Traditional plate oiling required up to four maintenance workers and approximately 20 minutes per mechanical rail joint. By applying Interflon Lube EPR without dismantling the joint, routine lubrication can now be completed by one person in approximately 30 seconds.

The challenge: labour-intensive rail joint lubrication

Mechanical rail joints must be able to accommodate the expansion and contraction of the rail. During periods of extreme heat, rail temperatures can exceed 50°C, causing the steel rails to expand and the joints to close.

If the joint components do not move freely, the fishplates can seize against the rail. This can make maintenance more difficult and increase the risk of expansion-related failures and service disruption.

Traditional maintenance, known as plate oiling, is highly labour-intensive. To apply conventional black grease, the joint must first be dismantled.

The work is typically carried out by two teams of two people:

• The first team removes the nuts and bolts and opens the joint. If the fasteners have seized, they may need to be cut off with a disc cutter.
• The second team applies black grease to the contact surfaces between the rail and the fishplates.
• The joint is then reassembled, and all fasteners must be correctly tightened and torqued.

This process can take approximately 20 minutes per joint and requires up to four maintenance workers.

The solution: lubrication without dismantling the joint

The rail joints were upgraded with:

• Staytite HARDLOCK Industry Nut fasteners
• Interflon Lube EPR - Extreme pressure dry-film lubricant

The HARDLOCK fasteners help maintain secure clamping under vibration and mechanical loading.

Interflon Lube EPR is applied along the top, bottom and sides of the fishplates. Its strong penetrating action allows the lubricant to travel between the fishplates and the rail and reach the internal contact surfaces.

MicPol® technology then forms a durable, low-friction protective film on these surfaces. This helps the joint components move freely during thermal expansion and reduces the risk of the fishplates, nuts and bolts seizing. 

As a result, the joint does not need to be dismantled for routine lubrication.

The lubricant reduces friction, helps the joint components continue moving during thermal expansion and helps prevent the fishplates, nuts and bolts from seizing.

Together, the HARDLOCK fasteners and Interflon Lube EPR provide an integrated fastening and lubrication solution for existing mechanical rail joints.

The result: reliable performance above 50°C

According to operational feedback, the upgraded joints continued to perform reliably during a period in which rail temperatures exceeded 50°C.

Key results included:

• No reported seized joints
• No reported expansion-related failures
• Joint closure temperatures remained within design specifications
• More than 100,000 joints upgraded across the rail network

Maintenance reduced from 20 minutes to 30 seconds

The largest maintenance benefit comes from the way Interflon Lube EPR is applied.

With conventional black grease, four people may be required to dismantle, lubricate, reassemble and torque the joint. The complete process can take approximately 20 minutes per joint.

With Interflon Lube EPR, one maintenance worker can apply the lubricant externally to the fishplates. The lubricant then penetrates the joint and reaches the required contact surfaces without the nuts, bolts or fishplates having to be removed.

As a result, routine lubrication can be completed by one person in approximately 30 seconds.

This significantly reduces:

• Labour requirements
• Track access time
• The use of cutting and dismantling equipment
• Maintenance disruption
• Whole-life maintenance costs

A practical upgrade for existing rail infrastructure

The Staytite and Interflon solution improves the reliability and maintainability of existing mechanical rail joints without requiring complete joint replacement.

By combining secure fastening with a penetrating, extreme-pressure lubricant, the system helps keep rail joints operational during extreme heat while dramatically simplifying routine maintenance.

Results at a glance

• 97.5% reduction in lubrication time: from 20 minutes to 30 seconds per joint
• 75% reduction in labour: from four workers to one
• More than 100,000 rail joints upgraded
• No reported seized joints during rail temperatures above 50°C
• No reported expansion-related failures

Want to improve rail joint reliability while reducing maintenance time and costs? Contact Interflon to discuss a fastening and lubrication solution for your rail infrastructure.

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