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TŘINECKÉ ŽELEZÁRNY, a.s. Třinec-Staré Město Průmyslová 1000, 739 70 Třinec Czech Republic tel.: +420-558-531 111 fax: +420-558-331 831 www.trz.cz
MORAVIA STEEL a.s. Třinec-Staré Město Průmyslová 1000, 739 70 Třinec Czech Republic tel.: +420-558-537 301, +420-558-535 865 fax: +420-558-324 355 www.moravia-steel.cz
TRINEC-CMC LTD. 5 Bradwall Court, Bradwall Road, Sandbach Cheshire, CW11 1GE, England tel.: +44-1270-759 441 fax: +44-1270-529 017 e-mail: ncauldwell@commercialmetals.com abudge@commercialmetals.com
CMC TRINEC STAHLHANDEL GMBH Gewerbepark Herweg, Cliev 19 D - 515 15 Kuerten Deutschland tel.: +49 2207 847 70 fax: +49 2207 847 777
CMC TRINEC STAHLHANDEL GMBH – OBERBAU Kardinal-Hengsbach-Strasse 4, 46236 Bottrop Deutschland tel.: +49-2041-107040, +49-2041-107041 fax: +49-2041-107042 e-mail: cmt.oberbau@t-online.de
MORAVIA STEEL SLOVENIJA D.O.O. Valvazorjeva 14, 3000 Celje, Slovenija tel.: +386 40 785 785 fax: +386 34 918 261 e-mail: MSSLOVENIJA@moravia-steel.si
MORAVIA STEEL ITALIA S.R.L. Via Niccolini 26, 20154 Milano, Italy tel.: +39-02-349 381 54 fax: +39-02-318 099 37 e-mail: info@moraviasteelitalia.com
MORAVIA STEEL IBÉRIA, S.A. Campo Grande, n 35 –9 A,1700 Lisboa Portugal tel.: +351 217 826 250 fax: +351 217 937 985 e-mail: moravia.s.iberia@mail.telepac.pt
CONTENT
03 THE MANUFACTURE OF RAILS
04 TESTING, CLASSIFICATION, AND ACCEPTANCE
05 RESEARCH AND DEVELOPMENT
06 TECHNICAL DATA AND PARAMETERS
11 SALES
12 CONTACTS
RAILS
T H E M A N U FA C T U R E O F R A I L S
THE MANUFACTURE OF RAILS The manufacture of rails is one of the principal manufacturing programs and, therefore, an extraordinary attention is paid to it in view of the quality control system. The following certificates have been granted by the company TĂœV NORD: the quality control system according to ISO 9001:2000, environmental management system according to ISO 14001:2004 and the quality management system according to VDA 6, part 1. The granted certificates are covering the complete production process, starting from the processing of an inquiry, proposal and sales contract, through the technological and technical development and the proper production up to the inspection and testing of finished products and services for the clients. The production process is tracked by means of check points and corresponding procedures to assure in all circumstances the quality of products which have to comply with customer’s demands, contracts, standards and other specific requirements. Achieving the required quality parameters of rails is proved by granting of the certificate Q1 and HPQ by the company Deutsche Bahn AG.
3
RAILS
T E S T I N G , C L A S S I F I C AT I O N , A N D A C C E P TA N C E
TESTING, CLASSIFICATION, AND ACCEPTANCE The fulfillment of the qualitative demands with regard to material properties and observance of the geometrical parameters of the produced rails is assured by the advanced system of testing and measurements followed by the acceptance. The ultrasonic testing of the internal homogeneity, testing of surface defects by using vortical flow and laser testing of the rail section is practiced during the production flow. After that the rails are tested in the independent test room where following practices are proceeded: • Mechanical properties are tested • Macroscopic and microscopic evaluationsare performed • Surface is checked • Rail shape is checked by means of pass templates Based on the client’s request also other tests can be performed (impact test, hardness test, oxygen content etc.). The individual results and values are documented and certified.
4
RAILS
R E S E A R C H A N D D E V E LO P M E N T
RESEARCH AND DEVELOPMENT Further development aims at the area of material innovation and profile innovation. The development projects are going on in accordance with the customers’ demands, the technical progress and advance of production of this product at the significant producers in Europe and the world.
Material development is oriented in two main directions 1. The development of bainite rails. The production is focused on the medium carbon steels with micro-alloying using Si, Cr, Mo and V. The chemical composition is selected in such a way as to achieve bainite microstructure after a spontaneous cooling in the air immediately after rolling. 2. The development of rails micro-alloyed with Cr, Mo and V to achieve the required hardness of 300, 350 and 400 HB. The development of these steels will not be oriented on the heat treatment but on the adjustment of their chemical compositions. Material analysis of the problem indicates that it will be the rail steel with a super-fine pearlite. The production of new steel grades is focused on the achievement of the required values, in particular, in accordance with UIC, AREMA, EN 13674-1 and CN 12-16C
5
RAILS
T E C H N I C A L D ATA A N D PA R A M E T E R S Basic dimensions and design data
FLAT BOTTOM RAILWAY RAILS
Rails shape 46E1 Dimension
M48
49E1 100ARA-A 50E6
54E2
54E3
54E1 115RE
60E2
60E1
R65
R65-A 136RE 141RE
unit SBB1
S49*
U50* UIC54E* S54* UIC54*
UIC60E2* UIC60*
mm
145
148
149
152.4
153
161
154
159
168.3
172
172
180
180
185.7
188.9
mm
125
120
125
139.7
140
125
125
140
139.7
150
150
150
150
152.4
152.4
mm
65
70
70
69.9
67.4
69.5
70
72.2
69.1
74.3
74.3
75
75
74.6
77.8
mm
14
14
14
14.3
15.5
16
16
16
15.5
16.5
16.5
18
18
17.5
17.5
(kg/m)
46.17
48.4
49.39
49.9
50.9
53.82
54.57 54.77 56.97
60.05
60.21 64.87 64.98 67.41
69.88
(cm2)
58.82 61.69 62.92
63.57
64.84
68.56
69.52 69.77 72.57
76.5
76.7
89.02
Jx (cm4) 1641.1 1745.4 1816
2028
2017.8
2307
2074 2337.9 2740.8 3022 3038.3 3543.1 3547.7 3916 4180.3
Wx (cm3) 217
245.7
248.3
276.4
262.8 278.7 296.4
Height
Bottom width
Head width
Web thickness
Mass 82.64 82.78 85.87
Cross-sectional area
Moment of inertia 234.7 240.3
Section modulus
The equivalent marking according to the old UIC standards. Hot marking of rails shape according to the EN 13674-1 standard or other marking on agreement.
x
x S
y B
FLAT BOTTOM RAILWAY RAILS
6
H
C y
330.4
333.6
359
359.8 388.8
414.5
RAILS
T E C H N I C A L D ATA A N D PA R A M E T E R S Basic dimensions and design data
SWITCH RAILS
Rails shape Dimension
unit Frog S49
Tongue I49
Tongue I65
Tongue UIC60
Tongue XXX
UIC 54A
mm
149
116
147
134
71.5
159
mm
125
145
150
140
89.5
140
mm
70
70.2
75.4
74.5
41.5
72.32
mm
44.5
40
43
44
–
28
(kg/m)
78.61
63.15
78
72.97
32
65.4
(cm2)
100.14
80.45
99.36
92.95
40.76
83.32
Ix (cm4)
2156.7
1106
2306.1
1727
–
2513.7
Wx (cm3)
269.1
166.1
280.5
229.7
–
291.2
Height B– Bottom width C– Head width S– Web thickness G– Mass A– Cross-sectional area
Moment of inertia
Section modulus
S
B
TONGUE RAILS
x
H
x
x
x
H
C y
C y
S y B
y
FROG RAIL S49
7
RAILS
T E C H N I C A L D ATA A N D PA R A M E T E R S Basic dimensions and design data
TRAM RAILS
Rails shape B3
B1
Dimension
unit
H– Height B– Bottom width CTotal head width S– Web thickness C1 – Width of passage head C2 – Groove width G– Mass A– Cross-sectional area Moment of inertia Section modulus
grooved
grooved
entering NT
mm
72
70
180
180
180
mm
156
156
150
150
150
mm
115
116
115
115
114
mm
–
–
14
13
14
mm
57
56
55.5
56
–
mm
35
45
36
42.7
–
(kg/m)
60.23
53.34
64.5
60.63
74.32
(cm2)
76.72
67.95
82.16
77.23
94.68
Ix (cm4)
318.7
260.7
3546.2
3278.7
4058.7
Wx (cm3)
77.6
62.7
412
369.7
523.2
y
C2
y
C2
x
x
x
x
x S
S y B y B
y B
GROOVED BLOCK RAILS B1 AND B3
8
C
GROOVED RAILS NT1 AND NT3
ENTERING RAILS NT
H
x
C
H
y
NT
grooved block (without web)
H
C
NT 3
grooved block (without web)
C1 C1
NT 1
RAILS
T E C H N I C A L D ATA A N D PA R A M E T E R S Basic dimensions and design data
RAILS FOR MINE AND FIELDS TRACKS
Rails shape Dimension
unit 70/10
80/14
Xa
mm
70
80
125
mm
58
70
110
mm
32
38
58
mm
6
9
12
(kg/m)
10
14
35.64
(cm2)
12.8
17.83
45.4
Ix (cm4)
85.7
154.0
925
Wx (cm3)
24.4
36.9
144.6
H– Height B– Bottom width C– Head width F– Web thickness G– Mass A– Cross-sectional area
Moment of inertia
Section modulus
x
x S
H
C y
y B
RAILS FOR MINE AND FIELDS TRACKS
9
RAILS
T E C H N I C A L D ATA A N D PA R A M E T E R S O ve r v i e w o f t h e m a i n c o nve n t i o n a l a n d u n c o nve n t i o n a l material qualities of rails
I. CONVENTIONAL PROPERTIES
Chemical composition (%) Steel grade
C
Mn
Si
P max.
S max.
V max.
Cr
Mo max.
Rm MPa
A5 % min.
HBW Hardness in the middle of traversing surface HBW
700
UIC860-V
0.40-0.60
0.80-1.25
0.05-0.35
0.050
0.050
–
–
–
680-830
14
–
900A
UIC860-V
0.60-0.80
0.80-1.30
0.10-0.50
0.040
0.040
–
–
–
880-1030
10
–
900B
UIC860-V
0.55-0.75
1.30-1.70
0.10-0.50
0.040
0.040
–
–
–
880-1030
9
–
1100
UIC860-V
0.62-0.82
0.80-1.30
0.30-0.90
0.030
0.030
–
0.80-1.30
–
min. 1080
9
–
R 220
EN13674-1 0.50-0.60
1.00-1.25
0.15-0.60
0.025
0.025
0.030
max. 0.15
–
min. 770
12
220-260
R 260
EN13674-1 0.60-0.82
0.65-1.25
0.15-0.60
0.025
0.030
0.030
max. 0.15
–
min. 880
10
260-300
R 260 Mn
EN13674-1 0.55-0.75
1.25-1.75
0.15-0.60
0.025
0.030
0.030
max. 0.15
–
min. 880
10
260-300
R 320 Cr
EN13674-1 0.60-0.80
0.75-1.25
0.50-1.10
0.020
0.030
0.20
0.75-1.25
–
min. 1080
9
320-360
STANDARD
AREMA
0.74-0.84
0.75-1.25
0.10-0.60
0.020
0.020
0.010
max. 0.25
0.060
min. 983
10
min. 300
IH
CN12-16C
0.70-0.82
0.70-1.10
0.40-1.00
0.030
0.020
0.010
0.40-0.70
0.050
min. 1014
8
min. 325
3 HB
CN12-16C
0.72-0.82
0.80-1.10
0.10-0.50
0.030
0.020
0.010
0.25-0.40
0.050
min. 983
10
min. 300
Note: • All specified steel grades are vacuum degassed on the RH equipment. • Steel grades different from the above given ones can be provided after an agreement is achieved with the producer.
THE FOLLOWING CONTENTS OF P, S, AI, H 2 ARE CHIEVED P
S
Al
H2
max. 0.020 % max. 0.020% max. 0.004 % max. 2.5 ppm max. 1.5 ppm based on client’s demand
II. UNCONVENTIONAL QUALITIES 1. Rupture toughness K1C 2. Fatigue crack expansion speed K 3. High-cycle fatigue – fatigue limit according to Wöhler curve 4. Residue tension measured in the rail bottom The values of the above given unconventional qualities are fully comparable with the rails manufactured by the leading European producers. TECHNICAL DELIVERY CONDITIONS The deliveries of rails to customers are realized in accordance with the technical terms specified by UIC860, EN 13674-1, ISO 5003 and other international standards based on the customers’ demands. The customers’ demands differing from these standards can be met after the preliminary technical consultation and agreement with the producer.
10
RAILS
SALES
SALES Remtechstroy a Steel Works, joint stock company), is a long-time producer of railway flat-bottom rails in the Bulgaria and EC. A part of rails production has also been exported to a number of countries of Europe and all over the world, such as Belgium, Egypt, the Netherlands, Poland, Hungary, Canada, Romania, Bulgaria, Finland, Croatia, Slovenia, Germany, Turkey, Switzerland USA and Brazil. In last years, in the rolling mills a big attention was paid to the so called RAILS PROGRAM whose aim was to achieve the quality of produced rails comparable with products of leading European producers. A number of partial modifications and innovations of the walking beam furnace (installation of a modern process control system) and the rolling mill (water descaling, lubrication of groves, hot and cold dimension measurement) have been implemented to improve internal and surface quality. The reconstruction of the cooling area makes it possible to cool rails up to 78 m in length. An automatic system of rails marking has been introduced too. In 2006, a device for detection of surface and internal defects of rails was modernized. In the finishing shop, the reconstructions enabling shipment of rails to 75 m long have already been performed and are continued. In 2003, the Rail Finishing Shop was submitted to a major reconstruction, which resulted in an installation of a new Lisinger-system double-sided sawing-and-drilling machine. The reconstruction makes it now possible to simultaneously process rails on two independent lines. Many significant railway companies e.g. DB, SBB, PKP, ŽSR, CN have granted our rails deliveries with many certificates.
11
RAILS
C O N TA C T S
CONTACTS Address your enquiries and questions to the Sales Department of REMTECHSTROY joint-stock company. REMTESTROY GROUP Varna 9000 Industrial zone Troshevo bl.56-A-6 Bulgaria tel.: +359-52-319980 fax: +359-52-319990 www.remtechstroy.eu
12
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Remtechno Varna - 9000 Troshevo, bl.56-A-6 Bulgaria fax: +359/52/319980 e-mail: web@remtechnology.eu http://www.remtechstroy.eu
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• Business & Marketing Director tel.: +359/52/319980 e-mail: business@remtechnology.eu
REMTECHSTROY GROUP CERTIFIKAT 2 REMTECHSTROY GROUP
EN ISO 9001:2000
REMTECHSTROY GROUP
EN ISO 14001