Crane Rail Equipment: Welding, Inspection & Installation Tools
Complete range of specialized equipment, tools, and inspection instruments for aluminothermic welding of crane rails, railway tracks, and industrial rail systems — engineered for field reliability and precision joint quality.
Complete Rail Welding Equipment Portfolio
Three specialized product lines covering the full aluminothermic welding workflow — from joint preparation and welding to post-weld finishing and quality inspection.
Welding Equipment
Post-weld trimming machines and rail profile grinders designed for the aluminothermic welding process, delivering precision joints in <40-second cycle times.
Installation Tools
Purpose-built tools for crane rail thermite welding preparation and execution — from preheaters and mold fixtures to rail alignment and slag handling equipment.
Inspection Instruments
Precision measuring tools for rail joint alignment, weld gap verification, and gas flow control — meeting DIN and ISO standards for industrial rail project acceptance.
Aluminothermic Welding Equipment for Crane Rails
Specialized post-weld processing machines designed for the aluminothermic welding workflow — removing weld flash and restoring rail profile to operational tolerance.
Weld Trimming & Grinding Machines
| Product | Specifications & Description |
|---|---|
| QLJ-III Manual Rail Weld Trimming Machine | Dedicated aluminothermic welding equipment for removing excess weld flash after rail joint completion. The manual hydraulic bidirectional drive delivers up to 200 kN thrust, with a feed speed of 3.5 mm per stroke cycle. Single-direction operation completes in ≤40 seconds, leaving the trimmed surface no more than 2 mm above the original rail profile. Opening: 135 mm max between dual cutting edges |
| QLJ-II Electric Hydraulic Weld Shear | Electric-powered hydraulic weld trimming machine for higher-volume rail welding operations. A 3.0 kW three-phase motor drives the hydraulic system, achieving a feed speed of 12 mm/s with a single-direction cycle time of ≤20 seconds. The power unit connects via flexible high-pressure hose for ergonomic positioning. Max Thrust: 200 kN |
| GDMJ-1 Rail Grinding Machine (Electric) | Post-weld rail profile grinding machine for precision finishing of the rail top surface after aluminothermic welding. Equipped with a 380 V, 2.2 kW motor running at 2800 rpm, driving a special cup grinding wheel (BL Φ150 × 85 × 80 mm). The cup wheel consumption ratio is 1:6, ensuring cost-effective operation. Weight: 68 kg |
| CFMG-5 Grooved Rail Groove Grinding Machine | Specialized grinding equipment for grooved rail (tram/streetcar track) post-weld finishing. A 380 V, 2.2 kW motor (2800 rpm) drives a radius grinding wheel (Φ250 × 25 mm) designed to restore the groove profile after aluminothermic welding. Suitable for 59R2 and 60R2 grooved rail profiles. Weight: 68 kg |
| Grooved Rail Precision Grinding Machine | Lightweight precision finishing machine for grooved rail groove surface refinement after welding. Powered by a single-phase 220 V, 1.2 kW motor with a Φ150 mm grinding wheel. At just 21.5 kg, it is easily transportable between work sites. Dimensions: 580 × 520 × 340 mm |
Supplementary Tools & Consumables
| Product | Specifications & Description |
|---|---|
| Angle Grinder (S1M-FF-150A) | General-purpose grinding tool for post-weld surface touch-up and rail edge finishing. Single-phase 220 V, 1200 W, 9000 rpm, fitted with Φ150 mm grinding disc. Model: S1M-FF-150A. |
| Handheld Straight Grinder (S1S-FF-125B) | Compact straight grinder for detailed weld finishing in confined rail joint areas. Single-phase 220 V, 710 W, 5300 rpm. Model: S1S-FF-125B. |
| Rail Cutting Disc (Φ400 mm) | Resin-bonded cutting disc for rail sectioning and joint preparation. Diameter Φ400 mm, thickness 4 mm. Compatible with standard rail cutting machines. |
Crane Rail Installation Tools for Thermite Welding
Purpose-designed tools for every stage of the crane rail aluminothermic welding process — from rail end preparation and mold setup to pouring and post-weld cleanup.
| Product | Specifications & Description |
|---|---|
| Preheater with Magnetic Stand | Custom preheater assembly for controlled joint preheating before thermite pouring. Features a 143TN brass grip, stainless steel nozzle tube, and A3 steel nozzle tip. The magnetic bracket (1.46 kg) holds the preheater in position during operation. Total weight: 3.8 kg. Dimensions: 620 mm length × 290 mm height. Comes complete with oxygen and LPG hose connections. |
| Crucible Lid | Safety cover for shielding against spark splatter during the thermite flux reaction. Fabricated from 2 mm cold-rolled steel plate, weight 3.2 kg. Max bottom opening diameter: Φ240 mm. Essential PPE-complementing safety equipment for every welding operation. |
| C-Clamp (Sand Mold Fixture) | Sand mold clamping tool for securing the mold assembly against the rail during welding. Constructed from 8 mm steel, weight 3.5 kg. Dimensions: 400 × 140 mm. Designed for rapid tightening and release between weld cycles. |
| Welding Sand Box Frame | Sand mold form assembly that uses tension springs in combination with C-clamps to tighten the mold against the rail profile. Built from 2 mm cold-rolled steel plate with an 8 mm steel base plate. Weight: 5.4 kg. Dimensions: 230 × 105 × 50 mm. |
| Slag Pan | Cast steel slag collection hopper for capturing excess molten slag discharged during the thermite pouring process. Weight: 5.4 kg. Dimensions: 250 × 170 × 80 mm. Designed for rapid positioning and removal between weld cycles. |
| Rail Aligner | Heavy-duty alignment tool for rapid positioning and leveling of both rail ends at the weld joint. Fabricated from 16 mm A3 steel, weight 10.0 kg. Main body dimensions: 310 × 80 mm. Ensures correct rail end alignment before mold placement and preheating. |
| Crucible Holder | Centering fixture placed on top of the sand mold assembly to secure the mold, support the one-shot crucible, and align the crucible pouring spout with the mold gate. Cast steel, 8 mm thickness, weight 2.0 kg. Dimensions: 290 × 120 × 50 mm. |
| Slag Cleaning Rod | Multi-purpose tool for post-pour slag pan removal and luting sand clearance around the mold. Made from Φ16 carbon steel round bar, weight 1.7 kg, length 995 mm. Provides anti-scald protection during hot slag handling. |
| Heavy-Duty Gas Hose (25 m) | Rubber gas hose set for oxygen and LPG supply connections from cylinders to the preheater. 25-meter length per roll, supplied as a 2-roll set. Suitable for field welding operations requiring flexible workstation layout. |
Crane Rail Alignment Inspection Tools & Instruments
Precision measuring and monitoring instruments for rail joint quality verification, weld gap control, and gas flow calibration — supporting DIN and ISO acceptance standards for industrial rail projects.
| Product | Specifications & Description |
|---|---|
| Oxygen Flow Meter (LZB-10) | Custom flow metering instrument for calibrating oxygen delivery during the rail preheating phase. Measuring range: 100–1000 L/h. Weight: 1.5 kg. Essential for controlling preheat temperature and ensuring consistent weld quality across every joint. |
| Oxygen Regulator (YQY-1A) | Precision oxygen pressure regulating instrument for cylinder-to-preheater supply control. Brass construction, weight 1.84 kg. Max inlet pressure: 15 MPa; max outlet pressure: 2 MPa. Complies with gas welding safety standards. |
| Propane Pressure Regulator (YQW-03) | Dedicated propane/LPG pressure regulating instrument for the preheater fuel supply. Weight: 1.2 kg. Rated pressure: 1.6 MPa. Designed for field welding environments with standard LPG cylinder connections. |
| Stopwatch | Purpose-built timing instrument for managing preheat duration and weld flash trimming timing. Plastic casing, lightweight. Critical for maintaining consistent 15–20 second preheat cycles and ≤40-second trimming windows as specified in welding procedure specifications. |
| Rail Alignment Straightedge (1000 mm) | Custom stainless steel straightedge for precision measurement of rail head alignment at the weld joint. Length: 1000 mm, thickness: 8 mm. Weight: 2.4 kg. Used to verify vertical and horizontal alignment meets the ≤2 mm tolerance requirement per DIN and ISO rail welding standards. |
| Rail Gap Gauge | Custom measuring tool for verifying weld gap between rail ends before thermite pouring. Aluminum alloy construction. Length: 240 mm, thickness: 8 mm. Measuring range: 16–71 mm. The specified reserved rail gap of 26 ± 2 mm can be verified with this gauge before mold placement. |
| Wedge Iron | Carbon steel wedge for adjusting rail joint height differences and achieving lateral alignment before welding. Weight: 6 kg. Dimensions: 150 × 40 × 20 mm (tapered). Used in combination with the rail aligner for final position adjustment. |
Aluminothermic Welding Consumables
High-performance thermite welding materials engineered for reliable, repeatable rail joint quality across all rail profiles.
Thermite Welding Kits — Flux, Sand Molds & Crucibles
Our complete consumables range includes thermite welding portion (flux), precision sand molds, one-shot crucibles, luting sand, and ignition rods. Engineered for all rail profiles including light rail (18–38 kg/m), heavy rail (38–60 kg/m), crane rail (QU70–QU120), grooved rail (59R2/60R2), and imported standards (UIC, AREMA, DIN, A-series, S-series, CR-series). The flux produces molten steel exceeding 2,500°C for strong, durable welded joints with tensile strength up to 780 MPa (980 MPa grade rail).
