The Conductix-Wampfler 4500 Ampere Welded Cap Rail is a premium composite conductor rail designed for heavy-duty electrification applications in subway, metro, and mass transit systems. Engineered with a robust aluminum body and a durable stainless-steel contact cap, this rail ensures optimal conductivity and long-term reliability under demanding operating conditions.
Complying with international standards, the 4500 Ampere Welded Cap Rail is tailored for the most common third rail profile used in DC traction power systems. Rated at 4500 A, it delivers exceptional performance with an ultra-low electrical resistance below 7 µΩ/m, minimizing energy losses and maximizing efficiency. The system meets EN50124-1 insulation standards for 750 VDC and 1500 VDC, guaranteeing safe and reliable operation in modern rail networks.
This advanced conductor bar solution supports various electrification configurations, including third rail, contact rail, hot rail, and even fourth rail systems. Its welded cap design enhances mechanical strength and reduces maintenance requirements, making it ideal for high-capacity transit lines.
| Parameter | Unit | Value |
| Height | mm | 105 |
| Head Width | mm | 92 |
| Feet Width | mm | 80 |
| Feet Height | mm | 11.8 |
| Trapezoidal Shape Angle | ° | 14 |
| Length | m | 11.8 or 15 |
| Aluminum Cross-Section | mm² | ≥ 4 800 |
| Linear Weight | kg/m | ≤ 20 |
Key Features and Benefits
Focused on your application needs- High Current Capacity: Rated at 4500 A continuous at 40°C, ideal for heavy-duty transit applications.
- Ultra-Low Electrical Resistance: Below 7 µΩ/m at 20°C, ensuring superior energy efficiency.
- Unique Wrap-Around Cap Design: Prevents collector contact with the aluminum conductor under all track and vehicle conditions, enhancing safety and reliability.
- Continuous Edge Weld: Creates zero distortion of the stainless-steel contact surface, guaranteeing positive power transfer to the vehicle.
- Multiple Cap Thickness Options: Available in 4 mm, 5 mm, and 6 mm stainless-steel caps to balance cost with duty cycle requirements.
- Dual-Side Welding with Inserted Tabs: Eliminates risk of delamination and positions welds outside the current path for optimal conductivity.
- Premium Materials:
- ASTM A240 / Grade 430 stainless-steel contact cap for durability and corrosion resistance.
- ASTM B317 / Grade 6101-T6 aluminum alloy for exceptional electrical conductivity and mechanical strength.
- Low Interface Resistance: Between the aluminum conductor and stainless-steel cap for efficient power transfer.
- State-of-the-Art Manufacturing: Advanced production processes and quality systems deliver high product quality at competitive cost.
- Precision Engineering: Automated drilling and cutting ensure accurate fit and seamless integration with accessories.
- Cover Options: Available in UPVC and GRP for added protection and customization.
- Versatile Applications: Suitable for third rail, contact rail, hot rail, and fourth rail electrification systems in subway, metro, and underground networks.
Manufactured to High Quality Standards
Controlled processes. Consistent results.
Our automated production line for welded cap transit rails is designed to deliver consistently high quality with tight tolerances. Precisely controlled and fully reproducible manufacturing processes ensure that every conductor rail meets defined specifications and performance requirements.
By minimizing manual intervention, process variability, errors, and scrap are significantly reduced. Integrated inline inspection systems and sensor-based monitoring continuously verify critical quality parameters throughout production.
Your benefit: You receive reliable welded cap rail systems with consistent electrical and mechanical performance, supporting long service life and dependable operation in demanding environments.
Verified through the Toughest Test Protocols
Tested to deliver when it matters mostOur 4500 A Welded Cap Rail has been rigorously tested to validate reliable performance in the most demanding mass transit environments. All tests have been successfully passed. For example, the short-circuit tests with the following parameters:
- 4 mm Cap | 129 kA | AC for 157 ms
- 5 mm Cap | 125 kA | AC for 163 ms
- 6 mm Cap | 125 kA | AC for 163 ms
- 6 mm Cap | 110 kA | DC for 150 ms
Questions about the test setup or further testing? Contact us directly.
3rd Rail System Setup
A proven setup for demanding transit projects
A well-designed third rail system ensures a reliable and uninterrupted power supply under the heaviest train operations. Optimized system design and robust components provide high system availability, minimize downtime, and support efficient train operations.
With durable materials and proven engineering, maintenance requirements are kept low, while the system delivers a long service life in demanding transit environments, including tunnels, elevated sections, and outdoor installations.
Accessories | Welded Cap Rail - 4500 A
Support Bracket Assembly
- The standard shape can be modified by project
- Vertical and horizontal adjustments by project
- Designed to withstand all static and dynamic mechanical stresses
- Welded steel tubing and plate construction, hot-dip galvanized per ISO 1461
- Attached to sleepers with railway screw spikes and double coil spring washers, with HDPE pad between bracket base plate and sleeper, track bed, or plinth
Insulator Assembly
- Complies with 1500 VDC per EN 50124-1 OV4-PD4B
- Meets all applicable mechanical and electrical standards
- Installed at 5 to 6 m pitch
- Withstands vertical, horizontal, and longitudinal forces from conductors and current collection devices
- Maintains contact surface of the third rail parallel to the Top of Rail (TOR)
- Engineered plastic bearings inside insulator jaws ensure low friction during thermal movement
- Available with UV protective coating for outdoor installations
Power Feed / Cable Terminal Assembly
- Connects third rail to substation feeders and across gaps at ramps
- Two designs for cable lug attachment:
- Horizontal Plate: accommodates “L” shape cable lugs
- Vertical Plate: accommodates flat/straight cable lugs
- Plates are pre-drilled to fit lugs
- Prevents electrochemical corrosion between copper and aluminum using bimetallic plates and electrical contact grease
- Maximum electrical contact resistance: 5 µΩ from cable lug to terminal plate
- Length adaptable to cable size (typically 240 mm² to 500 mm²)
- Designed to minimize heat rise due to current flow
Ramps
- Low-Speed:
- Speed: 35 km/h
- Slope: 1:30
- Length: 3 m to 3.5 m
- High-Speed:
- Speed: 100 km/h
- Slope: 1:50
- Length: 4.5 m to 5.5 m
Splice Joint Assemblies
- Electrical resistance below 7 µΩ/m at 20°C
- 15,000 mm² contact surface with each third rail
- Zinc-plated steel Huckbolts® (ASTM B633 & B695) | (Huckbolts® is a registered Trademark of Howmet)
Mid-Point Anchor Assembly
- Zinc-plated steel Huckbolts® (ASTM B633 & B695) | (Huckbolts® is a registered Trademark of Howmet)
Expansion Joint Assembly
- Provides electrical and mechanical continuity
- Length: 4 m
- Single Gap Assembly: 1 × 150 mm
- Double Gap Assembly: 2 × 100 mm
- Service life: 40 years (15 000 cycles)
- Linear electrical resistance of 35µΩ @20°C
UPVC Cover System
- For outdoor use only
- Provides continuous protection against electrical hazards by fully covering live parts
- High resistance to UV radiation, shocks, water, weather, chemicals, and corrosive environments
- Standard colors: Concrete Grey (RAL 7023) and Sulfur Yellow (RAL 1016)
- Fits within train’s dynamic gauge to avoid infringement with rolling stock
- Mechanical resistance: up to 1500 N
- Main Components:
- Cover Fastener: Installed without tools at max 420 mm pitch; maintains 40 mm air gap between conductor and cover. Allows air flow underneath the cover to help in cooling the system.
- Standard Cover: Form-fit over fasteners, sized to fit between insulators
- Insulator Covers: 400 mm length, overlap standard covers
- Accessory Covers:
- Ramp covers to match ramp geometry
- Expansion joint covers outside train’s dynamic envelope
- Power feed/cable termination covers
GRP- Glass Reinforced Polymer Cover System
- For use in covered areas such as tunnels and stations
- Fire resistant, UL94 V0 and NFPA 130 compliant
- Provides continuous protection against electrical hazards by fully covering live parts
- High resistance to shocks, water, chemicals, and corrosive environments
- Standard colors: Concrete Grey (RAL 7023) and SulfurYellow (RAL 1016)
- Fits within train’s dynamic gauge to avoid infringement with rolling stock
- Mechanical resistance: up to 1500 N
- Main Components:
- Cover Fastener: Installed without tools at max 420 mm pitch; maintains 40 mm air gap between conductor and cover. Allows air flow underneath the cover to help in cooling the system.
- Standard Cover: Form-fit over fasteners, sized to fit between insulators
- Insulator Covers: 400 mm length, overlap standard covers
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