1. Sersa Flash Butt Welding & Destressing System Presented by Martin Benkler Member of the Board Sersa(UK)Ltd

2. Cost reductions and push for higher productivity High output industrial type approach Integration of individual processes Concentration of various activities in the same time slots Reduction of amount of possesions and better usage Introduction of high quality and repeatable processes

3. Solution Welding and Destressing in one process Animation Serstar

4. Loosening the rail fasteners

5. Preparation of the joints

6. Positioning of the Joints

7. Welding machine Highly mobile Road/Rail machines Ready to weld within minutes Hight output (up to 8 welds per hour or more) High precision and fast alignment system Recording of welding parameters of each weld

8. Serstar Mobile Flash Butt Welding System

9. Serstar Mobile Flash Butt Welding System in Operation including rough grinding

10. Clamping and Alignment

11. Recording of weld parameters

12. Temperature measurement and calculation of required elongation Calculation according to the stressfree temperature rail temperature the lenght of rail to be destressed

13. Marking of the required elongation

14. Operation of Sersa Destressing Equipment

15. Passing over of Serstar mobile flash butt welder

16. Retightening of rail fasteners

17. Final grinding and marking of welds

18. Recording Weld Inspection Form Destressing Form FlashbuttWeldingInspectionformSersaUKLogo30-8-04.pdf DestressingFormsSersaUK15-9-04.pdf

19. Personnel on worksite Workin g teams Amount of operators Responsibility Remarques 1 2 Loosening of rail fasteners and provisional clamps 1 Person in Charge for Destressing (SERSA) 2 Inspectors from the German Federal Railways (DB) for welding and destressing 1 Lookout Total Personnel on worksite Productive Sersa15+1 Supervision German (DB) 3 2 2 Preparation of rail ends 3 2 Positioning of rails 4 2 Operation of Sersa Destressing Equipment 5 2 Flash butt welding and rough grinding 6 4 Retightening of fasteners 7 1 + Team 1 Final grinding and marking of welds

20. Average site productivity Basis Rail Length 120m Rail Profile UIC 60 E 2 Grade 260 Temperature Difference average 7 ° C Rail Fasteners Type Vossloh Monobloc concrete sleepers Track ballasted and tamped(at least first tamping) Productivity 2,5 to 3 hours for 1 km of track welded and destressed

21. Conclusion A high productivity and thus lower cost can be achieved by a production line approach an integration of various processes Use of high output machinery and processes Use of reproducable and as much as possible operator independant processes Very precise & thorough site planning and organisation