
system (ISO 7500-1:2018)
EN ISO 11666, Non-destructive testing of welds — Ultrasonic testing — Acceptance levels (ISO 11666)
EN ISO 17638, Non-destructive testing of welds — Magnetic particle testing (ISO 17638)
EN ISO 17640, Non-destructive testing of welds — Ultrasonic testing — Techniques, testing levels, and
assessment (ISO 17640)
EN ISO 23278:2015, Non-destructive testing of welds — Magnetic particle testing — Acceptance levels
(ISO 23278:2015)
EN ISO 23279, Non-destructive testing of welds — Ultrasonic testing — Characterization of discontinuities
in weld (ISO 23279)
3 Terms and definitions
For the purposes of this document, the terms and definitions given in EN 17343 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
austenitic component
part made from high manganese steel and austenitic micro structure with a manganese content of (11,5
to 14,0) % and a carbon content of (0,95 to 1,3) %
3.2
insert
is an intermediate part between the rail and the crossing when the crossing is made from austenitic
manganese steel
Note 1 to entry: The insert is compatible with the rail and the austenitic crossing material. It allows different
welding procedures between the rail/insert weld and the insert/crossing weld. In general, the insert material is a
stainless steel.
3.3
manufacturer
company that joins rails to rails, rails to crossings and rails to crossing components by flash butt welding
in a fixed plant
3.4
purchaser
buyer of the flash butt welded crossings working in accordance with the requirements of the railway
authority
3.5
railway infrastructure
permanent way of national or private railways
3.6
fixed plant
stationary machine for flash butt welding of rails to rails, rails to crossings and rails to crossing
components
3.7
die burn
damage caused by localised overheating on the electrode contact surfaces (see Annex A)
3.8
upset
metal extruded around the rail profile as a result of forging
3.9
specimen
portion detached from a welded component or a welded joint and prepared as required for testing
3.10
profile finishing
operation by which the rail or relevant part of the component at the weld is returned to original profile,
by removal of upset material
Note 1 to entry: This operation can be achieved by grinding, milling, planning or any other suitable means.
3.11
finished condition
welded and profile finished
3.12
flat spot
feature having a localised smooth texture when viewed in a vertical transverse section (see Figure A.1
and Figure A.2)
Note 1 to entry: When viewed longitudinally in macro this may appear as a lens-shaped feature.
3.13
lack of bond
area within the weld where there is no metal to metal contact (excluding flat spots and bright spots)
Note 1 to entry: This may appear as a linear discontinuity at the interfaces when examined in the finished condition
or after sectioning.
3.14
welded zone
area of 50 mm on either side of the weld centreline
3.15
throat flare
wing entry flare (front) machining or setting of wings to give an entry flare into the throat
3.16
foundry method
system to produce a casting made of austenitic manganese steel
3.17
workpiece
crossing component, insert rail or rail leg-end extension
3.18
railway authority (RA)
either the railway regulator or the owner of the railway infrastructure or the custodian with a delegated
responsibility for a railway infrastructure
3.19
as welded condition
rails that have been welded and/or trimmed only
3.20
bainitic component
part made from bainitic rail steel, whose chemical and mechanical properties are defined
4 Information to be supplied for approval of procedure
4.1 By the purchaser
The following information shall be supplied by the purchaser, agreed upon by the manufacturer, and shall
be fully documented:
a) the rail profile and crossing geometrical details;
b) the rail and crossing grades/materials;
c) the profile class of the rail leg-end extension as specified in EN 13674-1, EN 13674-2 or EN 13674-4;
d) alignment class/classes of the flash butt welds (see Table 1);
e) the type of fatigue tests (if applicable) for approval;
f) tolerances at rail ends on the delivered crossing;
g) minimum length of the rail leg-end extension;
h) rail profile, number and frequency of production bend tests (see 13.7);
i) requirements of any track trials;
j) where applicable: Chemical and mechanical properties of rail steels not covered by EN standards
(rail or crossing part).
4.2 By the manufacturer
The following information shall be supplied by the manufacturer, agreed upon by the purchaser, and shall
be fully documented:
a) a qualified weld procedure;
b) traceability system of the welds;
c) type and identification number of machine being used.
5 Approval of the manufacturer
5.1 General
The manufacturer shall meet the approval requirements as defined in 5.2 to 5.7. The purchaser reserves
the right to audit the manufacturer at any time.
5.2 Welding procedure
The manufacturer shall use welding procedures and flash butt welding machines that are approval by the
RA.
5.3 Operators
The manufacturer shall maintain a system that ensures the competence of their welding operators by
appropriate training and assessment.
5.4 Supervision
The manufacturer shall maintain a management and supervision system of flash butt welding that
complies with the requirements of the purchaser.
5.5 Weld inspection
The manufacturer shall maintain a system of weld inspection according to the purchaser requirements.
Instances of non-conformity found during these inspections shall be recorded in the traceability system.
5.6 Equipment
Equipment shall comply with the operating manual. Inspection and calibration equipment shall comply
with those requirements as agreed between the manufacturer and the purchaser.
5.7 Quality assurance
The manufacturer shall apply a quality management system approved and verified by an independent
body or any other organisational system of control accepted by the purchaser.
NOTE More information about quality management systems are provided by EN ISO 9001.
6 Requirements for the welding
6.1 General
All welding shall be carried out on a flash butt welding machine using an automatic, programmed welding
sequence using RA approved procedures.
6.2 Workpiece preparation
The crossing/insert/rail faces to be welded shall always be sawn, disc cut or machined prior to welding
and shall conform to the tolerances given in Figure 1. Areas of electrical contact on the workpieces and
the machine shall be clean and free of any deleterious materials that could affect current flow. The
workpieces shall not be damaged by the cleaning operation.
The total mismatch of the two workpieces shall not exceed 2 mm and shall be corrected by grinding or
machining prior to welding.
The crossing leg end profile has to be prepared in agreement with the casting supplier and the welding
plant to allow welding.
Key
1 elevation
2 plan
Figure 1 — Tolerances for rail end squareness
6.3 Clamping force
Workpieces shall be secured in the flash butt welding machine by clamps of such a surface shape or
contour, that when a clamping force is exerted on the workpieces, it shall not damage the workpiece. The
clamping force shall be sufficient such that slippage does not occur.
6.4 Initial burn-off
The workpieces should undergo initial flashing to ensure full rail end contact during the subsequent
preheating cycles.
6.5 Preheating
The fronts of the heating area shall progress such that at completion of preheating an even heat band is
present in both workpieces. On completion of welding there shall be no evidence of localized melting on
the ends of the workpieces.
6.6 Final flashing
Once initiated, final flashing shall be continuous.
6.7 Upsetting
Upsetting shall immediately follow flashing. Sufficient forging pressure shall be applied to ensure that
voids are closed and oxides are expelled such that they are kept to a minimum at the weld interface. The
weld interface shall extend into the upset.
The time between completion of upsetting and unclamping shall be sufficient to ensure required weld
integrity. During this time, sufficient longitudinal force shall remain present to prevent damage to the
weld.
6.8 Post-weld treatment
6.8.1 Before unclamping
Post-weld heating could be required for certain rail grades and alloyed steels.
6.8.2 After removal from machine
A post-weld controlled cooling could be required.
Additional post-weld heat treatment may be required after removal from the welding machine for certain
steel grades.
6.9 Welding parameters
The welding machine and/or management system equipment shall be capable of recording the following:
a) welding current;
b) upset force or pressure;
c) displacement;
d) welding time;
e) programme identification and setting details;
f) weld identification;
g) post-weld heat treatment (if applicable);
h) limits/range of the main welding parameters.
The welding programmes and any post-weld heat treatment shall be determined during procedural trials
and once approval has been granted, they shall not be changed without prior purchaser approval.
The welding parameters shall be monitored, checked against approval limits and recorded. These records
shall be referenced to the appropriate welds.
The post-weld heat treatment parameters shall be monitored, checked against approval limits and
recorded. These records shall be referenced to the appropriate welds.
6.10 Removal of upset and correction of weld alignment
The upset material shall be removed by the method carried out during the approval process and once
agreed shall not be changed without prior purchaser approval. In exceptions where upset material cannot
be removed, finish and dimensions shall be agreed between the purchaser and the manufacturer.
Removal of the upset shall not cause any mechanical or thermal damage to the crossing or rail.
Any surface where upset has been removed shall be free from visible cracking.
The correction of the weld alignment shall be carried out by pressing.
7 Profile finishing of the weld
The surface finishing shall be carried out in the longitudinal direction using machining/grinding.
Unless otherwise specified by the RA, the roughness limit within the welded zone shall be a maximum
value of:
a) 3,2 µm Ra on the underside, upperside of the welded rail foot and the foot tips;
b) 6,3 µm Ra in the wheel contact area;
c) 12,5 µm Ra in all other finished areas;
d) rail foot radius shall be rounded to guarantee at least the radius according to rail profile as per
EN 13674-1.
The profile finishing shall not cause any thermal or mechanical damage. The rail profile in the wheel
contact area shall be maintained during profile finishing. The remainder of the welded surfaces shall be
smoothly blended to the profile of the surrounding material, so as to avoid a localized stress
concentration.
Where this is not possible, the finished profile shall be agreed between the manufacturer and the
purchaser.
Profile finishing of the rail-head shall be contained in the shortest possible length, but shall in any case
not exceed 900 mm.
8 Weld geometry and dimensions
8.1 General
The alignment of the welded joint after pressing and profile finishing shall be measured, vertically and
horizontally within a 1 m span.
The vertical alignment of the rail head shall be measured on the running surface only.
The horizontal alignment of the rail head shall apply to running edges only.
Any deviation of alignment shall be in accordance with Table 1, at ambient temperature.
Any measurement of alignment made whilst the weld is hot, i.e. immediately following profiling, shall
take into account the effect that cooling will have on the weld, such that the limits identified in Table 1
are maintained.
Table 1 — Tolerances for alignment and flatness of flash-butt welds at ambient temperature
Tolerances [mm] Class 1 Class 2 Class 3 Class 4 Maximum
grinding length
Horizontally on the rail head 0/+0,3 0/+0,5 ±0,4  900 mm
Vertically on the running surface 0/+0,3 −0,1/+0,2 −0,3/0 +0,1/+0,3 900 mm
Flatness on the running surface at ≤ 0,1 ≤ 0,2
the length of the grinded area
Head width At the non-running side, 1,5 mm dip is permitted with
a minimum length of 100 times dip depth
NOTE 1 For horizontal alignment, positive tolerances will widen gauge. Vertical alignment positive tolerances
will create a hog, negative tolerances a dip.
NOTE 2 The purchaser selects different classes for vertical and horizontal alignment and flatness from the
above. The vertical and horizontal alignment can be mixed between classes. Horizontal and vertical alignment
are checked by use of a 1 m straightedge. Flatness are checked by use of a 200 mm straightedge in the grinding
zone to be in accordance with EN 14587-1 and EN 14587-2.
NOTE 3 Horizontal tolerances do not apply to crossings with built-in curvatures or where the weld is within
the throat flare area. Where crossings are manufactured with built-in curves, an agreement concerning the
tolerances is necessary between the manufacturer and the purchaser. For curved rails the tolerance apply to the
versine.
NOTE 4 Maximum grinding length is not necessarily symmetrical about the weld but no more than 450 mm

either side of the weld, unless stricter requirements apply.

The purchaser may select from the classes above, different classes for vertical and horizontal straightness
and flatness. If the class is not specified by the RA, Class 2 shall be used.
8.2 Alignment and flatness across the weld
Please refer to Annex H for the measurement methods of alignment and flatness (see Figure H.1 to Figure
H.8). Alignment and flatness across the weld shall be measured as follows:
a) the vertical alignment across the running surface shall be measured along the longitudinal centre
line of the rail with the weld centrally between and referenced to datum points on the rail 500 mm
either side of the weld;
b) the horizontal alignment of the weld across the rail head shall be measured on the running edge at a
point 14 mm below the running surface and referenced to datum points on the rail 500 mm either
side of the weld;
c) the running surface flatness at the level of the weld shall be measured by means of a 200 mm
straightedge positioned on the ground area. The maximum gap between the straightedge and the
profiled running table of the rail shall be in one of the classes in Table 1;
d) any alternative measurement system used shall first be agreed upon with the purchaser.
8.3 Foot dimensions
In order to control if the thickness is above the minimum thickness in the entire weld area, a NO GO Gauge
shall be used. The following tolerances apply:
a) a difference of up to 4 mm in the nominal foot width dimension is permitted in the weld zone, owing
to upset removal and manufacturing tolerances. Further reductions in the foot width may be
necessary owing to the angle of the crossing. In this instance, the manufacturer shall supply the
information to the purchaser;
b) at 14 mm from the foot tip, a tolerance of 15 % maximum thickness reduction from the minimum rail
foot thickness may be permitted subject to agreement between the manufacture and the purchaser.
Minimum thickness 4 mm
Without other indication, general tolerance is ±0,5 mm
Figure 2 — Gauge to measure the foot thickness
Table 2 gives the minimum foot thickness “t1” and “t2” for the standard rail profiles.
Table 2 — Tolerances for foot dimensions of typical profiles
“t2” Minimum
“t1” Minimum
thickness at
thickness at 14 mm
14 + 4 mm from foot
Rail profile
from foot tip
tip
[mm]
[mm]
45E2 9,6 10,4
46E2 9,7 10,0
46E4 9,5 10,3
49E1 and 49E5 10,0 10,5
50E2 11,4 12,1
50E3 9,5 9,9
50E4 and 50E5 9,6 10,0
50E6 10,5 10,9
54E1 10,1 10,5
“t2” Minimum
“t1” Minimum
thickness at
thickness at 14 mm
14 + 4 mm from foot
Rail profile
from foot tip
tip
[mm]
[mm]
54E2 11,0 11,3
54E3 and 54E4 11,3 11,7
56E1 10,3 10,6
60E1 and 60E2 10,2 10,4
9 Weld identification
A unique identification shall be recorded for each individual weld to permit traceability between the
crossing and weld production records.
NOTE Marking of the weld on the crossing is not required.
10 Procedure approval
10.1 General
Flash butt welding machines used in this work shall be individually approved by the RA; type approval is
not permitted. Approval is granted for welding procedures specified to the selected materials.
Approval for rail profiles within the same grade can be considered in groups (see Table 3). At least one
profile in a group shall undergo testing in accordance with 10.4; the remaining rail profiles within that
group shall undergo a minimum of five bend tests in accordance with 10.4.7.
Table 3 — Rail groups
Cross
sectional area Examples
(S) (cm )
40 < S ≤ 46 33E1(42.6)
46 < S ≤ 52 39E1(50.6)
52 < S ≤ 58 43E1 (55.8)
58 < S ≤ 64 49E1(62.9)
64 < S ≤ 71 52E1 (66.4)
71 < S ≤ 78 60E2 (76.5)
78 < S ≤ 85 49E1A3 (80.5)
85 < S ≤ 92 60E1A4 (88.9)
92 < S ≤ 99 60E1T2 (94.6)
NOTE 60E1 and 60E2 are considered as being the same profile.
The approval tests for rail grade/material combinations and extensions of these approvals are given in
10.4 and Clause 11.
The grades and materials shall be specified using the respective European standard or by their
mechanical and chemical characteristics in the absence of a European standard.
Procedure approval shall be carried out by testing weld samples produced in accordance with this
document; the samples shall be representative of those carried out in production.
Procedure approval testing shall be carried out on the rail/crossing profile and material grade specified
by the purchaser.
The intermediate buffer material used for the approval tests shall be the same as that used in production.
All test results and weld fracture faces shall be made available for inspection.
10.2 Test weld specimen preparation
Materials shall be cast, rolled, forged, heat treated, machined and inspected by the same method used for
production pieces. The foundry method used to produce cast manganese specimens shall be that used for
the normal production of cast crossings.
The prepared specimens shall be flash butt welded by the same programme(s) and sequence used in
production.
Welds shall be finished and inspected in accordance with normal production methods.
When employing non-austenitic materials, specimens for the bend tests shall be in the as-welded or
finished conditions.
10.3 Number of specimens
For welds with austenitic components, nine welds in the finished condition (see 3.9) shall be
manufactured. For welds without austenitic components, four welds shall be prepared in the finished
condition and five in the as-welded or finished condition. Depending on
...