150 lbs. Capped Aluminum Power Delivery (CAPD) Rail 6000A

Non-Insulated Transit Welded Cap Rails

150 lbs. Capped Aluminum Power Delivery (CAPD) Rail 6000 A - Underuning System Setup — This image shows the 6000A 150 lbs. CAPD (Capped Aluminum Power Delivery) Rail system in bottom contact configuration with rail, splice assemblies, expansion assembly, power feed connection, anchor blocks, insulators, and end ramp.

150 lbs. Capped Aluminum Power Delivery (CAPD) Rail 6000 A - Topruning System Setup — This image shows the 6000A rated 150 lbs. CAPD (Capped Aluminum Power Delivery) Rail.

The Conductix-Wampfler 150 lbs. Stainless Steel Capped Aluminum Power Delivery (CAPD) Rail is mechanically equivalent and electrically superior to the legacy steel rail currently in use in North America’s Transit Authorities. Aluminum power rail is the most advanced rail you can buy, providing the best available electrical performance per pound.

150 lbs. CAPD Rail for healthier substations, healthier trains, decreased headways, and happier maintenance crews.

Key Features and Benefits

High Current Capacity & Ultra-Low Electrical Resistance – Tired substations may find a little more life with better conductors. New, power-hungry trains are more demanding on the electrical grid and need a conductor that can rise to the occasion. Demand for additional capacity during peak service hours requires a conductor that can grow with decreasing headways.
Significantly Lighter – 150lb rails are named for their weight of 150lbs. per yard. The 150 lb CAPD rail weighs around 55lbs. per yard. At 1/3 the weight of 150lb. rail, you’ll have happier installation teams, less heavy equipment needed, and more rails per shipment (reducing carbon emissions and shipping costs).
Buy America Compliant – Stainless-Steel CAPD Rail is produced in Harlan, Iowa.
Drop-in Replacement – Designed with the same key interface points as the legacy 150 lbs. steel rail, so that existinginsulators and other system parts can be reused (sustainable implementation).
Premium Materials
- Durable, Corrosion Resistant Stainless-Steel cap to ensure long-life and reliability under all environmental conditions.
- Electrical Grade Aluminum for exceptional conductivity and optimal mechanical strength and stiffness.
Configurable Design – Requirements vary by system; our designs can be modified to fit your needs.
Precision Manufacturing = Quality Result – Use of a C-shaped cap welded to tabs along the side of the aluminum ensures a smooth running surface. As the weld cools, it produces a durable mechanical bond between the aluminum and stainless-steel, ensuring minimal electrical resistance between the conductor and cap.

Specification

Parameter	Value	Unit
Resistance	1.32 (4.33)	µΩ/ft (µΩ/m)
Height	4.07 (103.4)	in (mm)
Head Width	4.15 (105.5)	in (mm)
Foot Width	4.88 (124)	in (mm)
Foot Height	0.69 (17.5)	in (mm)
Foot angle	13	degrees
Length	≤ 40 (12.2)	ft (m)
Cross-Section	12.7 (8174)	in²(mm²)
Linear Weight	18.32 (27.26)	lb/ft (kg/m)

High Quality Manufacturing

Manufactured to High Quality Standards

Our automated production line for welded cap transit rails is designed to deliver consistently high quality with tight tolerances. Precisely controlled and fully reproducible manufacturing processes ensure that every conductor rail meets defined specifications and performance requirements.

Process variability, errors, and scrap are significantly reduced by minimizing manual interventions. Integrated inline inspection systems and sensor-based monitoring continuously verify critical quality parameters throughout production.

Your benefit: You receive reliable welded cap rail systems with consistent electrical and mechanical performance, supporting long service life and dependable operation in demanding environments.

Rigorously Tested

Verified through Agency Specific Tests

Our CAPD Third Rail product is designed and tested to meet agency-specific requirements. Conductix-Wampfler performs rigorous in-house tests and can also provide rail to independent, third-party testing labs. So, whether you need simple tests like salt-spray, heat rise, resistance, or cap peel; or more complex tests like short-circuit testing, Conductix-Wampfler has the experience and knowledge to get it done.

3rd Rail System Setup

A proven setup for demanding transit projects

A well-designed third rail system ensures a reliable and uninterrupted power supply under the heaviest train operations. Optimized system design and robust components increase system availability, minimize downtime, and support efficient train operations.

With durable materials and proven engineering, maintenance requirements are kept low, while the system delivers a long service life in demanding transit environments, including tunnels, elevated sections, and outdoor installations.

FAQ

What is the wear rate of the stainless-steel cap?

At a standard installation with 8-10 minute headways off-peak and 3-5 minute headways peak, we observed a worst-case wear rate of 0.5mm over a 15-year period. That is 0.03 mm of wear per year on a 6 mm cap and less than 2 mm over 40 years.

How much better is aluminum rail electrically over the legacy composite or steel rail?

While this depends upon what’s being compared, the 150 lb CAPD rail a 63% reduction in resistance compared to 150 lb. steel rail. This improvement in resistance can help ease the strain on old, overworked substations. Aluminum provides better electrical continuity to modernized, power-hungry rolling stock fleets. It can allow agencies to decrease headways to meet additional service demands. And it can help transit authorities save money through better returns on regenerative braking.

How can I convince my team to convert our system from the legacy composite or steel third rail to stainless-steel capped aluminum power delivery (CAPD) third rail?

Approving a new product is often a multi-step process for transit authorities. The most important part is taking the first step. Logically, transit authorities often require a product test before they use that product in the system. We agree that the process should start with a test of CAPD rail to understand its characteristics and benefits.

Please reach out to us to discuss how we can get a test system installed at your transit authority. While it’s testing, we can work together on the next steps – like crafting a specification, determining testing requirements, and getting product information loaded into your procurement system. We can support your internal conversations on topics such as life cycle cost analyses, technical concerns, training of installation and maintenance teams, etc. Our team is ready to help your agency determine if CAPD rail is the right solution for your operation.

Why Conductix-Wampfler CAPD Rail?

The wrap-around cap provides superior protection of the aluminum conductor compared to crimped or coextruded designs. Our Buy-America compliant CAPD Rail is field-proven in both top and bottom contact orientations

The global rail team at Conductix-Wampfler has experience with every style of third rail manufacturing, from crimped to edge welded to co-extruded to center-weld to the legacy composite. The edge-welded design presents the best combination of strength, durability, and manufacturability of any third rail design on the market. The product has a robust history – including design analysis, rigorous testing, and over 15 years of proven performance in the field. We’re proud of the result, and we’ve made improvements to the rest of the system too (insulators, brackets, cover boards, expansion joints, mid-point anchor assemblies, splice bars, ramps, etc.).

Why should I change from 84C, 85C, or 74C composite third rail or steel rail to a stainless-steel capped aluminum third rail?

The stainless-steel capped aluminum power delivery (CAPD) third rail is a mechanically equivalent and electrically superior option. Most third rail in North America was installed prior to the year 2000 and therefore does not represent state-of-the-art third rail technology. Additionally, the demands being placed on the third rail are now much higher than in the year 2000 (power-hungry trains, decreased headway requirements, etc.). The net result will be lower installation, maintenance, and energy costs.