ERICO CADWELD Rail Grounding Connections – Joint Head Bonds - Manual

!
!
!
!
!
!
!
!
!
!
!
CADWELD ® Rail Grounding Connections – Joint Head Bonds
Refer to the mold tag for applicable instruction sheets. IPRGJ_B
I. HOW TO READ THESE INSTRUCTIONS/WHAT THE SYMBOLS MEAN
The purpose of safety symbols is to attract your attention to possible
dangers. The safety symbols, and the explanations with them, deserve
your careful attention and understanding. The safety warnings do not by
themselves eliminate any danger. The instructions and warnings are not
substitutes for proper accident prevention measures.
SAFETY ALERT SYMBOL: Indicates warning or caution. It may be used in
conjunction with other symbols or pictographs.
WARNING: Failure to obey a safety warning may result in property damage,
serious personal injury or death, and the serious personal injury or death of others.
Always follow the safety precautions to reduce these risks.
CAUTION: Failure to obey a safety caution may result in property damage,
personal injury, and injury to others. Always follow the safety precautions to
reduce the risk of fi re, other property damage and personal injury.
NOTE: Advises you of information or instructions vital to the operation or
maintenance of the equipment.
In the following instructions, cautions and warnings, there are two types of
consequences for failure to heed:
A. IMMEDIATE, that may result in personal injury or a failed operation that
may result in a less than optimum bond and that will not give the physical
and electrical performance expected.
B. EVENTUAL, that may result in a later premature rail break, causing a serious
derailment accident with personal injuries or death, and loss of property.
II. GENERAL RULES FOR SAFETY IN THE APPLICATION OF EXOTHERMIC
JOINT HEAD BONDS AND WEB BONDS TO RAIL
WARNING: Do not attempt to make an exothermic bond until you have
thoroughly read and understand the instructions that accompany all of
the various components of the system and have been properly trained in
the use of this product. Use only the system components designed to be
used together from a single manufacturer. Failure to comply may result in
unsatisfactory bonding as well as accidents involving fi re, personal injury, and
rail damage that may lead to property damage, injury or death.
WARNING: Only the correct grinding equipment, welding equipment,
welding material, and bonds designed for the specifi c application
must be used. All items used must be designed and supplied by the same
manufacturer. All items must be in good condition and not worn, altered or
damaged. Failure to do so may result in an unsafe application with the risk
of personal injury and/or a less than optimum bond.
WARNING: The area where the bond is to be applied must be sheltered
suffi ciently if the weather is inclement. This is to keep the
rail surface, all equipment, and materials dry until the weld is
completed. Failure to do so may result in an unsafe application
with the risk of personal injury and a less than optimum bond.
CAUTION: The work area must be well ventilated. Workers should avoid
breathing the smoke of the exothermic reaction by positioning
themselves upwind of the mold before igniting the welding
material. After ignition, it is advisable to step back from the mold.
Failure to observe this instruction may result in lung irritation.
WARNING: The worker(s) performing the welding must be properly
dressed and equipped. Examples include cotton or woolen
garments (most synthetic fabrics melt rather than char when
exposed to fl ame, causing severe burns), safety footwear with
non-slip soles, head protection, leather gloves, eye goggles and other clothing
and equipment recommended or required by the person’s employer, industry
practice, or applicable laws and regulations. See Figure 1. The worker(s)
must not be under the infl uence of any alcohol, drugs or other chemicals
that would impair their judgment or performance of the job. Failure to
observe this may result in serious personal injury.
WARNING: Carefully following the instructions for exothermic
bonding is very important to achieving a quality reliable
bond. Failure to do so may cause hidden potential problems,
the least of which is a poor electrical connection, and the
most serious of which is an eventual broken rail leading to property
damage, injury or death to the installer and others.
1. Clean the rail surface and bond
terminals. Scrape off excess dirt
and grease, and wipe away any
remaining residue using a clean
rag saturated with a railroad
approved solvent. See Figure 3.
The cable and rail surface must
be dry prior to welding!
FIGURE 1
FIGURE 2
III. PREPARATION
WARNING: Protect against potential fi re hazards local to the
bonding area and remove all fl ammable materials
from the work area. Notify in advance other workers
in the immediate area that a welding procedure is
about to be done. Failure to do this increases the risk of fi re with the
possibility of property damage, personal injury and death.
NOTE: In case of a fi re involving large quantities of exothermic welding
material, CO
2
or large quantities of water applied from a distance are
required to reduce the spread of the fi re.
WARNING: The location of the bond is very important!
The intent of a rail head bond is to electrically join two rail sections.
Rail head bonds must be done only within the confi nes of the joint/splice
bar as near to the bar center as practical. Failure to observe this may
result in a rail break leading to property damage, injury or death to others.
HEAD CONNECTION BONDING MUST NEVER BE DONE ON OR
NEAR THE HEAD OUTSIDE THE CONFINES OF THE JOINT BAR,
OR NEVER ON THE BASE OF THE RAIL. See Figure 2.
FIGURE 3
!
CAUTION: The worker(s) must be certain that they can achieve
good footing in the area where the weld will be done.
They should be able to step away from the weld reaction, to be
upwind of it. Failure to observe this may result in personal injury.
Safety Helmet
Jacket or Shirt
and Trousers
Safety Shoes
Safety Goggles
Cuffed Leather
Gloves
www.erico.com 1