Aluminothermic Welding Equipment for Crane Rails

Specialized post-weld trimming machines and rail profile grinders engineered for the aluminothermic welding workflow — delivering precision rail joints in cycle times as fast as 20 seconds.

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Welding Equipment

Post-Weld Trimming & Grinding Machines

Designed for the complete aluminothermic welding post-processing workflow — from weld flash removal to rail profile precision finishing. Each machine is engineered for field reliability under demanding continuous operation.

QLJ-III Manual Rail Weld Trimming Machine

Manual hydraulic weld trimming machine for lower-volume rail welding operations. The QLJ-III packs the full cutting force into a single, self-contained steel frame — no separate power unit, no external connections. Weighing under 78 kg, it is easily maneuvered into position by a small crew and is particularly suited to remote job sites or projects with limited joint counts where simplicity and portability matter more than cycle speed.

Max Thrust: 200 kN
Cycle Time: ≤40 seconds
Feed Speed: 3.5 mm/stroke (manual hydraulic oscillation)
Cutting Opening: 135 mm max (between dual cutting edges)
Weight: ≤78 kg (single-piece construction)
Dimensions (L×W×H): 1000 × 420 × 440 mm
Drive: Manual hydraulic, bidirectional
Trimmed Surface: ≤2 mm above original rail profile
Material: Steel structure

GDMJ-1 Rail Grinding Machine (Electric)

Post-weld rail profile grinding machine for precision finishing of the rail top surface after aluminothermic welding. The machine restores the rail head profile to meet the dimensional tolerances required by rail welding acceptance standards, with a cup wheel consumption ratio of 1:6 ensuring cost-effective operation.

Motor: 380 V, 2.2 kW, 2800 rpm
Grinding Wheel: Cup type BL Φ150 × 85 × 80 mm
Wheel Consumption Ratio: 1:6
Machine Weight: 68 kg
Dimensions: 1030 × 760 × 220 mm
Application: Rail top surface finishing after thermite welding

CFMG-5 Electric Groovd Rail Grinder

Specialized grinding equipment for grooved rail (tram and streetcar track) post-weld finishing. The dedicated groove geometry restores the rail’s flangeway to specification, allowing uninterrupted wheel passage. Suitable for 59R2 and 60R2 grooved rail profiles commonly used in urban rail transit systems.

Motor: 380 V, 2.2 kW, 2800 rpm
Grinding Wheel: Radius type Φ250 × 25 mm
Machine Weight: 68 kg
Dimensions: 1030 × 820 × 220 mm
Compatible Rail: 59R2 / 60R2 grooved rail profiles
Special radius grinding wheel: 250×25 mm
Dimensions (L×W×H): 1030×820×220 mm

Grooved Rail Profile Grinder

Lightweight precision finishing machine for grooved rail groove surface refinement after welding. At just 21.5 kg, it is easily transportable between work sites and ideal for touch-up and final finishing passes. The compact size allows access to rail sections where larger machines cannot be positioned.

Motor: Single-phase 220 V, 1.2 kW
Grinding Wheel: Φ150 mm
Machine Weight: 21.5 kg — lightweight and portable
Dimensions: 580 × 520 × 340 mm

Electric Hydraulic Weld Shear

The QLJ-Ⅱ Electric Hydraulic Weld Shear is a highly efficient, heavy-duty tool engineered for modern aluminothermic rail welding operations. Powered by a robust bidirectional electric-hydraulic system, it delivers 200 kN of thrust to rapidly and precisely remove excess weld flash in under 20 seconds. Its split-unit design ensures maximum on-site flexibility while guaranteeing a flat, clean sheared surface.

Model: QLJ-Ⅱ (Electric)
Drive System: Electric hydraulic bidirectional drive with a flexible high-pressure hose
Motor: Three-phase 3.0 kW, 1400 rpm
Performance: Max thrust 200 kN; feed speed 12 mm/s
Shearing Capacity: Max shearing width 135 mm
Efficiency: Single-direction cycle ≤ 20 sec; trimmed surface ≤ 2 mm above the original rail
Weight: Cutting unit 63 kg | Power unit 75 kg
Dimensions (L×W×H): Cutting unit 1100 × 500 × 300 mm | Power unit 600 × 400 × 400 mm

Supplementary Tools

Angle Grinder

Model S1M-FF-150A. 1200 W, 9000 rpm, Φ150 mm disc. For post-weld surface touch-up and rail edge finishing.

Handheld Straight Grinder

Model S1S-FF-125B. 710 W, 5300 rpm. Compact grinder for detailed finishing in confined rail joint areas.

Rail Cutting Disc

Φ400 × 4 mm, resin-bonded. For rail sectioning and joint preparation before welding.

Frequently Asked Questions

What rail profiles are compatible with these welding machines?

Our QLJ-series trimming machines support all standard rail profiles through interchangeable cutting heads — 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). The grinding machines are profile-specific: GDMJ-1 is for standard rail top surface, while CFMG-5 and the precision grinder are designed for grooved rail.

Can the manual weld trimming machine handle high-volume projects?

The QLJ-III manual model is suitable for projects with moderate joint counts (up to 20–30 joints per day per crew). For high-volume projects with 40+ joints per day, we recommend the QLJ-II electric hydraulic model, which reduces cycle time from 40 seconds to 20 seconds and reduces operator fatigue.

How long does the grinding wheel on the GDMJ-1 typically last?

The cup grinding wheel has a consumption ratio of 1:6, meaning one wheel dressing cycle services approximately 6 weld joints under normal operating conditions. Actual wheel life depends on rail profile size, weld flash volume, and the operator's grinding technique.

Do you provide on-site training for these machines?

Yes. Forgesail offers on-site installation supervision and operator training as part of our complete service package. Our field engineers can train your crew on proper machine setup, operation, and maintenance procedures at your project site.