Pandrol Ind Inc Calorite Training Manual LP-AP CJ 2019 En-test (2)

PANDR

Pandrol Industries Inc.

175 John-F. Kennedy Street

Saint-Jerome, Quebec J7Y 4B5

Té1. : (800) 667-4709 ou (450) s6s-9100

Fax : (800) 442-9817

Trainee Workbook

Module L

Thermite Welding

with the

Pandrol LP CJ & AP CJ

Calorite Thermite \Melding Kit

.l

e

The LP CJ & AP CJ V/eld

Process

Trainee Workbook

2019 Edition

Trainee Worhbooh

Module I

e T."t

2

TYøinee Worhbook Module 1

Course Information

Introductíon

3

Tlainee Worhbooh Mod,ule 1

Table of Contents

page

I

il

Course Inforrnation

Table of Contents

Introduction

Foreword

General Course Goals & Objectives

Lesson Introduction

Course Content & Schedule

The LP CJ & AP CJ Thermite Weld

Rationale

Objectives

3

4

5

6

7-8

I

10

11

L2

12

III Module 1

The 13 Steps

Step l: Job Preparation

Step 2: Site Preparation

Step 3: Track Preparation

Step 4: Rail-end Preparation

Step 5: Rail-end Alignment

Step 6: Mold Preparation

Step 7: Preheating

Step 8: Charge Preparation

Step 9: Pouring

Step 10: Demolding & Shearing

Step 11: Hot Grinding

Step 12: Cold Grinding

Step 13: Finishing

Exception Conditions

13

I4

t7

18

20

24

27

39

44

48

50

53

57

59

61

63

IV Module 2

Hands-on LP CJ & AP CJ Wetd

67

4

Tlainee Worlzbook

Module I

Introductíon

Thermite welding is the application for welding rail of the aluminothermic process,

that is, the reduction of an oxide by a more reactive metal. In merely twenty seconds,

the charge, a mixture of aluminum, iron oxide and appropriate quantities of alloying

elements, produces enough molten steel to weld any size rail.

Calorite is the thermite charge developed by Railtech. Through over 90 years of

experience in the aluminothermic production of chromium and with the help of its steel

foundry engineers, Railtech has developed high efficiency charges adapted to the

different rail chemistries.

Pandrol Industries now manufactures Calorite materials in Canada. This permits

rapid delivery of all standard materials and a faster response to special requests.

There are two processes available. The limited preheat weld should be the choice when

the weld must be done quickly as in the case of rail laying programs. If the welds are

close together and the same people can start setting up the next weld during

preheating, the standard preheat process should be considered.

Thermite Welding - Important Points

1. The gap required of 25 - 28 mm (1", minus 0"/plus +1/8") is the same regardless of

the rail or process used. The rail are aligned with a slight crown at the joint to

compensate for the uneven cooling rates in the rail section. The Railtech rail

alignment beam and the A-Frame Aligner are designed to facilitate this operation.

2. The hardware is simple and universal. No need to carry different equipment for

different rails. The equipment has been made as light as possible. If space is a

problem, 25 mm (1") is all that is required under the rail.

3. Air propane preheating is available for both the limited preheat or standard

preheat processes.

4. Now it is time to make the weld. The crucible is positioned over the mold and, in

merely one minute, the weld is completed.

5. While the weld is cooling, it is time to start the Matweld or Railtech weld shear

which has been designed to facilitate the removal of surplus metal and make it

safer. Of course the hot cut chisel may still be used.

6. A little grinding around the rail head and the trains can run again

5

Trainee Workbook

Mod,ule I

Foreword

Calorite is a process for thermite welding which has been successfully used to weld rails

since 1903. Calorite materials are produced following precise formulas developed by

metallurgical engineers. The process has been proven on thousands of welds made

under various conditions in countries all over the world. Every precaution is taken to

insure that the materials in your kit are of the highest quality. However, the quality of

the weld will depend to a great extent on you and your ability to follow the procedures

outlined in this booklet. DO NOT TAKE SHORT CUTS. DO NOT SUBSTITUTE

any part of the welding apparatus with homemade or otherwise obtained components.

When welding under rain or snowfall, adequate cover must be provided to protect the

materials and crucible from moisture. Also make sure that there is no water under the

joints to avoid molten metal coming in contact with water when metal pours from the

crucible.

Finally it is very important to verifii that the disposable crucible and the cover have not

been damaged.

Equiprnent Required

Wood or Steel Wedges

Straight Edge

Gap Gauge

Support & Clamp Ass'y

Mold Frame Ass'y (3 pces)

Packing Rod

Slag Basin

Preheating equipment

Crucible Fork

Hot Cut Chisel and Sledge Hammer

Grinder

Rail Weld Shear (optional)

Alignment Beam (optional)

Rail Saw (optional)

Standard track hand tools

A-Frame Aligner (optional)

6

Trainee Worhbook Module 1

General Course GoaI

There are millions of thermite welds that have been installed across

Canada, with over 50,000 welds added every year. Incorrect or

inconsistent welding procedure is contributing to failures. The

safety and service implications of just one failure speak for

themselves-

The goal of the LP CJ & AP CJ Thermite Welding Course is to

provide you with the necessary skills ço that you will be able to

consistently perform a reliable LP CJ or AP CJ thermite weld in a

safe manner under a variety of weather and rail conditions with the

minimum amount of track down-time.

Traínee Worhbook

This Trainee W'orkbook is designed to act as a guide as you

participate in the course. It includes useful information on LP CJ

&AP CJ thermite welding in general, The 13 Steps in the AP & AP-

CJ thermite weld procedure, and exception conditions that you may

encounter. This workbook can also serve as a reference manual

that you can refer to whenever performing a LP CJ & AP CJ

thermite weld.

This workbook will be used throughout the course as both a

workspace and a resource guide. With the exception of the quizzes,

everything you need to read or write is in this workbook.

I

TYa.inee Worhbook

Mod,ule I

Course Objectiues

At the end of this course you will be able to:

1

2

3.

4.

5.

6

7

I

I

10.

11.

L2.

13

14.

15

Recognize the potential liability of weld failure in terms of

both financial and service costs;

Understand your role & responsibility in the reliability of

each weld;

List several advantages & difference between the LP CJ &AP

CJ weld procedure and other thermite processes;

List the fundamental techniques that guarantee a reliable

weld;

Recognize the track, rail & weather conditions necessary for

a successful thermite weld;

Recognize & assemble the required thermite welding

accessories & material;

List the 13 main steps in the LP CJ &AP CJ thermite

welding process;

Recognize & follow the correct welding sequence;

Recognize specific, time, temperature and exception criteria

within the steps;

Identify key process areas critical to weld reliability.

Prepare the track, rail & required thermite weld accessories;

Execute a LP CJ or AP CJ thermite weld with respect to

sequence, time, temperature and exception criteria;

Complete the weld and return the track & structure to

standard;

Perform a weld safely with a minimum of track down-time;

Complete the quiz: On the criteria related to thermite

welding.

I

Tlainee Worhbook

Mod,ule I

Lesson Introduction

The LP CJ &AP CJ Therrníte WeId

9

Tlaínee Worhbook Module 1

Lesson Introduction

Course Content

This morning's activities wilL include:

. An overview of what a LP CJ &AP CJ weld is

. Why we are all here to review the process

. An overview of the 13 major steps in the LP CJ &AP CJ

thermite welding process

o A detailed look at each of the 13 steps using video and

demonstration material

. A review of exception conditions... abnormal or unusual

situations that you may find when performing a weld

This afbernoon's activities will include:

. Performing and evaluating a LP CJ OR AP CJ weld in

teams of three

. A final quiz to reinforce the key points

Schedule

. There will be breaks in the morning session

. Lunch will be from approximately to

. Because of the workload, there will only be one break in

the afternoon

¡ With your cooperation, the course should finish by

-

10

Trainee Worhbook,

Module I

Course Introductíofl, (cont'd,)

The LP CJ &AP CJ Thermite Weld

o Thermite is an abbreviation of 'aluminothermic'...

because once ignited, a mixture of alloys, aluminum and.

iron burns at very high (thermal) temperatures

-

2480"C (4500'F)

-

creating molten steel that pours into

a mold around two rail-ends

. For those of you who may not be familiar with the LP CJ

process, LP stands for'Limited/Quick Preheat'... because

of the relatively short preheat time compared to other

processes. AP stands for'Avec Prechauffage'and refers

to the Longer Preheat process.

o CJ stands for'Creuset Jetable'which means the crucible

is disposable... making it a one-shot process that does

not require reusing the crucible.

. Some advantages of the CJ crucible are:

- you don't have to clean the crucible

- you don't have to preheat the crucible

- the thimble comes pre-installed

- you need fewer pieces of equipment

- the crucible is lighter

. As a result, the temperature of each LP CJ &AP CJ

pour is very consistent. Consistency is a word you will

be hearing a lot today because consistency is one of the

keys to a successful, reliable weld each and every time

¡ Also, the LP CJ &AP CJ is environment-friendly

because the crucible is biodegradable and decomposes as

it cools

11

TYainee Worhbooh

Mod,ule I

Course Introduction (cont'd,)

Rationale

. Analysis of weld failures reveal incorrect or inconsistent

welding procedures as one of the contributing factors

¡ Weld failure can lead to:

- train delays

- disruption of service

- derailments

- increased operating costs

Objectives

¡ Every time you perform a thermite weld, you put your

name on that weld

. The purpose of this course is to make sure that each

time you do, you have confidence in the reliability of the

weld you have just done

. We are going to achieve this by emphasizing 4

techniques that will guarantee you a reliable LP CJ or

AP CJ weld every time. It's called CAST. CAST are

four letters that stand for:

- Consistent work practices

- Accuracy

- the correct Sequence of $teps

- and Tirning

. If you remember those four letters and the words they

stand for, you will remember how to CAST a perfect

thermite weld every time

t2

T?ainee Worhbook

Mod,ule I

Module I

The 13 Steps

13

TYainee Worhbooh

Mod,ule I

The 13 Steps

A successful LP CJ &AP CJ thermite weld can be seen as

13 separate steps that must be done in a specifi.c sequence

EJ

1. Job Preparation:

¡ Using a standard checklist to assure that you have all

necessary tools, materials, equipment, and information

before you leave for the weld site

2. Site Preparation:

. Evaluate the general site condition

. Correct any situations that create a potential fire or

safety hazard

.,Ër

Fil

3. Track Preparation:

. Secure the rail so that it doesn't move during joint

preparation, alignment and welding

4. Rail-end Preparation:

. Inspect, & prepare the joint to a condition acceptable for

thermite welding

DI

5. Rail-end Alignment:

o Set-up the correct gap, peak (also called the'crown'or

'vertical alignment'), horizontal alignment, and

eliminate unequal cant between rail-ends

. A critical step where inconsistent work will lead to weld

failure

I4

TYainee Workbooh Module 1

The 13 Steps (cont'd,)

6. Mold Preparation:

. Prepare and assemble the mold components & apply

fusal paste

. Another critical area where poor work will lead to weld

defects

7. Preheating:

r Heat the mold & rail-ends for a specified time

o Another area where accuracy and timing are important

H .I 8. Charge Preparation:

. fnspect components for moisture and damage

. Assemble the CJ crucible & charge

9. Pouring:

. End the preheating at the correct time

o Position the CJ crucible centered over the mold

¡ Ignite the charge & monitor the pour

10. Demolding & Shearing:

o At a specified time after the pour... demold, shear and

remove debris

15

TYainee Worhbook

Mod,ule I

The 13 Steps (cont'd.)

11. Hot Grinding:

¡ Grind the weld close to the rail

¡ Blend the gauge & field surfaces

12. Cold Grinding:

. Grind the weld flush with the rail to blend with the

running surface

. Accuracy during hot & cold grinding contribute to weld

reliability

13. Finishing:

. fnspect, document & tag the weld

r Restore the track to standard

. Clear the site

. Cancel the track protection

16

Trainee Worhbooh

Module I

Step 1: Job Preparation

Consumables Checklist

t Fusal paste

tr lgnition fuses

tr Gasoline & oil for power tools

tr Sufficient gasoline, propane & oxygen

tr CJ kits (2 boxes) per weld

tr Three spare kits (per day)

tr Tie plugs

tr Spare railfasteners, tie plates & pads

tr Spare closure rail (weight, type, length)

tr Cutting disks

tr Grinding wheels

tr Soap stone

tr LD. tags & adhesive

D Forms, manuals, protection documentation

GJ Hardware Checklist

tr Mold clamp

tr Mold jackets (2)

D Base plates (2)

tr Slag basin

tr CJ fork

Pre & Post-heating Equipment

D Preheating unit

tr Burner & support stand

tr Regulator

D Air & propane hose

tr Turbo torch

tr Approved ignition device

tr Torch

f,¡ Heat retarding blanket or shield

Safetv Equipment Checklist {** recommendations)

tr Welder's goggles

tr Face shield

tr Welder's gloves

tr Leggings

tr Hearing protection

tr Respirator

tr First aid kit

tr Fire protection equipment

tl Manufacturer's Safety Data Sheets

Power Tools Checklist

tr Railsaw

tr lmpact wrench (optional)

tr Hydraulic rail expander

D Hydraulic weld shear

tr Profile grinder or utility grinder

Hand Tools Checklist

tr Adjustable wrench

tr Track wrench

tr Lining bar

tr Claw bar

tr Sledge hammer

tr Spiking maul

tr Hot cut chisel

D Hammer

tr Railpositioner

tr Clip applicator

D Anchor applicator (if required)

tr Tamping bar

tr Shovel

tr Wedges

tr Wire brush

tr l.D. tag stamps

Tools to fix power tools

D Rail alignment equipment: alignment beam,

rail raisers, decanter, positioner, gauge rods

(optional)

Measurement Tools Checklist

B Welder's straight edge, 1m (3 ft)

tr Taper & railwear gauge

D Railthermometer

tr Stop watch

tr Tape measure

D Temperature indicating crayons

lnformation Checklist

tr Arrange track protection

tr Conduct job briefing

**please refer to your company's safety

policy as it takes precedence

t7

T\ainee Worhbook Mod,ule 1

Step 2: Site Preparation

When you first get to the job site, certain things must be

done before you remove one single tool from the welding

truck.

¡ Check-out safety hazards:

- moisture, snow or frost in ballast

- slippery conditions

- multi-track

- obstacles

- traffic near level crossing

. Check-out fire hazards:

- dry grass, brush, wood chips

- flammable material

- combustible rail lubricators

. Find suitable location for disposal hole:

Caution!

Check for underground cables before digging!

. If necessary, update your job briefing so that:

- everyone knows about aII hazards

- each person is assigned responsibilities: (safety

watch, fire watch, first aid, etc.)

o Position fire fighting equipment nearby

o Wet down any dry/flammable material

Hot Tip! . Check for safety & fire hazards!

. Update your job briefing!

. Do not wet down the area immediately near the

weld or disposal hole!

. Make sure the area immediately near the weld or

disposal hole is free of anv form of moisture!

18

Trainee Worhbooh

Module I

Step 2: Site Preparation (cont'd,)

Questions

Ql: Why must you check to see if the ballast below the

weld atea and at the disposal hole is free of moisture,

snow or frost?

a

Q2: What precaution should you take when welding on

multi-track territory?

a

Q3: Why are obstacles near the weld area a safety hazard?

a

o

Q4: Why is welding near a level crossing considered a

safety hazard?

o

19

Trq,irLee Worhbooh

Module I

Step 3: Trach Preparution

'ån

. Verifr line & surface

. Place thermometer on rail

¡ Ensure rail type & weight is compatible w/ CJ kit

. Verifu that the gap is no closer than100 mm (4") from

tie. However, the design of the base plate holder

permits installation closer to a tie when necessary.

. Remove ballast for 100 mm (4") below the gap

. Tighten anchors for at least 15m (50 ft)

o Loosen/remove fasteners for 3 ties to each side of the

gap

. On wood ties: make match marks on rail base to tie

plate, tie plate to tie on third tie to each side of the gap

. On concrete ties: make match marks on rail base to tie

on third tie to each side of the gap

. Ties with match marks must be unanchored

. Check that the shear & grinder are operational

. If a rail expander is used make sure that it is properly

positioned to allow the use of the weld shear should this

equipment be used to cut the excess metal.

Hot Tip!

It is critical that all anchors or fasteners are tight and

the track secured. If the rail moves later on:

. The gap will change, and the rail-ends will not be

heated correctly!

. The fusal paste around the molds may crack,

causing a run-through!

20

Tlainee Workbooh Module 1

Step 3: Trach Preparatiorù (cont'd.)

Questions

Q1: Why must you eyeball the joint?

a

o

Q2: Why must you put the thermometer on the rail now,

and not later?

a

o

Q3: Why should you check the branding and stamping on

both rail-ends now?

o

2L

TYainee Worhbooh Mod,ule 1

Step 3: Trach Preparatiotù (cont'd,)

Q4: Why must the rail gap be at least 100 mm (a in) from

the nearest tie?

o

a

Q5: What can you do to make sure the gap doesn't change

while you are setting up the weld?

a

a

o

Q6: What must you do when making match marks on

wood ties?

1

2

3

On concrete ties?

1

2

22

Trøinee Worhbook

Mod,ule I

Step 3: Trach Preparatíotu þont'd,)

Q7: lVhy should you check out the weld shear & grinder

now?

o

a

23

TYainee Workbooh

Step 4: Rail-end Preparatíon

--II *-

Mod,ule I

r A gap must not be positioned over a tie

. Inspect rail-ends & bolt holes for cracks, batter, defects,

and previous weld material

. Veri& that any drilled holes are further than 100 mm (4

in) from the rail-end

. Rail-ends must always be cut with a rail saw

. Veri& that rail-ends are square/perpendicular with a

tolerance 0.8 mm (1/32 in)

. Clean the rail-ends with a wire brush (or grinding tool)

for at least 100 - 150 mm (a - 6 in)

. The weld aîea is defined as 0.5 m (18 in) to either side of

the gap

Hot Tip!

The rail-end.s must:

. be square & perpendicular

. be cut with a rail saw (Figure 1)

¡ not have been previously welded by gas or electric

welding

Otherwise a defective weld may result!

figure I

24

Trainee Workbooh Mod.ule 1

Step 4: Rail-end Preparatiorù (cont'd,)

Questions

Ql: Why can't a rail-end that has been built up by gas or

electric welding be thermite welded?

o

o

Q2: Why must the rail-ends be free of defects and foreign

material?

o

Q3: Why must the rail-ends be square & perpendicular?

o

o

25

Trainee Worhbook

Mod,ule I

Step 4: Rail-end Preparation (cont'd,)

Q4: Why must all drilled holes be a minimum of 100

mm (4 in) away from the rail-end?

o

o

Q5: Why must rail-ends that have been torch-cut and have

cooled be cut back a minimum of 100 mm (a in) with

a rail saw?

o

o

Q6: When using a standard LP CJ OR AP CJ kit, why can

the maximum difference in rail height not exceed

3/16th in?

o

a

26

Trainee Worhbooh Module 1

Step 5: Rail-end Alignment

Alignment is the most difficult and critical procedure in

any thermite welding process

. In the alignment step, there are 4 sub-steps to correctly

align the rail-ends for a thermite weld:

- Gap

- Peak (also known as vertical alignment)

- Horizontal alignment

- Unequal cant between rail-ends

o They must be done in that order

Eyeballing the weld

. Before you begin the alignment procedure you must

assess the general leveL of the roadbed, looking for

problems such as:

- Hanging ties

- Low joints

Hot Tip!

If you do have hanging ties or a low joint, surface

the area before continuing with the alignment

procedure!

. Remove any splice bars as well as any spikes, anchors,

rail fasteners, tie pads or insulators for one or two ties to

either side of the weld location

. Next, 'eyeball'the alignment of the weld location by

bend.ing over the rail and sighting along the upper

fillet... the area just underneath the rail head on the

gauge side

27

TYainee Worhbooh Mod,ule 1

Step 5: Raíl-end Alígnment (cont'd,)

¡ Look to see if the peak of the rail-ends is:

- level

- high

- low

- unequal

figure 2 figure 3

figure 4 figure 5

¡ And finally, see if the horizontal alignment is:

tn

out

in-line

figure 6 figure 7

figure I

28

Trainee Worhbooh Mod,ule 1

Step 5: Rail-end Alígnment (cont'd,)

. Eyeballing the rail gives you important information on:

- what rail movement will be necessary to align the

rail-ends

- where to position wedges, spikes & track jacks to

achieve alignment

Gap

. Measure the gap at both sides of the rail head & base

. The gap can onl)' be: 25 mm (1 in)

not more than 28 mm (1-1l8 in)

25 to 28 mm

(1 to 1-1/8 inch)

figure 9

Caution!

Never add or remove steel to the rail length unless

otherwise directed, as it will affect the stress-free

temperature of the rail.

29

Trainee llorkbook

Module I

Step 5: Rail-end Alignment (cont'd)

Peak (Vertical Alignment): Wood ties

. Tap in 1 wedge und.er each side of each tie plate to

either side of the gap... just enough so that each tie

plate is snug up against the rail base

. Place a welder's straight-edge across the gap

centered on the running surface. The clearance

between the end of the straight edge and the running

surface is how you measure the'peak'

. Check the peak with a Starrett taper gauge. For

wood ties it must be 3.2 mm (1/8 in)

. Taking into consideration what you saw when you

eyeballed the rail-ends... and what the straight edge

indicates... adjust the wedges until you have the

correct peak at both ends ofthe straight edge

o or... adjust the peak using a 'rail raiser', if available

. If a rail-end is too high (without wedges), lower it by

jacking up the high rail with a track jack placed 8 to

12 ties back from the rail-end

Caution!

o Do not to 'hump'the track! Slack offspikes!

o The track jacks must remain in place until the weld has

cooled down below 370"C (700'F).

o Never step on the rail during alignment.

o Don't step on the ties in the weld area until after the pour,

3.2 3.2 mm (1/8 in)

figure 10

30

Trainee lï/orkbook

Module I

Step 5: Rail-end Alignment (cont'd,)

r:

Ll

t:

Horizontal Alignment: Wood ties

r Check both sides of the head, web & base for the

entire length of the straight edge across both railends

. If the head, web or base of one rail is wider than the

other, divide any difference in width equally, keeping

the straight edge parallel to the surface

c[ËÉcEÊËcI

tCr:CËËLÌrlrlLl

tlr=LlËËL:Ët*Ê

t: f:C

L C:t

Crl

* r::

tü

rlür:r:C:gL:tËË

Bür:t:CÊCrlC'l

¡

r: r:

*r:

l:C

ct

c

rl

I

c:

Ll

Ë

C

c

C:üLll:Ctlr:

ccËÉ*¡:Ë

ÊËcc**rl

DrltCL:tË

figure 11

t

Ê

rl

ü

r:

Ê

L1

L:

t::

L:

|] r::

C: E:

üË

Cü

tl

T:

t:

c

rl

c f

r:: Cr::L*

ËÊE:trÊ

ËL:ËËL:

L: r:: Ë Ll C:

n

L

n

figure

*Ctl

ÐrlL:

¡l Ll f:

r:C: ü

12

. Taking into consideration what you sa\M when you


indicates... determine which rail is out-of-line... and

to which side (gauge/field)

o Move the out-of-line rail back into alignment using

the tie plate. This is done by driving a spike straight

down at least half-way into the tie, against the

outside of the gauge or field side of the tie plate under

the out-of-line rail

t:

Ë c

f:

Ê I

Ê t:

figure 13

Caution!

. Do not hit the rail with the

hammer! Move the rail with

the tie plate.

. Do not drive the spike in at

an angle. It will cause the tie

plate to ride up on the spike!

31

Trainee l{orkbook

Module I

Step 5: Rail-end Alignrnent (cont'd)

. Check the horizontal alignment with a straight edge

against the gauge side of the base of the rails across

the gap

¡ To adjust the alignment, move the tie plate by

bending the spike in slightly, then tapping it down

further into the tie.

r Repeat this procedure until the base of the out-of-line

rail is back in-line

. In a curve, a rail positioner or gauge rods will make

the job easier

e If available, a 'rail alignment beam' will facilitate

peak and horizontal alignment on wood ties...

especially in curves or at level crossings

Unequal Cant Between Rail-ends: Wood ties

. Check the gauge side of the heads & bases across the

gap with a straight edge

. If the bases are aligned... but the heads are not,

unequal cant between rail-ends is present

r The rail with the head furthest out is the rail with

excessive cant

. Raise the spikes on that rail for a minimum of 12 - I5

ties back foom the rail-end, on the side with excessive

cant

32

Trainee Workbook

Module I

Step 5: RaíI-end Alignment (cont'd)

a

I

figure 14

¡ On the same side of the same rail, place a wedge

under a tie plate L2 - L5 ties back... to 'roll' the rail

back into alignment

. Hold a straight edge on the gauge side of the heads

and tap in the wedge until the heads align

. Re-check the gap, peak, horizontal alignment, and

unequal rail cant between rail-ends... and adjust

accordingly

. fn a curve, gauge rods will make the job easier

. If available, a rail canter placed 4 ties back from the

rail-end can be used to correct unequal cant between

rail-ends... instead of a wedge

Hot Tip!

Never try to adjust unequal cant between rail-ends at the

immediate weld location!

Concrete Ties

. The alignment process for rail-ends on concrete ties is

a bit different because there are no tie plates to

wedge... and you can't use spikes to adjust the

horizontal alignment

. To align the rail-ends on concrete ties, begin the

same way as you do for wood ties:

- eyeball the weld location

- verifu the gap

Ða)

Trainee Workbook

Module I

Step 5: Rail-end Alígnrnent (cont'd)

Peak: Concrete ties

. Make sure the tie pads have been removed, and place

a welder's straight edge centered on the running

surface of the rail, across the gap

. For concrete ties, the peak must be 1.6 mm (1/16 in)

at both ends of the straight edge

. Taking into consideration what you saw when you


indicates... position one wedge under the rail, on the

side that appears to be furthest out-of-line

. Do this on the first tie on both sides of the weld

location

o Adjust the wedges until you have the correct peak at

both ends of the straight edge, or...

. adjust the peak using a 'rail raiser', if available

. If a rail-end is too high (without wedges), lower it by

jacking up the high rail with a track jack placed a

minimum of 8 to 12 ties back from the rail-end

Caution!

o Be careful not to 'hump' the track. Remove the fasteners

if necessary.

o The track jacks must remain in place until the weld has

cooled down below 370"C (700'F).

1.6 6i 1.6 mm (1/16 in)

c:

t

* r:

t::

Ë

t

C rLl

Ê rC:

C:C

ËË rl

rlI úrl

figure l5

34

Trainee llorkbook

Module I

Step 5: Rail-end Alígnment (cont'd)

Horizontal Alignment: Concrete ties

o If either of the rails is out-of-line, remove the gauge

or field side rail fastener from the second tie from the

rail-end, and position a short wedge on its side

between the rail base and the cast hold-down

. Check the horizontal alignment with a straight edge

against the gauge side of the base of the rails across

the gap

. Tap the sideways wedge in or out to adjust the base

of the out-of-line rail

¡ If available, a 'raiL alignment beam' will facilitate

peak and horizontal alignment on concrete ties...

especially in curves or at level crossings

. A'rail positioner'can also be used in curves to

maintain horizontal alignment

t: C t D

Ë

rl rl

c

Ër

Ll !l

t: t:C ËÉ

c: cc ¡-L !l

rl

rl

r:t

tlttC|::t

t r-j

CCL:

figure 16

35

Trainee llorkbook

Module I

Step 5: Raíl-end Alisnment (cont'd)

Unequal Cant Between Rail-ends: Concrete

. Check the gauge side of the heads & bases across the

gap with a straight edge

¡ If the bases are aligned... but the heads are not...

unequal cant between rail-ends is present

. The rail with the head furthest out is the rail with

excessive cant

. On the side with excessive cant, remove the rail clips

one at a time, working awal¡ from the rail-end

o If the heads are not aligned after removing six rail

clips, tap in a wedge under the rail base 12 to 15 ties

back on the same side of the same rail... to'roll' the

rail back into alignment

. Re-check the gap, peak, horizontal alignment, and

unequal cant between rail-ends... and adjust

. If available, a rail canter placed four ties back from

the rail-end can be used instead of a wedge

rl ç t: I:I: t ¡l

@

figure 17

Hot Tip!

o An incorrect gap can result in a poor bond between the

rail-ends!

o Incorrect peak means the running surface will be too high

or low when the weld cools!

o Poor line will result in irregular gauge!

o When possible, roll rail in to maintain gauge

o ljnequal cant between rail-ends will promote fatigue weld

failure!

o Removing track jacks too early will result in a misaligred

weld!

36

Traìnee l4/orkbook

Module l


Questions

Ql: When you'eyeball'a weld location, what are you

looking for?

o

a

O

Q2: Why must you align the rail-ends in the order of

gap, peak, horizontal alignment, and unequal cant

between rail-ends?

o

Q3: Why must you check the gap?

o

a

Q4: Why is there a specific gap tolerance?

a

a

37

Trainee Workbook

Module I


Q5: Why must you set up a peak on the rail-ends?

a

Q6: Why is the peak for wood & concrete ties different?

a

Q7: When correcting unequal rail cant between railends

with a wedge, why must it be placed a

minimum of 12 to 15 ties back from the rail-end?

a

Q8: Why must the rail bases be aligned when correcting

unequal cant between rail-ends?

a

Q9: Why must gap, peak, horizontal alignment &

unequal cant between rail-ends be checked again

after any adjustment is made?

o

a

38

Trainee llorkbook

Module l


o Protect mold from moisture

. Verifr LP or AP CJ kit contents

r Install support and clamp ass cj. Secure the mold clamp to

rail so that its arms are positioned as shown in FigurelS

when extended. W'hen welding short plugs, it is

recommended to place the clamp on the solidly fastened rail.

tI

I

a

I t

figure 18

-rE

¡ Cut a small notch in the top of matching edges of each halfmold

with hack saw blade (Figure 19). The notch should be

on the opposite side from the mold clamp assembly. This

makes an opening to let surplus molten slag fl.ow into slag

basin when weld is made.

fïgure 19

39

Trainee Workbook

Module I

o Place mold halves together on rail, and gently rub back and

forth against the rail so they seat properly and make good

contact at the top. Make certain all sand dust is removed

from the rail.

o Put each mold half in its frame and place on rail so that

mold is centered over gap. Be sure that faces of both rails

can be seen from the top of the mold looking down

(Figure 20). Secure to rail by tightening mold clamp screws.

Mold should not extend below rail. Grind if necessary to

remove excess by using the mold base plate or a fiIe.

fi¡5- Eri$

figure 20

¡ Place the mold base plate on the plate holder. Roll paste

into 25mm (1") cylinder and apply all around base plate.

Flatten to same thickness as base plate (Figure 21). Place

under mold halves and secure with hangers. Compact paste

on long edges with packing rod (Figurc 22). Press paste at

both ends with fingers.

a

figure 21 ftgure 22

40

Trainee Vlorkhook

Module I

. Tap base plate.

. Fill groove around the rail and between the mold halves

with paste (8 mm bead approximately) and press in firmly

with fi"ngers to avoid leaks. Then add a bigger bead of paste

(approximately 25 mm), again press firmly and smooth out

the paste surface (Figure 23). MAKE sURE No pAsrn DRops

INTO MOLD. NOrp: It is a good idea to cover mold opening

with cardboard during sealing operations to keep mold

cavity free of all foreign matter.

o Place slag basin on the rail under the opening in the mold.

Seal the joint between the basin lip and the mold with

additional paste (Figure 24). Line slag basin with dry

sand"/crushed mold

figure 23 figure 24

o Place dry sand on moist area under gap

4l

Trainee l4/orkbook

Module I

Step 6: Mold Preparation (cont'd,)

Centering the base plate

¡ When clamping the base plate in place under the mold

ensure it is centered on both sides of the mold.

Questions

Ql: Why must you examine the contents of a LP CJ or AP CJ

mold kit... even if the box is in good condition?

o

o

Q2: Why should you tap the base plate when mounting it to

the base of the rail?

o

Q3: Why must you check gap & alignment before installing

mold clamp ass cj

o

o

42

Trainee llorkbook

Module I

Step 6: MoId Preparation (cont'd,)

Q4: Why must you start packing a mold by smearing a small

amount of fusal paste in the crevice then back it up with a

larger amount?

o

o

Q5: Why must you rub the side molds on the rail?

o

Q6: Why is it important to center the side molds over the railends?

o

o

a

43

Trainee llorkbook

Module l

Step 7: Preheating

o Note & record the rail temperature

o Position & adjust the burner and its support stand onto the

rail. If necessary adjust centering screws so that the burner

is centered on the rail. This need only be done once for each

rail size. Position the burner on the stand so that t]rre nozzle

is centered on the gap (Figurc 25).

frgure 25

. Angle the nozzLe to the side to facilitate lighting

o Start the preheating motor

o Open the supply valve(s) to:

Mixture Air X'uel

Air/Propane 3.5 psi. 4-5 psi

Tip

You may have to increase the fuel pressure if the tanks are low or

cold.

44

Trainee Workbook

Moùile I

o Ignite the nozzle with a torch & reposition it

o Adjust the airlfuel supply for sound & flame height

Mixture

X'lame Heieht

Air/Propane

150 mm (6 in)

. Check that the heating colour on the 4 groove tops in the

mold is the same

o Start the stopwatch

o Make sure plug has been dried by heating over one riser for

10 - 15 seconds before the end ofthe preheat.

. Make sure both rail ends heat evenly until they are cherry

red, especially at the base. If one rail is heating faster than

the other, move the burner toward the hot rail. It may be

helpful to remove the burner to see the color of the rail. The

flame will resume when the burner is replaced.

o After removing the burner, shut the propane valve first and

then, stop the engine.

Hot Tip!

o Start the preheating stopwatch only after the flame has been

properly adjusted!

o Preheating time must be exactly 6 minutes for LP CJ

o Preheating time for AP CJ differs according to the type of rail and

process parameters. Ask Pandrol for assistance if required.

o Don't forget to heat the diverter plug on the edge of the mold...

where you won't forget it!

o Force gently the diverter plug into the gate!

45

Trainee Workbook

Module I

Step 7: Preheating (cont'd,)

Centering the Flame

¡ During the preheat, make sure that the flame is burning in

the mold... not just above the mold gates

o At the same time, you must verifii that the fl.ame is directed

straight down into the mold

*æ-

r

i

r

figure 26 frgure 27

Questions

Ql: Why is it necessary to note & record the rail temperature

before preheating the rail?

a

o

Q2: Why must you adjust the burner support stand & nozzle

in the gate position before lighting it?

o

Q3: Why should the burner nozzle be tilted slightly to the side

when lighting it?

o

46

Trainee Workbook

Module I

Step 7: Preheatíng þorut'd,)

Q4: Once the nozzLe is burning correctly, why is it important

to direct the flame straight down into the mold?

o

Q5: How do you check to make sure the flame is directed

straight down into the mold?

a

Q6: Why must you start the stopwatch only once the flame is

correctly adjusted?

a

o

Q7: Why must you constantly monitor the flame inside the

mold?

a

Q8: Why must the correct pressure on the fuel supply be

maintained?

a

Q9: Why must the diverter plug be heated?

a

47

Trainee Workbook

Module I

Step 8: Charge Preparation

o This step may be performed during the Preheating.

o Set up the crucible in a dry location

o Check the charge bag for signs of punctures or moisture

o Inspect the crucible for any damage or debris

. Verifu that the thimble is in place

o Open the bag and pour the contents into the crucible

o Stir the charge by hand and make a mound in the center

¡ Insert an ignition fuse and cover the crucible

o Place the packing boxes and charge bag in the disposal hole

Hot Tip!

Always veriflz that:

o the crucible is clean, free of defects with no cracks!

o the thimble is securely in place!

¡ the charge bag is sealed & dty... before opening!

48

Trainee Workbook

Module l

Step 8: Charge Preparatíorù (cont'd,)

Questions

Q1: What important step must be done after inspecting the

charge... but before opening the charge bag?

o

Q2: V[hy must the charge be stirred?

a

O

a

Q3: Why must the contents of a LP or AP CJ charge kit be

inspected before use?

o

o

a

49

Trainee l4torkbook

Module I

Step 9: Pouring

¡ Put on welder's goggles & gloves

o At 6 minutes remove the burner nozzle from the mold for LP

CJ weld

o Place the diverter plug snug into the top gate. Press down

firmly for good seal (Figure 28).

¡ Set the crucible on top. Twist the crucible either clockwise

or counter-clockwise locking the guide plates in place; this

ensures that the crucible is centered over the gap.

o While holding the cover open, Iight ignition fuse by touching

inside of mold.

r Insert ignition fuse at an angle into charge in crucible (to a

maximum depth of 25 mm or 1 inch), igniting the charge

(Figure 29).

!

Lr

¡,

figure 28 fi.gure 29

¡ Cover crucible. When reaction is complete and metal starts

to fLow, wear dark glasses for protection.

o When the slag stops pouring, start the stopwatch

50

Trainee l4/orkbook

Module I

Preheater shutdown

¡ While the crucible is being positioned and the charge

ignited, shutdown the preheater by:

- first shutting off the fuel supply

- then stopping the compressor

Hot Tip!

o Never shut-off the fuel supply to the burner while it is still

positioned in the mold!

¡ Place the ignition fuse only 25 mm (1 in) into the charge!

o The stopwatch must be started exactly when the last bit of slag

drips out of the mold!

51

Trainee ll'orkbook

Module l

Step 9: Pouríng ftont'd,)

Questions

Ql: What protective equipment must a welder be wearing

before igniting the charge?

o

o

Q2: Why must you stop the preheat for a LP CJ at exactly 6

minutes?

o

o

Q3: Why must the burner nozzle be removed from the mold

before the fuel supply is shut offl

a

Q4: Why must the diverter plug be in place?

o

Q5: Why must the ignition fuse be placed only 25 mm (1 in)

into the charge?

a

52

Trainee l(orkbook

Module I

Step 10: Demolding & Shearing LP CJ weld

At 4 minutes after the pour:

o Remove crucible using a crucible fork

o After slag solidifies (approx. 3 min.) remove slag basin and

dump in safe, dry place where workmen will not come in

contact with it. Keep it away from flammable material or

fire may result. CAUTION: AVOID DUMPING ON

DAMP GROUND OR IN WATER AS AN EXPLOSION

MAY RESULT. Place slag basin in safe place for cooling.

Caution workmen against touching or stepping on it.

Remove the mold clamp, mold jackets and base plate

o At 5 minutes after the pour

¡ After about 5 minutes, slowly release base plate retaining

mechanism (Figure 30).

¡ Release mold clamp screws. Remove mold frames and mold

clamp assembly (Figure 31).

t

figure 30

figure 3l

53

Trainee l(orkbook

Module I

. With a hot cut chisel, score the outside of mold at top of rail,

then with shovel on one side of mold, push mold slowly with

chisel into shovel (Figure 32) and place into a disposal hole.

If metal runs when the top of the mold is broken, maintain

the mold in place and wait a few more seconds.

o Remove any dry fusal paste from running surface

At,5-1.12 minutes after the pour

¡ Immediately after the mold has been broken a\ñ¡ay, cut off

surplus metal on rail head. There are two ways to do this:

1) With hot cut chisel and sledge hammer (Figure 33).

Avoid cutting into rail head or metal in the weld below

running level of rail. 2) With the Matweld weld shear

(Figure 34). This removes excess metal quickly and safely.

No more accidents due to metal splinters.

t

figure 32

figure 33

54

Trainee llorkbook

Module I

figure 34

¡ Nick risers at the bottom \ /ith chisel while still hot

(Figure 35). When cold, they can be easily broken away.

figure 35

Danger!

Hot Tip!

o CAUTION: If a rail expander has been used, do not release

pressure until the weld is sufficiently cool to avoid hot tears.

o Bend the base risers over so they are clear of the profiIe

der

o Carry the slag basin level so that hot weld material will not spill

out!

¡ Never dispose of hot weld material in water!

¡ Do not place a hot slag basin on a concrete tie!

¡ Do not empty the contents of the slag basin into the disposal hole

until it has cooled!

o Make sure the shear is ready!

¡ Demold at 5 minutes!

o Shear at 5-Il2 minutes!

55

Trainee Workbook

Module I

Step 10: Demolding & Shearing (cont'd,)

Questions

Ql: Why should the mold never be removed before 5 minutes?

O

Q2: Why should the head of the mold never be sheared before

5Il2 minutes?

a

Q3: What are the signs of a 'hot tear'?

o

56

Trainee l(orkbook

Module I

Step 11: Hot Grínding

o Put on personal protection equipment

- Face shield

- Hearing protection

- Respirator

- Leggings

o Grind weld metal to 0.8 mm (1/32 in) from rail steel

o Grind contour radius flush or blend-in

o Grind gauge and field side flush or blend-in

How Close?

o When hot grinding, it is important to leave at least 0.8

mm (1/32 in) of the weld metal on the running surface above

the rail steel

o If you grind the weld metal flush with the rail steel when

the weld is still hot, you will have a low weld when it cools

o Remove the wedges 15 minutes after the pour to allow the

weld to cool to level

¡ If track jacks were used to lower the rail-ends, they can be

removed 30 minutes after the pour

figure 36

figure 37

Hot Tip!

Keep your distance from the rail steel!

57

Trainee V[orkhook

Module I

Step 11: Hot Grinding (cont'd,)

Questions

Ql: What is the very fi.rst step in hot grinding?

a

Q2: At what time can you start hot grinding?

o

Q3: Why should you never grind the weld metal any closer

than 0.8 mm (L132 in) to the rail steel?

o

Q4: Why should the wedges be removed 15 minutes after the

pour?

o

58

Trainee llorkbook

Module I

Step 12: CoId Grínding

o Make sure the base risers have been removed

After t hour

o Eyeball the peak

o Finish grinding after weld cools to air temperature. Grind

until full length of 1 meter (3 feet) straight edge contacts rail

on running and vertical surfaces of rail head (Figure 38).

CAUTION: Trains should not run on track until rail has

cooled to less than 375" C (700" Ð.

I

a

figure 38

Hot Tip!

Take your time. Do not'blue'the weld!

59

Trainee llorkbook

Module I

Questions

Ql: Why must the base (inner) risers and mold material be

removed from the web & base?

a

Q2: How close can you cold grind weld metal to the rail steel?

o

Q3: Why should you avoid'blueing'the rail when cold

grinding?

o

Q4: Why veri$' the weld by checking it with a straight edge &

'eyeballing' it... after grinding?

o

Q5: What are the high low-low tolerances for cold grinding?

o

60

Trainee Vl/orkhook

Module I

Step l3: Fínishíng

¡ Visually inspect the weld

o Tamp 2 ties to each side of the weld... and any others that

need to be tamped

o Plug wood ties & replace all rail fasteners and-/or insulators

¡ Recheck rail level with 1 meter (3 feet) straight edge to

insure level surface.

o Locate all hot metal (slag, cut-offs, etc...) and put in sage location to

safeguard from fires.

o Collect all refuse for disposal (boxes, plastic bags, etc...).

o Fill in the disposal hole

o Load tools, thermometer, etc.

o Stamp and install the welding tag

¡ Complete the welding documentation

o Clear aII equipment & personnel from the site

o Cancel track protection once you are in the clear

Questions

Ql: Why must you inspect a weld once it is finished?

o

o

a

Q2: What information must be included on the welding

documentation form?

1

2

3

Ð

6

7

4

61

Trainee l|/orkbook

Module I

Q3: What is the last thing you do before leaving the job site?

a

62

Trainee Workbook

Module I

Exception Conditíons

There are situations where rail condition, different types of

metallurgy, or even temperature will require variations in the

standard LP CJ or AP CJ welding procedures. The most

common are:

o Partly worn rail where the difference in the wear of the head

width & height results in an uneven surface on the head,

gauge or freld side

¡ Cold weather conditions

o The use of rail expanders

o Afreeze-up (when a charge does not pour)

Worn rail

o In the case of unequal head width, the solution is to:

- Align the base & web of the rail

- When grinding after the weld, blend-in the field & gauge

side to line

o In the case of unequal rail height, less than 3/16th in, the

solution is to:

- Align the running surface and offset the height

difference in the base of the rail

DiffÉfi:ncè

ln He.:d

Webs

Båsss

figure 39 figure 40

63

Trainee Workbook

Module I

E xceptíon Conditions (cont'd,)

Difference in rail height greater than 3/16th in

There are limits to the acceptable difference in the height of the

two rail-ends.

¡ The difference in the height of the heads cannot exceed 3/16th

in

o If the difference is greater than 3/16th use the appropriate

compromise kit

Figure 41

Peak Adjustments

o As the rail gets colder, the rail needs more of a peak to

compensate for the increased tension placed on the weld as it

cools, pulling it down

o Therefore there are exceptions to the 1.6 mm to 3.2 mm (1/16

in to 1/8 in) peak rule... under extreme temperature conditions

+ +

figwe 42

64

Trainee Workbook Module 1

Exception Conditions (cont'd,)

Cold Weather Conditions

o Cold weather is defined as:

- Windy or precipitation (snow or rain)

- Temperature below 15'C (60'F)

Warm-up Procedure

o If the rail temperature is below 15'C (60"F), the rail must be

warmed up with a turbo-torch to 37"C (100"F) before or during

the pre-heating procedure

o The length of rail that you must preheat (measured to either

side of the mold) varies according to the rail temperature

Rail Temp

+15'C (60'F) to -9'C (16'F)

Lensth of rail to warm

76 cm (30 in) to 91 cm (36 in)

- 9"C (16"F) to -15"C (5'F) 91 cm (36 in) to 122 cm (48 in)

-15"C (5'F) or lower

I22 cm (48 in) minimum

table I

Cooling Procedure

o During cold weather conditions, there is also a risk that the

weld will cool-down too fast

o If the ambient temperature is below 15"C (60'F)... or if it is

extremely windy or rainy... cover the weld immediately after

shearing with a shovel and a heat retarding blanket or a

shield for at least 10 minutes before grinding

65

Trainee Workbook

Module I

Exceptíon Condítions (cont'd,)

Post-weld Procedure: Rail Expanders

¡ In the event that you are using rail expanders, you can only

remove them once the rail temperature has dropped below:

Stress

Tension

Compression

Temperature

370"C (700.F)

600'c (1100"F)

Emergency Procedure: Freeze-up

One rare and potentially dangerous situation that you may

encounter is a freeze-up... a condition where the charge ignites,

but the weld doesn't pour out within a minute.

o If this happens:

- Leave the crucible where it is and clear the weld site

- Return after the crucible has discharged & clean up

- Cut out the weld and cut in a closure rail

End of Module I

66

Tlainee Workbook Module 2

ule 2

Hands-On LP CJ &AP CJ Weld

67

Trainee Worþ,book

Mod,ule 2

Hands-On LP CJ & AP CJ WeId

Procedure

Work in teams of three:

o One observer who's job is to:

- Help prepare the necessary tools & material

- Monitor the progress of the two welders making sure:

' they follow the correct procedure

' they work safely through all stages

¡ Two welders who will work as a team to perform a LP or AP

CJ weld

Your work must be verified at critical'check-points' by the

instructor before:

1. Mold Preparation

- make sure the track is secure

- check the condition of the rail-ends

- check alignment

2. Preheating

- check the mold & preheat set-up

- verifiz weld shear & grinder are operational

- monitor starting & adjustment of preheater

3. Igniting the Charge

- check preheat & charge

- monitor ignition & pour

- watch for a run-through

4. Demolding and Shearing

- monitor demolding & shearing

- look for a'hot tear'

5. Cold grinding

- check hot grinding depth & alignment

- verifiz that wedges are removed at 15 minutes

Caution!

Do not proceed beyond these 5 'checkpoints' until you

have been checked out by the instructor and given the

'go-ahead' to continue.

68

Tlainee Workbook

Mod.ule 2

Hands-on LP CJ &AP CJ Weld (cont'd)

Note: Because the weld has to cool approximately one hour

before cold grinding can be done, cold grinding will not be done in

this hands-on exercise.

Once your hot grinding work has been checked, return the track

to standard and clean-up your work-site.

. At each of the 5'checkpoints', you will be asked to verifr:

1. Mold

I Track secure:

- sufficient anchors

- anchors tight against ties

- match marks.

r Rail-end condition:

- no foreign welding material

- rail-ends square & perpendicular

- clearance from ties, bolt holes, ballast

o Alignment:

gâp

peak (vertical alignment)

horizontal alignment

unequal cant between rail-ends

69

Tla,inee Worþbook

Module 2

Hands-on LP CJ &AP CJ Weld (cont'd)

2. Preheating

o Side molds correctly aligned:

- to each other

- to the gap

o Side molds correctly secured

o Base plate coruectly prepared with fusal paste, straight

and centered,

¡ Apply additional fusal paste:

- rail base, web & head

- joint between side of mold and slag basin

- ensure no excess paste inside mold (inspect with

flashlight)

o Slag basin in place w/ dry sand & diverter plug

o Preheating burner properly positioned

o Weld shear and grinder are operational

3. Ignite Charge

r Preheater is heating correctly

¡ Diverter plug heating on edge of mold

¡ Charge prepared in crucible & close by

¡ Ignition fuse in place

¡ Demolding tools ready nearby

¡ Personal protective equipment on

4. Demolding & Shearing

o Remove side plates, base plate and mold clamps at 4

minutes

o Demold at 5 minutes

o Shear at5Il2 minutes

¡ Check for'hot tear'

70

Trq,inee Workbook Module 2

Hands-on LP CJ 82, AP CJ Weld (cont'd)

5. Cold Grinding

o Weld:

- head cut & cleared

- risers removed

r Hot grind:

- no grinding of rail steel

- head contour to gauge & field side

- gauge & freld side flush and/or blended

Tip

Follow the procedure in your Job Aids and remember the

key to CASTing a good weld: Consistency, Accuracy,

the right Sequence of $teps and Tirning.

Evaluation

o Once you have all fi.nished, you will be evaluating another

team's work... based on the criteria that was established in the

course.

¡ When the exercise is frnished, help clean up the weld sites and

return/store the tools.

End of Module 2

7t

Instructor Guide

Module l

Step 2: Site Preparat¡on

Q1: Why must you check to see if the ballast below the

weld area and at the disposal hole is free of

moisture, snow or frost?

. lf any moist ballast comes in contact with molten

slag or sfeel it will explode and/or splatter hot

weld material

Q2: What precaution should you take when welding on

multi-track territory?

. Depending on the type of protection, a Safety

Watch may be necessary to ensure that

employees do not foul live track

Q3: Why are obstacles near the weld area a safety

hazard?

. Obstacles rncrease the risk of an accident :

- when handling hot weld material,

- when clearing the site in the event of an

u n stopp able r u n -th ro u g h

Q4: Why is welding near a level crossing considered a

safety hazard?

. A Safety Watch may be necessary to direct traffic

or protect employees from traffic

Step 3: Track Preparation

oÃ

Q1: Why must you eyeball the joint?

. lndicates what kind of line & surface the track has

at the weld e.g. is it high, Iow, in , out or level

. Determine if there is sufficient ballast section

. lt will help with rail-end alignment later

Q2: Why must you put the thermometer on the rail now,

and not later?

. The thermometer has to be on the railfor at least

10 minutes to get an accurate reading

. The railtemperature determines if a railwarm-up

is necessary

72

Instructor Guide

Module I

Step 4: Rail-end Preparation

Q3: Why should you check the branding and stamping

on both rail-ends now?

. Make sure that both rail-ends are compatible with

the weld kit before preparing the rail-ends

Q4: Why must the rail gap be at least 100 mm (a in)

from the nearest tie?

. Need room for the base plate

. Room for packing fusal paste around the base

plate

Q5. What can you do to make sure the gap doesn't

change while you are setting up the weld?

. Tighten anchors

. Make match marks

. Use hydraulic rail expanders, if required

Q6: What must you do when making match marks on

wood ties?... concrete ties?

. Wood:

- Mark base of railto tie plate

- Mark tie plate to tie

- Tie must be unanchored. or the tie may move

with the rail-

. Concrete:

- Mark base of railto tie

- Clips must be removed. or the tie may move

with the rail

Q7: Why should you check out the weld shear & grinder

now?

. Check shear jaws for sharpness & setting

. Make sure grinder has good grinding sfone

. Lasf chance to verify that shear & grinder are in

working order before the track is put out of service

Q1: Why can't a rail-end, that has been built up by gas

or electric welding, be thermite welded?

. Different metals present

. Thermite materialwill not bond correctly

73

Instructor Guide

Module I

Q2: Why must the rail-ends be free of defects and

foreign material?

. May result in a defective weld

Q3: Why must the rail-ends be square & perpendicular?

. Even heating

. Even distribution of metal during the pour

Q4: Why must all drilled holes be a minimum of 100 mm

(4 in) away from the rail-end?

. Cannot be tested ultrasonically if too c/ose

. Any closer may cause a defective weld or rail

Q5: Why must rail-ends, that have been torch-cut and

have cooled, be cut back a minimum of 100 mm (4

in) with a rail saw?

. Rapid heating & cooling from a torch cut may

result rn sfress cracks

. Removes a// sfress cracks created by torch cutting

Súep 5; Rail-end Alignment

Q6: When using a standard kit, why must the maximum

difference in rail height not exceed 3116 in?

. lf difference in rail height exceeds 3/16 in, the

standard mold will require too much fusal paste.

This could result in a run-through

. A Compromise Rit must be used

Ql: When you 'eyeball' a weld location, what are you

looking for?

. Hanging fies & low joints

. What rail movement willbe necessary to align the

rail-ends

. Where to position wedges, sprkes & track jacks to

achieve alignment

Q2: Why must you align the rail-ends in the order of

gap, peak, horizontal alignment, and unequal cant

between rail-ends?

74

Instructor Guide

Module I

. /f is the quickesf & mosf efficient way of achieving

correct alignment

Q3: Why must you check the gap?

. Make sure you have the required distance

between the rail-ends

. lt could change during the alignment procedure

Q4: Why is there a specific gap tolerance?

. Too wide: insufficient preheat temperature and

weld material

. Too narrow: rail heads too hot, ral öases not hot

enough, weld material overflow

Q5: Why must you set up a peak on the rail-ends?

. More metal in head area than web & óase so if

contracts more as rT cools, pulling down the weld

to levelwhen it returns to its originaltemperature

Q6: Why is the peak for wood & concrete ties different?

. Wood has more'give'than concrete, so the weld

drops more when cooling

Q7: When correcting unequal rail cant between railends

with a wedge, why must it be placed a

minimum of 12to 15 ties back from the rail-end?

. Any closer will affect peak & horizontal alignment

Q8: Why must the rail bases be aligned when correcting

unequal cant between rail-ends?

. Unequal canted rail may result in fatigue weld

failure

Q9: Why must gap, peak, horizontal alignment &

unequal cant between rail-ends be checked aqain

after any adjustment is made?

. Loosening/removing more fasteners can affect the

gap

. Adjusting unequal cant between rail-ends may

affect peak & horizontal alignment


75

Instructor Guide

Module l

Q1: Why must you examine the contents of a mold kit,

even if the box is in good condition?

. Damage to mold parts

. Sþns of moisture on mold

Q2: Why should you tap the base plate while mounting it

to the base of the rail?

. Make sure it fits properly (snug)

Q3: Why must you check gap & alignment again after

the base plate & brick are clamped on?

. Clamp can disturb alignment

. Lasf chance to check alignment before side molds

are positioned

Q4: Why must you start packing a mold by smearing a

small amount of fusal paste in the crevice, then

back it up with a larger amount?

. Small amount forms a fine seal

. Large amount backs up initial seal

Q5: Why must you rub the side molds on the rail?

. Adjusts each side mold to the minor differences ìn

rail suffaces. Better fit

Q6: Why is it important to center the side molds over the

rail-ends?

. They will be centered over the base plate

. lf the mold is off center, molten steelwill not be

distributed equally... causing defects

. lf mold is off center, rail-ends will not preheat

equally... causing defects

Step 7: Preheating

Q1: Why is it necessary to note & record the rail

temperature before preheating the rail?

76

Instructor Guide

Module l

. C/osesf record of the ra¡ltemperature at the time

of the pouring of the weld

. To determine whether or not the rail-ends have to

be warmed

Q2: Why must you adjust the burner support stand &

nozzle in the gate position before lighting it?

. Less adjustmenfs once the nozzle is lit achieves

the correct flame and temperature faster

Q3: Why should the burner nozzle be tilted slightly to

the side when lighting it?

. Makes it easier to light

Q4: Once the nozzle is burning correctly, why is it

important to direct the flame straight down into the

mold?

. Flame entering at an angle will not heat the railends

and mold uniformly... resulting in hot & cold

spofs

Q5: How do you check to make sure the flame is

directed straight down into the mold?

. Verify that the heating colour r.s fhe sarne on all

four groove tops

Q6: Why must you start the stopwatch only once the

flame is correctly adjusted?

. lf you do not have the correct flame temperature, it

will not heat the rail-ends to the correct

temperature during the 6 minute preheat

. lf flame rb nof correctly adjusted, it could go out

Q7: Why must you constantly monitor the flame inside

the mold?

. lf flame ts nof correctly adjusted, it may burn only

above the mold gafes... and not inside

Q8: Why must the correct pressure on the fuel supply be

maintained?

77

Instructor Guide

Module I

a

Correct pressure will deliver correct flame

temperature & will heat rail-ends to correct

temperature in 6 minutes

Súep 8; Charge Preparation

Sfep 9; Pouring

Q9: Why must the diverter plug be heated?

. To remove moisture... which will cause molten

steelto splatter during the pour

Ql: What important step must be done after inspecting

the charge... but before open¡ng the charge bag?

. Transfer the charge tag from the bag to the

welding report form

Q2: Why must the charge be stirred?

. Detect any lumps... which indicate moisture

. Mix any elements that may have settled

. Make a mound on the charge surface to get a

smoother reaction when ignited

Q3: Why must the contents of a kit be inspected before

use?

. Charge bag must not be punctured or moist

. Crucible must not be damaged

. Thimble must be in place

Q1: What protective equipment must a welder be

wearing before igniting the charge?

. Welder's g/oves & goggles

Q2: Why must you stop the preheat at 6 minutes?

. Insufficient preheat will cause defects... resulting in

a poor bond

. Excessive heat can cause run-through

78

Inslructor Guide

Module I

Q3: Why must the burner nozzle be removed from the

mold before the fuel supply is shut off?

. The cold air from the cornpressor will cool-down

the hot rail-ends.

Step 10: Demolding & Shearing

Step l1: Hot Grinding

Q4: Why must the diverter plug be in place?

. The diverter plug ensures the proper flow of

molten steel into the mold

Q5: Why must the ignition fuse be placed only

25 mm (1 in) into the charge?

. lf placed too deep, the charge reaction will be

abnormal, activating the thimble to release the

molten sfee/ foo soon

Ql: Why should the mold never be removed before 5

minutes?

. Too rapid cool-down will result in a defective weld

(it will be too brittle)

. Possib/e mold leakage on side

Q2: Why should the head of the mold never be sheared

before 6 1/2 minutes?

. Metal will be too soft, resulting in a 'hot tear'

Q3: What are the signs of a 'hot tear'?

. Small lateralfissures on gauge, field and running

surface

Q1: What is the very first step in hot grinding?

. Put on personal protection equipment

Q2: At what time can you start hot grinding?

79

Instructor Guide

Module l

lmmediately after shearing... unless you have cold

weather conditions or must post-heat the rail

Q3. Why should you never grind the weld metal any

closer than 0.8 mm (1132 in) to the rail steel?

. As the weld continues to cool, it willfall by

approximately that amount, leaving a low weld

Q4: Why should the wedges be removed 15 minutes

after the pour?

. The weld must be allowed to coolto level

Step l2: Cold Grinding

Q1: Why must the base (inner) risers and mold material

be removed from the web & base?

. lf there is a break at the weld, the nsers can bridge

the track circuit, and the block won't'drop'

Q2: How close can you cold grind weld metal to the rail

steel?

. Flush ... blending it in if necessary

Q3: Why should you avoid 'blueing'the rail when cold

grinding?

. Affects the microstructure of the running surface

Q4: Why should you verify the weld by checking it with a

straight edge & 'eyeballing' it... after grinding?

. Check fo see if it is 'high' or 'low'

. Use that information to adjust the peak on your

next weld

Step 13: Finishing

Q5: What are the high-low tolerances for cold grinding?

. 0.25 mm (0.01 in) high,0low

Q1: Why must you inspect a weld once it is finished?

. Look for sþns of 'hot tears'

. Look for visual defects

. Check alignment

80

Instructor Guide

Module I

Q2: What information must be included on the welding

documentation form?

. D"y, month, year

. Weld LD. number

. Charge tag

. Location (mileage)

. Welder number

. Railtemperature

. Weather conditions (under'Comments')

Q3: What is the last thing you do before leaving the job

site?

. Make sure the sife is clean & clear of allequipment

& material and safe for traffic

8t

InstrucÍor Guide

Name- PIN Date Score

Quiz 1: The LP CJ or AP GJ Welds

QI

Name four items of personal protection equipment that must be worn when

grinding.

1

2.

3.

4.

Q2

What two types of gauges must be included on your Measurinq Tools

checklist?

1

2

Q3: Welds must not be located over ties.

a) True

b) False

Q4: Anchors must be tightened for a minimum of _ to either side of the

rail-ends.

a)

b)

c)

d)

sm(15ft)

10 m (30 ft)

15 m (50 ft)

33 m (100 ft)

Q5: A tie must be a minimum of _ from the rail gap.

a) 75 mm (3 inches)

b) 100 mm (4 inches)

c) 125 mm (5 inches)

d) 150 mm (6 inches)

I

InsÍructor Guide

Q6:AnydrilledhoIemustbenoGloserthan-fromtheendoftherail.

a) 75 mm (3 inches)




Q7: During what step should the operation of the hydraulic weld shear be

checked?

a) Pouring

b) Preheating

c) Preparing the mold

d) Rail-end alignment

e) Rail-end preparation

Q8

Which of the following conditions require that the rail-end be cut back

beyond the defect, and a closure rail be cut in?

(More than one answer may be correct)

a) Crack in rail-end or bolt hole

b) Rail-end batter

c) Repair welding on rail-ends

d) Horizontal split head

e) Vertical split head

Q9

Burrs, flow, paint, oil, rust & scale must be removed for a minimum of

from the rail-ends?

a)

b)

c)

d)

e)

25 mm - 50 mm (1 to 2 inches)

50 mm - 100 mm (2to 4 inches)

100 mm - 150 mm (4 to 6 inches)

150 mm - 200 mm (6 to 8 inches)

200 mm - 300 mm (8 to 12 inches)

Ql0: Which following rail-end gaps would not be acceptable for a standard LP

CJ or AP CJ thermite weld?

a) 22 mm (7/8 inch)

b) 25 mm (1 inch)

c) 28 mm (1-1l8 inch)

2

Inslructor Guide

Ql1: On wood tie territory, what is the standard peak measured at each end of a

welder's straight edge?

a) 0.8

b) 1.6

c) 3.2

d) 6.4

mm (1/32 inch)

mm (1/16 inch)

mm (1/8 inch)

mm (1/4 inch)

Q12: Throughout the weld area, rail-ends must be horizontally aligned for at

least

a)

b)

c)

d)

0.5 m (18 inches)

1.0 m (3 feet)

1.5 m (4.5 feet)

2.0 m (6.0 feet)

Q13: To correct unequal cant between rail-ends, how far back from the gap must

the spikes be pulled and a wedge inserted?

a)4

b)8

c)1

d) 1

to 7 ties

to 11 ties

2to 15 ties

6 to 20 ties

Q14: You open both boxes of a weld kit and find the following components. One

important component is missing. What is it?

. 2 half molds

. 1 bottom brick

Missing:

' 1 welding charge in sealed package

. 1 CJ crucible & thimble

.1 CJ cover

Ql5: What is the correct 4!¡

pressure for an airlpropane preheat?

a)

b)

c)

3.0 psi

3.5 psi

pst

4to5

a

-t

Instruclor Guide

Q16: When us¡ng propane as a preheating fuel, how high must the flames extend

out of the riser holes?

a

b

c)

50 mm (2 inches)

100 mm (4 inches)

150 mm (6 inches)

Q17: During the preheating procedure, when must the stopwatch be started?

a) As soon as the preheating unit is started

b) As soon as the torch burner head is lit

c) As soon as the flame height & the sound is correct

Q18: How long must the rail-ends and mold be heated to achieve the correct preweld

temperature?

a) 3-112 minutes

b) 6 minutes

c) I minutes

d) 10 minutes

Ql9: lf a charge bag has clearly been punctured, but there are no signs of

moisture, can the charge still be used?

a

b

Yes

No

Q20: To time the cooling period, when must the stopwatch be started?

a) When the charge is ignited

b) When the charge begins to pour

c) When the slag begins to run into the slag basin

d) When the slag stops running into the slag basin

4

Instruclor Guide

Q2l: What p¡ece of personal protective equipment ¡s worn exclus¡vely during the

pour?

a) Leggings

b) Respirator

c) Welder's goggles

d) Face shield

Q22: At what time after the pour can demolding begin?

a) 3-112 minutes

b) 5 minutes

c) 8 minutes

d) 10 minutes

e) 15 minutes

Q23: At what time after the pour can the wedges be removed?

a)

b)

c)

d)

10 minutes

15 minutes

20 minutes

30 minutes

Q24: When cold grinding, what is the tolerance for the running surface of the

weld?

a)0

b)0

c)0

d) 0

25 mm (0.01 inch) high and 0.25 mm (0.01 inch) low

25 mm (0.01 inch) high and nothing low

37 mm (0.015 inch) high and 0.25 mm (0.01 inch) low

37 mm (0.015 inch) high and nothing low

5

Inslructor Guide

Quiz 2: Exception Conditions

Qf

When measuring the difference in rail height between the two rail-ends at

the gap, what is the maximum acceptable difference for a standard LP CJ

or AP GJ thermite weld kit?

a)

b)

c)

d)

3/16 inch

1/16 inch

1/8 inch

114 inch

Q2

Above what temperature is it p! necessary to protect a hot thermite weld

with a heat retarding blanket or shield?

a) 15"C (60'F)

b) 10.c (50.F)

c) 5'C (40'F)

d) 0"c (32.F)

Q3: How long must a heat retarding blanket or shield be kept on?

a) At least 3-112 minutes

b) At least 5 minutes

c) At least 10 minutes

d) At least 20 minutes

Q4: Above what rail temperature is it not necessary to use a turbo-torch to

warm up the rail-ends before preheating?

a)1 5.C (60"F)

b)1 0.c (50.F)

c) 5"C (40.F)

d) 0.c (32.F)

Q5

When required, to what temperature must the rail-ends be warmed up to,

before the preheating procedure?

a) 37"C (100'F)

b) 67.C (150"F)

6

Instructor Guide

c) 93.C (200.F)

7

Inslructor Guide

Q6: When under tension, the rail must cool down to what temperature before

the hydraulic rail expanders can be removed?

a) 370"C (700.F)

b) 425C (800.F)

c) 480"C (900.,F)

d) 600.c (1100.F)

Q7: lf a charge ignites, but does not pour out, how must you respond to the

'freeze-up' cond ition?

a) Carefully lift the crucible with the CJ fork & put it gently in the disposal hole

b) Leave the crucible where it is and evacuate the weld site

I

Inslructor Guide

Quiz Administration

Quiz l:

QT

Name four items of personal protection equipment that must be worn when

grinding.

1.

2.

3.

4.

5.

6.

Hearing protection

Respirator

Face shield

Leggings

Eye protection

Welder's gloves

Q2

What two types of gauges must be included on your Measurinq Tools

checklist?

1

2

Starrett taper gauge

Rail wear gauge (rail profile gauge)(head loss gauge)

Q3: Welds must not be located over ties.

a) True

b) False

A3: A weld must never be positioned over a concrete or wood tie

Q4 Anchors must be tightened for a minimum of _ to either side of the

rail-ends.

a) 5m(15ft)

b) 10 m (30 ft)

c) 15 m (50 ft)

d) 33 m (100 ft)

A4

Anchors must be tightened for a minimum of 15 m (50 ft) to either srde of the railends,

otherwise the rail(s) could move, changing the gap.

I

Instructor Guide

Quiz Administration

Q5: A tie must be a minimum of from the ra¡l gap.

a)

b)

c)

d)

75 mm (3 inches)

100 mm (4 inches)

125 mm (5 inches)

150 mm (6 inches)

A5

A tie must be a minimum of 100 mm (4 inches) from the ra¡l gap, to provide

sufficient room for the mold assembly.

Q6:AnydrilledhoIemustbenocloserthan-fromtheendoftherail.

a) 75 mm (3 inches)




A6

Any drilled hole must be no closer than 100 mm (4 inches) from the end of the

rail, otherwise it cannot be accurately tested.

Q7

During what step should the operation of the hydraulic weld shear be

checked?

a) Pouring

b) Preheating

c) Preparing the mold

d) Rail-end alignment

e) Rail-end preparation

A7= ldeally, the operation of the hydraulic weld shear should be checked during railend

preparation before aligning the rail-ends because if the weld shear is placed

on the rail (to check the jaw size & set-up), it could alter the alignment.

2

Instructor Guide

Quiz Administration

Q8

Which of the following conditions require that the rail-end be cut back beyond

the defect, and a closure rail be cut in?

(More than one answer may be correct)

a) Crack in rail-end or bolt hole

b) Rail-end batter

c) Repair welding on rail-ends

d) Horizontal split head

e) Vertical split head

A8

All of the listed conditions require that the rail-end be cut back beyond the defect,

and a closure rail of no /ess fñan the minimum specified length be cut in.

However, if a vertical split head is discovered in a string of CWR, the entire

length of railwith the same heat number, ingot number and rail letter must be

removed from the track... including any butt welds.

Q9: Burrs, flow, paint, oil, rust & scale must be removed for a minimum of

from the rail-ends?

a) 25 mm - 50 mm (1 to 2 inches)

b) 50 mm - 100 mm (2 to 4 inches)

c) 100 mm - 150 mm (4 to 6 inches)

d) 150 mm - 20O mm (6 to 8 inches)

e) 200 mm - 300 mm (8 to 12 inches)

A9: Burrs, flow, paint, oil, rust & sca/e must be removed for a minimum of 100 mm -

150 mm (4 to 6 inches) from the rail-ends... the approximate area the molds

cover.

Q10: Which following rail-end gaps would not be acceptable for a standard LP

CJ or AP CJ thermite weld?

al 22 mm (7/8 inch)

b) 25 mm (1 inch)

c) 28 mm (1-1l8 inch)

3

Instructor Guide

Quiz Administrafion

Ql l: On wood tie territory, what is the standard peak measured at each end of a

welder's straight edge?

a) 0.8 mm (1/32 inch)

b) 1.6 mm (1/16 inch)

cl 3.2 mm (1/8 inch)

d) 6.4 mm (1/4 inch)

Al l: On wood tie territory, the standard peak measured at each end of a welder's

straight edge ts 3.0 mm (1/8 inch). lt is only 1.5 mm (1/16 inch) on concrete ties

because they have /ess þive' than wood ties.

Ql2: Throughout the weld area, rail-ends must be horizontally aligned for at

least

a) 0.5 m (18 inches)

b) r.0 m (3 feet)

c) 1.5 m (4.5 feet)

d) 2.0 m (6.0 feet)

412: Rail-ends must be horizontally aligned for at least 1.0 m (3 feet) throughout the

weld area... the length of a welder's straight edge.

Q13: To correct unequal cant between rail-ends, how far back from the gap must

the spikes be pulled and a wedge inserted?

a) 4toTties

b) I to 11 ties

cl '12 to l5 ties

d) 16 to 20 ties

413: To correct unequal cant between rail-ends, sprkes must be pulled for 12 to 15

ties back from the gap, and a wedge inserted under the 12th to 15th tie. A Track

jack is placed I to 12 ties back to lower a rail-end that has too much peak.

Q14: You open both boxes of a LP CJ or AP CJ weld kit and find the following

components. One important component is missing. What is it?

. 2 half molds

. 1 bottom brick

Missing. diverter plug

. 1 welding charge in sealed package

. 1 CJ crucible & thimble

.1 CJ cover

4

Instructor Guide

Quiz Administration

Q15: What is the correct a¡r pressure for an a¡r/propane preheat?

a) 3.0 psi

b) 3.5 psi

c) 4to5psi

Q16: When us¡ng propane as a preheating fuel, how high must the flames extend

out of the riser holes?

a) 50 mm (2 inches)



416: The flames extend out of the riser holes for 150 mm (6 inches) when us¡ng

propane as a preheating fuel, 100 mm (4 inches) when using qasoline.

Ql7: During the preheating procedure, when must the stopwatch be started?

a) As soon as the preheating unit is started

b) As soon as the torch burner head is lit

c) As soon as the flame height & the sound is correct

417: During the preheating procedure, the stopwatch be started as soon as the flame

height & the sound is correct.

5

Instructor Guide

Quiz Administration

Ql8: How long must the rail-ends and mold be heated to achieve the correct preweld

temperature?

a) 3-112 minutes

b) 6 minutes

c) 8 minutes

d) 10 minutes

418: The rail-ends and mold must be heated for exactly 5 minutes to achieve the

correct pre-weld temperature. Any shorter will result in poor bonding and

poss,ö/e weld failure... any longer will dry out the fusal paste risking a poss/b/e

run-through.

Ql9: lf a charge bag has clearly been punctured, but there are no signs of

moisture, can the charge still be used?

a)

b)

Yes

No

419: Any charge bag that has been punctured, regardless of the absence of any signs

of moisture cannot be used. lt must be mixed with dry sand & scattered along

the right-of-way.

Q20: To time the cooling period, when must the stopwatch be started?

a) When the charge is ignited

b) When the charge begins to pour

c) When the slag begins to run into the slag basin

d) When the slag stops running into the slag basin

420: To time the cooling period, the stopwatch be started when the slag sfops running

into the slag basin.

Q21: What piece of personal protective equipment is worn exclusively during the

pour?

a) Leggings

b) Respirator

c) Welder's goggles

d) Face shield

A2'l: Welder's goggles with glass /enses must be worn during the pour to protect your

eyes from weld splatter... which will melt a face shield.

6

Instruclor Guide

Quiz Administration

Q22:. At what time after the pour can demolding begin?

a) 3-112 minutes

b) 5 minutes

c) I minutes

d) 10 minutes

e) 15 minutes

422: Demolding must beg¡n at 5 minutes. Any sooner will risk a run through or'hot

tear'... any later, and the top of the mold will be difficult to cut off.

Q23: At what time after the pour can the wedges be removed?

a)

b)

c)

d)

10 minutes

15 minutes

20 minutes

30 minutes

l.23= Wedges must be removed 15 minutes after the pour... to allow the weld to cool

to level.

Q24:. When cold grinding, what is the tolerance for the running surface of the

weld?

a) 0.25 mm (0.01 inch) high and 0.25 mm (0.01 inch) low

b) 0.25 mm (0.01 inch) high and nothing low

c) 0.37 mm (0.015 inch) high and 0.25 mm (0.01 inch) low

d) 0.37 mm (0.015 inch) high and nothing low

l.24: When cold grinding, the tolerance for the running surface of the weld is 0.25 mm

(0.01 inch) high and nothing low.

7

Instructor Guide

Quiz Administration

Quiz 2= Exception Conditions

QI

When measuring the difference in rail height between the two rail-ends at

the gap, what is the maximum acceptable difference for a standard LP CJ

or AP CJ thermite weld kit?

a) 3/16 inch

b) 1/16 inch

c) 1/8 inch

d) 114 inch

A1

When measuring the difference in rail height between the two rail-ends at the

gap, 3/16 inch is the maximum acceptable difference. Any greater difference in

rail height requires a Compromise kit.

Q2: Above what temperature is it not necessary to protect a hot thermite weld with a

heat retarding blanket or shield?

a)1 5"C (60.F)

b)1 0.c (50.F)

c) 5.C (40.F)

d) 0.c (32"F)

A2 A hot thermite weld must be protected by a heat retarding blanket or shield

under cold weather conditions... which is defined as an ambient temperature that

rs /ess than 15t (60T), and/or when windy or rainy.

Q3: How long must a heat retarding blanket or shield be kept on?

a) At least 3-1l2 minutes

b) At least 5 minutes

c) At least 10 minutes

d) At least 20 minutes

A3: A heat retarding blanket or shield must be kept on for at least 10 minutes after

demolding.

I

Instructor Guide

Quiz Administration

Q4: Above what ra¡ltemperature is it not necessary to use a turbo-torch to

warm up the rail-ends before preheating?

a) 15"C (60.F)

b) 10"c (50"F)

c) 5"C (40"F)

d) 0.c (32"F)

A4: A turbo-torch must be used to warm up the railwhen the rail temperature is

below 15t (60F).

Q5

When required, to what temperature must the rail-ends be warmed up to,

before the preheating procedure?

a) 37'C (100"F)

b) 67.C (150.F)

c) 93"C (200'F)

A5: lf necessary, the rail must be warmed up to 37 t (100f) before the preheating

procedure.

Q6

When under tension, the rail must cool down to what temperature before

the hydraulic rail expanders can be removed?

a) 370"G (700"F)

b) 425"C (800.F)

c) 480"C (900"F)

d) 600.c (1100"F)

A6

When under tension. the rail must cooldown to 370f (700T) before the

hydraulic rail expanders can be removed. lf they are removed any sooner, the

weld could be stretched.

Q7: lf a charge ignites, but does not pour out, how must you respond to the

'freeze-up' condition?

a) Carefully lift the crucible with the CJ fork & put it gently in the disposal hole.

b) Leave the crucible where it is and evacuate the weld site.

A7:,

lf a charge ignites, but does not pour out, the crucible is unstable and could

collapse, releasing molten steel around the weld location. Leave the crucible

I

Instructor Guide

Quiz Administration

where it is and evacuate the weld site. Return later to clean up the site once the

sfee/ fias cooled.

t0

Pandrol Ind Inc Calorite Training Manual LP-AP CJ 2019 En-test (2)

Create successful ePaper yourself

Delete template?

Save as template?