ERICO CADWELD Propulsion Rail - Web Bond - Manual (Page 2)

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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
2
or large quantities of water applied from
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.
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!
Bond
4.00" [102] Minimum
Joint Bar
Mold
& Frame
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.
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 2
FIGURE 3
FIGURE 4
FIGURE 5
FIGURE 6
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.
www.erico.com 2
CADWELD ® Propulsion Rail - Web Bond
Refer to the mold tag for applicable instruction sheets. IPRPW_C
WARNING: Rebonding over the application of an
earlier web 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.