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K930 / K945 / K950 / K955Mobile Rail Welding Machines
K930, K945, K950 and K955 form a high-force family of mobile flash-butt rail welding machines for demanding field welding and continuous-welded-rail applications. The four models share the same general force and power class, while model selection is based on rail cross-section, upsetting-cylinder stroke, rail profile and project-specific operating requirements.
Technology & System Architecture
The machines use flash-butt rail welding with hydraulic upsetting. The programmed welding cycle controls flashing and upsetting for repeatable field operation. Final welding programs and tooling are selected for the approved rail profile and steel grade.
Clamping & Alignment
High-force hydraulic clamping holds and aligns the rail during flashing and upsetting. The family is designed for applications where stable rail positioning must be maintained during the high-force stage of the welding cycle.
Removal of excess upset
Removal of excess upset as part of the mobile welding cycle. Removal of excess upset tooling is selected for the approved rail profile.
Control & Quality
Programmable welding-process control monitors the welding cycle and machine systems. The exact Siemens / KZESO WeldReg functionality is defined by the approved control configuration for the delivered machine.
Cooling & Hydraulics
The complete welding machine uses a matched 210 bar hydraulic system and cooling equipment for the welding transformers and current-carrying assemblies.
Technical Specifications
K930
Rail cross-section — 6,500–12,000 mm²Mains voltage — 380 / 400 VFrequency — 50 HzMaximum secondary current — 67 kAPower at 50% duty cycle — 211 kVA Hydraulic pressure — 210 barRated upsetting force — 1,200 kNRated clamping force — 2,900 + 200 kNUpsetting stroke — 200 mmWelding head weight — 3,500 kgMaximum productivity — Up to 15 welds/h
K945
Rail cross-section — 6,500–12,000 mm²Mains voltage — 380 / 400 VFrequency — 50 HzMaximum secondary current — 67 kAPower at 50% duty cycle — 211 kVA Hydraulic pressure — 210 barRated upsetting force — 1,200 kNRated clamping force — 2,900 + 200 kNUpsetting stroke — 400 mmWelding head weight — 3,500 kgMaximum productivity — Up to 15 welds/h
K950
Rail cross-section — 6,500–12,000 mm²Mains voltage — 380 / 400 VFrequency — 50 HzMaximum secondary current — 67 kAPower at 50% duty cycle — 211 kVA Hydraulic pressure — 210 barRated upsetting force — 1,200 kNRated clamping force — 2,900 + 200 kNUpsetting stroke — 250 mmWelding head weight — 3,500 kgMaximum productivity — Up to 15 welds/h
K955
Rail cross-section — 6,400–12,000 mm²Mains voltage — 380 / 400 VFrequency — 50 HzMaximum secondary current — 67 kAPower at 50% duty cycle — 211 kVA Hydraulic pressure — 210 barRated upsetting force — 1,200 kNRated clamping force — 2,900 + 200 kNUpsetting stroke — 150 mmWelding head weight — 3,500 kgMaximum productivity — Up to 15 welds/h
StandardsFinal conformity, standards and certification are confirmed for the ordered model, rail profile, configuration and destination market.
How to Select the ModelSelection within the family is based primarily on the required rail cross-section, upsetting stroke, rail profile and project operating conditions. K930 provides a documented 200 mm upsetting stroke for 6,500–12,000 mm² rail cross-sections, while K955 provides a documented 150 mm stroke for 6,400–12,000 mm². K945 and K950 are configured against the approved project specification.
Key Advantages
Available Configurations
Welding Head
Welding head with integrated welding transformers/current-carrying assemblies, hydraulic clamping and upsetting mechanisms, flash-removal mechanism where applicable, and machine-side sensors, valves, actuators and connection points required for integration.
Complete Welding Machine
Everything included in the Welding Head configuration, plus the matched hydraulic pumping station, control cabinet and welding-process control system, cooling equipment, interconnecting power/control cables, hydraulic and cooling hoses, and required auxiliary equipment.
Containerised Solution
Complete Welding Machine integrated into a project-specific transportable system with hydraulics, cooling, control equipment, autonomous power generation where required, welding-head handling equipment, container infrastructure and project-specific safety systems.
Frequently Asked Questions
Why are K930, K945, K950 and K955 presented on one page?
The four machines belong to the same high-force mobile welding family and share the same principal force, power and productivity class. A single page allows customers to compare the model-specific rail range and upsetting stroke directly.
What are the main differences between the models?
The principal selection differences are rail cross-section, upsetting-cylinder stroke, rail profile and project-specific operating requirements. The K930, K945, K950 and K955 differ in the stroke of the upsetting cylinders: 200, 400, 250 and 150 mm respectively.
Does the machine allow the clamping and upsetting forces to be adjusted depending on whether welding is performed using the tensioning method or conventional joint welding?
Yes. Thanks to the installed regulating valve, the machine can adjust the clamping force depending on the requirements and conditions of the welding process.
What is the rated upsetting force?
Rated upsetting force is 1,200 kN
What supply configurations are available?
The selected model can be supplied as a Welding Head, Complete Welding Machine or as the welding subsystem of a project-specific Containerised Rail Welding Solution.
Does the machines enable rail welding using the "tension" method?
Yes, the machine provides the capability to perform rail welding using the "tension" method, which makes it possible to install continuous welded rail (CWR).
What control and monitoring systems are used in the K930, K945, K950 and K955?
K930, K945, K950 and K955 are equipped with a modern control system based on a Siemens PLC and a hydraulic system using Bosch Rexroth components. This ensures precise control of the welding and hydraulic processes, reliable operation and high repeatability of welding cycles.
The machine is also equipped with a modern welding parameter monitoring and recording system. The main welding parameters are recorded during each welding cycle and can be used for subsequent analysis and quality control.
After welding, the system generates a welding report containing the recorded key welding parameters, a process graph and the final welding result, indicating whether the weld meets the specified requirements (OK / NOK).
This provides full traceability of the welding process and helps reduce the influence of operator-related factors on weld quality.
Why are K930, K945, K950 and K955 presented on one page?
The four machines belong to the same high-force mobile welding family and share the same principal force, power and productivity class. A single page allows customers to compare the model-specific rail range and upsetting stroke directly.
What are the main differences between the models?
The principal selection differences are rail cross-section, upsetting-cylinder stroke, rail profile and project-specific operating requirements. The K930, K945, K950 and K955 differ in the stroke of the upsetting cylinders: 200, 400, 250 and 150 mm respectively.
What is the rated upsetting force?
Yes. K922-1 can be supplied as the welding subsystem of a KZESO Containerised Rail Welding Solution.
What supply configurations are available?
The selected model can be supplied as a Welding Head, Complete Welding Machine or as the welding subsystem of a project-specific Containerised Rail Welding Solution.
Does the machine allow the clamping and upsetting forces to be adjusted depending on whether welding is performed using the tensioning method or conventional joint welding?
Yes. Thanks to the installed regulating valve, the machine can adjust the clamping force depending on the requirements and conditions of the welding process.
Does the machines enable rail welding using the "tension" method?
Yes, the machine provides the capability to perform rail welding using the "tension" method, which makes it possible to install continuous welded rail (CWR).
What control and monitoring systems are used in the K930/ K945/ K950/ K955?
K930/ K945/ K950/ K955 are equipped with a modern control system based on a Siemens PLC and a hydraulic system using Bosch Rexroth components. This ensures precise control of the welding and hydraulic processes, reliable operation and high repeatability of welding cycles.
The machine is also equipped with a modern welding parameter monitoring and recording system. The main welding parameters are recorded during each welding cycle and can be used for subsequent analysis and quality control.
After welding, the system generates a welding report containing the recorded key welding parameters, a process graph and the final welding result, indicating whether the weld meets the specified requirements (OK / NOK).
This provides full traceability of the welding process and helps reduce the influence of operator-related factors on weld quality.