Thermit® News June 2016



New and sustainable: charged single use crucible I without clamping ring

The ongoing development of our products is a key component of our company philosophy. Your personal experiences of using our products have once again shown us how important it is for us to have two-way communication with you, our customers. The latest outcome is the new functionality of the charged single use crucible I. The clamping ring has been omitted from the single use crucible I: the cover is now securely sealed by a machine, protecting the Thermit® portion against unwanted access prior to the actual weld and guaranteeing increased process reliability during the welding operation.

The charged single use crucible I (without clamping ring) is an environmentally-friendly consumable which guarantees improved safety and process reliability with our customary excellent quality.

Delivery of the new charged single use crucible I will begin at the start of July 2016.  This replaces the previous single use crucible I with clamping ring.

The improved cover can be removed effortlessly and with no problems after welding or, for example, to add the filter socket. For this purpose, we recommend the crucible opener (item no. 257141) in addition to the conventional crow bar (item no. 250564). The two items can also be used in combination following welding to remove the crucible from the mould shoes and to remove the slag pan.

This avoids the issue of clamping rings lying around the construction site and the resultant unnecessary waste.

If you have any questions about the new charged single use crucible I, please contact your account manager in Sales, who will be happy to answer your questions.

Thermit® Plus+: greater flexibility, fewer welding defects

As a system supplier for aluminothermic welding, Elektro-Thermit GmbH & Co. KG produces and supplies all consumables required for the Thermit® welding procedures, including: flameproof casting moulds, reaction crucibles, machines and tools and the Thermit® portions which form the basis of our welding procedures. The Thermit® in the portions is composed of aluminium granules and iron oxide, which produces a strong exothermal reaction after initial ignition. The high heat of the reaction and the alloy elements included in the portion make it possible to produce liquid steel at up to 2,300°C without using external sources of energy, as a result of which the ends of rails can be welded together.

In the case of both standard quality rails and high-strength perlitic grades of rails, the properties of the rail material and of the Thermit® steel produced can lead to surface defects in the form of small cracks or nicks. These defects can ultimately lead to fractures in the weld. The harder and more brittle the material, the more sensitive the weld is to such issues.

Our research and development teams set themselves the task of examining the key factors responsible for this in minute detail in order to create a less sensitive Thermit® steel and thus a more reliable and robust solution. They made use of a novel alloy concept to develop the innovative Thermit® Plus+. The improved formulation gives significantly better ductility. This means that the weld has greater flexibility, thereby optimising the flexural strength. By creating an improved tolerance range in respect of surface defects, the susceptibility of the weld seam is minimised and the durability and lifetime of the weld is substantially increased. Thermit® Plus+ gives the steel exceptional ability to handle discontinuities in the surface, so minimising the potential for cracking. It also provides resistance against rolling contact fatigue, offering a sustainable and efficient response to the material characteristics of head-hardened grades of rail. Thermit® Plus+ is exclusively applicable to our single use crucible system.



Tailor-made high-speed line

Between 23 April and 8 May 2016, Deutsche Bahn AG and stakeholders in the sector renewed the track bed on the line between Hanover and Kassel. This section of track experiences heavy use.

In the vicinity of Göttingen, it was necessary to take measurements to determine the stress equalisation over a distance of 30 kilometres. Together with its British affiliate company Thermit Welding (GB) Ltd, Elektro-Thermit GmbH & Co. KG carried out the measurements on the continuously welded track. Thanks to our special equipment Railscan and VERSE, our experts were able to determine the forces acting within the track non-destructively. In the case of positive measurement results, the rails can be used again immediately. Our measurement technicians can evaluate the results instantaneously, allowing a rapid and flexible response in the event of rail warping or other damage to the track. Our globally unique service for determining stress in the rails provides added safety for the track.

Do you have any questions about our products and services in the field of measurement technology? Our measurement technology team are on hand with the answers.



Enhanced training offer for your staff

We provide the course “BrS, SkV-Elite/L50/L75, SkV/L50/L75, THR, MT (for DB-approved welding procedures)” through the welder training organisation GTA mbH. As a new development, this can now also be completed as a short-duration intensive training course within 3 weeks. The number of training units stays the same but the training time is compressed.

A requirement for taking part in the course is practical on-the-job experience – confirmed by the employer – of at least two months in the track division, preferably in a track welding division. The course is not available to those looking for work.

The benefit to you: your employees will get the familiar high quality training in a shorter time, meaning that they are available to your company for work again more quickly.

The following training dates are currently available:

04.07. - 22.07.16, Spandau
Training number: ET/GTA-9-2016*
Registration deadline: 06.06.16, registration still possible

26.09. - 14.10.16, Spandau
Training number: ET/GTA-8-2016*
Registration deadline: 29.08.16

You can find more information about our training activities and funding options for the course here.

Interested? Please get in touch with the contact person at GTA mbH directly for a non-binding quote.

Training in the Ivory Coast

It is especially important for a global company like Elektro-Thermit GmbH & Co. KG to also be available locally to provide rapid, professional service. Technical consultation, initial and ongoing training – our service engineers enjoy an excellent reputation with our customers and are highly valued as partners.

At the end of April, staff from our Technical Service and Sales teams travelled to Abidjan in the Ivory Coast to train local welders from the company Sitarail in the SoW-5 welding process. This process, certified to DIN EN 14730-1, is characterised by outstanding robustness and durability, making it ideally suited to the weather conditions and geographical situation of the West African region. The process was implemented by the local track laying company with increasing success.

The successful completion of the training meant that the welders were able to apply the welding procedure in practice while complying with our safety standards. We are delighted to have been able to make a contribution to continuous track welding in the Ivory Coast by training the SoW-5 welders, thereby connecting the world.

If you have any questions about initial and ongoing training or about the SoW-5 welding process, please contact our colleagues in Technical Service and Sales.

Updated: work instructions for the Thermit® welding process

The processing of our consumables into high-quality end products by your trained employees can only be implemented using the current work instructions.

Below you are provided with an overview as to which work instructions have been edited since the last edition of the newsletter.

The complete overview of the work instructions, sub-divided according to language and methods are available here. You can obtain the required version of the work instructions from your contact in the Technical Service or Sales department.



Roadshow 2016: Finland

“Next stop Finland!” On the next stage of our 2016 roadshow, Elektro-Thermit presented components from its range of services. Among other things, participants had the opportunity to experience the Thermit® Head Repair and SkV-Elite L25 welding processes as well as Smartweld Spark, the Railstraights, the grinding machine GP 4000 D and the switch heating system up close. Employees from Technical Service and Sales gave top-quality presentations to interested spectators, providing an ideal platform for two-way discussion about our product range.

Proximity to the customer and understanding the challenge of working on the track are of primary importance for us.

If you would also like to experience one of our unique roadshows, please contact Technical Service or Sales. Our employees would be happy to take your enquiry and put together an individual product presentation for you.

Iran Rail Expo 2016, Tehran & ETS Spoor in-house exhibition, Purmerend

Following the lifting of sanctions on Iran, Elektro-Thermit GmbH & Co. KG took part in the International Iran Rail Expo for the first time. Alongside exhibitors from China and Russia, the Expo – which was held from 15 to 18 May 2016 – also saw Germany represented in Tehran with numerous sector stakeholders such as Elektro-Thermit GmbH & Co. KG. The trade fair gave us the opportunity to present our wide range of products to interested visitors, including the welding processes Thermit® Head Repair and SmW-F as well as the insulated rail joint of design MT. The lively discussion with interested trade professionals was an excellent opportunity for us to generate key contacts for future business relationships.

ETS Spoor invited a number of sector and press representatives to an Open Day under the slogan “The Railway of the Future”. The reasons for the event included the opening of the new company headquarters in the Dutch city of Purmerend. The sales partners of ETS Spoor were given the opportunity to present their products and services at the event on 2 June 2016 through live talks and presentations. Elektro-Thermit GmbH & Co. KG's display included the Thermit® Head Repair welding process, Railstraight Dual, the Railstraight App and the new single use crucible I without clamping ring. Our affiliate companies Goldschmidt Thermit Railservice Germany and Austria presented products including Railshape Eco, the profile grinder GP 4000 D and the ballast tamper TB 5000 P.



InnoTrans: 20 to 23 September 2016 in Berlin

You should be looking forward to the most important and most successful trade fair for the rail industry, being held in Berlin from 20 to 23 September 2016. The InnoTrans trade fair attracts visitors from right around the world, and, with its international range of exhibitors, scientists and developers, it promises an insight into the latest future-oriented and sustainable trends. This year we shall once again be sharing a trade fair stand with Goldschmidt Thermit Group.

You can find us in hall 25, stand 325.


For comments or questions, please contact:
Manuela Illmer

Elektro-Thermit GmbH & Co. KG
Chemiestr. 24
06132 Halle (Saale), Germany

Managing Directors:
Dr.-Ing. Matthias Wewel (CEO)
Dr.-Ing. Jörg Keichel (CTO)
Dipl.-Ing. (FH) Johannes Braun

Editorial (v.i.S.d.P.): Manuela Illmer
Tel.: +49 (0) 345 7795-718

VAT Reg. No.: DE 203131971
Tax No.: 110/112/02561
Registration office: Stendal
Registration number: HRA 34021