Stray Current Insulation Protection System

APPLICATION SCENARIOS

1. Urban metro track systems – prevents stray current corrosion of rails

2. High-speed railway lines – protects rails and infrastructure integrity

3. Electrified railway systems – safeguards tracks beneath the overhead catenary

4. Critical zones such as rail bridges and turnouts – provides targeted protection

Product Description

This system integrates a polymer composite encapsulation layer with a weather-resistant dual-hydrophobic insulating coating, achieving a breakthrough in rail-to-ground transition resistance exceeding 30 Ω·km. The dual-layer protection effectively blocks electrochemical corrosion pathways, ensuring long-term insulation stability of the rails under harsh conditions such as rain, snow, and salt spray. This significantly enhances the reliability of track circuit signal transmission.

PRODUCT FUNCTION

Leap in insulation performance:  

Special polymer substrates form a three-dimensional wrapping layer, blocking current leakage between metal and ground.  

The amphiphobic (hydrophobic and oleophobic) insulating coating inhibits the formation of surface conductive films, achieving a transition resistance of ＞30Ω·km.  

All-environment weather resistance:  

Amphiphobic coating resists rain/snow infiltration, salt spray condensation, and dust adhesion, ensuring insulation stability in humid environments.  

UV resistance and ability to withstand temperature alternations from -40℃ to 80℃, suitable for deployment across global climate zones.  

Doubled anti-corrosion performance:  

The wrapping layer physically isolates rails from ballast media, reducing electrochemical corrosion rate by over 70%.  

The coating contains corrosion-inhibiting ions, delaying the oxidation process of metal surfaces.  

Optimized operation and maintenance costs:  

25-year maintenance-free service life (compliant with EN 50122 standards), reducing track circuit failure rate by 90%.

PERFORMANCE INDEX

Core Technology: Polymer Encapsulation Layer + Nano Dual-Hydrophobic Insulating Coating

Electrical Performance: Rail-to-ground transition resistance >30 Ω·km (IEC 62128 wet condition test)

Mechanical Strength: Encapsulation layer peel strength ≥8 kN/m; ballast impact resistance >5000 cycles

Environmental Durability:

Salt spray resistance >1000 hours (ISO 9227)

UV aging resistance >3000 hours (ISO 4892)

Temperature Range**: -40℃ to 80℃, no cracking after 200 dynamic thermal cycles

Safety Certification**: Compliant with EN 45545-2 fire protection standard

APPLICATION AREA

High-Speed Rail: Enhanced rail insulation for ballastless track sections

Heavy Haul Railways: Anti-electrolytic corrosion protection for dedicated mining lines

Subway Tunnels: Signal reliability assurance for track circuits in humid environments

Coastal Railways: Extended rail insulation lifespan in high salt-spray regions

Turnout Zones: Preventive protection in high-failure areas of track circuits