ERICO CADWELD Propulsion Rail - Joint Bond - Manual (Page 3)

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IV. WELDING PROCEDURE
1. Place bond in welder with fl at surface against rail head and
end of terminal against bond clip. This correctly positions
bond in the weld cavity. Be sure the bond clip is in good
condition and properly positions terminal under the center
of the tap hole as shown. See Figure 7.
2. Position the welder with attached molds on the rail head.
The bottom edge of the mold should be aligned with the
lower edge of the rail head. Use the mold height adjusting
screws to properly align the mold. See Figure 8.
3. Close clamp to lock welder on rail. Clamp is adjustable for
rail sizes. Check that mold face fi ts against rail and bond
terminal is held against rail by clevis. See Figure 8.
WARNING: Correctly positioning the mold against the
rail head 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 9. (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 that could result in a rail
break leading to property damage, injury or death to others.
4. Insert one steel disk, dished (concave) side up, in the crucible
to cover the taphole. See Figure 10.
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 11.
5. Dump the contents of the welding material container into
the crucible, being careful not to upset the disk.
Disk
FIGURE 10
FIGURE 11
FIGURE 7
FIGURE 8
FIGURE 9
CADWELD ® Propulsion Rail - Joint Bond
Refer to the mold tag for applicable instruction sheets. IPRPC_C
Welding Material
Starting Material
Bond Clip
Disk
Graphite Cover
Mold Height Adjusting Screw
Clamp Adjustment Screw
Splice Bar
Tap Hole
Bond
Terminal
Bond Clip