Embedded Rail Heaters
Waterproof Heating for Embedded
Light Rail and Trolley Systems

Many light rail and trolley systems are integrated with city and urban infrastructure so that rail and rail switches are embedded in shared roadway with automobiles. The embedded nature of these systems presents a challenge when rain, ice, and snow result in standing water or flooding, especially in areas with inadequate drainage. In the winter, salt used to de-ice roadways often results in heaters being submerged in highly corrosive saltwater.

To protect rail switches from the damaging effects of moisture and keep operations running smoothly, NIBE has created the first-of-its-kind waterproof embedded rail heater. Built to withstand extreme conditions, these heaters are ideal for light rail and trolley systems.

Below Grade Rail Heating Impervious to Flooding and Drainage

NIBE’s embedded heating solution provides the best protection against the elements for below grade applications. Our embedded flat heater is sheathed in MONEL 400—a combination of copper and nickel-based alloy—that is impervious to salt and chemical corrosion. The embedded heater’s termination head is a completely sealed assembly with an integrated cable. The result is a rugged heater that provides optimal thermal transfer with a coefficient almost twice that of the next best alloy for switch heating, stainless steel.

The heater is installed by sliding it into the channel of the embedded rail with an attached stainless steel "wave" spring to push it against the rail for optimal channel conductivity. Our embedded heaters are shipped flat, not coiled, for ease of installation and secure contact with the rail.

The heater connection in an embedded rail construct is usually accompanied by a below grade “Junction Box” (JB). This JB would be subject to the same flooding as the heaters. In order to protect this below grade connection, we provide a hermetically sealed Gel Box that will protect the connections and allow a long-sealed lead to come up above grade to connect to the heating control system.

Benefits of NIBE’s Embedded Rail Heating System include:

  • Monel 400 alloy is impervious to salt water, unlike stainless steel which disintegrates easily.
  • Completely sealed connection with zero risk of malfunction due to moisture or termination corrosion.
  • Advanced European rail heating technology and U.S. manufacturing expertise.
  • Turnout sizes support switching rail lengths from 10 to 21 feet.
  • Easy to install and available in flexible lengths.
  • Rugged design and proven performance.
  • 10-year warranty.
  • Shipped flat for greater conductivity with the rail.

Gel Box

The challenges of protecting connections and heaters submerged in corrosive salt water, resulting from salt used to de-ice roadways, and moisture in general are particularly acute for tramlines. NIBE’s hermetically sealed Gel Box, for below grade connectivity, is built to withstand extreme conditions.

In the event an element needs to be replaced, NIBE’s Gel Box enables easy replacement in the field. The halogen-free, polypropylene enclosure is designed to house straight and branch connections and the termination heads come as one complete assembly with an integrated cable. A strain relief is integrated within the enclosure and is easily installed with two cable ties.

Benefits of the Gel Box include:

  • Waterproof, hermetically sealed junction box.
  • Protects below grade connections.
  • No moisture intrusion during maintenance under severe weather conditions.
  • Easy to install.