Rail: The central interface in the track system

Basically, three factors determine the rail: length, shape (profile), and material. In terms of rail length, voestalpine Railway Systems has already set standards with its 120-meter rail. The rail lengths of other manufacturers are 74 or 108 meters. Together with a competitor, we are now the only manufacturers offering a length of 120 meters. This allows us to significantly reduce the number of welds — from ten to a hundred weld joints per construction site. Each weld means additional construction and maintenance work and represents a potential weak point. So, we have made a significant contribution to increasing the robustness of the track and improving safety. 

Due to our proximity to the steelworks in Donawitz, we have always paid particular attention to materials. With targeted material development and a deep understanding of the wheel-rail system, we have developed material solutions for typical damage and wear phenomena. We also work intensively with simulations to understand and predict contact stresses and damage. To do this, we need measurements of rail and wheel profiles and their development over time. Ultimately, practical experience proves our success: if maintenance cycles and rail service life are extended, we know that we are on the right track. 

The rail plays a crucial role in the overall track system. It can protect other components such as intermediate layers, sleepers, or ballast. The aim is therefore not only to extend the service life of the rail, but also to optimize the entire superstructure. The static properties of the rail—such as height or rail foot width—are decisive parameters here. The foot width allows tension and forces to be distributed more evenly across the interlayers, which also has a positive effect on other components. In our new superstructure system, we have therefore specifically optimized the ratio between the contact surface and height. Not in isolation, but in interaction with all components. That is our long-term goal: to think about the overall system. 

We recommend the product for the respective application and work together to develop maintenance recommendations for the optimal timing. Our digital systems, measuring systems, and expertise will help to ensure that the rail can be used for as long as possible in the future. In this way, we also make a clear contribution to sustainability.

Speaking of sustainability, voestalpine aims to achieve net-zero CO₂ emissions in steel production by 2050 with greentec steel. The rail is made of 100% steel, which is why this change affects us in particular. However, our research projects and strict quality controls clearly show that customers will not notice any difference in quality between steel for rails produced in a blast furnace or an electric arc furnace. The decisive advantage lies in significantly lower CO₂ emissions. This is our contribution to green rail and climate-friendly railways.  

The big advantage of rails is that they are 100% recyclable. That is why we are also striving to establish a circular economy with our customers. For example, we have implemented a project together with the Dutch national railway company, ProRail. We took back old rails from ProRail and used them to produce new rails at our facility — with virtually no additional alloying elements. We then sent them back to the Netherlands, where they will soon be installed.