TRANSWERK - Wagon Train Construction and Refurbishment and Rail Freight Services

TRANSWERK, part of the Transnet Group, is the South African market leader in the refurbishment, upgrade and manufacture of railway rolling stock. Product focus is assured through six internal businesses: locomotives, wagon build, coaches, components, Rail Freight Refurbishing (RFR) and tarpaulins.

TRANSWERK's Wagon Build business sector carries out a wide range of rail wagon construction services, from heavy haul and freight bogie designs to welding processes and brake engineering. Services offered by TRANSWERK's RFR business include rail car repair, heavy overhauls, conversions and upgrades, as well as fleet management and production runs for special purpose wagons.

All work is carried out in accordance with industry-accepted railway codes of practice and all factories have ISO 9001:2000 accreditation. TRANSWERK's esteemed reputation in Africa and Europe is due to the development of technically sound wagon solutions for the rail transport industry.

WAGON BUILD: HEAVY HAUL COAL AND IRON-ORE WAGON TRAINS

TRANSWERK has built some of the heaviest and longest trains in the world, with tare ratios of 5:1. As the dominant new wagon-builder in Africa, TRANSWERK's Bloemfonstein-based Wagon Build business is the major supplier to the 10,000-strong heavy haul coal and iron-ore fleets in South Africa.

Examples of TRANSWERK's wagon designs include:

• 104t gondola tippler coal wagon with a 4:2:1 tare ratio
• 120t tippler iron ore wagon with a 5:1 payload tare ratio
• 120t bottom discharge iron-ore wagon
• Oil tank wagons with internal heating
• Cement tank wagons for pneumatic discharge

Part of the Wagon Building business's success lies in a superb technological competence in three crucial areas - bogies, welding processes and brakes.

Complementing the Wagon Build business's world-class engineering designs are the materials used to produce the quality wagons. All coal wagons are built using 3CR12, a South African corrosion-resistant stainless steel. Iron-ore wagons are offered in 3CR12 or Corten steel, depending on specific requirements.

TRANSWERK has the engineering and manufacturing capacity to custom-build wagons that meet clients' exact requirements. The Wagon Build business is geared to build two wagons per day: 460 a year. However, this production can be expanded to 690 units a day.

HIGH-SPEED SELF-STEERING FREIGHT BOGIES

TRANSWERK is also accredited with the design of the high-speed, self-steering freight bogie. Developed in South Africa and internationally respected for exceptional performance in heavy-haul applications, the design is popular worldwide for heavy-haul wagons due to its superior wheel life, reduced rail and track wear and increased trailing load per unit of tractive effort.

RAIL FREIGHT REFURBISHING (RFR)

TRANSWERK's Rail Freight Refurbishing (FRF) business is the major provider of refurbishment services to the 100,000 strong wagon fleet in Southern Africa; services that include wreckage repairs, heavy overhauls, conversions and upgrades.

TRANSWERK's RFR business also refurbishes and upgrades wagons, bogies and brake systems, in order to achieve higher axle loads or to match different track gauges. Designs and specifications for conversions are sourced in-house from TRANSWERK, and can be adapted to meet client requirements.

The business is at an advanced stage of establishing Centres of Excellence for all bogie repair facilities. Centres of Excellence exist for air / vacuum brake and drawgear system components.

RFR's customer-centred culture also extends to dedicated services such as fleet management, prototype developments and production runs for special purpose wagons.

RAIL WAGON, BOGIES AND RAIL BRAKE SYSTEM REFURBISHMENT: PRODUCTION PROCESS

The production process is undertaken in well-equipped and controlled environments, ensuring the hallmarks of RFR's operation - quality and high-standards of workmanship, all of which are fully guaranteed.

After refurbishment, products go through a surface treatment facility where they are shot-blasted and treated with a range of paint schemes.

Various steel grades such as 3CR12, Corten and carbon steels, as well as aluminium, are utilised in the refurbishment process of wagon types.

RFR's strong position in the rail industry is underpinned by:

• An SAP-driven logistics system
• Geographically well-positioned factories with advanced equipment
• A skilled and experienced workforce
• Design and product development capabilities