Railroad tracks are the foundation of any rail infrastructure – inconspicuous in appearance, but indispensable in their function. They carry trains weighing thousands of tons, keep them precisely on track and combine technology with mobility. Whether high-speed traffic, local traffic or freight transport – modern rail traffic would be unthinkable without resilient rail tracks, stable rails and adapted train rails.
But what makes railroad tracks so special? What materials, shapes and profiles are used? And how do technical details such as the rail foot, rail web or running surface affect operation and service life?
In this article, we provide an in-depth overview of the technology, function and significance of railroad tracks. We shed light on rail types, materials, loads and installation in the system – in a practical, understandable way and with a focus on the requirements of customers, planners and infrastructure operators.
What is a railroad track?
A railroad track is a linear, metallic component that transfers the forces of rail vehicles to the substructure and at the same time ensures precise track guidance. It is part of an overall system of railroad tracks, which also includes sleepers, ballast, fasteners and switches.
In contrast to simple steel girders, the railroad track is specially designed to withstand dynamic loads: Wheelset loads, braking forces, temperature differences and vibrations act on them every day – for years on end.
Typically, railroad tracks are made of high-strength steel with special requirements in terms of hardness, toughness and corrosion resistance. Compared to classic beams or profiled girders, they have to continuously absorb and distribute forces – without giving way.
Depending on the area of application, one speaks of:
- Train tracks on main lines with high wheelset loads
- Track rails for inner-city applications (e.g. streetcars)
- Special profiles for curves, switches or bridge elements
The railroad track is therefore much more than just a piece of metal – it is a highly developed technical element with central importance for the safety, availability and service life of railroad systems.
Technical basics of railroad tracks
Tasks and requirements
The railroad track performs several key tasks in the track system: it guides the train wheels precisely in the track, transfers vertical and transverse forces to the substructure and provides an even, durable running surface. At the same time, it has to withstand enormous dynamic loads – particularly due to high wheelset loads, acceleration forces and temperature fluctuations.
Typical requirements for the rail are
- High wear resistance and hardness of the tread
- Dimensional stability even under continuous load
- Dimensional accuracy for secure connection with other track elements
- Economic efficiency in terms of service life and maintenance
You can find out more about the requirements for modern track systems on our Rail technology – solutions for safe infrastructure page.
Structure and components of a railroad track
The technical design of railroad tracks follows a clearly defined structure that is designed for maximum load-bearing capacity and durability. Each component fulfills a precise task – the result is a component that can reliably withstand millions of load changes.
Rail head (running surface)
The running surface, i.e. the top of the rail head, is the direct point of contact between the wheel and the rail. It must be extremely wear-resistant and offer lasting dimensional stability – even under heavy loads from braking, acceleration or lateral forces in curves. An even surface also reduces vibrations and noise.
Rail bridge
The rail web connects the head and foot. It transfers the vertical load to the rail foot and has a stabilizing effect against bending stresses. Its height varies depending on the rail profile, which influences the bending behavior and dynamic load capacity.
Rail foot
The rail foot forms the base of the rail. It rests on the sleeper and is attached using clamping plates, screws or clamping caps. Its width determines the contact surface – important for the even distribution of force on the substructure.
Underside of the rail
The underside plays a decisive role in vibration transmission and acoustic properties. In high-traffic areas or on bridges, elastic intermediate layers are often used to dampen sound and protect the infrastructure.
Materials
Modern railroad rails are predominantly made of unalloyed or low-alloy steel, optimized for hardness, toughness and weldability. The rail steel is produced using the rolling process, whereby specific properties can be set through targeted alloying and heat treatment.
Manufacturing and rail production
The production of railroad rails is a highly specialized process. The rail blank is shaped in a hot rolling process and then tested in several stages – including for:
- Surface defects
- Dimensional accuracy
- Material structure
- Hardness profile in cross section
Depending on the intended use, the material is then cut to standard or special formats. Bending for curved segments can also be integrated at the factory.
Rail shapes and areas of application for rails
The world of railroad tracks is more diverse than it seems at first glance. Depending on the area of application, load and environment, different rail shapes and types are used. They differ in profile, height, weight, connection technology and material properties.
3.1 Vignol rails – the standard in mainline traffic
The so-called Vignol rail is the most widely used rail profile in Europe – standardized, stable and proven. Typical designs are
- S49 (49.43 kg/m): frequently on branch lines, industrial tracks
- UIC 54 / UIC 60 (54-60.34 kg/m): on main lines, high-speed corridors, freight axles
These rails are characterized by high dimensional stability, long service life and good weldability. Their symmetry allows them to be used on both sides as wear progresses – a plus point for maintenance.
3.2 Grooved rails – for urban areas
So-called grooved rails are used in streetcar networks and mixed traffic zones. They enable flush installation in road surfaces – a recessed groove accommodates the wheel flange.
Typical applications:
- Streetcars
- Light rail crossings
- Traffic-calmed zones with track integration in asphalt or paving
3.3 Train tracks – robust for high wheelset loads
Train rails are rails with increased load-bearing capacity – usually in UIC-60 design or with a hardened running surface. They are mainly used on:
- Highly frequented freight routes
- Transitions to bridges or switches
- Shunting and container terminals
Thanks to their high wear resistance and hardness, they are particularly durable even with low maintenance frequency.
3.4 Special shapes and special profiles
In addition to standard shapes, there is a wide range of special solutions:
- Curved rails with factory bending
- Transition rails with profile change
- Switch rails with machined zones for switch blades, frogs, wheel links
The right type of rail is selected on the basis of detailed criteria:
- Bending radius: Tight curves require flexible or pre-bent profiles
- Traffic load: axle load, speed, frequency
- Installation position: track bed, bridge, road, platform, tunnel
- Ease of maintenance: interchangeability, wear reserves
- Connection to switch systems and transition pieces
Precise coordination plays a key role in turnout areas in particular. You can also find out how complex the structure of a turnout is in our article [Structure of a turnout].
Applications in Germany, Switzerland and Europe
Railroad tracks are not only infrastructure carriers, but also a reflection of regional planning philosophies. In Germany, heavy vignole rails dominate – typically S49 (49.43 kg/m) for branch lines and UIC 60 for main axes. This allows high speed with good maintainability.
In Switzerland, on the other hand, depending on the topography, lighter and specially curved profiles are also used, for example on mountain routes where tight radii and changing loads require special solutions. Rack railroads or meter-gauge railroads also require special profile shapes.
Throughout Europe, the demand for multifunctional rail systems that enable combined use – for example by rail, streetcar and logistics traffic – is increasing. Example: The conversion of old industrial tracks into mixed routes for freight and passenger transport.
Another trend is the use of high-strength rail steels with increased hardness in the running surface area – especially where there is high wear or heavy cornering. These materials extend maintenance intervals and reduce life cycle costs.
As a specialist in locking systems and mounting plates, Bharat Forge supplies Bharat Forge CDP Railsystems supplies key components for rail infrastructure throughout Europe – from high-speed lines to municipal renovation projects.
Examples from practice
Case 1: Integration of grooved rails in inner-city streets
The streetcar network in a major European city was to be expanded – with flush integration into the asphalt surface. The challenge: tight radii, varying heights, high loads due to mixed traffic. The solution was milled grooved rails with a special head geometry and wear-optimized material. The installation was modular, including elastic intermediate layers for vibration damping.
Case 2: Curved area with high wheelset loads – individual locking solutions
A siding for a logistics terminal required a special solution for a tight curve area with a high wheelset load. Customized locking systems were required for precise installation and safe track guidance – tailored to pre-bent rails and the existing infrastructure. Bharat Forge CDP Railsystems supplied resilient, precisely fitting plate and locking elements that optimally supported the installation under the given conditions.
Our rail technology solutions enable precisely such special applications – reliable, custom-fit and future-proof.
Rails in the system: railroad tracks and track infrastructure
Railroad tracks are never used alone – they are part of a highly complex overall system: the railroad track. This consists of several coordinated components that together ensure safety, stability and durability.
4.1 Elements of a railroad track
A complete rail track includes:
- Rails (Vignol, grooved, train rails depending on use)
- Sleepers (made of concrete, wood or plastic) for load distribution
- Fastening systems (e.g. screw clamps, tension clamps)
- Substructure with gravel bed, subgrade and drainage
- Connecting elements such as connecting tabs or weld seams
Full functionality can only be guaranteed if all components are precisely matched to each other – even under changing loads, at extreme temperatures or when cornering.
4.2 Track rails vs. railroad tracks
The term track rail is often used for rails that are installed in conjunction with roads or switch systems – e.g. in urban areas or at crossings. Special requirements apply here:
- Installation depth and height
- Drainage and sound insulation
- Easy to install during renovation
Railroad tracks, on the other hand, are traditionally mounted on their own track – for example in long-distance traffic or on freight routes.
4.3 Technical dependencies in the rail system
The performance of a rail system depends heavily on the interaction of the elements. For example, a substructure that is too soft can lead to deformation of the underside of the rail, which in turn affects the running surface and wear.
Changing rails – for example during maintenance work – also requires precise planning in order to correctly implement geometry, spacing, height and connection details. Precise rail profiles and defined installation routines are essential here.
Innovation and the future of rail
Digitalization and modern maintenance concepts
The future of the railroad track does not lie in the material alone – it lies in the integration of smart maintenance and servicing solutions. While classic rail components impress with their robust design and long service life, the focus today is increasingly on efficient and standardized maintenance. The aim is to minimize disruptions and maximize operational safety.
A good example of this is the EVZ toolkit for maintenance work on switch systems. It bundles all the relevant tools for the professional installation, adjustment and maintenance of locking systems – regardless of the type of setting – in two compact cases. Advantages:
- Complete equipment for the service technician – ready for immediate use on site
- Standardized processes, independent of system manufacturer or switch type
- Time savings and work safety thanks to precision-fit tools
Such solutions are exemplary of the increasing process orientation in rail operations: it is not just the product that counts – but its handling, interchangeability and maintainability in real operation.
In addition, the integration of digital monitoring systems is progressing. Infrastructure providers are increasingly relying on:
- Condition-based maintenance using measurement sensors at critical rail points
- Monitoring of tread quality by ultrasound or video analysis
- Data-supported evaluations that detect wear patterns at an early stage
These developments open up new possibilities for preventive maintenance – a key component for the reliability of modern rail lines.
Sustainability and life cycle optimization
Rail tracks are also becoming increasingly important in terms of environmental friendliness. Steel as a material is not only highly resilient, but also almost completely recyclable. The reuse of used rail materials – for example as secondary rails, industrial tracks or construction site protection – has long been standard practice.
Modern production processes also contribute to CO₂ reduction:
- Recycling of old scrap directly in the rolling process
- Energy-efficient production thanks to optimized oven technology and process control
Another lever: service life optimization through material selection. High-strength, heat-treated rail steels with hardened running surfaces extend the service life and reduce the frequency of replacement. Geometrically optimized profiles that minimize rippling and slippage also contribute to sustainability.
The rail track thus becomes a future-proof component – technically mature, digitally integrable and ecologically responsible.
Decision support for customers: The right rail for every requirement
Selecting the right rail is a complex process – influenced by technical, economic and operational factors. Whether it’s a new construction project, refurbishment or switch extension: if you want to build efficiently and safely in the long term, you need to precisely coordinate the material, profile shape and installation method.
Selection criteria at a glance
Profile shape and weight:
Heavy profiles such as UIC 60 or S54 are recommended for main lines with high speeds and loads – they offer high stability and low wear rates. For branch lines, urban or industrial railroads, lighter profiles with more flexible installation are advantageous. Grooved rails with an integrated track guide channel are also required depending on the environment.
Building environment:
City center, railroad crossing, bridge or tunnel? Every installation location brings its own challenges. Short lengths, curved guides or variable height installation positions require customized solutions.
Traffic load:
Daily train frequency, wheelset load, braking and acceleration forces – all these parameters influence which material proves its worth in the long term. For intensive use, heat-treated profiles with a hardened tread are recommended.
Assembly and maintenance concept:
Especially in the turnout sector, maintenance costs are decisive for life cycle costs. Standardized assembly systems – such as our EVZ Toolkit – offer clear advantages in maintenance logistics.
Conclusion: Railway tracks as a key component of future-proof infrastructure
Railroad tracks are far more than just a piece of steel – they are the supporting structure of modern mobility systems. Their quality, shape and workmanship are crucial to the safety, efficiency and cost-effectiveness of railroad lines worldwide.
In this article, we have highlighted the key aspects relating to railroad tracks:
From the technical basics to material selection and rail profiles, from practical application examples to future trends such as digitalization, maintenance optimization and sustainability.
What becomes clear:
A rail is never just a standard product – it is always part of a complex overall system consisting of substructure, connection technology, switches and vehicles. It is therefore important to make a sound selection and implement it professionally – both for new construction projects and for maintenance.
Bharat Forge CDP Railsystems offers you the necessary expertise, experience and flexibility. Whether as a supplier of high-quality switch components or as a development partner for special solutions – we stand for reliability, technical precision and practical implementation.
Further information & contact
Find out more about our rail technology and infrastructure services, or discover our EVZ toolkit for maintenance teams.
Please also read our related articles:
- [What is a turnout?]
- [Repairing the turnout – what is important]
- [Structure of a turnout – explained with a system]
Are you planning a project or need advice on choosing rails?
Then contact us – we will support you with technical expertise, clear communication and tailor-made solutions.