Rail – joint maintenance
Faster, safer alternative to fishplate maintenance
Initial situation
A fast-growing railway maintenance and renovation contractor in France (or Europe?) was looking to improve the efficiency of lubricating fishplate connections — a recurring and time-consuming task. Traditionally, each connection required full dismantling, taking around 15 minutes. Bolts were often seized and had to be cut with angle grinders, while the work had to be scheduled at night or during traffic halts, raising costs and safety risks.
Standard greases used for this job degraded within 2–3 years due to exposure to weather. As a result, joints failed to absorb rail expansion properly, increasing the risk of track deformation — a serious concern for operational safety.
Solution
To modernise its process, the contractor adopted Interflon Lube EPR, a high-performance penetrating lubricant developed for harsh conditions.
Enhanced with MicPol® technology, Interflon Lube EPR forms a durable, dry-running film. This film bonds to the metal surface, offering long-lasting protection against moisture, pressure and vibration — even in exposed outdoor environments.
A key advantage: no dismantling is needed. Each joint can now be treated in just 30 seconds, without interrupting rail traffic.
Key benefits
- No dismantling required(!), cutting labour time and risk
- Rapid application – 30 seconds per joint
- Flexible planning – work done during regular operations
- Improved reliability – Lubricants with MicPol® technology resists washout and wear
- Enhanced safety – joints remain functional year-round
- Better working conditions – fewer tools, less strain
The solution has been validated by a national rail authority for use on high-speed lines (expansion joints and safety fishplates). Broader approval is pending, due to annual inspection requirements — unlike the 6–8 year intervals of conventional greasing — but this does not limit use on private lines.
Cost comparison over 6 years (2,000 joints):
- Traditional method: €120,000
- Interflon method (incl. service): €81,200
- Direct savings: €38,800
Additional gains include lower machine use, fewer injuries, and no need for traffic closures. The savings increase further when in-house teams carry out the work.
Conclusion:
Since adopting Interflon Lube EPR, the contractor has streamlined its rail joint maintenance and significantly reduced costs and operational risks.
