Professional Documents
Culture Documents
14730-2:2006
Railway applications
Track
Aluminothermic
welding of rails
Part 2: Qualification of aluminothermic
welders, approval of contractors and
acceptance of welds
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BS EN 14730-2:2006
National foreword
Summary of pages
This document comprises a front cover, an inside front cover, the EN title page,
pages 2 to 18, an inside back cover and a back cover.
The BSI copyright notice displayed in this document indicates when the
document was last issued.
BSI 2006
English Version
Applications ferroviaires - Voie - Soudage des rails par Bahnanwendungen - Oberbau - Aluminothermisches
aluminothermie - Partie 2 : Qualification des soudeurs par Schweien von Schienen - Teil 2: Qualifizierung
aluminothermie, agrments des entreprises et rception aluminothermischer Schweier, Zertifizierung von
des soudures Betrieben und Abnahme von Schweiungen
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the Central Secretariat or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the official
versions.
CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania,
Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
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2006 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 14730-2:2006: E
worldwide for CEN national Members.
Contents Page
Foreword..............................................................................................................................................................3
1 Scope ......................................................................................................................................................4
2 Normative references ............................................................................................................................4
3 Terms and definitions ...........................................................................................................................4
4 Qualification of aluminothermic welders ............................................................................................5
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4.1 Initial training and issue of a Diploma in Aluminothermic Welding of Rails ...................................5
4.2 Permit to Weld........................................................................................................................................6
4.3 Welder identification .............................................................................................................................7
4.4 Welder records.......................................................................................................................................7
5 Approval of aluminothermic welding contractors..............................................................................7
5.1 General....................................................................................................................................................7
5.2 Quality management system ................................................................................................................8
5.3 Practical experience ..............................................................................................................................8
5.4 Aluminothermic welders .......................................................................................................................8
5.5 Training...................................................................................................................................................8
5.6 Equipment ..............................................................................................................................................8
5.7 Purchase, management and control of consumables .......................................................................8
5.8 Supervision ............................................................................................................................................8
5.9 Weld inspection .....................................................................................................................................8
5.10 Traceability .............................................................................................................................................8
5.11 Audits ......................................................................................................................................................9
6 Acceptance of aluminothermic welds .................................................................................................9
6.1 General....................................................................................................................................................9
6.2 Weld inspector qualification.................................................................................................................9
6.3 Weld inspection .....................................................................................................................................9
6.4 Geometric requirements .......................................................................................................................9
6.4.1 General....................................................................................................................................................9
6.4.2 Alignment and match of the weld collars..........................................................................................10
6.4.3 Welded rail alignment..........................................................................................................................11
6.5 Weld integrity .......................................................................................................................................14
6.6 Documentation.....................................................................................................................................15
Annex A (informative) Diploma in Aluminothermic Welding of Rails ........................................................16
Annex B (informative) Permit to Weld ...........................................................................................................17
Bibliography ......................................................................................................................................................18
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EN 14730-2:2006 (E)
Foreword
This document (EN 14730-2:2006) has been prepared by Technical Committee CEN/TC 256 Railway
applications, the secretariat of which is held by DIN.
This European Standard shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by February 2007, and conflicting national standards shall be withdrawn
at the latest by February 2007.
The purpose of this standard is to provide systems for successful delivery of aluminothermic welds in track.
Acceptance of welds.
The minimum information requirements shown in Annex A and B are normative. The format is informative.
The standard contains "alternative requirements" in certain clauses, which enable a railway authority to select
a position that will protect those principles which might be considered as "sovereign rights."
When installing aluminothermic welds in track across Europe, railway authorities, process suppliers and
contractors shall comply with rules, regulations and codes of practice pertaining to the country where the work
is executed.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic,
Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden,
Switzerland and United Kingdom.
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1 Scope
This standard applies to aluminothermic welds made on Vignole rails of 46 kg/m and above as contained in
EN 13674-1:
the system for training, testing and maintaining the skills of aluminothermic welders. It applies to those
aluminothermic welding processes compliant with the requirements of EN 14730-1 "Railway applications
Track Aluminothermic welding of rails Part 1: Approval of welding processes". It requires that the
system for training and testing of welders shall be approved by the relevant railway authority;
the systems and requirements for the approval of aluminothermic welding contractors. It applies to those
contractors using aluminothermic welding processes compliant with the requirements of EN 14730-1
"Railway applications Track Aluminothermic welding of rails Part 1: Approval of welding processes"
and who employ welders who are in possession of a valid Permit to Weld as defined in Clause 4 of this
standard;
the acceptance requirements for aluminothermic welds. It requires that weld inspectors are competent in
aluminothermic weld inspection and are approved by the relevant railway authority. It covers the final
inspection of aluminothermic welds for acceptance in track. It does not cover any previous inspections by
welders or others.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
EN 14730-1, Railway applications Track Aluminothermic welding of rails Part 1: Approval of welding
processes
3.1
railway authority
either the railway regulator or the owner of a railway infrastructure or the custodian with a delegated
responsibility for a railway infrastructure
3.2
aluminothermic welder
track operative trained and certified for the joining of rails by aluminothermic welding processes
3.3
welding contractor and welding subcontractor
company accepted in accordance with the requirements of a railway authority to execute the production of
aluminothermic welds on that particular infrastructure
3.4
process supplier
company which provides an approved aluminothermic welding process accepted in accordance with
EN 14730-1 and which is approved by the railway authority to supply consumables and tools for the execution
of aluminothermic welds
4
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EN 14730-2:2006 (E)
3.5
employer
company that employs aluminothermic welders who are approved by a process supplier and railway authority,
or by the railway authority itself
3.6
process manual
manual referred to and described in EN 14730-1, produced by the process supplier, identifying all the
consumable materials and equipment used and the operating method to be followed for all steps of welding.
The manual specifies the critical parameters of the welding process and their safe bounds
3.7
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training establishment
welder training organisation or centre approved by the railway authority
The process supplier shall provide the process manual and determine the duration of training and the
minimum number of welds to be made.
The initial training shall be carried out in accordance with the supplier's process manual. In addition to the
welding processes the initial training shall include as a minimum:
rail identification;
basic grinding;
The training shall conclude with a practical and theoretical test or tests so designed to confirm the trainees'
ability to carry out the aluminothermic welding of rails in accordance with the requirements of that supplier's
process manual.
Upon the successful completion of training and testing the welder shall be issued with a Diploma in
Aluminothermic Welding of Rails by the training establishment. The minimum information to be given on the
diploma is:
Date of birth;
Date of examination;
Number of diploma;
Process supplier;
Skill modules;
Extra skills;
Cutting method(s);
Training establishment;
A specimen Diploma in Aluminothermic Welding of Rails showing the format is given in informative Annex A.
The possession of the Diploma in Aluminothermic Welding of Rails shall be a prerequisite to applying for the
Permit to Weld.
Diplomas in Aluminothermic Welding of Rails shall remain the property of the welder.
The Permit to Weld shall remain the property of the railway authority.
The railway authority shall define any relevant conditions relating to the training, testing, re-training, re-testing
and the validity and renewal of the Permit to Weld as well as the extension of the welder's skill.
The subjects to be included in the training for a Permit to Weld shall be defined by the railway authority. The
employer shall be responsible for ensuring that the training of aluminothermic welders to obtain a Permit to
Weld is in accordance with the requirements of the railway authority.
Upon successful completion of the requirements and demonstration of the necessary competencies, which
shall include railway authority tests if required, the welder shall be issued with a Permit to Weld by the relevant
railway authority upon receipt of the relevant qualifying information from the employer. The issue of the Permit
to Weld shall be via the welder's employer who shall maintain up to date records.
The Permit to Weld shall include a unique identification relating to the particular welder and the employer, and
shall contain as a minimum:
Employer;
Certificate number;
Stamp number;
Issue date;
Expiry date;
Line categories;
Process supplier;
Process;
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EN 14730-2:2006 (E)
Surrender conditions.
In any instance of a welder changing employment to another welding contractor or employer, the railway
authority shall issue a new Permit to Weld on the request, and receipt of relevant qualifying proof, from the
new welding contractor or employer.
The railway authority shall, at any time, withdraw the Permit to Weld upon evidence of poor performance by
the welder and ask the employer to return it.
The railway authority shall also withdraw the Permit to Weld upon accepted documented notification from the
employer. The employer shall return it to the railway authority.
Upon request from the employer, the Permit to Weld shall be renewed by the railway authority as may be
necessary to reflect the maintenance and/or extension of the welders skills. Such renewal shall require
receipt of the relevant qualifying information from the employer.
To identify the welder, each and every weld shall be marked by the stamp number allocated in the Permit to
Weld.
The contractor or sub-contractor shall maintain welder records, which shall form part of a quality management
system and which shall include:
Weld records;
5.1 General
The railway authority shall be responsible for specifying the requirements for the qualification of
aluminothermic welding contractors.
A certifying document shall be issued by the railway authority or the authorised body to contractors meeting
the requirements.
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The welding contractor shall operate a quality management system which addresses this European Standard
to ensure that aluminothermic welds consistently comply with the specified requirements.
The railway authority may require prospective contractors to provide evidence that they have the necessary
experience for the type of work to be carried out.
The welding contractor shall employ aluminothermic welders who are in possession of a valid Permit to Weld,
as defined in Clause 4 of this standard.
5.5 Training
The welding contractor shall maintain a system that ensures the competence of their aluminothermic welding
personnel by appropriate training and assessment.
5.6 Equipment
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Aluminothermic welding equipment shall comply with the process supplier's manual. Inspection and calibration
of equipment shall comply with those requirements specified by the process and equipment supplier and the
relevant railway authority.
The welding contractor shall maintain a system of welding consumable purchases, management and control
in line with the process supplier's specifications.
5.8 Supervision
The welding contractor shall maintain a system of management and supervision of aluminothermic welding
that complies with the regulations of the railway authority.
The welding contractor shall maintain a system of weld inspection according to the railway authority
requirements. Non-conformances found during these inspections shall be recorded in the traceability system.
5.10 Traceability
As a minimum, each weld shall be marked at the time of production with the welder's unique identification, as
defined in 4.3, and with the year of installation.
The welding contractor shall maintain a traceability system. The system shall include a daily record signed by
the welder, detailing every weld produced.
Date of installation;
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EN 14730-2:2006 (E)
Weather conditions;
Stress balancing activities e.g. welds made between tensors or in conjunction with rail heaters;
Any non-conformances with the process manual and the railway authority requirements before or during
welding including track conditions such as battered, bent or twisted rail ends.
5.11 Audits
6.1 General
Documentation and records as defined in 5.10 shall be made available upon request by the railway authority.
All welds installed in accordance with this standard shall be inspected and documented.
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6.2 Weld inspector qualification
Persons carrying out final weld inspections, called "Weld Inspectors" in the following clauses, shall have
completed and passed a railway authority approved course on aluminothermic weld inspection. These Weld
Inspectors shall be approved by the relevant railway authority and shall as appropriate act on behalf of that
authority.
A Weld Inspection Report containing the result and details of the weld inspection shall be completed.
6.4.1 General
The misalignment and the mismatch of the weld collar shall not exceed the values specified in the following
figures.
Key Key
1 Rail head 1 Rail head
2 Rail foot 2 Rail foot
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EN 14730-2:2006 (E)
Key Key
1 Rail head 1 Rail head 3 Collar under foot
2 Rail foot 2 Rail foot 4 Collar above foot
Figure 3 Mismatch (two piece moulds): Figure 4 Mismatch (three piece moulds):
c = 3 mm d = 3 mm
6.4.3.1 General
The welded rail alignment after final grinding shall be measured over 1 m with the weld central. The tools used
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for measurement of weld alignment shall be accurate and calibrated in accordance with the requirements of
the equipment supplier and the railway authority.
The length over which the rail surface has been ground on the full width of the running surface "L" (see
Figure 5) or on the full height of the running edge "M" (see Figure 6) is shown as follows.
Key
L Grinding length
1 Rail head
2 Rail foot
Key
M Grinding length
1 Rail head
2 Rail foot
Peaked weld
h1 + h 2
The peak value P is calculated with the following formula: .
2
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EN 14730-2:2006 (E)
Dimensions in millimetres
Key
1 Flatness
2 Rail
h1,h2 Values at the rule extremity
Dimensions in millimetres
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Dipped weld
Key
1 max. dip under the rule
2 Rail
Horizontal alignment shall be measured on the running edge 14 mm below the running surface. It is defined
by Figure 9.
Dimensions in millimetres
Key
1 Maximum horizontal misalignment
2 Rail head
3 Rail foot
The acceptance criteria of the weld alignment are defined in the following Tables 1 and 2. The railway
authority shall specify categories from each of these tables. Values from within categories shall not be mixed.
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Measurements in millimetres
Category A B C D E F G H
Peaked weld Peak max. 1,0 1,0 0,5 0,5 0,3 0,3 0,2 0,3
Peak min. 0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,1
Flatness -0,20 -0,20 -0,20 -0,20 -0,20 -0,15 -0,10 -0,15
Dipped weld Dip max. -1,0 -0,5 -0,5 0,0 -0,2 -0,15 -0,1 0,0
Maximum grinding length 900 900 900 900 600 600 600 600
The weld collar shall be formed to the complete shape of the mould and shall be free from deformation.
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EN 14730-2:2006 (E)
There shall be no damage to the rail from escaped liquid metal, slag or splashes.
Limits for other visible defects shall be specified by the railway authority.
Other non-destructive examination shall be carried out in accordance with the requirements of the railway
authority where appropriate.
6.6 Documentation
The results from other non-destructive examinations that may have been specified.
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Annex A
(informative)
is hereby awarded to
NOTE The diploma may contain additional important data required by the railway authority.
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EN 14730-2:2006 (E)
Annex B
(informative)
Permit to Weld
PERMIT to WELD
Welder's Full name ___________ Stamp No ____________ Photo
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The above mentioned person has been deemed qualified and competent in the following additional areas:
Bibliography
[1] EN 13674-1, Railway applications Track Rail Part 1: Vignole railway rails 46 kg/m and above
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