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Engineered for high stability and perfect compatibility with Germany's rail profiles
Understanding the local requirements for continuous welded rails in Germany's capital
Berlin, a major European metropolis and the capital city of Germany, serves as one of the most critical hubs in the Trans-European Transport Network (TEN-T). The city's transport infrastructure is defined by an intricate web of heavy rail systems, urban transit corridors, regional express routes, and inland harbor crane rails. As the city continues to expand its green transport initiatives, the demand for highly reliable, long-lasting, and noise-reducing rail connections has skyrocketed. This is where high-quality thermit welding portions play a pivotal role. The alignment of continuous welded rails (CWR) is essential to ensure passenger comfort, freight safety, and structural longevity across the region.
In Berlin, the daily operations of the S-Bahn (suburban rapid transit) and the BVG U-Bahn (underground metro system) demand track joints that can withstand hundreds of train passes every single day. Traditional mechanical joints with fishplates are increasingly obsolete due to the high maintenance costs, noise pollution, and wear on rolling stock. Modern rail networks in Berlin rely heavily on aluminothermic welding technology to create seamless joints. By utilizing specialized thermit welding portions, maintenance crews can execute welds that match the chemistry and wear resistance of the original rail steel, ensuring that the tracks remain smooth, silent, and structurally sound under all weather conditions, from freezing winter nights to hot summer afternoons.
The Berlin S-Bahn and U-Bahn networks operate under tight schedules with minimal maintenance windows. The use of premium thermit welding portions ensures that rail joints can be welded, sheared, ground, and put back into service within hours, preventing traffic disruptions across busy transit corridors like the Ringbahn and the central Stadtbahn route.
Beyond passenger transit, Berlin's industrial logistics hubs, such as the Westhafen inland port and the CleanTech Business Park in Marzahn-Hellersdorf, rely heavily on heavy-duty rail infrastructure. Gantry crane rails and freight tracks at terminal facilities carry immense wheel loads. Standard welding methods often fail under these extreme localized forces. Our specialized thermit welding portions are formulated to provide high hardness and superior yield strength, ensuring that crane rail systems remain perfectly aligned and free from structural defects. This reduces downtime for logistics operators and ensures that heavy machinery can move containers without the risk of derailment or joint collapse.
RMTS - Your Trusted Partner in Railway Welding Excellence
RMTS is a manufacturer specializing in railroad thermit welding materials, based in Tianjin, China. With a factory spanning 5,500+㎡ and 30+ professionals dedicated, we are committed to delivering reliable and efficient thermit welding solutions to clients across the globe. Our products are designed to meet the highest industry standards, ensuring durability and performance in various applications.
We understand that successful welding projects require not only high quality products but also expertise and knowledge. That’s why we offer comprehensive on-site training programs to help our clients master the thermit welding process, enabling them to achieve optimal results and build a strong reputation in their respective fields. Additionally, our experienced team provides project welding instruction services, offering hands-on guidance and support to ensure seamless execution, no matter where the project is located.
Driven by a customer-centric approach, RMTS is dedicated to fostering long-term partnerships by delivering exceptional products and services tailored to the unique needs of our clients. Whether you are looking for reliable thermit welding materials, expert training, or project support, RMTS is your trusted partner in achieving welding excellence.
Pioneering advanced metallurgical formulations for modern railways
At RMTS, our continuous investment in research and development allows us to manufacture thermit welding portions that meet the strict mechanical standards of European railway networks, including Deutsche Bahn specifications. Our modern factory utilizes state-of-the-art testing equipment to ensure chemical composition consistency and high wear resistance in every batch we produce.
RMTS have a highly skilled R&D team that works tirelessly to ensure that we produce thermit welding materials that meet the specific needs of each type of rail.
In addition to its strong R&D capabilities, RMTS actively participates in railway projects across China and abroad. The company collaborates with railway authorities, construction companies, and maintenance organizations.
By participating in railway projects, RMTS contributes to the development and maintenance of China's extensive railway network and global lines, ensuring structural integrity and safety.
Furthermore, RMTS maintains partnerships with research institutions, universities, and industry experts in China, strengthening our R&D capabilities in thermit welding technologies.
Leading-edge crucible systems for high-purity metallurgical joints
Our One-Shot Crucible technology is designed to simplify on-site welding operations while maximizing safety and environmental compliance. By utilizing a single-use container, operators eliminate the need for crucible cleaning and preparation, reducing labor costs and minimizing the risk of contamination in the molten steel. This technology is highly favored for urban light rail and metro maintenance projects in cities like Berlin, where working time is extremely limited.
For large-scale railway construction projects and high-volume welding yards, our Long-Life Crucible technology offers an exceptionally cost-effective solution. Engineered with high-grade refractory linings, these crucibles can withstand multiple high-temperature thermit reactions before requiring replacement. This technology ensures excellent thermal insulation and consistent tapping performance, making it a reliable choice for mainline railway expansion projects across Europe.
Providing robust support for critical transportation networks worldwide
Our main markets are in areas such as railway main lines, seaport crane rails, subways, trams, and high-speed railways. Aluminothermic welding plays a crucial role in these fields. No matter the scenario, RMTS welding technology, with its excellent performance, serves as a powerful support for promoting industry development and ensuring operational safety.
Optimizing logistics and planning for railway construction in Berlin
To achieve a perfect aluminothermic joint, a precise set of consumables is required for every single weld. Thermit portion, sand mould, luting sand, and ignitors are the main consumables for aluminothermic welding. The industry standard follows a strict rule: 1 weld, 1 set of consumables. This ensures that the chemical reaction is perfectly balanced and that there is no variation in the metallurgical quality of the joint.
For planning large-scale infrastructure projects, such as the expansion of the S-Bahn lines in Berlin or the construction of new freight spurs in the Brandenburg industrial zone, calculating the required materials is a straightforward process. By understanding the total length of the track and the standard rail section lengths, engineers can accurately estimate the number of welding kits required, minimizing waste and optimizing storage space on site.
For a 10km track construction project using standard 12.5m rail lengths:
Calculation formula: 10000 / 12.5 × 2 = 1600 sets of consumables
By purchasing complete kits from RMTS, project managers in Berlin can ensure that every set contains the exact weight of thermit welding powder, a matched pair of sand moulds tailored to the specific rail profile (e.g., UIC60, 54E1, or S49), high-performance luting sand, and reliable ignitors. This comprehensive packaging simplifies supply chain logistics and guarantees that field technicians have everything they need for a successful weld.
Over 20 years of experience in aluminothermic welding technology
RMTS is a passionate and progressive aluminothermic welding manufacturing company. We provide comprehensive technical support, from historical process insights to hands-on field instruction for European rail projects.
Aluminum thermite welding, also known as aluminothermic welding or thermit welding, is a specialized welding technique that utilizes a chemical reaction to generate intense heat for joining steel rail components. Over the past century, this process has evolved to match modern rail steel alloys, offering unparalleled joint strength.
Preparation: Step 1. Ensure the rail ends to be welded are clean, free from rust, oil, and moisture, and properly aligned. The gap size (space between two rails to be welded) shall be 26±2mm. Preheating and mold clamping must be done with precision to ensure a clean weld flow.
Thermit welding materials will fail if exposed to water. All welding materials should be kept away from any moisture in storage, as well as in the welding process. Always store in dry, well-ventilated locations and transport in sealed, moisture-proof containers.
How automation and green technology are shaping the future of rail connections in Berlin
The railway industry is undergoing a digital and ecological revolution. As Germany aims to achieve carbon neutrality in its transport sector, rail networks are expanding rapidly. This growth requires new technologies that make track installation and maintenance faster, safer, and more environmentally friendly. In Berlin, local authorities are prioritizing technologies that reduce carbon emissions during construction and minimize the environmental impact of track maintenance.
One of the most critical phases of the thermit welding process is preheating the rail ends. If the temperature is too low, the molten steel will cool too quickly, leading to poor fusion and potential joint failure. If the temperature is too high, it can alter the metallurgical structure of the rail steel, reducing its wear resistance. To combat this, the industry is moving toward automated preheating systems equipped with digital temperature sensors. These systems monitor the rail temperature in real-time and automatically signal the operator when the optimal temperature is reached. This digital integration minimizes human error, ensures consistent weld quality, and provides a digital record of every weld for quality assurance purposes.
Occupational health and safety regulations in Germany and the wider European Union are among the strictest in the world. Traditional sand moulds and luting sand can release silica dust during handling and welding, which poses health risks to workers. Modern manufacturers are investing in the research of dust-free pre-formed moulds and organic binder systems that release significantly fewer fumes during the exothermic reaction. RMTS is committed to this ecological shift, continuously refining our sand mould formulations to ensure they comply with European safety standards while maintaining the high thermal stability required for the thermit reaction.
Modern high-speed rail lines and heavy freight tracks use head-hardened (HT) rails to resist wear and plastic deformation. Welding these rails requires specialized thermit portions that contain alloying elements such as chromium, manganese, and vanadium. These elements ensure that the welded joint achieves a hardness profile that matches the parent rail, preventing localized wear (known as "soft spots") that can cause track roughness and noise. Our R&D team continuously develops custom portion mixtures to match the evolving steel grades used by European rail manufacturers, ensuring that our clients in Berlin receive the highest quality materials for their specific track requirements.
Complete product range for railway construction, maintenance, and alignment
