Discover easy maintenance.

An innovative portfolio that sets new standards.

 In demand worldwide!
Rail and turnout maintenance by Vossloh

Turnout HSG-2 in China

processing
in Sweden

HSG-city in Milling train in Sweden

Dusseldorf

HPM Milling Train HSG-city in

in Germany Toulouse (France)

HSG-city System Flexis in Nuremberg

in Berlin

HSG-2 in the Gotthard tunnel (Switzerland) HSG-city in

Harbin (China)

2 3
 Maintenance
is this easy

Create and continually

expand database
> Rail maintenance machines are also digital
diagnostics vehicles
> Measurements are taken during normal
scheduled operations without track closures
to determine the condition of the rails.
> Diagnostics data are transferred directly to
the app
> The database grows with every
maintenance cycle

Determine
maintenance
The right solution for The key element of the maintenance
scenarios
>D
 ata are interpreted and
cycle: the Smart Maintenance App
every line >Y our rail network at your fingertips: visual displays of where, when
maintenance scenarios including
costs are determined from this
data
and which machining procedures are required
>Y ou no longer have to draw up maintenance schedules yourself.  esults are clear and easy to
>R
Now you just make decisions. understand

Whether you operate a light rail network, heavy goods freight > Manually fine-tuned or fully automatic work procedures: the
algorithm makes it as easy for you as you want it to be.
route or a high-speed passenger line, we offer intelligent and
coordinated solutions for the maintenance of your rails and
turnouts. Commission the machining work
>Y
 ou choose a recommended maintenance scenario or
With everything from comprehensive rail status analyses you can have alternatives calculated for you almost
instantaneously
to app-based smart maintenance planning and innovative >E
 asy submission of your work order to us via the app
>O
 ur portfolio covers everything you need: corrective
machines for preventive and corrective rail machining, our milling and preventive grinding of rails and turnouts for
technology sets new standards for operating speeds and Our fleet:
both mainline track and light rail networks.

quality of work.

We make maintenance easy. For safe, durable, quiet rails

and turnouts.

4 5
 MAINTENANCE PROCEDURES

The perfect strategy for

all types of rail defects
We create the best possible combination of corrective and preventive methods
to increase the availability of your lines and significantly reduce life cycle costs.

Head checks Squats Break-outs Skid spots Varying cross profiles Corrugations Indentations Machining errors

are minute cracks caused by are depressions with a V-shaped are symptomatic of advanced- are instances of localized har- are caused by wear. They impair include short and long pitch result from hard foreign objects such as bluing of the metal re‑
rolling contact fatigue. They or semicircular crack that opens stage or untreated rail damage, dening of the rail material that the wheel-rail contact and corrugations, slip waves and on the rail or in the wheel being sult from grinding “aggressively”
can propagate deeper into the towards the running edge. e.g. head checks where the result from friction between the prevent vehicles from running cross-profile defects caused by run over. They can initiate by using actively-driven grinding
rail’s interior and ultimately They can be caused by lateral material is so badly damaged rails and the spinning wheels of smoothly. wheel-rail contact, especially in cracking. stones at increased grinding
cause rail material to break compression of the metal, pre- that pieces break out. accelerating traction vehicles. bends. Also caused by incorrect pressures and rotation speeds.
away. existing damage or grinding machining.
errors.

Corrective milling – You‘ve never seen rail damage Preventive grinding – You‘ve never been so
removed this fast before. sure that you‘ll never see rail damage again.
Rail condition and depth of defect permitting, the Linsinger-built rail-milling With High Speed Grinding (HSG), we have developed a unique preventive and
machine and the road-rail milling truck can machine the entire profile in a acoustic grinding procedure that can be carried out during scheduled railway
single pass. operations and without track closures. Our HSG-2 train and the HSG-city machine
We also provide two innovative machines – high performance milling (HPM) and are equipped with special, passively-driven grinding stones that rotate with the
multi-purpose milling (MPM) – for correcting aggravated rail defects. The plant’s Rail-milling train HSG-2
vehicle‘s forward motion. Rail defects are thus prevented before they can even
advanced machining precision and efficiency allow us to reprofile track in a single
form.
sweep and achieve almost as-new results.

> Fastest method worldwide: grinds without track closures

> World’s cleanest procedure: dust-free, spark-free
> Effective prevention of rail damage
> Effective correction of rail defects
> Extends the rail‘s service life by up to 100 %
> Extends life span of rails
> Reduces rail noise by up to 10 decibels

Road-rail milling truck Time / load HSG-city

HPM

Using HSG
preventive
grinding
Damage depth

Using
conventional
Damage progression
grinding
without machining

Wear limit Using milling

MPM Flexis System
6 7
 GRINDING

High Speed Grinding inside the timetable

HSG-2 HSG-city grinding machine
Top Features
Preventive rail maintenance on
short-haul routes
Standard gauge HSG-city is currently the fastest light-rail and short-haul grinding
mainline HSG-city Facts
machine on the market. With variable operating speeds of between
8 and 60 km/h, it can be scheduled to fit in with any timetable
> Grinding wheels: 24 in use at any one time
and requires no track closures or preparation work at all. High
> Operating speed: 8–60 km/h
80 km/h Speed Grinding (HSG) doesn‘t just remove minor and medium rail > Non-stop grinding: 30 km
operating speed damage and reliably prevent new defects from forming; it also > Rail roughness: Ra ≤ 10 µm
effectively reduces noise emissions produced by rail traffic by up >Suitable for use in tunnels
to 10 decibels. The machine itself is also comparatively quiet, > Process parameter documentation
which significantly reduces disruptions for nearby residents when > HSG-city controlled remotely from traction vehicle
No track
closures machining work is being carried out. The HSG-city’s compact > E xternal traction, pulled or pushed, thanks to low
shape means it works well in tunnels and is compatible with any design height
clearance gauge. The machine is ideal for many kinds of traction > Works in either direction
vehicles as it can be used when travelling forwards or backwards. > F its inside any structure gauge (including London
60 km Non-stop
Tube or “Berlin klein”)
grinding

Rail life
extended by
up to 100 %
HSG-city
Top Features
QUICK. SMART. SOLID. FAST. FLEXIBLE. QUIET.
Reduces noise by
3 to 10 decibels

Light rail and

short-haul
HSG-2
Preventive rail maintenance for
mainline tracks Operating speeds of
up to 60 km/h

Specially designed for use on mainline rail routes, High Speed

HSG-2 Facts
Grinding (HSG) doesn‘t just remove minor and median rail de-
fects; it prevents new defects from forming and extends the rail‘s No track
>Grinding wheels: 96 in use at any one time closures
service life by up to 100%. Thanks to high operating speeds of up
>Operating speed: 60 – 80 km/h
to 80 km/h, the HSG-2 is extremely flexible and can be scheduled >Transit speed: up to 120 km/h
to slot into any timetable without any track closures or track >Output per shift: up to 250 km
preparations whatsoever. The HSG-2‘s revolutionary technology >Rail roughness: Ra ≤ 10 µm Suitable for tunnels
allows up to 60 km of track to be ground non-stop. It produces >Suitable for use in tunnels
virtually no sparks or dust during the operation and effectively >Process parameter documentation
reduces the noise emitted by rail traffic by 3 to 10 decibels. >Removal of corrugations and slip waves
>Recommended for machining “Specially Monitored Rail life
Tracks”, e.g. in residential areas extended by
up to 100 %
>Officially recommended by the Chinese ministry
responsible for the maintenance of high-speed rail lines

Reduces noise by
up 10 dB

8 9
 MILLING

Milling: remove deep rail damage

PROVEN. RELIABLE. EXACT.

PRECISE. CLEAN. EFFICIENT.

HPM
Top Features Standard- Exact reprofiling No dust and no sparks Operating speeds High removal rate
gauge mainline of up to 2 km/h possible per pass

Milling train
Top Features
HPM milling train HPM Facts
Standard-gauge Exact reprofiling No dust and no sparks
mainline
High removal rate
possible per pass
Reduces noise
Reprofiles badly damaged rails
> Max. material removal per pass:
- on the running surface: up to 3 mm
High-caliber performance on light-rail lines, heavy goods - on the running edge: up to 9 mm
Rail-milling train SF03 W-FFS Rail-milling train Facts freight lines and high-speed passenger lines thanks to the most > Max. feed rate / operating speed:
Complete machining of profile in a single pass advanced technology available. HPM is effective at removing - to remove 0.5 mm: 2,000 m/h
> Number of passes: 1 even the most severe defects from the rail head‘s cross-sectional - to remove 1.0 mm: 1,200 – 1,500 m/h
> Feed rate: 7-20 m/min and longitudinal profiles, as well as deformations and damage > Roughness Ra: ≤ 6 µm
Rail condition and depth of defect permitting, this Linsinger-built rail-milling >M  achining depth on the running surface: caused by material fatigue. At 1,400 mm in diameter, the milling > Bunker capacity: 14 m3 (sufficient for up to 2 shifts)
machine can machine the entire profile in a single pass. The train can be 0.3–1.8 mm > Fire hazard: none
wheel is more than twice the size of a standard milling wheel,
configured on a modular basis and is also ideal for high-speed sections of a rail >M  achining depth on the gauge corner: > Suitable for use in tunnels: yes (no dust and no sparks)
which ensures less residual ripple after machining, a very high-
network. As well as correcting rail-head defects in cross and longitudinal profiles, max. 5 mm > Energy concept: diesel-electric
quality surface, faster operating speeds and a higher material
adjusting track lines and modifying rail profiles, the rail-milling train minimises > Cross profile tolerance: ± 0.3 mm > Diameter of the main milling wheel: 1,400 mm
> L ongitudinal profile tolerance: removal rate. A single pass reprofiles the rail and then gives it
wear and tear and reduces noise levels in sensitive areas. The integrated grinding > Number of main milling wheels: 1
up to ± 0.01 mm an exact finish that reinstates the rail to near-new condition. The
technology also fine-grinds the rail and in so doing further extends the rail‘s > Finishing system: face milling
> Rail profile: As per customer specifications innovative face-milling technology for the finishing produces > Service life of cutters: 5,000 m on average
service life. Realignments are also possible. Due to the low levels of dust and
sparks produced the SF03 W-FFS is very environmentally friendly. > Weight incl. fuel and swarf: max. 120 t neither dust nor sparks, which, when combined with its efficient > Change profiles during machining procedure: possible
> Max. speed (self-propelled & towed): extraction system, makes HPM milling practically emission-free. > Tool changing: semi-automatic from inside the machine
100 km/h > Preparation/removal of rail switching equipment: not required
> Noise level: < 78 dB (A) > Optional installation of integrated measuring systems: yes
> Roughness: 3–5 µm > Loading gauge: W6a (English gauge)

10 11
 MILLING

MPM Rail-milling truck SF02 W-FS

Top Features
COMPACT. VARIABLE. POWERFUL. Transport lorry and milling machine in one

This Linsinger-built SF02 W-FS rail-milling truck is extremely

Standard-gauge Rail-milling truck Facts
versatile as it can be used on roads. High degree of mobility,
mainline
easy to mount and dismount from track, very short set-up times:
> Minimum number of passes: 1
the convenient road-rail design simplifies logistics, making the
> Feed rate: 6–15 m/min
milling truck the perfect solution for tram-track assignments and > Machining depth on the running surface: 0.3–0.9 mm
Light rail and small jobs within larger projects. Track switching equipment is
short-haul > Machining depth on the gauge corner: max. 5 mm
not required. Rail condition and depth of defect permitting, the > Adjustable track gauge
SF02 W-FS can machine the entire profile in a single pass. As well > Cross profile tolerance: ± 0.3 mm
as correcting rail-head defects in cross and longitudinal profiles > Longitudinal profile tolerance: up to ± 0.01 mm
Exact reprofiling the truck also reduces noise levels in sensitive areas. Adjustments > Rail profile: As per customer specifications
to track gauge can be made at any time. The integrated grin- > Points adjustment possible
ding technology also fine-grinds the rail and in so doing further > Transportation speed (by rail): 45 km/h
extends the rail‘s service life. Realignments and point adjust- > Transportation speed (by road): 80 km/h
No dust and
> Noise level: < 80 dB (A)
no sparks ments are also possible. Due to the low levels of dust and sparks
> Roughness: 3–5 µm
produced the SF02 W-FS is very environmentally friendly.

Flexible deployment

Suitable for tunnels Milling truck

Top Features Standard-gauge Light rail and Exact reprofiling No dust and High removal rate
mainline short-haul no sparks possible per pass

Turnouts and rails

MPM milling machine FLEXIBLE. PRECISE. EFFICIENT.

Reprofiles rails and turnouts on short-haul routes
and in tight spaces
Small and flexible, the Multi Purpose Milling Machine (MPM) was gauge and also easy to transport. It fits into a standard container
designed to rectify serious damage to rail and turnout hotspots (TEU-compatible) and can be towed to a deployment location on
in commuter and urban transit systems, and especially in tunnels. a flat wagon or delivered there by truck. The MPM can operate
Highly efficient, MPM removes as much as 2 mm of material on either ballasted or slab tracks and on either Vignole or
per machining run. The machine‘s compact size and light weight grooved rails, and can be adjusted for use on all of the common
make it compatible with virtually every structure clearance track gauges.

MPM Facts

> Adjustable wheel gauge: 1000 – 1668 mm > Suitable for use in tunnels: yes (no dust, sparks
> Milling wheel diameter: 360 mm or exhaust fumes)
> Max. material removed per pass: 2 mm > Tool change: manual
> Operating speed: approx. 180 m/h, max. 270 m/h > Preparation / removal of trackside equipment:
> Fire risk: none not required

12 13
 SWITCH MACHINING

Flexible gauge

(3)

3
Flexis System
The easy maintenance system for turnouts

Turnouts are a central component of a rail network. Heavy loads

preventive
Preventive

Preventive

Corrective

Corrective

Corrective

Corrective

Corrective
Flexis Facts
and heavy traffic cause wear and rail defects such as skid spots,

Type
head checks and corrugations. In order to avoid expensive rail
> Additional measuring technology: material removal, longi-

and
replacements and reduce the risk of operational failure, we
tudinal profile, cross-sectional profile and eddy current
have developed the Flexis System for preventive maintenance. > Track gauge: 990 mm up to 1,550 mm
A turnout’s condition is carefully analyzed before machining > Material removal from preventive to corrective
begins in order to determine how much material to remove. The (up to 1.5 mm)

760 mm radius
turnouts up to
up to 800 m/h

up to 500 m/h

up to 300 m/h
grinding work is then done in a series of work steps. The Flexis > Average machining time: 4 hours for a turnout with a

up to 2 km/h
System is compatible with all international track gauges (light

4 hours for
radius of up to 760 mm

Speed
rail and mainline) and excels thanks to its short track possession > Weld-based removal of isolated defects

80 km/h

60 km/h
times, flexible handling and precise surface machining. > Grinds the entire area requiring machining
No preparation work is necessary and turnouts and rails can be > Grinds of break-outs in point blades
vacated in a matter of minutes, which allows machining to
be done without disrupting the timetable.

Removal rate

up to 0.3 mm
0.3–0.9 mm
0.5–2 mm
0.5–3 mm

0.5–2 mm
0.035 mm

0.01 mm
Flexis
FLEXIBLE. EXACT. UNIVERSAL. Top Features

Turnout
Universally

(3)

(3)
deployable

3
3 3

3 3
Discover easy maintenance
Exact machining

Track

3 3

3
Flexible
deployment

UTS

HSG-city 3

3
One portfolio for all your needs
Machines the
entire turnout

Main line

3
Can also be used
during short
track posses-

System Flexis
sions

SF03 (plus)
(fast off-railing)

HSG-2

MPM
SF02
HPM
14 15
Our machines and services are used by the operators of very different
rail networks all around the world. From machining high-speed lines
in Germany and China to the urban light rail networks of many
European cities and preventive rail grinding in the Gotthard Tunnel –
our customers put their trust in our expertise and ingenuity.

We would be delighted to discuss your needs and

explain what we can do for you. Simply contact us:

Tel. +49 40 430931-0

info.ls@vossloh.com
www.vossloh.com

Vossloh Rail Services GmbH

Hannoversche Straße 10
21079 Hamburg · Germany