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TRACKWORK SYSTEMS

CROSSINGS

Integrated foundry, heat-treatment, machining, welding, testing and quality-control capabilities support controlled production from the initial casting to the finished crossing.

TRACKWORK SYSTEMS

BUILT FOR THE POINT OF HIGHEST IMPACT

Railway crossings operate within one of the most demanding areas of the track, where wheel loads transfer through intersecting rail paths. CAL Group manufactures cast manganese steel crossing solutions around the required geometry, loading conditions and rail interfaces.
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CROSSING RANGE

CONFIGURED FOR DIFFERENT TRACK AND INTERFACE REQUIREMENTS

SPECIAL CROSSINGS

Special crossings are developed for layouts, geometries or operating requirements that cannot be addressed through a standard configuration. Each solution is engineered around the applicable rail section, crossing angle, wheel-transfer path, interface conditions and customer specification.

WELDABLE CAST MANGANESE STEEL CROSSINGS

Weldable CMS crossings allow the manganese steel crossing to be flash-butt welded directly to adjoining rails. This removes the bolted crossing-to-rail interface, reduces the number of mechanical joints and supports a smoother transition through the crossing zone.

OBTUSE CMS CROSSINGS

Obtuse CMS crossings are manufactured for track layouts requiring an obtuse crossing geometry. Material behaviour, casting soundness, running-surface geometry and rail interfaces are controlled around the requirements of the complete arrangement.

CAST MANGANESE STEEL CROSSINGS

CMS crossings use the work-hardening behaviour and impact resistance of austenitic manganese steel to support demanding wheel-transfer zones. Casting, heat treatment, machining and inspection are controlled around the applicable drawing and service conditions.

ENGINEERED AROUND THE WHEEL TRANSFER

MATERIAL, GEOMETRY AND INTERFACES UNDER CONTROL

Turnout design begins with an understanding of how the route will be used, what loads it will carry and how it must fit within the available railway layout.

CROSSING GEOMETRY

The crossing angle, nose geometry, flangeway, running surfaces and adjoining rail paths are developed around controlled wheel movement.

MATERIAL PERFORMANCE

Manganese steel chemistry and treatment parameters are controlled to achieve the required combination of toughness, impact resistance and work-hardening behaviour.

CASTING DEVELOPMENT

Gating, risering, feeding paths and solidification behaviour are evaluated around the crossing geometry to support casting soundness.

HEAT TREATMENT

Controlled heat-treatment and water-quenching cycles develop the required metallurgical condition throughout the casting.

PRECISION MACHINING

Running surfaces, rail interfaces, bolt locations and other critical dimensions are machined and inspected against the applicable drawing.

FLASH-BUTT-WELDED INTERFACES

For weldable CMS crossings, controlled flash-butt welding creates a continuous connection between the crossing and the adjoining rail sections.

QUALITY CONTROL

VERIFIED FROM HEAT TO FINISHED GEOMETRY

Crossing production is supported by chemical, physical, metallurgical, dimensional and applicable non-destructive testing. Product identity and inspection records remain linked through the production cycle to support traceability and final acceptance.
CHEMISTRY
Material composition is verified against the applicable specification and approved production requirements.
METALLURGY
Microstructural and other applicable metallurgical checks support confirmation of the required material condition.
DIMENSIONS
Critical running surfaces, interfaces and component geometry are inspected against controlled drawings.
NON-DESTRUCTIVE TESTING
Applicable ultrasonic, radiographic or dye-penetrant testing supports the identification of internal or surface discontinuities.
TRACEABILITY
Material, heat-treatment, machining and inspection records are connected to the identified product.

ENGINEERING FOR CRITICAL WHEEL-TRANSFER ZONES.

Discuss crossing geometry, rail interfaces, material requirements and project-specific operating conditions with our team.
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