The all-inclusive package for turnouts

The most flexible form of rail processing

Flexis system

As the only way to change tracks, turnouts are often the focus of maintenance strategies. Naturally, the failure of a turnout always affects several routes, which can lead to widespread operational disruptions across an entire network. Efficient, high-quality solutions for turnout maintenance are of fundamental importance for scheduled and safe operation.

 

With the Flexis system, Vossloh offers a complete solution for turnout maintenance. Handheld and track-guided, the machines are on track within minutes and cover all processing stages – from initial grinding of new installations to preventive, acoustic, and maintenance grinding, all the way to corrective repair measures. In addition, the Flexis teams can take on special tasks, such as double junctions, rail extensions, level crossings or short track sections with individual faults, such as slip zones, squats, etc., which large machines cannot perform due to their design or whose use is too costly.

High-quality processing according to identified needs

In order to keep artificial wear to a minimum, the turnout is measured precisely in accordance with the regulations and customer requirements before each machining operation. In addition to the precise recording of the longitudinal and transverse profile, the detection of head checks using eddy current technology is also part of the standard process. As part of the final verification documentation, measurement of vertical material removal is added to the previously mentioned procedures.

To meet the unique maintenance and servicing requirements of each turnout, the following rail processing machines are used for appropriate and cost-effective treatment:

  • Flexis grinding machine for machining the running edge (transverse profile)
  • Riffel grinding machine for machining the running surface (material removal and longitudinal profile)
  • Deburring machine and
  • handheld tools (e.g. angle grinders for switch blade backs).

 

The machines are track-guided, which ensures that the longitudinal and transverse profile machining remains consistent across the entire turnout section. Thanks to the low contact pressure, grinding marks or thermal material alterations are reliably excluded. In addition, each device can be adjusted precisely to the existing track width, from narrow to wide gauge. The versatility of the system is also evident in its ability to process all types and profiles of rails. Customers therefore come from a wide variety of sectors. Flexis is used throughout Europe on high-speed lines operated by national railways, on conventional main lines, and in local transportation. However, there are also project references from industrial customers and port facilities. For jobs in tunnels or underground stations, machines with electric motors are used instead of the traditional fuel-powered rail processing machines.

Areas of application

Turnout maintenance

Preventive maintenance

Machining of newly-laid rails

Breakouts in the hardened rail head layer

Maintenance of level crossing

Routes with a longitudinal gradient of > 40‰

Rail expansion joints

Hotspot processing

  • Turnout maintenance

  • Preventive maintenance

  • Machining of newly-laid rails

  • Breakouts in the hardened rail head layer

  • Maintenance of level crossing

  • Routes with a longitudinal gradient of > 40‰
  • Rail expansion joints
  • Hotspot processing

Turnout maintenance

Designed as a complete system for comprehensive turnout maintenance, the Flexis system combines the latest measurement technologies with technically versatile grinding machines. All relevant surfaces are treated comprehensively and precisely according to previously determined requirements in several passes in accordance with the client's specifications as preventive or corrective maintenance (removal up to 1.5 mm). The repair work also includes the elimination of individual welding defects by trained track welders. The Flexis system has been approved for use by DB since 2013.

  • Comprehensive processing of all relevant areas
    • for Vignole rails in accordance with EN 13231:3-2012 of the rail head
    • for grooved rails, from the running surface to the running edge, including the groove base
  • Frog assembly including ramp and wing rail
  • Switch blade assembly with stock rail
  • Rails including connectors and insulated joints
  • Individual faults in turnouts are eliminated by specially trained personnel, including cases involving over-elevated wing rails. 

Preventive maintenance

A combination of HSG technology and Flexis is also possible in terms of grinding technology. Many customers use the complete service from a single source with the HSG grinding train or the HSG-city grinding machine to reduce track closures to an absolute minimum.

Machining of newly-laid rails

Larger deployment teams are often requested for new rail processing in turnouts or for turnouts with a radius from 1,200 meters upward. On average, initial grinding of a turnout with a 300-meter radius takes approximately four hours. Depending on the size of the team, the processing time for a turnout can be reduced by up to 40 percent. The pool currently comprises 30 machines.

Breakouts in the hardened rail head layer

Even in cases of breakouts in the hardened rail head layer, the rail can still be salvaged, provided there is sufficient wear reserve. In Le Havre, the Flexis team removed approximately 2 mm from the grooved rail below the wide or double groove – the so-called heat-affected zone.

Maintenance of level crossing

During the cold season, the rail surfaces of level crossings are subject to particular stress. To ensure rapid clearance of the level crossing when a train approaches, this area is treated with an especially high amount of anti-slip material. The granulate used for this purpose is distributed by road vehicles across the entire crossing area and ultimately also comes to rest on the running surface. The next time trains pass over, the track will be severely damaged both in this area and in the surrounding area. Thanks to roadside access, such defects can be quickly remedied using the Flexis system.

Routes with a longitudinal gradient of > 40‰

Routes with a longitudinal gradient of > 40‰, such as the Mont Blanc Express in France, are considered steep-grade lines and may not be used by conventional rail vehicles without special provisions (additional braking locomotive, etc.).

 

The autonomous deployment capabilities of Flexis enable rail processing even on Europe’s steepest railway – with extreme gradients of up to 90‰ – without significant effort.

Rail expansion joints

Due to their construction, rail expansion joints cannot be machined by heavy rail-reprofiling machines at all, or else only with considerable logistical effort. As a consquence, they are mostly overlooked. For the purpose of comprehensive track maintenance, Flexis machines have virtually unlimited adjustment options, which allow expansion joints to be resurrected to near-perfect condition very quickly.

Hotspot processing

Efficient hot-spot processing continues with the removal of slip zones, which are typically classified as isolated defects. These occur on inclines before signals or in sections with stop-and-go traffic. Thanks to the flexible and independent deployment of Flexis machines, additional localized rail defects – such as squats, indentations, or sharply angled welds – can also be eliminated in the shortest possible time.

Flexis System - Technical Datasheet PDF

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Factory or mobile machining of new rails PDF

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