Crimped Cap Rail - 4500 A
Non-Insulated Transit Crimped Cap Rails
The Conductix-Wampfler 4500 Ampere Crimped Cap Rail is a premium composite conductor rail designed for medium to light duty electrification applications in LRT, subway, and metro systems. Engineered with a robust aluminum body and a durable stainless-steel contact cap, this rail has over 40 years’ proven service in a wide range of environments.
The 4500 Ampere Crimped Cap Rail has been applied in both 3rd and 4th rail DC traction power systems for metros, LRTs and monorails. Rated at 4500 A, it delivers exceptional value with an ultra-low electrical resistance less than 7 µΩ/m, minimizing energy losses and maximizing efficiency. Its crimped cap design ensures reliable contact of the stainless-steel cap to the aluminum body for low interface resistance. The system meets EN50124-1 insulation standards for 750 VDC, guaranteeing safe and reliable operation in modern rail networks. This proven conductor rail solution supports various electrification configurations, including third rail, contact rail, hot rail, and fourth rail systems.
Key Features and Benefits
- High Current Capacity: Rated at 4500 A continuous at 40°C, ideal for medium to light-duty transit applications.
- Ultra-Low Electrical Resistance: Below 7 µΩ/m at 20°C, ensuring superior energy efficiency.
- Premium Materials:
- 300 series stainless-steel contact cap for durability and corrosion resistance.
- 6000 series aluminum alloy for exceptional electrical conductivity and mechanical strength.
- Low Interface Resistance: Reliable contact between the aluminum conductor and stainless-steel cap provides efficient power transfer.
- State-of-the-Art Manufacturing: Advanced production processes and quality systems deliver high product quality at a competitive cost.
- Precision Engineering: Automated drilling and cutting ensure accurate fit and seamless integration with accessories.
- Versatile Applications: Suitable for third rail, contact rail, hot rail, and fourth rail electrification systems in subway, metro, and underground networks.
- Specification
- Accessories
- High Quality Manufacturing
- 3rd & 4th Rail System Setup
Specification
| Parameter | Value | Unit |
| Resistance | 6.56 (2.0) | µΩ/m (µΩ/ft) |
| Height | 92.5 (3.64) | mm (in) |
| Head Width | 86.1 (3.39) | mm (in) |
| Foot Width | 82.6 (3.25) | mm (in) |
| Foot Height | 17 (0.67) | mm (in) |
| Length | < 12 (40) | m (ft) |
| Cross-Section | 5300 (8.2) | mm2 (in2) |
| Linear Weight | 14.7 (9.88) | kg/m (lb/ft) |
Accessories
Support Insulator Assembly
- Can be configured for top or bottom contact for 3rd systems and side contact for 4th rail systems
- Provides vertical and horizontal adjustments based on project requirements
- Meets all applicable mechanical and electrical standards
- Designed to withstand all static and dynamic mechanical stresses
- Withstands vertical, horizontal, and longitudinal forces from conductors and current collection devices
- Maintains contact surface of the conductor rail relative to the Top of Rail (TOR) for optimal current collector contact
Power Feed / Cable Terminal Assembly
- Connects third rail to substation feeders and across gaps at ramps
- Plates are pre-drilled from a single piece of aluminium of uniform cross-section with no welds. This maintains a low resistance connection from the feed cable to the conductor rail.
- Geometry and dimensions are adaptable to cable size and the quantity of feeder cables
- Designed to minimize heat rise due to current flow
Ramps
- Two designs available to ensure smooth pickup of the collector shoe and transition to the conductor rail:
- Manufactured from a section of rail cut and machined to meet the length and slope requirements of the system.
- Manufactured from welded stainless-steel sections cut and machined to meet the length and slope requirements of the system.
- Low-Speed:
- Speed: up to 35 km/h
- Slope: 1:30
- Length: 3 m to 3.5 m
- High-Speed:
- Speed: up to 100 km/h
- Slope: 1:50
- Length: 4.5 m to 5.5 m
Splice Joint Assembly
- Electrical resistance below 7 µΩ/m at 20°C
- Standard stainless-steel bolts or Zinc-plated steel Huckbolts® (ASTM B633 & B695) (Huckbolts® is a registered Trademark of Howmet)
Mid-Point Anchor Assembly
- Standard stainless-steel bolts or Zinc-plated steel Huckbolts® (ASTM B633 & B695) | (Huckbolts® is a registered Trademark of Howmet)
Expansion Joint Assembly
- Provides electrical and mechanical continuity
- Length: 3 m
- Single Gap Assembly: 1 × 150 mm
- Service life: 40 years (15 000 cycles)
GRP- Glass Reinforced Polymer Cover Board System
- For use in covered areas such as tunnels and stations
- Fire resistant, UL94 V0 and NFPA 130 compliant
- Provides protection against incidental (top) contact
- High resistance to shocks, water, chemicals, and corrosive environments
- Located outside the train’s dynamic gauge to prevent interference with rolling stock
High Quality Manufacturing
Our precision production line for crimped cap transit rails is designed to deliver consistently high-quality systems 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 crimped cap rail systems with consistent electrical and mechanical performance, supporting long service life and dependable operation in demanding environments.
3rd & 4th Rail System Setup
A well-designed third or fourth 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.
