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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
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