Rail Overheating & Blueing
- Burn marks on rails after grinding
- Bluish discoloration (temper colors) on rail surface
- Surface scratches or scoring after grinding
Rail Grinding Solution
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Rail Grinding Solution
Why Precision Rail Grinding is Essential for Track Performance
Inadequate Rail Grinding Profile
- Ground profile fails to match the target rail contour
- Insufficient metal removal (< 0.02 mm per pass)
- Excessively low surface roughness (< 10 μm Ra)
Poor Rail Surface Condition
- Excessively high surface roughness after grinding
- Non-uniform contact patch (light band) after grinding
- Excessive number of grinding passes
RailwayCare
Solving Local Challenges with a Global Perspective
With a decade of experience honed in China's most extreme and complex railway networks, and over 3 million kilometers of grinding practice, RailwayCare provides professional solutions to overcome the three core challenges: rail overheating, profile deviation, and surface roughness. We are committed to integrating proven reliability, precision, and efficiency into your operations, serving clients worldwide and defining the standard of excellence.
Since 1999
Comprehensive Track Grinding by RailwayCare
Railwaycare has been committed to improving railway safety and efficiency, becoming a trusted leader in the China market,we now provide world-class rail grinding products and grinding technologies to global customers.
Grinding
The RailwayCare Grinding LifeCycle
01
Grinding Inspection
Track surface analysis using visual and ultrasonic inspection tools
02
Grinding Planning
Selection of grinding wheel type and parameters based on rail material and defect type.
03
Grinding Process
Controlled removal of metal layers using specialized grinding wheels
04
Grinding Verification
Rail geometry checked after grinding using profile gauges or optical systems
Rail Grinding Solution
Rail Grinding Process & Technology
Mainline Inspection
Periodic full inspection of mainline tracks covering geometry, surface, and internal defects for safety and smoothness.
Turnout Inspection
Specialized inspection of turnout components including switches, frogs, and precise geometry measurement.
Small Radius Curve Inspection
Enhanced inspection for curves with radius ≤600m, focusing on side wear, gauge, and geometry maintenance.
Profile Design
The target rail head profile is designed according to operational parameters (train type, axle load, speed, and track curvature).
Track Condition Analysis
Before determining the grinding process, a detailed track condition analysis is conducted to understand the rail’s structural and operational status.
Grinding Execution Strategy
It is a closed-loop workflow of precise analysis, controlled execution, and rigorous verification, ensuring every grinding action is justified and effective.
Equipment Selection
Grinding plans are developed based on rail material, defect severity, traffic conditions, axle load, speed, and track curvature.
We provide solutions for both mainline continuous grinding and localized turnout or corrective grinding.
Rail Grinding Train
Grinding Machine
- After grinding, a comprehensive profile verification and quality assessment is carried out to confirm that the rail meets all geometric, surface, and safety requirements defined in the grinding plan.This stage ensures that the rail achieves the designed contour, smoothness, and structural integrity before it is released for service.
Verification Objectives
Measurement & Testing Methods
Acceptance Criteria
Documentation Reporting
Improvement
Application Scenarios by Railway Type
Tailored rail grinding solutions designed for different railway systems and operational demands.
RailwayCare provides customized rail grinding solutions for mixed, freight, and high-speed lines — ensuring safety, precision, and reliability across every railway network worldwide.
Mixed Passenger–Freight Lines
- Passenger trains cause short-pitch corrugation; freight trains induce head crushing and side wear. Precision grinding addresses both in a single operation.
- With maintenance windows often under 3 hours, high-efficiency grinding delivers long-lasting results—reducing intervention frequency by 50% or more.
- Over-polished rails risk freight slippage; rough surfaces degrade passenger comfort. Controlled surface roughness from precision grinding meets both needs.
Heavy Freight Lines
- 30-ton axle loads crush rail heads and spawn fish-scale cracks; repeated cycles cause spalling and rail breaks. Preventive grinding removes damage before it propagates.
- Curves wear 5–8 mm per year under heavy tonnage; frequent rail replacement drives up costs. Profile grinding slows side wear and extends service life by 30%+.
- Contact fatigue cracks grow beneath the surface; white-etching cracks can cause sudden failures. Regular grinding eliminates initiation sites and redistributes wheel-rail stress.
High-Speed Rail Lines
- High speeds turn sub-millimeter ripples into violent vibrations; unpolished welds create impact noise and force spikes. Precision grinding delivers micro-level smoothness for stable, quiet operation.
- Even minor rail profile errors destabilize high-speed turnouts; irregular contact increases derailment risk. Grinding restores design geometry to ensure safe, high-speed switching.
- Passenger comfort demands near-perfect track quality; Sperling index violations trigger service alerts. Fine grinding maintains ride quality within strict operational limits.
Customer types
Tailored Solutions for Every Type of Rail Grinding Customer
Local Rail Operator
Core Needs:
Cost-effectiveness, ease of operation, long product lifespan, comprehensive technical support.
Recommended Procurement Package:
Collaborative grinding plan development + Grinding equipment (primarily grinding trains with matching wheels).
Urban Rail Operator
Core Needs:
Maximum efficiency, low noise & dust emissions, night-time operation suitability, precision grinding.
Recommended Procurement Package:
Collaborative grinding plan development + Grinding equipment (primarily grinding trains with matching wheels)
Rail Engineering Contractor
Core Needs:
Broad product coverage, high equipment availability, sufficient supply capacity.
Recommended Procurement Package:
Inspection services + Data analysis + Grinding plan formulation + Grinding equipment (primarily grinders with matching wheels)
Specialized Rail Gang
Core Needs:
Equipment portability & versatility, extreme cost-performance ratio, rapid technical support, flexible procurement options.
Recommended Procurement Package:
Grinding equipment (primarily grinders with matching wheels).
products
Rail Grinding Equipment Recommendations
RAIL PROFILE MEASURING INSTRUMENT
It can accurately measure rail profiles and calculate key parameters such as rail side wear, vertical wear, superelevation, track gauge, equivalent conicity, and wheel-rail contact characteristics.
Rail Grinding Vehicle
Precision rail grinding vehicle for micro-defect removal and geometric restoration.
Rail Grinding Wheel
Precision grinding stones for rail profile restoration and surface defect elimination.
Rail Grinder
Precision rail thermite/flash-butt welding for seamless joint fusion and fatigue strength enhancement.
Core Advantage
Delivering Comprehensive Value
Proven Industry Experience
A Decade of Expertise, Millions of Kilometers of Experience With 10 years in the industry, we have accumulated 3 million kilometers of total rail grinding project experience, delivering proven practical expertise.
Complete Equipment Solutions
Complete Equipment Portfolio, Wide Applicability We supply a full range of grinding equipment and accessories suitable for all types of railways and environments, ensuring precise matching to your needs.
Railway-Certified Expert Team
Expert Team with Industry Pedigree Our technical team is composed of core members from within China's railway system, bringing deep professional expertise and hands-on field capability.
Industry Standards Contributor
Contributing to Industry Standards We have actively participated in and helped shape the formulation of grinding industry standards within China's railway system, committing to defining industry best practices.
Building success together
A Clear and Reliable Project Partnership Journey.
We believe successful collaboration stems from a clear roadmap and seamless execution. Our five-phase methodology, with an emphasis on iterative validation, is designed to deliver certainty and outstanding results.
Step 1
Scope & Commit
Step 2
Design & Plan
Step 3
Test & Prove
Step 4
Verify & Validate
Step 5
Deliver & Close
Case
Our Cases of Rail Grinding Solutions
- 20,000kilometers
China National Energy Group
RailwayCare has long provided grinding solutions for China National Energy Group, with a total grinding mileage exceeding20,000 kilometerson the Shenshuo and Huanghua lines.
- 9000kilometers
China Nanning Railway Bureau
Railwaycare uses GEMAC to provide grinding services for rail grinding operations at Guilin West Station in Guangxi, with a total grinding mileage exceeding900 kilometers.
- 1100kilometers
China Jinan Railway Bureau
RailwayCare's GMC-96B grinding wheels were used for grinding operations at Shouguang Station on the Shandong High-Speed Railway, with a cumulative grinding mileage exceeding1100 kilometers.
faq
Frequently Asked Questions
For more questions about track grinding, please contact our experts.
- What is the lead time for your main products and equipment?Standard grinding equipment lead time is 1-2 months.
- What types of railways can your grinding solutions cover ?We fully support standard Chinese rail profiles (50/60/75 kg/m), covering speeds from 120-350 km/h.
- Do you provide operator training and ongoing technical support after the equipment purchase?We provide full-cycle service from training to long-term support.
- What factors determine the rail grinding cycle? Is it a fixed schedule, or a customizable plan?We employ a data-driven, customized approach instead of fixed intervals.
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