SLEEPER MANUFACTURING PLANTS

WEGH Group builds complete plants for the manufacture of prestressed reinforced concrete sleepers to be fitted in both conventional and high speed lines using the Long-Line and Carousel technologies existing on the market. Each technology has its own specificities and must be selected based on the context of use. Each sleeper type can be supplied with the fastening system selected by the client (Vossloh, Padrol E-Clip, Pandrol Fast-Clip, Denik, Ars, SB3, etc.).

LONG-LINE PLANTS

Long–Line plants for the manufacture of sleepers and switch bearers are one of WEGH Group historical products and they have been installed in each and every part of the world. These plants feature electromechanical control systems with standard and easy-to-find components, which is a crucial advantage when working in difficult areas and contexts.
WEGH Group Long-Line technology allows for the loosening and cutting of the pre-stressing wires as well as sleeper demoulding without any movement of the moulds.
The moulds designed and manufactured for the Long-Line system are available in solutions with interchangeable rail pads, thus allowing for the use of different types of fastening systems such as Pandrol e-clip, Fast clip, Vossloh, D.E. clip, Denik, Stedef, KB, ARS, etc. The manufacturing process is fully assisted by semi-automatic machinery. Railway sleepers are cast upside down and they are turned automatically during the demoulding stage. Long-Line plants are characterised by the use of the bonded tendon system, which is a remarkable saving in the production of concrete railway sleepers because with it products as they are on the market, i.e. without any further processing or special accessories, can be used.

CAROUSEL PLANTS

Carousel plants are characterised by a high level of automation. Machinery used in the production cycle are PLC-controlled and they have high level technological features and performances. WEGH Group has been building plants for the manufacture of railway sleepers made of prestressed reinforced concrete – either post-tensioned or pre-tensioned – with the Carousel system since 1982. Such plants are organised as a closed loop where the moulds, each featuring 2 to 4 sleeper moulds, can support the pre-stressing force.  Moulds, as configured above, travel along the production line through the various processing stations where work processes are performed before they move on to the next step. The moulds designed and manufactured for the Carousel system are available in solutions with interchangeable rail pads, which allows for the use of different types of fastening systems such as Pandrol e-clip, Fast clip, Vossloh, D.E. clip, Denik, Stedef, KB, ARS, etc. WEGH Group offers customised solutions for the design and construction of both the plants and the moulds.
Carousel plants offer the opportunity to chose among a range of various pre-stressing systems:
– pre-tensioned wire pre-stressing with smooth steel wires threaded to the steel head plates;
– pre-tensioned wire pre-stressing using bonded tendons;
– post-tensioned wire pre-stressing using sheathed steel wires bolted with steel plates to the ends of the sleeper.

Main features

 

 

 

 

 

 

 

 

 

 

 

Sleeper type
Monoblock

Production output
400 to 1600 sleepers/day in standard version
Other production outputs upon request

Pre-stressing type
Bonded tendons (indented wires/strands)

Transfer to pre-stressing station
By hydraulic cylinders

Concrete transfer to distribution station
By automatic systems upon request

Concrete casting
Assisted with semi-automatic machines

Concrete vibration
By external, high frequency electric vibrators

Strand cutting
Assisted with semi-automatic machines

Mould oiling – laying of wires/strands
Assisted with semi-automatic machines

Sleeper demoulding
Assisted with semi-automatic machines featuring a vacuum system

Main features

 

 

 

 

 

 

 

 

 

 

 

Sleeper type
Monoblock

Production output
25-50-75-100-125-150 sleepers/hour

Pre-stressing type
Bonded tendons (pre-stressing)
With head anchoring (pre-stressing)
With sheathed wires (post-tensioning)

Transfer to pre-stressing station
Simultaneous on both sides and on all tie-rods

Concrete transfer to distribution station
By automatic systems upon request

Concrete casting
Assisted with automatic machines

Concrete vibration
By vibrating benches featuring external, high frequency electric vibrators

Manufacturing steps
Semi-automatic to automatic, depending on plant output/type

Main features

 

 

 

 

 

 

 

 

 

 

 

Sleeper type
Bi-Block

Production output
25-50-75-100-125-150 sleepers/hour

Concrete transfer to distribution station
By automatic systems upon request

Concrete casting
Assisted with automatic machines

Concrete vibration
By vibrating benches featuring external, high frequency electric vibrators

Manufacturing steps
Semi-automatic to automatic, depending on installation output/type

To learn about the peculiarities of and find information on all the projects we have implemented in our history, consult the References page.

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