Page 1
Refer to the mold tag for applicable instruction sheets. IPRPW_C
CADWELD® Propulsion Rail - Web Bond
IPRPW_C
I. HOW TO READ THESE INSTRUCTIONS/
WHAT THE SYMBOLS MEAN
The purpose of safety symbols is to attract your
attention to possible dangers. The safety symbols,
and the explanations with them, deserve your careful
attention and understanding. The safety warnings do
not by themselves eliminate any danger. The instructions
and warnings are not substitutes for proper accident
prevention measures.
!
SAFETY ALERT SYMBOL: Indicates warning or caution. It may
be used in conjunction with other symbols or pictographs.
!
WARNING: Failure to obey a safety warning may result in
property damage, serious personal injury or death, and the
serious personal injury or death of others. Always follow the
safety precautions to reduce these risks.
!
CAUTION: Failure to obey a safety caution may result in
property damage, personal injury, and injury to others. Always
follow the safety precautions to reduce the risk of fi re, other
property damage and personal injury.
NOTE: Advises you of information or instructions vital to the
operation or maintenance of the equipment.
In the following instructions, cautions and warnings, there are
two types of consequences for failure to heed:
A. IMMEDIATE, that may result in personal injury or a failed
operation that may result in a less than optimum bond and
that will not give the physical and electrical performance
expected.
B. EVENTUAL, that may result in a later premature rail break,
causing a serious derailment accident with personal injuries
or death, and loss of property.
WARNING: The area where the bond is to be
!
applied must be sheltered suffi ciently if the weather is
inclement. This is to keep the rail surface, all equipment, and
materials dry until the weld is completed. Failure to do so may
result in an unsafe application with the risk of personal injury
and a less than optimum bond.
CAUTION: The work area must be well ventilated.
!
Workers should avoid breathing the smoke of the exothermic
reaction by positioning themselves upwind of the mold before
igniting the welding material. After ignition, it is advisable to
step back from the mold. Failure to observe this instruction may
result in lung irritation.
WARNING: The worker(s) performing the welding
!
must be properly dressed and equipped. Examples include
cotton or woolen garments (most synthetic fabrics melt rather
than char when exposed to fl ame, causing severe burns), safety
footwear with non-slip soles, head protection, leather gloves,
eye goggles and other clothing and equipment recommended or
required by the person’s employer, industry practice, or applicable
laws and regulations. See Figure 1. The worker(s) must not be
under the infl uence of any alcohol, drugs or other chemicals that
would impair their judgment or performance of the job. Failure
to observe this may result in serious personal injury.
Safety Helmet
Safety Goggles
FIGURE 1
Jacket or Shirt
and Trousers
Cuffed Leather
Gloves
II. GENERAL RULES FOR SAFETY IN THE APPLICATION
OF EXOTHERMIC WEB BONDS TO RAIL
!
WARNING: Do not attempt to make an exothermic bond
until you have thoroughly read and understand the
instructions that accompany all of the various components
of the system and have been properly trained in the use
of this product. Use only the system components designed
to be used together from a single manufacturer. Failure to
comply may result in unsatisfactory bonding as well as accidents
involving fi re, personal injury, and rail damage that may lead to
property damage, injury or death.
!
WARNING: Only the correct grinding equipment, welding
equipment, welding material, and bonds designed for the
specifi c application must be used. All items used must be
designed and supplied by the same manufacturer. All items
must be in good condition and not worn, altered or damaged.
Failure to do so may result in an unsafe application with the
risk of personal injury and/or a less than optimum bond.
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Safety Shoes
CAUTION: The worker(s) must be certain that
!
they can achieve good footing in the area where the weld
will be done. They should be able to step away from the weld
reaction, to be upwind of it. Failure to observe this may result in
personal injury.
WARNING: Carefully following the instructions
!
for exothermic bonding is very important to achieving
a quality reliable bond. Failure to do so may cause hidden
potential problems, the least of which is a poor electrical
connection, and the most serious of which is an eventual broken
rail leading to property damage, injury or death to the installer
and others.
1
Page 2
Refer to the mold tag for applicable instruction sheets. IPRPW_C
CADWELD® Propulsion Rail - Web Bond
III. PREPARATION
WARNING: Protect against potential fi re hazards
!
local to the bonding area and remove all fl ammable
materials from the work area. Notify in advance other
workers in the immediate area that a welding procedure
is about to be done. Failure to do this increases the risk of fi re
with the possibility of property damage, personal injury and death.
NOTE: In case of a fi re involving large quantities of exothermic
welding material, CO
or large quantities of water applied from
2
a distance are required to reduce the spread of the fi re.
WARNING: The location of the bond is very important!
!
Rail track connection web bonds must be made at the neutral
axis of the rail. Failure to observe this may result in a rail break
leading to property damage, injury or death to others. TRACK
CONNECTION BONDING MUST NEVER BE DONE ON OR
NEAR THE HEAD OUTSIDE THE CONFINES OF THE RAIL
JOINT BAR OR NEVER TO THE BASE OF THE RAIL.
See Figure 2.
FIGURE 2
Joint Bar
Bond
FIGURE 4
3. Lightly grind the rail surface using an ERICO approved
grinding wheel that is self-cleaning or a CADWELD
®
brand
Rail Head and Web Cleaner (Part SBB394C). Grinding wheels
with resin binders tend to leave a surface fi lm that may
contaminate the surface, interfering with the achievement
of an optimum bond and causing weld porosity.
WARNING: The area of the rail web to be bonded must
!
be lightly ground to a bright fi nish with no visible scratch
marks or gouges (normal uniform fi nishing marks are
acceptable). Failure to observe this may result in visible scratches
or gouges due to overly aggressive grinding that are potential
crack initiators and that may lead to rail breaks causing
derailment accidents with property damage, injury and death
to others. See Figure 5.
FIGURE 5
4.00" [102] Minimum
Mold
& Frame
1. Clean the rail surface and bond terminals. Scrape off excess dirt
and grease, and wipe away any remaining residue using a clean
rag saturated with a railroad approved solvent. See Figure 3.
The cable and rail surface must be dry prior to welding!
FIGURE 3
WARNING: The area of the rail where the web bond
!
will be applied and the bond terminals must be clean
and dry. Failure to comply can cause poor bonding, excessive
weld porosity, and/or spewing molten welding material with
the potential for serious burns to the worker.
2. Use abrasive cloth or wire brush on the bond terminals
if needed to remove surface oxidation.
CAUTION: The bond terminals must have a bright surface.
!
Failure to comply with this may result in a less than optimal
weld. See Figure 4.
CAUTION: Grinding must not be done more than 4 hours
!
prior to bonding. If the time lapse is longer, suffi cient
contaminating rust may re-form requiring additional grinding.
Failure to observe this may result in a less than optimum bond.
4. Dry the mold and rail by heating them to about 250°F (120°C)
with a small propane torch.
WARNING: The rail and mold must both be warmed to
!
drive off moisture. Failure to observe this may result in weld
spatter with the potential for serious burn injury, and a less than
optimum bond with excessive porosity. See Figure 6.
FIGURE 6
WARNING: Rebonding over the application of an
!
earlierweb bond is strictly forbidden! Rebonds must be
applied at least two inches away (centerline to centerline) from
an earlier bond to avoid serious structural harm to the rail.
Failure to observe this may result in a rail break leading to
property damage, injury or death to others.
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2
Page 3
Refer to the mold tag for applicable instruction sheets. IPRPW_C
CADWELD® Propulsion Rail - Web Bond
WARNING: Back-to-back bonding of web bonds is strictly
!
forbidden! Bonds made on the opposite side of the rail to
an earlier web bond must be applied at least two inches away
(centerline to centerline) from the earlier bond to avoid serious
structural harm to the rail. Failure to observe this may result in a
rail break leading to property damage, injury or death to others.
IV. WELDING PROCEDURE
1. Place bond in welder with fl at surface against rail web and
end of terminal against bond clip. This correctly positions
the bond in the weld cavity. Be sure the bond clip is in good
condition and properly positions the terminal under the center
of the tap hole as shown. See Figure 7.
FIGURE 7
WARNING: Correctly positioning the mold against the
!
rail web with the welder device is critical for safety and
success in making a bond. There must be no cracks between
the lower part of the mold that contains the weld cavity and the
rail surface; if a crack is present, the mold should be discarded
and a new one used. See Figure 10. (Molds can generally be
used for up to 50 welds.) The exothermic reaction reaches a
temperature in excess of 4000°F, therefore great care must
be exercised to avoid spillage of the molten metal. Failure to
observe this warning may result in molten metal leakage onto
the rail with the immediate risk of personal injury, and potentially
serious structural damage to the rail. Failure to locate the bond
at the neutral axis of the rail may also contribute to premature
rail damage. Either could result in a rail break leading to
property damage, injury or death to others.
FIGURE 10
2. Position the welder with attached mold on the rail.
Use the mold height adjusting screw of the positioning bar
to locate the bond terminal at the neutral axis of the rail.
See Figures 8 and 9.
FIGURE 8
FIGURE 9
3. Insert one steel disk, dished (concave) side up, in the crucible
to cover the taphole. See Figure 11.
FIGURE 11
Disk
CAUTION: The steel disc must be correctly installed into
!
the mold crucible. Failure to properly position it may result
in premature leakage into the mold area, resulting in an
unacceptable weld. See Figure 12.
FIGURE 12
4. Dump the contents of the welding material container into
the crucible, being careful not to upset the disk.
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T20-Clamped Position
3
Page 4
Refer to the mold tag for applicable instruction sheets. IPRPW_C
CADWELD® Propulsion Rail - Web Bond
CAUTION: Install only the specifi ed welding material in
!
the mold crucible. Use only the welding material size that is
specifi ed on the mold. ERICO brand of welding material (F80) is
formulated specifi cally for use with rail steels; it is packaged in
a blue tube with a yellow cap. Dump all of the welding material
into the crucible, then carefully tap the tube on a hard surface
to loosen the starting material from the bottom of the tube and
distribute half on top of the welding material, close the mold
cover, and pour the remainder in the opening of the mold cover.
See Figure 13. Failure to comply may result in diffi culty getting
the reaction started and/or an unacceptable weld.
1/2 Starting Material
FIGURE 13
Crucible Cover
1/2 Starting Material
Welding Material
Disk
5. Place welder against rail web. Hold fi rmly or clamp if using
T20 style. Clamp is adjustable for rail sizes. Check that mold
face fi ts against rail and bond terminal is held against rail.
NOTE: Clamp on T20 style can be swung out of way to make
hand held welder. See Figure 14. Maintain correct positioning
of the hand held welder at the neutral axis of the rail web
(refer to “
the rail web...
WARNING: Correctly positioning the mold against
” on page 3).
7.
Carefully open the mold cover and break up the slag in the crucible
using the blade of the mold cleaning tool. Dump the slag from the
crucible and remove slag from the taphole using the curved end of
the mold cleaner. Dump slag in the ballast, not onto the ties.
8. Check the molds for breakage or residual slag before proceeding
with the next weld.
V. INSTRUCTIONS FOR FIELD-MADE TERMINALS
1. Strip insulated conductor a minimum of sleeve length
plus 1 inch (25 mm).
2. Cable and sleeve must be clean, bright and dry.
3. Insert conductor through sleeve so strand ends protrude
approximately 0.02–0.04 inches (0.5
Positioning Sleeve
0.02 – 0.04 inches (0.5 –1.0 mm)
FIGURE 15
4. Place sleeved conductor into designated hammer die, locate
fl are of sleeve against side of die.
5. Close die, use hammer or press to form terminal (use care to
maintain sleeve and conductor ends in position).
–1.0 mm). See Figure 15.
6. Top of die must be tight against die body to properly form
terminal.
7. Mark terminal using saw cut in hammer die when provided.
Trim bond at mark. See Figure 16.
FIGURE 14
CAUTION: Avoid direct eye contact with the “fl ash” of light
!
from the ignition of the starting material.
FIGURE 16
6. Position yourself upwind of the mold, on the fi eld side of the
rail. Place the tip of the fl int igniter at the cover opening and
ignite. Remove the igniter quickly to prevent fouling.
CAUTION: Allow 15 seconds for mold cooling after the
!
reaction. This will permit the molten metal to solidify. Then
carefully disengage the welder device and pull the mold straight
back from the rail. Failure to observe this may result in mold
damage and its premature scrapping. Molds can generally be
Note: If you have any questions or require further instructions,
or would like training, contact ERICO at 1-800-447-7245.
re-used up to 50 times.
Copyright ©2010, 2012, 2013 ERICO International Corporation. All rights reserved.
CADDY, CADWELD, CRITEC, ERICO, ERIFLEX, ERITECH, and LENTON are registered trademarks of ERICO International Corporation.
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Forming – Using Hammer-Die
4
IPRPW_C R1297IS09WWEN PUR1113
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