• email: info @ aferpi.com
  • Cevital Group

Long Rails

slider imageslider imageslider imageslider imageslider image

Long Rails up to 108 meters unwelded

Since 1909, rails and railway structures used for the construction of the whole Italian network are manufactured in Piombino plant.

It is possible to produce rails from 27 to 75 kg/m  up to 108 metres unwelded with very strict and uniform tolerances that satisfy European and international standards and technical specifications.

The use of high definition video cameras and of laser sources during the rolling phase allows for the constant measuring and monitoring of the profile dimensions and of all the process data such as product temperature, speed, the rolling rate, the efficiency of the equipment and the ID-tracking. The rail plant is equipped with two automatic hot marking machine controlled by the information system which manages the entire production line.

The machines have a revolving head 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 & Straightening

    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 independently moving rails on the cooling bed. 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, Eddy Current Test, Ultrasonic Test

    The rails produced in the Piombino factory are analysed in an integrated "system" of Non-Destructive Tests (NDT). Thistesting 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. 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 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 Ultrasonic examination is carried out in a continuous and automatic way, 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 & Finishing

    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). 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. 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 weight individual rails. Final material identification - conforming, non-conforming - is relied 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.

  • 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 required by the Customer (cutting into smaller sizes, drilling, packing, etc.).

  • Shipment & 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 AFERPI is able to operate in international markets with maximum flexibility.

The Group & its Projects