Railroad Switch Heating

Thermal-Flex Systems has been manufacturing railroad switch heating components and hardware for more than 30 years.  During that time we have developed a number of rail heating products and “systems” to satisfy many diverse and demanding heating applications.

Today, Thermal-Flex Systems is the only manufacturer of flexible rail heating elements.  Our patented design permits the rail heating element to be installed either behind, or around track braces and other obstructions.

To maximize the heating effect when using lower wattage, energy efficient heating elements, we took a systems approach to railroad switch heating by designing an insulated cover for the rail element; the first company to develop and utilize this technology.  Our reusable aluminum, or stainless steel containment channel features a high density thermal insulating material held captive in the channel by a locking insulator plate.  The combination of thermal insulation and channel geometry helps to drive heat into the rail rather than being lost to the environment.

The patented Thermal-Flex heating element is encased in a flexible, spiral fluted, watertight tube.  The tube, or rail heater, is typically positioned at the neutral axis on the field side of the stock rail.  The rail heater is covered by the containment channel and the completed assembly is held in place by spring steel track clips.

The components of the Thermal-Flex High Capacity Switch Heating System are shown in the diagram below.

For extreme environmental conditions, Thermal-Flex manufactures a wide range of high wattage rail heating elements; up to 500 W/ft.  A key feature of our rail heaters is the SlimLine connector.  Utilizing the small diameter connector allows the rail heater to be easily installed behind rail braces thereby reducing trackside access time and installations costs.

To complete the “system”, Thermal-Flex switch heating systems are configured with crib or ballast heaters; a typical turnout uses two.  Our crib heaters are one of the smallest and lightest designs in the industry making the installation under the switch rods simple and quick.