ERICO CADWELD Rail Grounding Connections – Web Bonds User Manual

Cadweld, Rail grounding connections – web bonds

CADWELD

Rail Grounding Connections – Web Bonds

Refer to the mold tag for applicable instruction sheets.

IPRGW_B

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.
II. GENERAL RULES FOR SAFETY IN THE APPLICATION OF EXOTHERMIC

JOINT HEAD BONDS AND 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.

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.

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.

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 OR 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!

FIGURE 1

FIGURE 2

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 a distance are

required to reduce the spread of the ﬁ re.

FIGURE 3

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.

Safety Helmet

Jacket or Shirt

and Trousers

Safety Shoes

Safety Goggles

Cuffed Leather

Gloves

Neutral

Axis