Hi-Flex tracks

Hi-Flex Track is designed to use with Rail Tug and Rail Titan welding tractors. It enables working on both straight and curved surfaces down to 1.5 meter diameter as well as on ferrous and non-ferrous materials depending on units in use (see possible unit options below).

  • For circumferential, irregular and straight line applications
  • Minimum curve radius on convex surface is 0.75 m (30”)
  • Minimum curve radius on concave surface is 1.7 m (67”)
  • Minimum OD 1.5 m (60”) for external run
  • Length of a single rail 1.52 m (5 ft)
  • The maximum number of units is 15 pcs (if narrow magnetic units are in use)
  • Joinable for unlimited run length
  • Can be fixed on both ferrous and non-ferrous materials by means of magnetic or vacuum units to allow travel in any plane or position

Technical Info

Ref.Product codeDescription
1TRO-0673-00-00-00-0Hi-Flex Track min OD 1500 mm
2DYS-0482-19-00-00-0Bracket for magnetic unit for semi-flexible track and Hi-Flex track
3ZSP-0475-92-00-00-0Magnetic unit
4ZSP-0475-93-00-00-0Heat-resistant magnetic unit
5DYS-0582-10-00-00-0Bracket for magnetic narrow unit for semi-flexible track and Hi-Flex track
6PDS-0582-10-00-02-0Narrow magnetic unit with hexagon
7ZSP-0475-85-00-00-0Pivoting magnetic unit
8ZSP-0523-19-00-00-0Spacing-adjustable magnetic unit
9DYS-0541-11-01-00-0Bracket for vacuum modular unit for semi-flexible track and Hi-Flex track
10MST-0541-10-02-00-0Vacuum modular unit

Welding positionQty. of units
per track
PA/ 1Gmin. 8 pcs
PB/2Fmin. 8 pcs
PC/2Gmax 15 pcs*
PD/4Fmax 15 pcs*
PE/4Gmax 15 pcs*
PF/3Fmax 15 pcs*
PF/3Gmax 15 pcs*
* using the narrow magnetic units

  • Rail Titan Min 3400 mm OD
  • Rail Tug Min 3400 mm OD
  • Rail Titan Min 1500 mm OD
  • Rail Tug Min 1500 mm OD

Units dedicated for Hi-Flex

Vaccum modular unit

  • Allows clamping tracks on both ferromagnetic and non-ferrous materials
  • Maximum holding force up to 1400 N
  • Consists of 2 vacuum pads and manifold block
  • Can be easily assembled for 4 different purposes as entry unit, middle unit, extension unit or end unit


  • Suitable for:

  • Hi-Flex track (Rail Tug, Rail Titan)
  • Semi-flexible track (Rail Bull, Rail Tug, Rail Titan)
  • Rigid track (Rail Bull, Rail Tug, Rail Titan)
  • V-track (Dragon, Dragon HS)
  • Flexible trackway (Gecko, Gecko HS, Gecko Battery)


  • Product code: MST-0541-10-02-00-0

    Heat-resistant magnetic unit

  • Suitable for working on more heated ferromagnetic surfaces
  • Maximum holding force up to 2500 N
  • Intermediate position (between OFF/ON) with partial holding force helps to adjust the right track position


  • Suitable for:

  • Hi-Flex track (Rail Tug, Rail Titan)
  • Semi-flexible track (Rail Bull, Rail Tug, Rail Titan)
  • Rigid track (Rail Bull, Rail Tug, Rail Titan)
  • V-track (Dragon, Dragon HS)
  • Flexible trackway (Gecko, Gecko HS, Gecko Battery)


  • Product code: ZSP-0475-93-00-00-0

    Spacing-adjustable magnetic unit

  • Allows clamping tracks to ferromagnetic pipes with diameters of 25–230 mm (1–9’’) and the distance between pipe axes of 170–230 mm (6.7–9.1’’)
  • Maximum holding force up to 2500 N
  • Intermediate position (between OFF/ON) with partial holding force helps to adjust the right track position


  • Suitable for:

  • Hi-Flex track (Rail Tug, Rail Titan)
  • Semi-flexible track (Rail Bull, Rail Tug, Rail Titan)
  • Rigid track (Rail Bull, Rail Tug, Rail Titan)
  • Flexible trackway (Gecko, Gecko HS, Gecko Battery)


  • Product code: ZSP-0523-19-00-00-0

    Magnetic unit

  • Allows clamping tracks to ferromagnetic surfaces
  • Maximum holding force up to 2500 N
  • Intermediate position (between OFF/ON) with partial holding force helps to adjust the right track position


  • Suitable for:

  • Hi-Flex track (Rail Tug, Rail Titan)
  • Semi-flexible track (Rail Bull, Rail Tug, Rail Titan)
  • Rigid track (Rail Bull, Rail Tug, Rail Titan)
  • V-track (Dragon, Dragon HS)
  • Flexible trackway (Gecko, Gecko HS, Gecko Battery)


  • Product code: ZSP-0475-92-00-00-0

    Pivoting magnetic unit

  • Allows clamping tracks to flat, concave or convex ferromagnetic surfaces and pipes ID of at least 800 mm (31.5”)
  • May also be fixed on surfaces that differ in height up to 80 mm (3.1’’)
  • Maximum holding force up to 2500 N
  • Intermediate position (between OFF/ON) with partial holding force helps to adjust the right track position


  • Suitable for:

  • Hi-Flex track (Rail Tug, Rail Titan)
  • Semi-flexible track (Rail Bull, Rail Tug, Rail Titan)
  • Rigid track (Rail Bull, Rail Tug, Rail Titan)
  • Flexible trackway (Gecko, Gecko HS, Gecko Battery)


  • Product code: ZSP-0475-85-00-00-0

    Narrow magnetic unit with hexagon

  • Allows clamping tracks to ferromagnetic surfaces and very close to their edges
  • Maximum holding force up to 1500 N
  • Intermediate position (between OFF/ON) with partial holding force helps to adjust the right track position


  • Suitable for:

  • Hi-Flex track (Rail Tug, Rail Titan)
  • Semi-flexible track (Rail Bull, Rail Tug, Rail Titan)
  • Rigid track (Rail Bull, Rail Tug, Rail Titan)
  • V-track (Dragon, Dragon HS)
  • Flexible trackway (Gecko, Gecko HS, Gecko Battery)


  • Product code: PDS-0582-10-00-02-0

    Hi-Flex accessories

    Hi Flex Track Guiding Rollers (Product code: ZSP-0673-07-00-00-0) will let you work on both convex and concave surfaces.

    Set of Hi Flex Track Guiding Rollers (4 pcs)
    for Rail Tug and Rail Titan
    Product code: ZSP-0673-07-00-00-0

    Applicable for: