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Gap Preparation and Alignment

Alumino-thermic welding on the railtech PLA process

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Radoi Olteanu
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129 views

Gap Preparation and Alignment

Alumino-thermic welding on the railtech PLA process

Uploaded by

Radoi Olteanu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Aluminothermic Welder Training

The Railtech PLA Process

1
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process

Part One:

Preparation of the welding gap and


alignment of the rails

2
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process
Rails must be positively identified before any cutting is started:

3
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process

Measurement of rail wear:

• check height of both


rails 25mm from rail end
• amount of wear must not
exceed 7mm on either
rail

4
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process
Marking the gap:

Mark the welding gap clearly and accurately on


the rail head

5
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process
Gap preparation:

• welding gap must be disc


or saw cut
• flame cutting or flame
washing is not permitted
• welding gap 25mm
+/- 2mm (23 to 27mm)
• position cutting disc to cut
inside the marked line

6
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process

Rail cutting:

It is essential that the


correct PPE is worn
during any potentially
hazardous process

7
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process

Verticality:

• both rail ends must be


vertical to a tolerance
of +/- 2mm

8
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process

Squareness:

• both rail ends must


be square to a
tolerance of +/- 2mm

9
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process

Welding gap:

• welding gap must be:


• 25mm +/- 2mm (23
to 27mm)
• checked in rail head,
web and both feet

10
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process

Alignment
Using Wedges

11
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process
Running surface
alignment:

• set vertical alignment with


wedges beneath each rail
on the first sleeper

12
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process
Four point contact:

The rail must contact the straight


edge at all four points to achieve
1.5mm of lift

13
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process
Twist adjustment:

Align foot tips using small side wedges

14
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process

Lateral alignment:

• set lateral alignment


• using large and small
wedges in combination

15
The National Focus for Rail Welding Technology and Practice Copyright © 2004
The Railtech PLA Process
Application of datum marks:

• on completion of alignment
process, datum marks shall
be applied to the rail foot
on either side of the joint
• datum marks shall be
checked:
• after luting
• during preheating
• after the pour

16
The National Focus for Rail Welding Technology and Practice Copyright © 2004

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