Safetrack® Pin Brazing System – Reliable Electrical Bonding for Railways
Safetrack® Pin Brazing is a patented cable bonding system developed for railway signalling systems, return current systems, grounding and rail bonding applications where reliable electrical continuity and long service life are essential. It enables fast, safe and durable electrical connections directly to rails and other steel structures without welding.
Using a precisely controlled electronic process powered by 36 VDC, Safetrack® Pin Brazing delivers consistent, high-quality electrical connections in all weather conditions while preserving the integrity of the rail steel.
What is Pin Brazing?
Pin Brazing is a low-temperature (approximately 650°C) cable bonding process that uses a specially developed silver-based alloy and a controlled electrical discharge to create a molecular silver bond between the cable and the rail. The connection provides an ultra-low transition resistance of approximately 5 µΩ without melting or metallurgically affecting the parent material.
Unlike fusion welding and thermite welding, Pin Brazing minimizes heat transfer, helping preserve the mechanical properties of the rail while delivering a reliable, long-lasting electrical connection.
Why choose Safetrack Pin Brazing?
Modern railway infrastructure requires durable electrical connections that can withstand vibration, harsh weather and demanding operating conditions. While conventional welding melts the parent material and creates a heat-affected zone, Pin Brazing forms a strong molecular silver bond at approximately 650°C without melting or altering the rail steel. As a result, there is no metallurgical impact on the base material, preserving its mechanical properties while ensuring a reliable, low-resistance electrical connection. Combined with fast installation and minimal equipment requirements, the Safetrack® method provides a safe and efficient solution for railway signalling and bonding applications.
Key Benefits of Safetrack Pin Brazing
- Low-temperature brazing - only the silver alloy melts (650°C / 1200°F), helping protect the rail material.
- No damage to the rail - unlike traditional welding methods, the base material remains unaffected.
- Fast installation - the brazing process takes approximately one second, with minimal preparation required.
- All-weather performance - suitable for installation in rain, snow and harsh weather conditions.
- Supports rail break detection - rail bonds can be attached to the side of the rail head without drilling holes.
- Cost-effective solution - low consumable costs and minimal maintenance requirements.
- Safe for operators - fully automated, battery-powered equipment with no open flames.
- Corrosion-resistant electrical bonds - designed for long-term reliability and low contact resistance.
- No molds or external power required - ideal for field installations.
- Portable battery-powered equipment - compact 36V DC system for efficient on-site work.
- No fuse wire required - The electronically controlled Pin Brazing gun automatically controls the entire brazing process.
Typical Railway Applications
- Railway signalling systems
- Rail bonding
- Return current systems
- Grounding applications
- Track circuit installations
- Rail maintenance projects
Download Pin Brazing for Railway Brochure
Trusted Worldwide
Safetrack Pin Brazing systems are used in more than 85 countries by railway operators, contractors and infrastructure owners.
Selected Railway Customers
- Network Rail
- Union Pacific
- Canadian National Railway
- Siemens
- Alstom
- Stockholm Underground
- Indian Railways
Pin Brazing Equipment
Discover Safetrack's Pin Brazing equipment, developed for fast, reliable and repeatable cable connections in railway environments. The electronic system delivers constant energy output for consistent results without damaging the rail, making it ideal for signalling, bonding and return current applications.
Pin Brazing Consumables
Achieve maximum performance with original Pin Brazing consumables. Our brazing pins, rail bonds and ceramic ferrules are engineered to work together with the Safetrack® system, ensuring consistent, low-resistance electrical connections.
Complete Cable Connection Systems
Pin Brazing is part of Safetrack's complete range of cable connection systems for railway, cathodic protection and industrial applications. Our innovative solutions are designed to deliver safe, reliable and long-lasting electrical connections in demanding environments.