Beruflich Dokumente
Kultur Dokumente
Code of Practice
for the
THERMIT- quick welding procedure
SoW-5
E-Mail: info@elektro-thermit.de
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Table of contents
0. Preliminary remarks
1. Data sheets
1.1 Data sheet Rail grades and portions (Vignol rail)
1.2 Data sheet Standard gap for SoW-5 (propane / oxygen)
1.3 Data sheet L50 for SoW-5 (propane / oxygen)
1.4 Data sheet L75 for SoW-5 (propane / oxygen)
2. Accident prevention
3. Storage, selection, preparation and handling of welding materials
4. Execution of welding
5. Welding and permanent way
6. Responsibility of Railway Authority
7. List of equipment
0. Preliminary remarks
This Code of Practice describes the steps for executing THERMIT welding procedures and
includes supplementary information.
1. Data sheets
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1.1.
Prior to the beginning of flame cutting and welding work, the steel grade shall be determined
according to the rolling mark.
If different welding grades are welded to each other, the THERMIT portion shall be used
according to the steel grade with the lower hardness.
Special steel grades incl. bainitic steel grades on request.
Rail grade former
designation
700
(680 N/mm2)
800
(780 N/mm2)
900A
(880-1030 N/mm2)
900A
(880-1030 N/mm2)
900B
(880-1030 N/mm2)
1100
(1080 N/mm2)
head-hardened
(880/1180 N/mm2)
Rail grade
designation
acc. to CEN
R200
Brand
Rolling mark
Portion grade to be
used
S700
ohne
Z70
R220
S800
Z70 80
R260
S900
Z90
R260V
Z90
R260Mn
Z90
R320Cr
Z110
R350HT
Z120,
alternative: Z90 HC
with heat posttreatment
Z120,
alternative: Z90 HC
with heat posttreatment
on request
Z120,
alternative: Z90 HC
with heat posttreatment
on request
on request
R350LHT
R370CrHT
R400HT
R370LHT
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31 1)
33E1
33 1)
35E1
36 1)
36 1)
36 1)
37E2
37 1)
45E2
45 1)
45 1)
46E1
46 1)
46E2
46 1)
46E3
46 1)
49E1, 49E5
49 1)
50E2
50 1)
50E4
50 1)
50E6
50 1)
54E3, 54E4
54 1)
54E1
54 1)
54E2
54 1)
55E1
55 1)
60E1,
60E2, 60 1)
60E2-40
63 1)
71b 1)
A.S.C.E.401)4)
A.S.C.E.601)5)
Pre-heating Start of
time 2)
trimming after
[min]
pouring
[min] 2)3)
3,0
5,5
3,0
5,5
on request
5,5
3,0
5,5
on request
5,5
on request
5,5
4,5
5,5
4,5
5,5
4,5
5,5
4,5
5,5
4,5
5,5
5,0
5,5
5,0
5,5
5,0
5,5
5,0
5,5
5,5
5,5
5,5
5,5
5,5
5,5
5,5
5,5
6,0
5,5
5,5
6,5
2,0
2,0
5,5
5,5
4)
5)
1)
The designation of the portion is composed of the designations for the rail profile, the quality of the
welding material (refer to Data sheet Rail and portion grade) and the welding procedure.
Example for profile 60E1 / portion grade Z90 / procedure SoW-5 / long-life crucible:
60
90
SoW-5
When using the single-use crucible, use portions with the suffix E.
Example for profile 60E1 / portion grade Z90 / procedure SoW-5 / single-use crucible:
60
90
SoW-5-E
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2)
For profile transition, use the THERMIT portion, the pre-heating and trimming time of the
relevant larger rail profile. This THERMIT portion shall be used together with one additional
portion 0515E. which is enclosed the ordered moulds for the relevant profile transition.
3)
The start of trimming after pouring, according to table 1 can increase by up to 0,5 min when
using the single-use crucible.
For portion grade Z120, the trimming should start as late as possible.
4)
specifics for A.S.C.E.40:
Torch height 65 mm
When using the single-use crucible, use the clamping device E for Rg28 (Art.No.256207).
When using the long-life crucible, use a universal clamping device on request
pair of mould shoes for suspended joints, only for using luting paste (Art.No.253743).
The cardboard caulking 100x62x2 from the mould box has to be manually shortened in
order to project beyond the mould surface.
pair of shear blades SMR29 type B (Art.No.251963),
Start of trimming after pouring:
long-life crucible 4,5 - 5,5 min , single-use crucible 5,0 6,0 min
5)
specifics for A.S.C.E.60:
Torch height 65 mm
When using the single-use crucible, use the clamping device E for Rg28 (Art.No.256207).
When using the long-life crucible, use a universal clamping device on request
pair of mould shoes for suspended joints, only for using luting paste (Art.No.253743).
The cardboard caulking 100x62x2 from the mould box has to be manually shortened in
order to project beyond the mould surface.
pair of shear blades S30 type B (Art.No.252105),
Start of trimming after pouring:
long-life crucible 5,0 6,0 min , single-use crucible 5,0 6,0 min
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55.502
oxygen: 4,0 bars; propane: 1,5 bars
recommended 1,8 2,2 mm at both sides each at a length of 0.5 m
40 - 50 mm
within a range of 30 - 45mm the minimal possible torch height must be set
according to Data sheet Standard gap SoW-5 (propane / oxygen)
The basic portion 1) given in the Data sheet for SoW-5 (propane / oxygen) shall be used
together with the additional portion 8121) SoW-5-L50 of the same grade.
(*only profile 50E5: optional usage of 2 portions PRA 50E5-L50 Rxxx.)
refer to 1) and 2) in Data sheet Standard gap
Example for profile 60E1 / portion grade Z90 / procedure SoW-5-L50 / long-life crucible:
Basic portion
60
90
SoW-5
and
Additional portion
812
90
SoW-5-L50
When using the single-use crucible, use portions with the suffix E.
Example for profile 60E1 / portion grade Z90 / procedure SoW-5 / single-use crucible:
Basic portion
60
90
SoW-5-E
and
Additional portion
812
90
SoW-5-E-L50
and
Additional portion
812
90
SoW-5-L50
When using the single-use crucible, use portions with the suffix E.
Example for profile 60E1 / portion grade Z90 / procedure SoW-5 / single-use crucible:
Basic portion
60
90
SoW-5-E
and
Additional portion
812
90
SoW-5-E-L50
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55.502
oxygen: 4,0 bars; propane: 1,5 bars
recommended 2,0 2,4 mm at both sides each at a length of 0.5 m
65 - 75 mm
within a range of 40 - 65mm the minimal possible torch height must be set
according to Data sheet Standard gap SoW-5 (propane/oxygen)
The basic portion 1) given in the Data sheet for SoW-5 (propane / oxygen) shall be used
together with the additional portion 11121) SoW-5-L75 of the same grade.
refer to 1) and 2) in Data sheet Standard gap
Example for profile 60E1 / portion grade Z90 / procedure SoW-5-L75 / long-life crucible:
Basic portion
Additional portion
60
1112
90
and
90
SoW-5
SoW-5 -L75
When using the single-use crucible, use portions with the suffix E.
Example for profile 60E1 / portion grade Z90 / procedure SoW-5-L75 / single-use crucible:
Basic portion
Additional portion
60
1112
90
and
90
SoW-5-E
SoW-5-EL75
For L75 may be used single-use crucible I high design with crucible cap wide gap
Possible rail profiles at L75
35,7NSB=NSB40
S41R14, S41R10=40E1, 41E1
DSB45=45E2
NP46=46E3
S49=49E1, 49E5
JRS50N
EB50T=50E2
UIC50=50E4
U50=50E6
UIC54E=54E1
S54=54E3, 54E4
UIC60=60E1, 60E2, 60E2-40
JRS60
VRC60=S60
R65
Transition UIC60=60E1, 60E2, 60E2-40 /
DSB45=45E2
Transition EB63T / EB50T=50E2
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29 mm
minimum 30 mm
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2. Accident prevention
The accident prevention regulations of the pertinent accident insurance company are decisive
and must be complied with during THERMIT welding. Pay attention to the following regulations
in particular:
-
Principles of prevention
Grinding work and power-driven tools and equipment
Railway track service
Work in the area of tracks
Welding and cutting with gases
Handling of gases and liquid gases
Fire prevention
Protect the welding portions, crucibles, moulds, tapping thimbles and igniters against
moisture.
Keep the igniters in a container separate from the welding portions for storage or
transportation. Do not carry loose igniters in your clothing.
Check the connected gas fittings for leaks. Tighten the torch sleeve nut firmly with a spanner.
Before igniting the torch, first open the oxygen valve and then the fuel gas valve. When
shutting off, first close the fuel gas valve and then the oxygen valve. In the event of a flame
flashback, which is indicated by a whistling noise, immediately close both torch valves and
then cool the torch in water with the oxygen valve opened. After that carry out the suction test.
Do not stand closer to the welding point than is necessary for the work during the THERMIT
reaction.
Always wear protective clothing and, in addition, use filters for welding and related techniques
- scale number 6 (EN 166/169) during flame cutting, the THERMIT reaction and when the
steel is poured into the mould.
Ensure that the reacting welding portions and hot reaction products do not come into contact
with water and are not extinguished by water but, if necessary, are covered with dry sand
instead.
On completion of steel pouring, lift the single-use crucible which is standing on the mould
shoes from the mould by its handle using a suitable tool such as a crowbar or ballast fork.
Place hot slag pans and hot single-use crucibles in a safe place on a dry, non-combustible
surface. Protect the surroundings from radiant heat as well as slag and steel spatter.
Wear protective clothing and goggles during any grinding work. Do not operate the grinding
machine without guards. Pay attention to and take precautions against flying sparks.
Use a safety harness of an approved design when working at heights. Provide scaffolding
when there are no catwalks.
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Profile and steel grade of a rail defined the type of the THERMlT portion used. For the
designation of the relevant THERMlT portions refer to the Data sheet Rail grades and portions
and the relevant data sheet.
Protect welding portions from moisture! Keep them in the portion container at the building site.
Moist portions must not be used even if they have been dried.
Undamaged portion bags only shall be used. Do not mix the content of several portion bags
unless defined additional portions are required explicitly in the code of practice and the relevant
data sheet.
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3.2 Moulds
The mould shall be selected such that they match the rail profile and the welding gap (standard
gap, L50 or L75).
Store moulds in a dry place and protect them from frost and moisture.At the site they should be
kept dry. Do not use damaged moulds. Two-part moulds can be used for suspended and
supported joints. Three-part moulds are also available for specific applications.
Partly transition moulds are available for welding different rail profiles; also for rails of the same
profile with different level of wear. Refer also to section 4.9, adaptation of moulds by filing.
Refer also to section 4.9, adaptation of moulds by filing.
3.3 Ignitors
Ignitors shall be kept separately from portions and not in the portion containers or clothing
.
For the transport on vehicles to the site design approved single overpacks type 4G (Dangerous
Goods) are deliverable on request.
3.4 Gases
Propane / oxygen are preferably used with the pre-heating torches. The use of acetylene / oxygen
or gasoline / compressed air is also possible. When selecting the fuel gas and associated
equipment you may have to observe the relevant safety regulations for working in tunnels or
below ground level.
Propane:
The required purity according to DIN 51622 or DIN EN 589 with at least 95 percent by weight of
propane and propene (propylene) must be guaranteed. The propane content must be higher.
A sufficient vapour pressure and mass flow of the liquid gas must be ensured during the whole
pre-heating time as follows:
Propane cylinders with a volume of at least 20 kg must be used when gas is drawn from
individual cylinders. In exceptional cases at least two cylinders have to be coupled in parallel as a
battery for gas tapping and/or electrically operated blankets for the cylinders must be used.
See also section 4.18.
Acetylene:
Please refer to the specifics for pre-heating with acetylene / oxygen
Gasoline / compressed air
Please refer to the specifics for pre-heating with gasoline / compressed air
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3.5 Crucibles
Two crucible systems can be used alternatively:
Long-life (LZT) or single-use crucible I and II.
a) Long-life crucible
Refer to section 4.13. Preparation of long-life crucible
or
b) single-use crucible I and II
Refer to sections 4.17 Preparation of single-use crucible I and II for standard gap and 4.18.
Preparation of single-use crucible I for gap L50/L75.
3.6 Tapping thimbles
The tapping thimbles must be protected from moisture. They are used only for long-life crucibles.
The single-use crucibles I and II are provided with an integrated automatically opening closure.
richtig
falsch
Do not use sand which is too moist. Prepare dry sand with water prior to the beginning of welding
work. Check the paste prior to use. Use paste only which can still be kneaded.
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4. Execution of welding
The equipment and consumables must be complete and in good condition prior to the beginning
of welding work.
4.1 Cleaning and examining the rail ends
Rail ends must always be cleaned before welding. Rail ends may not be welded with defects at
fishplate holes or with holes made by flame-cutting. In specific cases, the first fishplate holes must
be closed by welding (refer to THERMIT welding procedure LSV).
If possible, cut out rails with excessively worn ends and low lying deformed rails as occurring
sometimes at steel fishplate joints
4.2 Preparation of welding gap
Preferably, prepare the welding gap by a mechanical separating cut. Prepare the welding gap
widths according to the data sheets.
Pulling the rails, disk cutting, sawing or flame-cutting can all be used for the preparation of the
welding gap. However, the requirements of the Railway Authority must be followed. The cuts shall
be straight and at right angle at all sides. The allowances for gap widths shall be kept.
4.3 Rails with fishplate holes
After preparation of the welding gap, the closest drilling hole edge must be at least 38 mm from
the rail end. Make sure that this drilling hole is free from cracks.
4.4 Welding under traffic
Rail cutting is only permitted in closed tracks.
If traffic has to be passed over a prepared welding gap before the weld has been executed, the
rail must be secured according to the Railway Authority regulations.
4.5 Flame cutting
The area in which the flame cut is to be made, must be cleaned with a wire brush to remove
grease, corrosion and ducts from the rail ends. Wooden sleepers must be protected from fire.
HESA cutting torches to be operated with the following pressures:
Propane:
1.5 bars
Oxygen:
4.5 - 5.0 bars
Always use a flame cutting gauge.
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Alternatively, the E clamping device can be used if no long-life crucible but a single-use crucible is
to be used and placed onto the mould shoes.
Code of Practice SoW-5 english as per 21.08.2012
Arbeitsanweisung SoW-5 englisch Stand 21.08.2012
copyrighted by ELEKTRO-THERMIT GmbH & Co KG
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The pre-heating torch must then be set centrally to the welding gap as well as vertically to all rail
axes.
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If wear is less than 3 mm, it is possible to rework the moulds by filing. However, the collar
geometry must be kept. Refer also to section 3.2.
Slightly tighten the toggle screws of the clamping devices slightly at both sides of the mould.
Check the seat of the plug by inserting into the moulds as a trial.
If rails of different heights or differently worn rails are to be welded, the spaces between the
mould and the rail under the foot and head must be filled with cardboard from the mould box to
prevent sand or paste from being pushed inside the mould. The cardboard caulking must project
beyond the mould surface or, in the case of paste luting, into the paste groove. Follow the hints
for use given as attachments in the mould boxes.
The joints between the rails and the moulds/mould shoes as well as the bottom joint must be
sealed by luting sand, or, alternatively by paste. Firmly press the paste into the circumferential
groove.
Code of Practice SoW-5 english as per 21.08.2012
Arbeitsanweisung SoW-5 englisch Stand 21.08.2012
copyrighted by ELEKTRO-THERMIT GmbH & Co KG
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Press on the thimble firmly and fix it to the applicator by gently tapping the applicator with the ball
of the thumb.
Distribute the plugging sand from the packing sleeve evenly around the tapping thimble. The
hood at the applicator prevents the sand from falling into the metal sleeve which might cause
tapping failure. Do not lift the applicator vertically before the plugging sand is filled in completely.
Then check again that no foreign body is within the metal sleeve.
4.15 Filling the portion in the long-life crucible
Carefully pour the THERMIT portion. Get an ignitor ready for use.
Cover the long-life crucible with the crucible cap and protect the filled in THERMIT portion from
moisture.
Do not fill the long-life crucible over the mould but slew it clear.
4.16 Alignment of long-life crucible and crucible tripod E with the single-use crucible inserted
Place the filled long-time crucible together with the crucible tripod onto the pipe socket of the
universal clamping device and slew it over the mould as trial for alignment. Correct the position of
the crucible such that the outlet is centrally over the plug seat centre. Do not align the long-life
crucible over the mould but slew it for this purpose.
The distance of the crucible bottom from the top edge of the mould should be approx. 3 cm.
Carefully slew back the long-life crucible in order to observe subsequent pre-heating.
Analogously align the crucible tripod E with the single-use crucible inserted.
Use of the crucible tripod E is recommended if L75 shall be welded by the high design of the
single-use crucible.
4.17 Preparation of single-use crucible I and II
The single-use crucible shall be kept dry and closed and protected from damage during transport.
The single-use crucible need not be dried. Moist single-use crucibles cannot be dried and thus,
must not be used.
For filled single-use crucibles:
Check the outside of the single-use crucible for damage. Do not use damaged single-use
crucibles. Prior to the beginning of pre-heating, prepare the filled single-use crucible by slewing it
to and fro twice in each direction as shown in the picture in order to loosen the portion and
facilitate ignition.
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Dry the slag pans for a short period of time before positioning the pre-heating torch with torch
saddle centrally on top of the mould and fix it by the set screw.
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35cm
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4.20 Particular features for flame cutting and pre-heating with acetylene/oxygen
Use the specific devices for this type of gas for flame cutting and pre-heating with
acetylene/oxygen (refer to list of equipment in section 7.).
The usual rules of work shall be applicable here; however, couple at least two 50 litre acetylene
cylinders (both with equal cylinder-pressures) parallel as a battery for pre-heating.
This configuration and the minimal acceptable inclination of the cylinders during usage are shown
as follows:
couple only equal cylinder pressures!
4
3
>0,4m
1,0m
Legend
1:
two-cylinders coupling acetylene
2:
acetylene cylinders 50l both with equal cylinder-pressures
3:
single step pressure reducing valve for acetylene HESA 70
4:
flashback arrestor acetylene
Set a neutral flame pattern for flame cutting and pre-heating.
The torch flame shall not be operated at excess oxygen.
The working pressures and pre-heating times specified in the data sheets for propane/oxygen
will change to:
Working pressures
Oxygen:
4.5 bars
Acetylene:
1.0 bar
For single-use crucibles the pre-heating times are unchanged.
For long-life crucibles the pre-heating times change. Please consult the manufacturer.
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Influences on the waiting time after pouring until mould head removal are shown as follows:
Influences
high
low
intend
single-use crucible
long-life crucible
nearer to upper limit
nearer to lower limit
extend
intend
extend
intend
new rail
extend
worn rail
intend
rail temperature
crucible type
gap width
height of rail head,
equal rail profiles
extend
extend
too long
extend
too short
intend
intend
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Welding:
If possible, do not weld at temperatures below + 10 C. If necessary, heat both rails ends at a
length from 0.5 to 1.0 m to approx. 50 C prior to placing the mould.
When welding the above mentioned rails to other steel grades, use the portion for the rail of the
lower hardness.
For these rails it is necessary to reduce the cooling down rate of the weld. Thus cover the weld all
around by a rail covering hood or a glass wool blanket for cooling down below 500 C after having
removed the excess welding material from the rail head. This cover can be removed for short
periods of time, if trains pass over the rail.
7. List of equipment
The following equipment is required for issue to a welding crew (recommended spare parts are
indicated in brackets ):
General tools
1
flat chisel, long
1
hand hammer, 1.5 kg
1
sledge hammer 3 kg
spare hammer shaft
2
combined goggles for welding/safety
1
wire brush, narrow
1
crowbar, 750 mm long
2
pairs of fire-resistant gloves
1
bucket for sand
1
bucket for water
1
rasp, half-round
1
machine saw blade
1
spatula
1
1
1
1
(+ 1)
(+ 1)
if required:
umbrella with plug-on tube
umbrella holder on request
set of rail head covers, (short and long)
temperature measuring instrument or pin
(+ 4)
(+ 8)
Code of Practice SoW-5 english as per 21.08.2012
Arbeitsanweisung SoW-5 englisch Stand 21.08.2012
copyrighted by ELEKTRO-THERMIT GmbH & Co KG
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1
1
2
4
if required:
gap measuring wedge
crown measuring wedge
sets of insulated rail gauge (1 set = 2 pieces) including
spanner SW 41
half ribbed plates
Welding tools
1
torch saddle
2
slag pans
1
1
1
if required:
portion container
set of tamping devices for supported joints
plate for sand collection
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1
1
1
1
1
(+1 to 2)
(+1 to 2)
if required:
rail heating device
rail trolley
rail covering hood for profile (information required)
or insulation blankets
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(+ 1)
(+ 1)
(+ 1)
(+ 1)
(+ 1)
if required:
pair of mould shoes L50 for supported joints, profile ...
base plate for supported joints on request
(+ 1)
if required:
pair of mould shoes L75 for supported joints, profile...
base plate for supported joints on request
(+ 1)