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LUCCHINI SeverStal Rails and rolled products for railway applications

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Rails Products

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Page 1: Rails Products

LUCCHINISeverStal

Rails and rolled productsfor railway applications

Page 2: Rails Products

Our quality steel in your daily life

Page 3: Rails Products

Lucchini, now part of the Severstal Group, is one of the world leaders in the manufacture of long products from quality and special steels. In the railway sector the Lucchini Group produces rails and track products in the Piombino plant and cast manganese crossings for railway points in the BFM plant in Bari. The rapid evolution of transport systems and the need for more and more sophisticated materials have required the creation of safe and efficient products suitable for high speed use. In this context of high technological demands Lucchini is one of the leading figures on an international level thanks to a balanced combination of competent human resources, an innovative engineering ability and an integrated plant system. The rails and railway equipment produced at Piombino have been used by the Italian State Railway and for the construction of the whole Italian network since 1908/09 when they were first rolled in the Piombino (LI) factory. The continuous modernisation of Piombino rails production line has allowed Lucchini to reach a leadership position on an international level and to become one of the most important business partners for the delivery of rails and railway equipment. By investing in research and technology and thus being able to use leading edge plants to deliver high quality and safe products Lucchini fulfils the steadily increasing requirements of the railway market. It does so in terms of standards, technique and quality and it facilitates cost reduction in direct

Railway products and services

intervention on the railway network. In the context of the company strategy technological innovation has taken into account the following important factors:

The development of high speed systems;•National and international technical standards, •ever more oriented satisfying safety, comfort and environmental issues;The directives of the European Union concerning •railway transport.

Page 4: Rails Products

Continuous caster

Degassing PlantL.F. Converter Blast furnace

Wharf

Mineral yard

Rehating furnace

Break mill

2 Reversible stands

Horizontal and vertical straightness machines Samples

Cooling bed 108 m

Cut and drilling (on demand)

Straightness control

Inspection bed for client inspection and weight

Service center

Delivery

Horizontal finishing stand

Non destructive control system US and E.C.

Wharf

Page 5: Rails Products

Manufacturing process

Steel production in the Piombino factory is based on integrated cycle. The raw material arrives by ship at the company’s private dock, where it is stored before converting into cast iron in a blast furnace with a daily production capacity of around 6.600 tons. The liquid cast-iron is transferred to the steelworks in torpedo cars with an average capacity of 150 tons. In this phase the cast-iron undergoes an initial treatment called HMD (Hot Metal Desulphurization) aimed at reducing the sulphur content.The transformation process takes place in three 120 ton oxygen converters (BOF - Basic Oxygen Furnace) of the LBE-CBS type (Lance Bubbling Equilibrium - Control Bottom Stirring). Suitable secondary metallurgy (LF) working practices

allow the completion of the steel before it is transferred to the degassing plant. The degassing plant used in the Piombino factory is a Tank Degasser. Degassing not only reduces the hydrogen and other gas value, it also permits significant internal cleaning due to the drawing of inclusions towards the surface of the bath. After degassing the steel is cast by the continuous casting process based on the most modern and precise control systems. The plant produces square section blooms with a 320 mm side or rectangular 340x245 mm blooms destined to rolled rails with high quality metallurgical characteristics.

Continuous caster Rail mill Coke plant

Blast furnace

Wire rod millBar millMineral yardCoal yardWharf

Steel plant

Management

Service center

From raw minerals to finished productCare and attention is paid from the selection of raw materials to the delivery of the finished product.

Page 6: Rails Products

Rolling of Rails

The recently reconstructed rolling mill at the

Piombino factory is based on the most modern

technologies available in the field of rolling.

It is possible to produce rails from 27 to 70 kg/m in

finished bars up to 108 metres long with very strict

and uniform tolerances that satisfy European and

international standards and technical specifications.

This system guarantees maximum production

flexiblity and the satisfaction of the highest Customer

quality standards.

The reduction ratio of continuous cast blooms

through a series of rolling processes is higher than

the ratio required by the standards.

In this way the internal structure and homogeneity

of the finished product are improved, as well as the

mechanical characteristics (rails heavier than 50

kg/m are produced from a square 320 mm bloom).

The use of high definition video cameras and of

laser sources during the rolling phase allows the

constant measuring and monitoring of the profile

dimensions and of all the process data such as

product temperature, speed rolling rate, efficiency of

equipment and ID-tracking.

Furthermore during rolling, the whole rail section is

checked by means of a 6 high definition

cameras integrated system that is conveniently

positioned to control the presence of any surface

defect.

Tradition and innovationLucchini has been producing rails for 100 years. Today the most modern available technologies are utilized in order to satisfy even the most demanding technical specifications.

Page 7: Rails Products

Hot marking

The rail plant is equipped with two automatic hot

marking machines controlled by the information

system which manages the entire production line.

The machines have a revolving heads and can print

multiple markings on the rolled product moving on

the roller-way at the foreseen rolling speed.

This marking system guarantees the identification

of every single rail produced as required by the

international standards and/or by the Customer’s

technical specifications.

Cooling bed

Rails are trimmed at one end before leaving the

rolling stands and are positioned on the 120 metres

long cooling bed by means of 52 lifting conveyors.

The conveyors are each other independent moving

rails on the cooling bed. In this way the bars are

positioned with a curve which straightens out during

cooling. This facilitates their feeding into the cold

straightening plant.

All is aimed at reducing to a minimum the mechanical

pressures necessary for straightening and

consequently at reducing internal stresses.

The advancement of the rails is obtained by a

“walking-beam” system.

Advanced technologyThanks to the continuous modernisation of its production line Lucchini produces rails as long as 108 meters without welding.

Page 8: Rails Products

Rail straightening

The straightening line has two straightening units positioned after the cooling bed. The straightening pressures are applied onto the relevant axis at the rail height for vertical straightening and onto the head sides for horizontal straightening.

Non-Destructive Tests

The increasing requirement for products with fewer surface defects derives from a variety of different reasons such as: safety in use, operational reliability, extension of life cycle, travel comfort, track geometry, increased speed, increased axial loads, increased railway traffic.For the above mentioned reasons and for the many requirements of product quality control, the rails produced in the Lucchini Piombino factory are analysed in an integrated “system” of Non-Destructive Tests (NDT). This testing system consists of Eddy current equipment and of ultrasonic equipment. The NDT system has been specifically developed and created for controlling all rail profiles required by the market.

Eddy Current Test

The Eddy Current test allows the continuous and automatic control of the head and of the feet of the rail at a speed of 1m/sec. The method is based on the operation of 6 rotating probes (for flat areas) and of 2 fixed probes (for

Non-destructive control systemSafety and reliability for railway applications.

Page 9: Rails Products

gauge corner) and uses the magnetic permeability of

steel. All the probes transmit information concerning

the number of detected defects, their distance from

the ends and their position within the section.

The calibration of the Eddy Current system is carried

out with a sample rail with a length of 12 metres in

which defects of known position and dimensions are

artificially produced.

Ultrasonic Test

The Ultrasonic examination is carried out in a

continuous and automatic mode soon after the Eddy

current test. The system is equipped with 16 probes

of the “squirter” type (with water jet) without direct

contact with the rail that allow to check the whole

section of the rail for its entire length.

The defects detected by the Eddy current and

ultrasonic control systems are processed in real time

and signalled to the technicians both on monitors and

on inspection reports.

The defect detected is highlighted on the rail by

means of an automatic paint spray.

Cutting to length

After the checks with the NDT system the rails are

cut to length and drilled if required, by means of a

dedicated facility. Finishing operations can also be

carried out at the service centre (CSE).

High SpeedTechnological solutions for an expanding market.

Page 10: Rails Products

Cold checking of straightness

Straightness is checked by means of a no-contact high definition cameras system. The system is completely static and does not require any electro-mechanical positioning. The processed data are recorded and a reporting is generated. The control is performed on the final rail length.

Finishing

After cold cutting and straightness control, the rails are transferred to the inspection bed for the final controls. A dedicated, automatic handling system - capable of managing lengths of up to 108 metres turns the rail on all four sides for the visual surface control. On request, this system can also weigh individual rails. Final material identification - conforming, non-conforming - is relyed to the application of an adhesive label with a bar code. When this label is read, all the information needed for successive operations is loaded into the warehouse management information system.

Straightness check systemEmploying a no-contact high definition camera system and laser sources.

Page 11: Rails Products

Rail service centre

The rails are then transferred to the Service Centre (CSE) for warehousing in dedicated areas equipped to handle rails from 4 to 108 metres in length or for extra finishing operations requested by the Customer (cutting into smaller sizes, drilling, packing, etc.).

Shipment and logistics

Rails can be shipped from the Piombino plant either by rail or by sea using the plant’s own port facility. By managing its own fleet of wagons to transport rails up to 108 metres in length and via continuous innovation at the port for shipping rails up to 108 metres long Lucchini is able to operate in international markets with maximum flexibility. These systems also guarantee service quality and punctuality all the way to the destination indicated by the Customer. Internal and external handling operations are executed with special systems and equipment to guarantee maximum product integrity.

In the heart of MediterraneanEfficient logistics for clients. Maximum flexibility and punctual service.

Page 12: Rails Products

The rolling mill is designed to produce 108 metres rails without any welding, for conventional networks and for high speed ones (rails from 27 kg/m to 70 kg/m). The production range also includes: tongue bars, baseplates and check rails.

Lucchini is able to design and to produce all the profiles requested by the market in order to satisfy the Customer.

production range

Products for traditional applications and for High Speed marketLucchini is able to design and produce a wide range of profiles re-quested by the market

Quality grades % in weight ppm ppm MPa % HB

EN 13674 series C Mn Si Cr S P max 0 max H max Rm min A min

R200 0,40/0,60 0,70/1,20 0,15/0,58 0,15 max 0,008/0,035 0,035 20 3 680 14 200/240

R220 0,50/0,60 1,00/1,25 0,20/0,60 0,15 max 0,008/0,025 0,025 20 3 770 12 220/260

R260 0,62/0,80 0,70/1,20 0,15/0,58 0,15 max 0,008/0,025 0,025 20 2,5 880 10 260/300

R260Mn 0,55/0,75 1,30/1,70 0,15/0,60 0,15 max 0,008/0,025 0,025 20 2,5 880 10 260/300

R320Cr 0,60/0,80 0,80/1,20 0,50/1,10 0,80/1,20 0,008/0,025 0,02 20 2,5 1080 9 320/360

UIC 860.O

700 0,40/0,60 0,80/1,25 0,05/035 / 0,05 max 0,05 / / 680 14 /

900A 0,60/0,80 0,80/1,30 0,10/0,50 / 0,04 max 0,04 / / 880 10 /

900B 0,55/0,75 1,30/1,70 0,10/0,50 / 0,04 max 0,04 / / 880 10 /

1100 0,60/0,82 0,80/1,30 0,30/0,90 0,80/1,30 0,03 max 0,03 1080 9 /

AREMA

Standard carbon 0,74/0,84 0,75/1,25 0,10/0,60 0,25 max 0,020 max 0,02 / 1,5 982 9 300 min

IRS-T-12-96

880 0,60/0,80 0,80/1,30 0,10/0,50 / 0,035 0,035 / 3 880 10 260 min

Page 13: Rails Products

SPecificationS Profile WeigHt (kg/m) H Wf Wt WH

AREMA141RE 69,83 188,91 152,40 17,46 77,79

136RE 67,44 185,74 152,40 17,46 74,61

UIC 860.O

60UIC 60,34 172,00 150,00 16,50 72,00

54UIC 54,43 159,00 140,00 16,00 70,00

54UIC E 53,81 161,00 125,00 16,00 67,00

UNI 3141

50UNI 49,85 148,00 135,00 14,00 66,88

46UNI 46,79 145,00 135,00 14,00 65,00

36UNI 36,19 130,00 100,00 14,00 60,00

27UNI 27,35 120,00 95,00 11,00 50,00

BS 11:85

BS113A 56,39 158,75 139,70 20,00 72,01

BS 100A 50,18 152,40 133,35 15,08 72,00

BS 90A 45,02 142,88 127,00 13,89 66,68

BS 80A 39,76 133,35 117,47 13,10 65,43

BS 80R 39,67 133,35 127,00 13,49 63,50

BS 70A 34,81 110,33 123,82 12,30 62,19

BS 60R 29,82 114,30 109,54 11,11 57,15

EN 13674-1

60E1 60,21 172,00 150,00 16,50 72,00

60E2 60,05 172,00 150,00 16,50 72,00

56E1 56,30 158,75 140,00 20,00 69,85

54E1 54,77 159,00 140,00 16,00 70,00

54E2 53,82 161,00 125,00 16,00 67,01

54E4 54,30 154,00 125,00 16,00 67,00

50E5 49,90 148,00 135,00 14,00 67,00

50E6 50,90 153,00 140,00 15,50 65,00

49E1 49,39 149,00 125,00 14,00 67,00

46E1 46,17 145,00 125,00 14,00 65,00

46E2 46,27 145,00 134,00 15,00 62,00

46E4 46,90 145,00 135,00 14,00 65,00

AFNOR NF 52-523U50 50,63 153,00 140,00 15,50 65,00

U33 46,30 145,00 134,00 15,00 62,01

DIN 5902

S49 49,43 149,00 125,00 14,00 67,00

S49A 49,05 148,00 125,00 14,00 67,00

S40 36,54 128,00 115,00 13,00 58,27

S33 31,18 126,00 105,00 11,00 58,00

GOST R 51685 - 2000 P65 64,84 180,00 150,00 18,00 75,00

Other Specifications

ER52 51,68 155,00 141,00 15,00 66,00

R48 48,00 150,00 127,00 14,00 68,00

46 SBBI 46,16 145,00 125,00 14,00 65,00

R45 45,40 150,80 127,00 13,80 67,47

DAN 45 45,46 141,00 126,00 13,76 72,20

81lb/yd 40,31 127,00 127,00 13,89 63,50

R31 31,58 125,00 106,00 12,00 56,00

Rails

Vignole Rails

WH

WH

Wf Wf

Wt

Wt

H

H

Bars for Points

Unlimited availability upon request

Page 14: Rails Products

SPecificationS Profile WeigHt (kg/m) H Wf Wt WH

Italian Railway SpecificationA 60UNI 69,09 134,00 140,00 40,00 72,00

A 50UNI 61,04 148,00 135,00 28,00 66,88

EN 13674-260E1A2 69,04 134,00 140,00 40,00 72,00

50E1T1 60,96 148,00 135,00 28,00 67,00

SPecificationS Profile WeigHt (kg/m) a b c d

Italian Railway Specification60 P4U 58,384 370 152 15,5 29,5

60 P5U 58,384 370 152 15,5 29,5

UNI 3551

50 UNI 1/20 59,648 355 137 14 33

60 UNI 1/20 64,187 370 152 15 33

50S UNI 55,153 390 137 14 33

60S UNI 55,153 390 152 14 33

Other Specifications PB 68 68,42 360 142 20 33

Baseplates

Tongue Bars

db

a Wf

WtH

c

Baseplates in Bars Check Rails

Tongue bars are turnouts components which, after machining operations, are transformed into blades and used in switch.

Baseplates are used on track to secure the rail to the underneath sleepers.

Unlimited availability upon request

SPecificationS Profile WeigHt (kg/m) H Wf Wt

Italian Railway SpecificationCr 1 - 60U 40,03 192,00 72,00 18,00

Cr 4 - 60U 47,34 222,00 72,00 18,00

EN 13674-340C1 39,89 192,00 72,00 18,00

47C1 47,07 222,00 72,00 18,00

Check Rails

check rails are used to guide the flange of the wheel while the train runs trought the switch.

Unlimited availability upon request

Unlimited availability upon request

Page 15: Rails Products

research and development

In this field, Lucchini dominates thanks to a whole series of implemented process and product development programs, aimed at increasing the reliability, life, and safety of its products and the range of products. Innovative products have been studied, perfected and tested such as: rails with improved mechanicals properties specifically studied to reduce rolling contact fatigue phenomena in Phalesia 110 steel grade. This allows Lucchini to reach extremely high quality standards in terms of the performance and life of the products it offers.

The innovative steel: higher strength and reliability

®

Quality directed to the futureProduct and process development programs aimed towards higher quality standards.

Page 16: Rails Products

www.lucchini.com

Lucchini S.P.A.Headquarters25128 Brescia Italy

Via Oberdan 1/a

Tel. +39 030 39921

Fax +39 030 3992517

E-mail: [email protected]

Piombino Plant - Rail Business57025 Piombino (Livorno) - Italy

Largo Caduti sul Lavoro, 21

Tel. +39 0565 64111

Fax +39 0565 64133

E-mail: [email protected]

Lucchini UK LtdWheel Forge Way

Trafford Park - Manchester

M17 1EH

Tel +44 161 8860340

Fax +44 161 8722895

Lucchini IberiaAv. Josep Tarradellas 84-88

08029 Barcelona - Spain

Tel. +34 93 3691973

Fax +34 93 4197064

[email protected]

Lucchini Asia Pacific21 Tan Quee Lan Street

02-10 Heritage Place

188108 Singapur

Tel. +65 6 3346775

Fax +65 6 3347015

[email protected]

Lucchini SiderprodukteGrindlenstrasse 5

8954 Geroldswil - Switzerland

Tel. +41 44 749 2111

Fax +41 44 748 4710

www.siprosthal.ch

[email protected]

Lucchini USA660 White Plains Road

10591 Tarrytown - NY

Tel. +1 914 3327550

Fax +1 914 3327551

[email protected]

LUCCHINISeverStal