Rail Tensor

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Rail tensiometer (also known as a hydraulic rail stretching device or rail stress adjuster) is specialized equipment used in railway track laying and maintenance. Its core function is to apply controlled tension or stress adjustment to rails during operations such as stress relief of continuously welded rail (CWR) lines, long rail laying, rail welding, and routine maintenance. Through a hydraulic system, it stretches the rail to the designed length or to a zero-stress state corresponding to the locking rail temperature (stress-free temperature). This eliminates internal stress caused by temperature variations, prevents abnormal rail gaps, rail deformation, or rail breakage due to thermal expansion and contraction, and effectively enhances track structure stability and operational safety.

Our YLS-900 hydraulic rail tensiometer is suitable for stress relief of CWR lines, long rail laying, and on-site thermite rail welding. Within a certain range below the stress-free temperature, the equipment can forcibly stretch rails from a zero-stress state to the length required at the locking rail temperature, after which the rails are secured or welded. The equipment features a lightweight body, easy operation, and high pulling force. It is equipped with a hydraulic power unit (available with either a diesel engine or an electric pump), hydraulic cylinders, rail clamping devices, connecting rods, and high-pressure hoses. The clamping device adopts a wedge-type rail web gripping design, which automatically increases clamping force as the tensile load rises. It does not contact the rail head surface, thereby avoiding damage to the rail.

As a leading manufacturer of railway maintenance machinery, we are committed to providing efficient and reliable technical solutions for railway construction and maintenance. AGICO Rail offers professional hydraulic rail tensiometers and various other types of track maintenance equipment, including rail grinding machines, track lifting and lining machines, rail cutting machines, rail drilling machines, and tamping machines. If you are interested in our tensiometers, we are pleased to provide detailed technical information, equipment demonstrations, and even arrange on-site trials.

AGICO Hydraulic Rail Tensor Models

 YLS-900 Hydraulic Rail Tensor

This is the primary basic model in AGICO's long rail stress management series. Its key feature is the wedge blocks that clamp the rail web. The clamping force automatically increases with the tensile force, and it does not contact the rail head running surface, avoiding damage during operation. The dual cylinders provide a synchronized pulling force of up to 900kN, coupled with a long 1500mm working stroke, enabling efficient completion of long rail laying or stress relief operations to bring the rail to the designed zero-stress state.

 

YLS-900I Hydraulic Rail Tensor

As an upgraded and enhanced version of the YLS-900, it maintains the 900kN maximum pull while adopting a rail head clamping design. This allows the equipment to be installed directly on the rail surface without prior cleaning of the ballast under the rail, significantly improving on-site convenience and speed. The body is made of high-strength alloy steel for greater durability and robustness, and technical parameters can be customized for specific project requirements, making it suitable for more demanding working conditions.

 

YFT-400 Hydraulic Rail Tensor

This is a device designed specifically for adjusting rail gaps. Through its wedge clamping mechanism and lever linkage system, it provides a maximum pulling force of 400kN to efficiently pull rails and reduce gaps. Its hydraulic power pack is available in both manual and electric versions, offering flexibility for different site conditions (especially environments without power). The design emphasizes ease of operation, safety, and reliability.

 

YFT-400II Hydraulic Rail Tensor

This is the functional upgrade of the YFT-400, with the biggest improvement being the integration of both rail pushing and pulling functions. A single machine can complete both widening and narrowing of rail gaps, providing a comprehensive rail gap adjustment solution. The overall design is lightweight and simple to operate, with integrated anti-jamming functionality, enhancing both operational efficiency and safety/user experience.

 

Selection Guide

You can quickly filter based on your primary work objective:

• For stress relief of CWR or long rail laying: Choose the YLS-900 series. Opt for the YLS-900 if protecting the rail surface and requiring an extremely long stroke are priorities; choose the YLS-900I for installation convenience, no need for ballast cleaning, and greater adaptability.
• Specifically for rail gap adjustment: Choose the YFT-400 series. Select the YFT-400 for常规 rail pulling work; choose the YFT-400II for comprehensive gap adjustment requiring both pushing and pulling.

All AGICO tensors feature a modular design, allowing selection of electric or diesel-engine-driven hydraulic power packs based on site conditions. If you can specify the particular application scenario (e.g., new line long rail locking, existing line stress adjustment, or routine gap maintenance), we can provide more specific analysis for you.

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AGICO Rail Tensor Advantages

Our design philosophy is Robust, Precise, User-Friendly.

Powerful Symmetrical Pulling System

Features a dual-hydraulic cylinder synchronous drive design, ensuring the pulling force is strictly perpendicular to the rail axis and synchronized on both sides, preventing rail twist or rollover.

Core pulling force range covers mainstream demands, offering models from 500kN to 800kN and even higher capacities, easily meeting the stretching requirements for 60kg/m, 75kg/m (UIC/CHN), and various heavy rails.

High-Precision Control & Measurement

Dual-Mode Control: Provides both force display (via high-precision hydraulic pressure gauge) and displacement display (via clear mechanical scale or optional digital displacement sensor), allowing operators to perform dual verification against design parameters.

Precise Execution: Enables millimeter-level control of elongation, ensuring minimal error in the achieved stress-free temperature.

Reliable and Sturdy Clamping Mechanism

Specially designed alloy steel clamping jaws, heat-treated for high hardness and wear resistance.

Self-locking or mechanical locking design absolutely prevents jaw slippage during stretching and pressure holding, ensuring operational safety.

Modular & Ergonomic Design

Quick Installation: Compact equipment structure with easy module connection allows for rapid positioning on the track.

Flexible Power Options: Choice of electric motor unit (for sites with power) or diesel engine unit (for field operations without power) based on site conditions.

Sturdy Frame: Overall steel structure optimized via FEA, offering high rigidity and stable load-bearing, equipped with wheels for short-distance movement.

Comprehensive Safety Protection

Hydraulic system integrates safety relief valves to prevent overpressure.

Equipped with pressure holding valves to maintain cylinder pressure for extended periods in case of pump stoppage or accidental line issues, providing ample time for locking operations.

Application

The AGICO Rail Tensor is a powerful assistant for the following critical operations:

• Long Rail Installation on New Lines: Final stress release and locking after the welding of rail strings to establish the designed initial stress state.
• Stress Adjustment on Existing Lines: Periodic re-release and adjustment of stress for sections with uneven stress distribution or "stress peaks" caused by seasonal changes.
• Rail Replacement Work: Precisely matching the stress state between new and existing rails when inserting new rails or replacing damaged ones.
• Track Major & Intermediate Maintenance Projects: Coordinating with operations like sleeper replacement and tamping to comprehensively restore track geometry and stress state.

Operational Safety & Maintenance

AGICO is committed to providing safe products and services. We provide a detailed Chinese/English Operation & Maintenance Manual with each unit. Key points include:

• Operators must be trained and familiar with hydraulic principles and equipment procedures.
• Pre-operation routine checks: Hydraulic oil, hoses, clamps, fastener conditions.
• Strictly prohibit any maintenance or loosening of connections under pressure.
• Regular maintenance schedule: Includes changing hydraulic oil and filters, inspecting seals, lubricating moving parts, etc.

Why Choose AGICO?

• Engineering DNA: We deeply understand the on-site challenges of railway construction; our equipment design stems from practice.
• Quality Commitment: A strict quality control system from raw materials to finished products ensures reliability and durability.
• Global Service Network: We provide timely technical support, operator training, and spare parts supply.
• Solution-Oriented: Beyond selling equipment, we are willing to share professional expertise in CWR stress management.