Since entering service in late 2016, Arc’s K1000 Flashbutt welder has produced more than 33,500 Flashbutt welds, playing a key role in the construction and maintenance of the Arc network.
Flashbutt welding is an alternative to exothermic welds as a method for joining sections of rail. By using electricity to heat the rail ends before pressing them together under high force, it creates a strong, continuous rail with a seamless join.
The K1000 was purchased by Brookfield Rail, to replace the original AI Flashbutt Machine built by the AI Engineers in Scotland which was initially put into production in 1979. The new machine arrived at the former Flashbutt Depot in Bellevue in late 2016, where it was commissioned and completed qualification tests before its first production weld in May 2017.
In mid-2022 the K1000 was relocated to the new Kenwick Depot from Bellevue. Production at the new facility recommenced in January 2023, which marked the start of the team’s biggest year. During 2023 they produced in excess of 4,800 welds meaning there was no impact on production from the downtime require to relocate and recommission the welder. To achieve this remarkable milestone th team worked through numerous teething issues and invested considerable effort to understand the new operating system.
On 8 January 2025 at 11:31 am, the K1000 completed it’s 20,000th weld, a 41kg rail weld that successfully passed hand ultrasonic testing the following day. The completed 107m rail string (Length 20-25) was despatched on the 12 January 2025 and is now installed on the Mingenew to Dongara section of the MR line.
Head of Maintenance Support Tim Underwood speaks highly of the team, who take great pride in maintaining the machine to such a high standard.
“After around 20,000 welds and almost a decade of service, the machine reached a point where it required a major overhaul. When the technicians came to inspect K1000, they commented that they had seen much newer machines with significantly fewer welds that were in far worse condition.
“This is a testament to the attention and care shown by Kim Ellis, Alan Foulger and the team at Bellevue, and now Kenwick, who have operated and maintained the K1000 since it entered production,” said Tim.
Knowing the overhaul would require the machine to be offline for approximately six months Paul Jones, Kim and Alan developed an innovative solution. They sourced a hired flashbutt welder, integrated it into the Kenwick production line, and continued delivering for the business. Over the two-month Christmas period, the team completed more than 1,600 welds to ensure the success the of the ASCI project.
Tim said that as the K1000 approaches a decade in service, it’s a fitting opportunity to recognise the hard work, expertise and care shown by everyone involved.
“Their ability to adapt, solve problems and continue delivering outstanding results is something they should be incredibly proud.”
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