RAILTECH INTERNATIONAL, SA au capital de 15 851 323 €uros – Siège Social : Z.I. du Bas Pré – B.P. 9 – 59500 RAISMES - FRANCE

Tél +33(0)3 27 22 26 26 – Fax +33(0)3 27 22 26 00 - www.railtech.fr

RCS Valenciennes 389 670 142 – Siret 389 670 142 00030 – Ident. TVA FR 00 389 670 142

Etablissement de RAISMES

Z I du Bas Pré

BP 9

59500 RAISMES

FRANCE

Tél +33(0)3 27 22 26 26

Fax +33(0)3 27 22 26 00

Email : raismes@railtech.fr

Siret 389 670 142 00030

PP RR OO CC EE SS SS

FF OO RR

AA LL UU MM II NN OO TT HH EE RR MM II CC WW EE LL DD II NN GG

S R G

41 GP - UK

O N E S H O T C R U C I B L E

REVISION N°0.5 (14/11/2013) Décembre 2012

REF MAN /SRG/25/LU-JS/OP/CJ/12-2012/SB N° C 40 20 5 EN

G A P

L U T I N G

P R E H E A T I N G

O N E - S H O T - C R U CI B L E

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CONTENTS

PART I - GENERAL OPERATING INSTRUCTIONS

PART II - PRELIMINARY WORKS

PART III - APPLICATION - WELDING EXECUTION

PARTIE I - GENERAL OPERATING INSTRUCTIONS

I/ 1 - GENERAL REMARKS 6

I/ 1.1 - Quality 6

I/ 1.2 - Before leaving for the site 7

I/ 1.3 - Safety 8

I/ 2 - CHECK OF THE JOINT TO BE WELDED 9

I/ 3 - IDENTIFICATION 10

I/ 3.1 - Consumables 10

I/ 3.1.1 - Sand moulds kit 11 I/ 3.1.2 - Felt moulds kit 11 I/ 3.2 - Kit marking 12

I/ 3.3 - Portion marking 13

I/ 3.4 - Mould marking 13

PARTIE II - PRELIMINARY WORKS

II/ 1 - ONE-SHOT CRUCIBLE 15

II/ 2 - ADJUSTING THE SHEARING TOOLS 16

II/ 3 - VERIFICATION OF PREHEATING MATERIAL 17

II/ 3.1 - Oxy-propane preheating 18 II/ 3.2 - Safety measures before preheating set starting 18

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PARTIE III - APPLICATION - WELDING EXECUTION

PREPARATION OF THE JOINT TO BE WELDED 20

III/ 1 - ADJUSTING THE JOINT 21 III/ 1.1 - Welding gap 21 III/ 1.2 - Vertical alignment (PEAK) 21 III/ 1.3 - Twisting of the rails 22 III/ 1.4 - Horizontal alignment 22 III/ 1.5 - Gap checking 22

III/ 2 - MOULDS SETTING 23

III/ 2.1 - Groove core setting 23 III/ 2.2 - First half mould setting 23 III/ 2.3 - Second half mould setting 24 III/ 2.4 - Setting the briquet 24 III/ 2.4.1 - Sand briquet 25 III/ 2.4.2 - Felt briquet 25

III/ 3 - LUTING 27

III/3.1 - Sand moulds 27 III/3.2 - Felts moulds 27

III/ 4 - PREHEATING 28

III/ 4.1 - Oxy-propane preheating 32

III/ 5 - ONE SHOT CRUCIBLE LOADING 34

III/ 6 - POURING 35 III/ 6.1 - As soon as the preheating is over 35 III/ 6.2 - Reaction 35

III/ 7 - WITHDRAWING THE SLAG TRAY 37

III/ 8 - UNMOULDING 37

III/ 9 - SHEARING 38

III/ 10 - REMOVING RISERS 38

III/ 11 - ROUGH GRINDING 39

III/ 12 - FINAL WELDING 40

III/ 12.1 - Final grinding 40 III/ 12.2 - Cleaning 40 III/ 12.3 - Verification 40 III/ 12.4 - Marking and tracking 40

APPENDICES 41

Appendices 1-A-B-C Welding Tools 42 Appendices 2-A-B-C Preheating tools 45 Appendices 3 Check list for a welding team 49 Appendices 4 Line of preheating 54

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FOREWORD

This manual concerns instructions for successfully carrying out the welding:

SRG Oxy Propane with ONE SHOT CRUCIBLE

The SRG process is used with two kinds of gap:

Normal gap 25mm

Respect the general instructions and apply the specific requirements in

accordance with your worksite and rail profile.

The SRG process could be used with

Sand moulds

Felt moulds

The SRG process could be ignited with two systems:

Ignitor

STARTWEL® ignition system

THIS DOCUMENT DOES NOT REPLACE THE RAILWAYS SPECIFICATIONS AND SAFETY

INSTRUCTIONS CONCERNING EXECUTION OF WELDING OPERATIONS AND RECEPTION OF

WORKS DETERMINED BY THE CUSTOMERS

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PART I

GENERAL OPERATING INSTRUCTIONS

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I/ 1 - GENERAL REMARKS

I/ 1.1 - QUALITY Quality is achieved when all precautionary measures are required at each step of the works in progress, CHECK:

The gap value, the tolerance span limits

Joint inspection

Rail adjustment

Moulds inspection

Moulds and briquet centring

Luting

Burner positioning

Preheating time

Preheating pressures

Portion bag

Crucible inspection

Crucible centering

Tapping time

Unmoulding time before shearing

Adjusting shear blades

Cooling time

Final grinding

It is recommended to carry out the welding at a temperature over > 0°C. If the temperature is under this limit we get gas characteristics (flow/pressure) inappropriate

to achieve the expected quality level.

In any case: All consumables (crucible, moulds ...) and hardware

as well as the work site should be carefully protected from the rain.

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I/ 1.2 - BEFORE LEAVING FOR THE SITE

Make sure that the operator disposes of the equipment necessary for the performance of the works and more particularly:

Enough kits to perform all the welds and check if the kits are appropriate to the profiles to weld and to the types of welds (See § I/ 3 - Identification)

For Oxy-propane :

Check the condition of the preheating equipment and if there are enough consumables, connection, flexible joints, hoses, manometer, pressure reducers in perfect condition…

Complete set of hardware (base plate, jackets, mould clamp) (See Appendix 1 - Welding hardware)

Control tools: straight edge, wedges, chronometer, gauge...

Procedure or welding draft in force on the network

The necessary equipment to prepare and to finish the welds : A frame aligners, grinding machine, and the necessary expendable (oil, petrol, grinding disks, ...)

The tools necessary to perform small reparation concerning hoses, etc...

Safety equipment (goggles, gloves ...), safety signs and so on...

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I/ 1.3 - SAFETY

Welding includes all the usual risks to be found in on-site work.

The personal safety equipment must be wear at any time during welding operations.

Fireproof industrial clothing

Leather gloves

Fireproof gloves

Safety shoes

Leggings

Safety goggles with side protections again sparks (plain glasses)

Welder's goggles (protection glasses)

Consult the safety regulations in force in your network

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I/ 2 - CHECK OF THE JOINT TO BE WELDED

Clean (remove the grease) and brush rail ends in order to

eliminate all traces of oxidation («rust»). A poorly cleaned rust deposit can cause some porosities into the weld.

Check the geometrical aspect of the two rails ends.

Check if there is no crack (cut again the rail with cutting machine if necessary).

Check if there is no steel smudge which can affect the correct positioning of the moulds (grinding if necessary)

The gap shall be:

23 mm to 27 mm for SRG 25 (25 +/- 2 mm)

In order to obtain this gap, it may be necessary to cut the rails. In this case use only a rail saw or a disc cutting machine.

Strictly follow the safety instructions (notice) concerning the use of your saw.

It is forbidden to weld directly on rail ends cut by oxy propane cutting flame. If necessary, take care to clean them up carefully by taking off the slag from the rail ends.

The out of square ness of the rail ends must not exceed 1,5mm. To obtain the right value, use equipment which is in good aspect, correctly fixed to the rail.

CAUTION

The cut shall be carefully cleaned to remove all traces of grease and oxidation to avoid having any defects.

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I/ 3 - IDENTIFICATION

I/ 3.1 - CONSUMABLES

In order to avoid any lack of the products necessary for the welding operation on site all products are put into a same package which is called kit. To avoid having humidity into the product, a plastic wrapped protection is put around the kit.

Opening the kit: it is important to check if the original packaging has been preserved, if it is correctly closed and shows neither deformation nor moisture spots.

Only use the portion supplied into one kit. Never mix the components of 2 different kits available for others grades or profiles. Never use an open or defective bag. Do not add anything else. Never mix 2 welding portions

II

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PP

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I/ 3.1.1 - SAND MOULD KIT

The kit consists of:

2 half moulds

1 briquet

1 plug

1 groove core

1 portion bag (plastic) watertight

I/ 3.1.2 - FELT MOULD KIT

The kit consists of:

2 half felt moulds

1 felt briquet

1 plug

1 groove core

1 portion bag (plastic) watertight

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I/ 3.2 - KIT MARKING

Kit identification has the following indications on the box

- on one side the tracing of the product

and on the other side the identification of the product : profile, process…

SAND MOULDS

FELT MOULDS

Profile Moulds Process Profile Moulds Process

41GP SRG 41GP JS SRG

Portion Process Gap Grade Charge Process Gap Grade

D44 SRG CJ 25 G D44 SRG CJ 25 G

Batch Batch

2D4160 2D4160

Preparation date Article code

5 October 2012 XXXXXXXX

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I/ 3.3 - PORTION MARKING

The references indicated on the snap set adhesive label shall be kept for tracing of the weld.

I/ 3.4 - MOULDS MARKING

The printing of the mould packaging includes the following informations :

SAND MOULDS

FELT MOULDS

Profile Moulds Profile Moulds

41GP 41GP JS

Process Gap Process Gap

SRG 25 SRG 25

Date Preparator Date Preparator

05.09.11 81 05.09.11 81

Article code Article code

XXXXXXXX XXXXXXXX

Article code /

X X X X X X X X X /

Preparation date / Batch

5 Septembre 2012 / 2D4160

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PART I I

PRELIMINARY WORKS

The different stage developed in this part are essential and must be realised with harshness to obtain in a hand a good quality, and in an other hand

security for the workers.

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II/ 1 - ONE SHOT CRUCIBLE

The one-shot crucible is made from a refractory compound by means of a resin. It can be used as such and does not require any preparation. The fusible component allowing the automatic tapping is placed during fabrication.

However to keep good safety conditions and quality it is absolutely necessary to check:

The original packing

The crucible is not damaged or wet

The crucible should be stored in standing position in a dry place and free of moisture

The automatic tapping is not damaged

Safety :

In the exhaust of non tapping The melting steel flows through the safety valve. The crucible is then pulled out with the special fork. NEVER REMOVE THE CRUCIBLE MANUALLY.

In the exhaust of non tapping of the safety valve or crucible

Leave the crucible in its position until self-destruction

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II/ 2 - ADJUSTING THE SHEARING TOOLS

For each rail profile, one shearing blade is dedicated

Adjustment of blades:

To increase the shearing, the adjustment of the blades must be done systematically after sharpening or the changing of the blades themselves.

Allow a gap of 1,5 mm minimum between the blades and the laterals faces of the head.

The weld shear blades must de adjusted to leave 1,5 to 2mm of weld metal above the running surface for profile grinding.

Adjustment of screws:

To avoid damaging the blades, the shear blades must de adjusted to leave 1mm between them by adjustment of the screws dedicated.

Sleeper Sleepers Adjustable stop

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II/ 3 VERIFICATION OF PREHEATING MATERIAL

The material is presented in appendix 3 (Cf preheating)

II/ 3.1 - OXY-PROPANE PREHEATING

The preheating is fed with a blowpipe, equipped with propane and oxygen hoses by two pipes which are 10 mm in diameter for the oxygen and 8mm in diameter for the propane and 20 m long under pressure.

II/ 3.2 - SAFETY MEASURES BEFORE PREHEATING SET STARTING

Check gas cylinder are full enough to ensure a full duration of the preheating procedure,

Check the blowpipe is in good general condition,

Check the regulator to obtain a good flame. The darting flame shall be maintained around 25 mm,

Check the hoses,

Check cylinders are in correct vertical position.

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PART I I I

WELDING PERFORMANCE

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PREPARATION OF THE JOINT TO BE WELDED

Dismount the fastenings on 3 sleepers on each side of the joint to be welded ( and more in a curve depending on its radius)

Clean and brush the ends of the rail in order to eliminate all traces of grease or oxidation.

Check the dimensional quality of the ends to be welded (Cf § I/2)

> 6 IN CURVE > 3 IN ALIGNMEN

>6

>3 >6

>3

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III/ 1 - ADJUSTING THE JOINT

This adjustment is especially important because

it determines the geometric quality of the welding and insure its lifespan

III/ 1.1 - WELDING GAP

This is the distance between the two rails ends.

25 +/- 2 mm for SRG 25mm

This space is measured with a graduate gauge on both sides of the rail, at the rail head and base, that is to say at 4 different places.

The limit values of the four measurements taken must fall within the tolerance span determined above.

The limit values of the four measurements taken must fall within the tolerance span determinated above

III/ 1.2 - VERTICAL ALIGNMENT (PEAK)

The rails shall show a peak before welding. This peak is absolutely necessary because it equalizes metal shrinking after cooling. The value of the peak must be adjusted by the welder, depending on the track.

The importance of the slope shall be measured after finishing grinding. The railway company shall indicate the final angle.

The rails shall never show hollows

Measurements approximately 50 mm from the ends of the straight edg

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III/ 1.3 - TWISTING OF THE RAILS

Inclination of the rails must be carefully checked

- The inside surface of the railhead (1)

- The base and web of the rail (2)

III/ 1.4 - HORIZONTAL ALIGNMENT

Check the inside face of the rail

Recommandation In general, during operation of adjustment it advices to use A frame aligners.

III/ 1.5 - GAP CHECKING

Check if the gap is still into the tolerances

The gap must remain in the values of 25 +/- 2 mm or 48 +/- 3 mm.

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III/ 2 - MOULDS SETTING

III/ 2.1 - GROOVE CORE SETTING

Position the clamp assembly in relation to the gap axis.

Apply luting paste in the groove to avoid that the core moves.

III/ 2.2 - FIRST HALF MOULD SETTING

Position the clamp assembly in relation to the gap axis

Place each half mould on respective mould shoe. The levers are placed toward the inside in open position.

The correct position of the lateral side plate on the mould is visible by the orifice on each side plate.

Fit the first half mould centrally to the welding gap axis.

Maintain this half mould in position and tight the screw of the clamp assembly.

Orifice of visualisation

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III/ 2.3 - SECOND HALF MOULDS SETTING

Place the second half mould centrally to the gap.

Loosen slightly the screw of the clamp. (without breaking the moulds by over tightening).

Adjust the moulds if they are not correct centre into the gap.

Tighten the clamp sufficiently

Check that no sand has entered into the moulds.

III/ 2.4 - SETTING THE BRIQUET

Check with the briquet the vertical angle of both rails.

Place the briquet in its base plate. Make sure that it suits in the plate correctly (no wobbling)

CAUTION When the rails present a difference of wear, check the perpendicularity of moulds to rail:

- Loosen slightly the screw of the clamp - Centre moulds into the gap axis. - Tighten the clamp sufficiently

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III/ 2.4.1 - SAND BRIQUET

Luting paste shall be applied into the two recesses on either side of the briquette.

Cut the paste in excess. The upper surface of the paste layer shall exceed the upper surface of the briquette.

Place the bottom plate set under the rail and centre it in relation to gap and rail.

III/ 2.4.2 - FELT BRIQUET

Preparing the tube of paste

Cut the cartridge tip, screw the nozzle on,

Cut the tip in such a way as to obtain approximately a 20 mm outlet,

Fit the distributor with the cartridge.

Apply a strip of luting paste first of all in the two recesses on

either side of the refractory felt, (Pict. A), and secondly on the width of the base plate (both sides) (Pict B).

Take care not apply paste on the felt.

(pict. a)

Put the base plate under the moulds.

(pict. b)

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Attache the fasteners to either side and check the centring of the plate in relation to the moulds,

Handle with each hand the two handfuls.

Turn both hands at the same time.

It is recommended to cover the moulds with cardboard when these operations have been done.

After briquette setting, tap the bottom plate set and making of correct support

Moulds and briquet have auto-centering system. During setting briquet with the two locking handles, visualise the correct position of the base plate and briquette.

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III/ 3 - LUTING

III/ 3.1 - SAND MOULDS

Apply a strip of luting paste into all recesses around the perimeter of the rail, moulds joints, including the bottom of the base.

Level carefully the paste exceeding the higher lever of the bottom briquet.

III/ 3.2 - FELT MOULDS

Apply a continuous paste trip into all recesses around the perimeter of the rail and mould joints.

Apply additional paste to the vertical mould joint above the rail head.

Place the slag tray and seal the parting line between the slag tray and the moulds.

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III/ 4- PREHEATING

The SRG process is used with one kind of preheating:

Oxy-propane preheating (§ III/4.3)

The preheating consist in heating at characteristic process temperature the ends of the rail

during a limited time.

The good execution of preheating is essential for the life span of the weld. It is thus compulsory to respect carefully the specification described below.

Preheating is an operation of major importance. Its function lies in the elimination of residual

humidity from the moulds and to raise the temperature of the rail ends to a determined value

characterised by the process.

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II/ 4.1 - OXY - PROPANE PREHEATING

RAILTECH materials recommended

(Conf Appendices 2B)

III/ 4.1.1 - BLOWPIPE FITTING

To obtain a correct preheating:

Fit the blow pipe in its support and centre the nozzle in the middle of the moulds.

The distance between the end of the nozzle and the rail top is to 50 mm. (d)

Remove the blowpipe from its support.

III/ 4.1.2 - LIGHTING THE BLOWPIPE

At first, open the oxygen tap and then propane tap,

Adjust progressively the gas flow until taps are completely open. The manometer of propane and oxygen cylinders must indicate respectively 0,6 bar and 1,2 bar.

The cone length must measure around 25 mm.

d

WARNING ! Propane and oxygen pressures must be maintained throughout the duration of the

preheating.(see appendix 2-C) The cone length must measure around 25 mm.

If it is not the case, adjust the propane pressure.

Caution: Low temperature

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After the blowpipe lighting gas exhaust shall be regular and symmetric at the both side pipe in order to get 40cm flames at the exhaust.

Place the plug by the exhaust with the upper side against the flame. (Take care not block the exhaust)

III/ 4.1.3 - PREHEATING TIME

After having adjusted the flame, the burner has to preheat during 4 minutes for the gap 25mm.

During this time, prepare the crucible (see§ III/ 5 )

III/ 4.1.4 - BLOWPIPE REMOVING Once the preheating is completed, respect strictly the safety instruction.

Remove the blowpipe and take care not to damage the inside of the moulds,

First turn the propane feed off and then the oxygen feed.

If there is backfire (whistling), Turn off propane feeding at once.

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III/ 5 - ONE SHOT CRUCIBLE LOADING

Open the bag and pour the portion into the one-shot crucible

Place the crucible by the working area and place the ignitor or the starter STARTWEL® in the portion ready to use,

CAUTION : For STARTWEL® application, the portion must always be horizontal in the crucible.

NO YES

Place the CJ fork and the shovel waste

Caution ! It is important that only use the welding portion delivered with the kit. Never mix the contents of two different kits (never use moulds from one kit, the welding portion from another, the thimble from a third, etc…). Never use a welding portion bag which is gutted or incomplete. Do not add anything. Never mix two welding charges. Never use a damaged or cracked crucible

Always use the fork provided for this purpose (Never manually)

IMPORTANT

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III/ 6 - POURING

Welding in wet weather: All consumables must be kept dry and wet rails dried for welding

III/ 6.1 - AS SOON AS THE PREHEATING IS OVER

Put the plug into its lodging with the pliers provided for this purpose and slightly drive it

III/ 6.2 – REACTION In the case of ignition with the ignitor: Light the ignitor by contact with inside hot mould

wall.

Don't dip the ignitor too much, only stitch it into the portion (3 cm). Tapping time could be affected and should be under the minimum value i.e. 17 seconds.

In the case of ignition with STARTWEL®:

Remove the pin from the starter.

Insert the starter in the hole in the cap (In case of filter cover, remove the lid first, take care not to put sand in the portion)

(Filter cover)

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Centre the crucible lead

The reaction develops in a few seconds and the

pouring will automatically take place at reaction completion (if no tapping see II/1).

The tapping time should be between 17 to 32

seconds.

Position the ignition glue indicator in front of you.

Place the electrodes of the electric handle on

the terminals of the STARTWEL® starter.

Press and hold the trigger until ignition (charge has started when the red light becomes visible)

The reaction occurs in a few seconds and the casting is carried out automatically after the end of the reaction

The tapping time should be between 17 to 32 seconds.

After the casting, removed the crucible with the fork.

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III/ 7 - WITHDRAWING THE SLAG TRAY

Break the solidified slag between the moulds and the slag tray.

Breaking the solidified slag tray will prevent breaking into the moulds too early.

III/ 8 - UNMOULDING

It is absolutely necessary to remove the mould before shearing

Before removing the jackets wait:

Start the unmoulding at around:

Shear the upper part of the moulds with the hot cut chisel and check if the steel is not still liquid.

GAP 25MM

3 minutes After the

pouring 5 minutes

Caution! The slag tray must be removed only after its content has fully solidified. Place the slag tray with hot content on a dry spot (not on sleepers). Do not place or throw slag tray with hot content on wet surface or into water

Caution! Do not unmould if the steel is still liquid.

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III/ 9 - SHEARING

Start the shearing at:

Mould sand and loose paste must be cleaned from the rail head each side of the weld, by wire brushing.

Begin the shearing operation by running surface, rail head and risers.

III/ 10 - REMOVING RISERS

There are two operating ways to remove the risers:

Use an electric disk equipped with a disk allowing cold or hot shearing of the risers

or

Begin with hot notching. This operation shall be performed quickly after shearing, if not metal is too hard. After notching break the risers.

GAP 25MM

6 minutes After the

pouring

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III/ 11 - ROUGH GRINDING

Rough grinding of the rail head portion of the welding can be performed after shearing or hot cutting is completed

Rough grinding of the running surface of the rail shall be performed with an approved surface grinding wheel.

Let an excess metal thickness on the running surface according to the customers requirements.

III/ 12 - WAITING TIME BEFORE RUNNING

The utilisation of weld corresponds at passage of circulation, train of works, so traction of the weld with hydraulic stretcher (traction with the stretcher, carrying of stretcher…)

The utilisation of weld is possible:

That is correspond at the temperature of 350°C

Wait about 15 minutes after the casting to remove tools using for the rails adjustment.

GAP 25 MM After the casting

25 minutes

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III/ 13 - FINAL WELDING

III/ 13.1 - FINAL GRINDING

The target of the final grinding is to establish a perfect continuity between the two rails which were welded.

The final grinding is realised according to the customers requirements.

The final grinding should be done on a cold rail and totally stabilised.

III/ 13.2 - CLEANING

Remove all the sand, paste…left around the weld.

Remove all burrs with a grinding wheel

Grind the excess of steel (base of the risers) according to the customer requirements. (According to the customer requirement)

III/ 13.3 - VERIFICATION (According to the customer requirement)

III/ 13.4 - MARKING AND TRACKING (According to the customer requirement)

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A P P E N D I C E S Appendix 1 / A - B - C - D WELDING TOOLS Appendix 2 / A - B - C - D PREHEATING TOOLS Appendix 3 INCORRECT PRESSURES Appendix 4 CHECK LIST FOR A WELDING TEAM Appendix 5 PREHEATING LINE RAILTECH

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APPENDIX 1 – A – Welding Tools

BOTTOM PLATE The bottom plate is the same for gap 25 or 48mm.

BOTTOM PLATE 83100004

SIDE PLATE The side plate is the same for gap 25 or 48mm.

SET OF SIDE PLATES 83200001

SLAG TRAY

SLAG TRAY 81532010

PLUG TOOLS This tool allows the insertion of the plug after the preheating.

PLUG TOOL 83432920

GAUGE This gauge allows control of the gap.

GAUGE S0000150

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APPENDIX 1 – B – Welding Tools / For One Shot Crucible

ONE SHOT CRUCIBLE

CJ1G1 83450127 CJ1G1 CCF* 83450129

*CCF: One Shot Crucible with filter cover

CLAMP ASSEMBLY ONE SHOT CRUCIBLE FOR RAG

This moulds clamp is equipped with a U clamping for fixing to the rail.

CLAMP ASSEMBLY 832500004

FORK

The fork allows the removal of the CJ after casting.

FORK CJ 82631411

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APPENDIX 1 – C – Welding Tools / Ignition Tools

IGNITOR

IGNITOR BOX (x100) 82632450

STARTERS STARTWEL®

BOX OF 10 STARTERS STARTWEL® 82632501

BOX OF 100 STARTERS STARTWEL® 82632502

ELECTRIC HANDLE COMPLETE 82632503

ELECTRIC HANDLE ONLY 82632509

BATTERY 14,4V 82632503

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APPENDIX 1 – C – Welding Tools / Ignition Tools

CHARGER

CHARGER 220V FR 82632505

EMPTY METAL CASE

EMPTY METAL CASE 82632506

VALISE COMPLETE The complete case includes:

A handle (1) 14.4 V battery with a lithium-ion (2) A battery charger (4)

1 box of 10 starters STARTWEL® (3)

COMPLETE CASE 82632507

CASE WITHOUT CHARGER The bag includes: A handle with a 14.4 V battery Li-Ion

1 box of 10 starters thermal STARTWEL®

CASE WITHOUT CHARGER 82632508

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APPENDIX 1 – D – Welding Tools / Luting Tools

LUTING WITH PASTE CAULKING DISTRIBUTOR – FELTS MOULDS

PASTE CAULKING DISTRIBUTOR

PASTE CAULKING DISTRIBUTOR 83461109 PASTE CAULKING DISTRIBUTOR COMPENSATION 83461110

LUTING PASTE

PASTE CARTBRIDGE(unity) 83661130 PASTE CARTBRIDGE (Box of 12) 83661111

MANUAL LUTING – SAND MOULDS

LUTING PASTE

LUTING PASTE BUCKET (10Kg) 83661130

WORN RAIL – SAND MOULDS

FELT SEAL

FELT SEAL BOX (x30) 83661115

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APPENDIX 2 – C – Preheating Tools / Oxy-Propane preheating

BLOWPIPE

BLOWPIPE 22HOLES 35910229

BLOWPIPE SUPPORT

BLOWPIPE SUPPORT FOR RAG 11234004

GAS LIGHTER

GAS LIGHTER 48402002

For the others elements, see appendix 4 – PREHEATING LINE RAILTECH

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APPENDIX 3 – Incorrect pressures

IN CASE OF INCORRECT PRESSURES

The pressures must be maintained throughout the duration of the oxy – propane preheating.

The manometers must be adjusting to: 0,6 bar for the propane 1,2 bar for the oxygen

The cone length must be always around 25 mm. If it is not the case, adjust the propane pressure at the regulator.

It’s very important to check the pressure of propane and oxygen throughout the duration of the preheating. In the other cases, two solutions can be considered according to requirement of building site:

The welder carries out the welding until his term and declares this welding as defective.

The welder has to restart again his weld since the beginning (checking of the gap, setting new moulds…)

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APPENDIX 4 – Check list for a welding team

HAND TOOLS TYPE QUANTITY RÉFÉRENCES

WIRE BRUSH 1 48401004

ELECTRONIC TIMER 1 48703001

PLUG HOLDER 1 83432920

HOT CUT CHISEL 5 KG 1 48401110

BALLAST FORK 1 48401050

ADJUSTABLE PLIERS 0 TO 46 1 48401131

ADJUSTABLE SPANNER 0 TO 30 1 48401010

SET OF SCREWDRIVERS 1 48401015

SET OF 5 FLAT SPANNERS 1 48401130

TOOLS BOX 1 48401008

HAND HAMMER 1 48401013

HAMMER 1 48401013

HOT CUT CHISEL WITH HANDLE 1 11311001

TRANCHE À ÉVENT DE PATIN AVEC MANCHE 1 11311002

COLD CHISEL 1 48401009

BALLAST FORK 1 48401050

SET OF NUMBER-PUNCH 1 48409002

SET OF LETTER-PUNCH 1 48409003

SET OF THICKNESS GAUGES 1 48701005

COPPER HAMMER 1 11319002

REFUSE TRAY 1 48401014

METAL JERRYCAN 20LITRES 2 48401052

METAL JERRYCAN 5 LITRES 2 48401051

FUNNEL 2 48409001

TARPAULIN 1 19311001

46 | P a g e

APPENDIXE 4 – Check List for a welding team

ADJUSTMENT OF RAILS TYPE QUANTITY RÉFÉRENCES

HC 355 RAIL SAW 2 14221022

DISC 355 X 3.6 X 25.4 6 47901024

STRAIGHT EDGE 1M 1 19123001

1M BEVELLED STRAIGHT EDGE 1 19123002

“A” FRAME ALIGNER 1 PAIR 11115002

GAUGE TIE RODS FOR CURVE RADIUS < 350M 1 PAIR

WOODEN EDGE 20 11114002

WELDING TYPE QUANTITY REFERENCES

WELD SHEARING MACHINE TYPE RAG 1 11332006

RAG BLADES 1 PAIR 11335030

GRINDING TYPE QUANTITY RÉFÉRENCES

FLEXIBLE SHAFT RAIL TRACK GRINDING MACHINE 1

OR

TWO-WHEEL FLEXIBLE SHAFT GRINDING MACHINE FOR ROLLING ON TRACK 1

FLEXIBLE SHAFT 1 14341002

RAPID COUPLING 2 14342002

GRINDING LAPIDARY HEAD 1 14343013

DISC GUARD 115 X 50 1 14343006

GRINDING WHEEL 115 X 50 WITH COUNTERSUNK NUT 1 47901006

OR

DISC GUARD 150 X 40 1 14343007

GRINDING WHEEL 150 X 40 WITH COUNTERSUNK NUT 1 47901009

1 M BEVELLED STRAIGHT EDGE 1 19123005

47 | P a g e

APPENDIXE 4 – Check List for a welding team

NIGHT WORK TYPE QUANTITY RÉFÉRENCES

GENERATOR 1 19412001

FLOODLIGHT 1

SPARE BULBS 4

ELECTRIC TORCH 1

TRANSPORT AND LOCKING TYPE QUANTITY REFERENCES

LORRY WITH BRAKE, USEFULL LOAD 1,5T 1 12111003

“T” SPANNER FOR SLEEPER SCREWS 1 11335030

WRENCH FOR NUT N°28 1 48101125

COACH SCREWING MACHINE (TOOLING REQUIRED) 1 13211002

SAFETY EQUIPMENT TYPE QUANTITY RÉFÉRENCES

LEATHER GLOVES 1 48801002

FIREPROOF GLOVES 1 48801003

SAFETY SHOES 1

LEGGINGS 1 48801004

WELDING GOGGLES WITH TINTED GLASS 1 PAIR 48802001

SAFETY GOGGLES, CLEAR GLASS FOR GRINDING 1 PAIR 48802003

This list is given for information purposes and is not necessary complete. Welding includes the usual risks found on a site work.

48 | P a g e

Appendix 5 / Line of preheating RAILTECH

LIG

NE

DE

PR

EC

HA

UF

FA

GE

OX

Y-P

RO

PA

NE

RA

ILT

EC

H 2

2 T

RO

US

VE

RS

ION

C

OX

Y-P

RO

PA

NE

PR

EH

EA

TIN

G L

INE

RA

ILT

EC

H 2

2 H

OL

ES

VE

RS

ION

C

Ho

se P

rop

ane

8mm

Bo

re x

20m

lo

ng

3/8

BS

P t

o 9

/16

UN

F N

ut L

/HT

uyau

Pro

pane

Ø 8

mm

, Lo

ngue

ur 2

0mR

éfér

ence

Har

ris

: H22

32

Gau

ge

8E68

6 0-

2.5

bar

gas

Man

omèt

re

gaz

Réf

éren

ce H

arri

s : H

2223

OX

YP

RO

PA

NE

BL

OW

TOR

CH

RA

ILTE

CH

22

HO

LE

S

CH

AL

UM

EA

U R

AIL

TEC

H 2

2 TR

OU

S P

réch

auff

age

oxy

-pro

pan

eR

éfér

ence

Rai

ltec

h :

1123

1007

OX

YG

EN

AC

ET

YL

EN

E

Fla

sh g

uar

d H

arri

s 88

-6C

VTR

Oxy

gen

Cla

pet

antir

etou

r H

arris

88-

6CV

TR

R

éfér

ence

Rai

ltec

h :

4830

2005

Ref

eren

ce H

arri

s : H

4018

Reg

ula

tor O

xyg

en M

od

el 9

96 1

0.0

bar

Man

odét

ende

ur O

xygè

neR

éfér

ence

Har

ris

:H10

43

Fla

shb

ack

Arr

esto

r H

arri

s

Mo

del

188

-2TR

GB

Oxy

gen

Cla

pet

pare

flam

me

oxyg

ène

Réf

éren

ce H

arri

s : H

1307

Ho

se O

xyg

en 1

0mm

bo

re x

20m

lo

ng

3/8

BS

P t

o 9

/16

UN

F n

ut R

/HT

uyau

Oxy

gène

Ø 1

0mm

, Lo

ngue

ur 2

0mR

éfér

ence

Har

ris

: H22

31

Reg

ula

tor P

rop

ane

mo

del

896

4.0

bar

Man

odét

ende

ur P

ropa

neR

éfér

ence

Har

rish

: H

1029

Fla

sh g

uar

d H

arri

s 88

-6C

VTL

Fu

el G

as

Cla

pet

antir

etou

r H

arris

88-

6CV

TL

Réf

éren

ce R

ailt

ech

:48

3020

06R

éfér

ence

Har

ris

: H40

17

T-p

iece

in li

ne

9/16

BS

P L

/H

Té

gaz

Réf

éren

ce H

arri

s : H

2222

RTI

Har

ris

F43

Pro

pan

e M

ixer

Mél

ange

ur R

TI H

arris

F43

Pro

pane

Réf

éren

ce R

ailt

ech

: 48

3020

03

RA

ILTE

CH

22

Ho

les

Pre

-Hea

ter

Bus

e A

llong

e R

TI 2

2 T

rous

Réf

éren

ce R

ailt

ech

: 35

9102

29

Gau

ge

8E66

1 0-

6.0

bar

Oxy

gen

Man

omèt

re O

xygè

neR

éfér

ence

Har

ris:

H52

00 T-p

iece

in li

ne

9/16

BS

P R

/H

Té

Oxy

gène

R

éfér

ence

Har

ris:

H22

21

Har

ris

Mo

del

K:4

3-2

Sh

ank

Man

che

Har

ris M

odel

K:4

3-2

Réf

éren

ce R

ailt

ech

: 48

3020

04R

efer

ence

Har

ris

: H21

25

Fla

shb

ack

Arr

esto

r G

as M

od

el 1

88-2

TLG

B

Cla

pet

pare

flam

me

Gaz

Réf

éren

ce H

arri

s : H

1308

Det

ails

of t

he

no

zzle

22

Ho

les

Dét

ails

de

la b

use

22 T

rous

Ru

bb

erco

ver

for g

aug

e

Pro

ctec

tion

pour

man

omèt

reR

éfér

ence

Har

ris

: H52

32

H=70mm

H=50mm

Det

ail o

f th

e P

re-H

eate

r H

old

er

for

hei

gh

t ad

just

men

tD

étai

l du

sup

port

de c

halu

mea

upo

ur le

rég

lage

de

la h

aute

ur

Pre

-Hea

ter

Ho

lder

RA

ILTE

CH

22

Ho

les

Pie

d su

ppor

t de

chal

umea

u R

AIL

TE

CH

22

Tro

us

Fo

r w

idth

of

rail

hea

d <

80m

m

Pou

r un

e la

rgeu

r de

cha

mpi

gnon

<80

mm

Réf

éren

ce R

ailt

ech

: 11

2340

03

Fo

r w

idth

of

rail

hea

d >

80m

mP

our

une

larg

eur

de c

ham

pign

on >

80m

mR

éfér

ence

Rai

ltec

h :

1123

4004