Direct Rail Wheel Braking Systems
Network Rail Approved Direct Rail Wheel Braking Solutions
In 2012, Allan J Hargreaves Plant Engineers (AJH) secured the contract to develop, supply, and install Direct Rail Wheel Braking (DRWB) systems for Type 9B high-rail excavators operating across the UK rail network. Since then, AJH has become a recognised specialist in this critical rail safety enhancement, helping infrastructure owners, plant operators, and contractors improve operational safety and reduce the risk of uncontrolled machine movement.
Our Direct Rail Wheel Braking system was developed specifically to provide an additional level of braking performance on rail-guided plant, significantly enhancing machine control and mitigating the risk of runaways when operating on the railway.
Today, AJH's Direct Rail Wheel Braking solution has been successfully installed on more than 320 rail excavators, making a substantial contribution to improving safety standards throughout the UK rail industry.
Extensive Testing and Development
The development of the AJH Direct Rail Wheel Braking system involved a comprehensive programme of design, testing, and validation to ensure reliable performance under a wide variety of operating conditions.
Extensive prototype trials were undertaken at Network Rail's High Marnham Test Track, one of the UK's leading railway testing facilities. These trials simulated a range of real-world track conditions, gradients, weather scenarios, and operational environments, enabling our engineering team to fully evaluate system performance, reliability, durability, and service life.
The testing programme incorporated machines from multiple weight categories to ensure the system could perform consistently across the broad range of rail excavators operating within the UK market.
Test platforms included:
- Colmar T10000 – representing heavyweight rail excavators and one of the largest machines operating on UK rail infrastructure.
- Case 988 Megarailer – representing medium-weight machines.
- Komatsu PW130 – representing lightweight rail excavators.
All variants successfully achieved approval requirements and returned to service, demonstrating the effectiveness and versatility of the braking system across different machine types and operating environments.
How the Direct Rail Wheel Braking System Works
The AJH Direct Rail Wheel Braking system is engineered to provide highly reliable braking performance while integrating seamlessly with the excavator's existing control systems.
Each rail wheel is equipped with a hydraulically operated brake caliper featuring a fail-safe spring-applied design. This means that in the event of a loss of hydraulic pressure, the brakes automatically engage, providing an additional layer of safety for railway operations.
Key design features include:
- Hydraulically operated brake calipers
- Fail-safe spring-applied braking technology
- Monoblock caliper construction
- No external mechanical linkages
- Integrated operation through OEM machine controls
- Brake disc protection guards fitted as standard
- Robust, low-maintenance design
- Enhanced stopping and holding performance
The braking force is applied through a dedicated brake disc mounted to the inboard side of each rail wheel. By acting directly on the rail wheel rather than through the transmission system, braking efficiency is improved and machine control is enhanced.
Integrated brake disc guards protect critical components from ballast, debris, and accidental damage during day-to-day railway operations, helping to maximise reliability and minimise maintenance requirements.
Designed for Safety and Reliability
Safety was the primary driver behind the development of the AJH Direct Rail Wheel Braking system. The solution was specifically engineered to address one of the most significant hazards associated with rail-mounted plant: uncontrolled movement.
Benefits of the system include:
- Reduced risk of machine runaways
- Improved braking performance
- Enhanced operator confidence
- Increased safety for track workers and railway operations
- Greater compliance with rail industry safety requirements
- Proven reliability in operational environments
- Minimal impact on machine usability and productivity
By providing direct braking at each rail wheel, the system delivers improved control in both operational and emergencies, offering a valuable safety enhancement for rail plant owners and operators.
Versatile Across Multiple Machine Platforms
One of the key strengths of the AJH Direct Rail Wheel Braking system is its adaptability. The compact design enables installation across a wide range of high-rail excavator models while maintaining machine functionality and ease of maintenance.
The system has been engineered to:
- Fit a broad spectrum of rail excavators operating in the UK
- Maintain operator visibility and machine usability
- Minimise service and maintenance requirements
- Reduce lifecycle costs
- Deliver long-term reliability in demanding rail environments
This versatility has contributed to the widespread adoption of the system throughout the rail industry and its continued success on hundreds of machines nationwide.
Why Choose AJH for Direct Rail Wheel Braking?
With decades of experience in rail plant engineering, AJH combines practical operational knowledge with advanced engineering design capabilities to deliver proven safety-critical solutions.
Our expertise includes:
- Rail plant modifications
- High-rail excavator engineering
- Safety-critical braking systems
- Bespoke engineering design
- Network Rail compliance support
- Installation, testing, and commissioning
- Ongoing technical support and maintenance
Through innovation, rigorous testing, and a commitment to safety, AJH's Direct Rail Wheel Braking system has become a trusted solution for improving rail excavator safety across the UK rail network.
Contact AJH Plant Engineers today to discuss Direct Rail Wheel Braking installations, upgrades, inspections, or support for your rail plant fleet