SSÄ TEB-0343 Welding Technology Joint Welding of Track: Emma Selén

1(10)
Traffic administration TECHNICAL PROVISION Case/Doc. Id..

Strategic development SL-S-1785536
Traffic and infrastructure development version
Infosäk. class
2
K1 (Open)
Established by:
Faegh Adel Pour
Reviewed by:
Torbjörn Svensson
Established by:
Emma Selén
SSÄ TEB-0343 Welding technology

Joint welding of track
Roles name date
Information manager Faegh Adel Pour 2020-03-23
Reviewed by Torbjörn Svensson 2020-03-23
Determined by Emma Unosson Selén 2020-03-23
Region Stockholm Delivery address: Phone: +46 8 686 16 00 Seat: Stockholm

Transport Lindhagensgatan 100 Fax: 08-686 16 06 Org.nr: 232100-0016
Administration The freight reception Email: registrator.tf@sll.se www.sll.se
105 73 Stockholm 112 51 Stockholm
Visit us: Lindhagensgatan 100. Communications: Stadshagen/Thorildsplan

2(10)

Infosäk. class
2
K1 (Open)
Audit history
date Audit Reason for revision Information Fact-checked by
number manager
2020-03-23 2 General review, new Faegh Adel Pour Torbjörn Svensson
standards and names
3(10)

Infosäk. class
2
K1 (Open)
table of contents
1 generally .................................................................................................
#Pages[4] 4
2 WELDING CONDITIONS ............................................................... 4
#Pages[4]
2.1 generally.....................................................................................................
#Pages[4] 4
2.2 application .............................................................................................
#Pages[4] 4
2.3 Conditions ......................................................................................
#Pages[4] 4
3 HEAT TREATMENT BEFORE AND DURING WELDING ............ 5
#Pages[5]
3.1 generally.....................................................................................................
#Pages[5] 5
3.2 preheating ...........................................................................................
#Pages[5] 5
3.3 Increased working temperature
................................................................... 5
#Pages[5]
4 Filler ............................................................................
#Pages[5] 5
4.1 generally.....................................................................................................
#Pages[5] 5
4.2 Electrodes ................................................................................................
#Pages[5] 5
5 welding .............................................................................................
#Pages[6] 6
5.1 generally.....................................................................................................
#Pages[6] 6
5.2 Welding gap opening
................................................................................
#Pages[6] 6
5.3 Alignment .............................................................................................
#Pages[6] 6
5.4 Form welding .........................................................................................
#Pages[7] 7
5.5 Heat treatment after welding
#Pages[10] ..................................................... 10
6 grinding ................................................................................................
#Pages[10] 10
6.1 generally....................................................................................................
#Pages[10] 10
6.2 Tolerances ...............................................................................................
#Pages[10] 10
7 control .............................................................................................
#Pages[10] 10
4(10)

Infosäk. class
2
K1 (Open)
1 generally
For joint welding of the track, the form welding method is used. The
process is based on metal arc welding with coated electrodes.
Welding is done so that a welding gap is first made. After that, the foot of
the rail is welded supported by a base plate, after which welding the life
and head of the rail is done between copper jaws.
2 WELDING CONDITIONS
2.1 generally
Form welding goes under the heading «Hot work». A fact that requires
measures to prevent fire. Consultation is therefore required with
management on how to arrange welding fire protection.
2.2 application
The undertaking carrying out welding must have a quality assurance

equivalent to EN 729-4 or similar. Welding work must be carried out
according to the approved welding data sheet after EN 288.
Personnel to carry out welding operations shall have the necessary

competence in accordance with:
SS EN 287-1 or similar.
Taking into account the loads to which the track is subjected, welding class
D according to SS ISO 5817 (welding class WC according to BSK 94) shall
apply.
2.3 Conditions
· An unconditional prerequisite for the success of form welding in
terms of quality is that the ends of the joint are clean and absolutely
dry.
· Examine the ends ocularly. No cracks or instructions must be
provided before the start of injection mould welding.
· Grind away slag residues and cutting scratches from the ends before welding.
· Make sure that the preheating temperature is correct before

welding. Propane/oxygen burner is the most suitable preheating
equipment. Avoid preheating with acetylene/oxygen to avoid point
heat.
5(10)

Infosäk. class
2
K1 (Open)
3 HEAT TREATMENT BEFORE AND DURING

welding
3.1 generally
Depending on the grade of steel and its weldability, heat treatment before
and during welding can be used to obtain the mechanical properties
required. The track is made of lightly welded non-alloy steel, which creates
more favourable Conditions for welding work. for measurement Av.
Temperature bark approved digital temperature gauge or
temperature crayons used .
3.2 preheating
Preheating is a heating of the workpiece before welding begins so that it is
hot, when the work is initiated. Preheating should give the workpiece a
temperature at which the material is tough and also speed up the removal
of hydrogen.
Suitable preheating temperature is 60 - 100 °c, measured 75 mm from

welding site on either side.
3.3 Increased working temperature

Only the heat generated during the welding process during the work must
be supplied to the workpiece, i.e. no additional heat shall be added .
4 Filler
4.1 generally
Coated electrodes are used for form welding. To achieve the correct quality
of welding, the electrodes must be handled in accordance with the
instructions of the manufacturer and/or the manufacturer. Electrodes
electrodes must be
should be stored stored
dry. in cogs
During at 50 to 80
the work, °c. Injured
electrodes are discarded.
4.2 Electrodes
The welding data sheet must indicate which electrode to use.
following Electrodes can Recommended for form welding Av.

track:
6(10)

Infosäk. class
2
K1 (Open)
Steel grade electrode diameter Current/Voltage

mm A/V
Unalloyed steel
*) OK48.00 5,0 200-260/~23
OK 74.78 5,0 190-260/~24
*) See Track 750/Standard Technical Track SSÄ TEB-0342
5 welding
5.1 generally
The welding sequence for joint welding of the track is basically the same as
for joint welding of railway rails.
5.2 Welding gap opening
A welding gap of 15 – 17 mm is arranged between the ends of the current

rails. If necessary, the gap can be cut perpendicularly with
acetylene/oxygen burner or cut with a fixing cutting machine. After gas
cutting, impact residues shall be removed and cutting scratches deeper than
1,0 mm shall not be present.
5.3 Alignment
The ends should be oversalted about 2.0 – 2.5 mm. The guide value of the
over-elevation is measured by a 1.0 meter long ruler. The track should
always be welded completely sideways in curves and straight grooves and
should not be angular. See Figure 1
Figure 1. A maximum of 1 mm edge displacement is recommended in the foot.

7(10)

Infosäk. class
2
K1 (Open)
5.4 Form welding

Before welding, ensure that good contact is achieved between the
reconductor and the welding joint.
The ends are preheated to working temperature and then the root support
that can become type OK 21.21 or a copper back is mounted. When using
the last
mentioned, the arc shall never be directed towards the copper hill. If it is
copper oxide may form in the weld.
The foot of the track is welded together. The first string is welded without
widening and with a short arc towards the lower edge of the foot. The first
and second strings must not be bridged over. Binding errors can occur
when the third string is welded. Avoid changing the electrode while
welding the first three strands. See Figures 2, 3 and 4
The footplate is removed and the root starvation is checked.
Figure 2. This is how the first and, after electrode change, the second string is laid.
8(10)

Infosäk. class
2
K1 (Open)
Figure 3. How to place the third string after electrode replacement

.
Figure 4. The fourth and subsequent strings in the foot are welded with
.
widened strings all over the welding column
The copper jaws are mounted, then life and head are welded with a short
arc. When welding the transition between life and head, the arc must never
be directed towards the copper jaws. See Figures 5 and 6
9(10)

Infosäk. class
2
K1 (Open)
Figure 5. Installation of the copper jaws
Figure 6. To avoid pore formation in the weld, welding must be done with a
short arc. Electrode changes must be made so fast that the slag does not
have time to solidify.
Make sure that the melting bath floats in front of the arc evenly distributed
between the sides of the head. Continue welding without interruption until
the melting bath reaches the outer edges of the railhead. Weld with calm
pendulum movements. Make sure to bring the edges so that a clean
melting bath is achieved.
Interruptions other than for electrode replacements must not be made
when welding life and head. If there is a break, the copper jaws must be
removed and the weld must be cleaned before . welding can continue
10(10)

Infosäk. class
2
K1 (Open)
5.5 Heat treatment after welding
No heat treatment is required after welding.
6 grinding
6.1 generally
Rough grind immediately after welding. Leave about 1 mm of upper cargo
for shrinkage. If the weld is sanded flat with the upper surface, there is a
risk of under-goods when the welding hub has cooled .down. Fine-tune
when the joint has cooled
6.2 Tolerances
Grinding is done with a grinder based on the following tolerance requirements.
When checking with a 1 m long ruler:
Contact surface (top surface) ±0.6 mm
Edges ± 1.0 mm
7 control
After welding, the joint shall be checked visually and periodically with OFP
for the geometry of the joint and, where applicable, the joint. welding
discontinuities. After welding, the track shall be straight both sideways
and vertically, binding defects, melting ditches,. pores and cracks shall not
be present

SSÄ TEB-0343 Welding Technology Joint Welding of Track: Emma Selén

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SSÄ TEB-0343 Welding Technology Joint Welding of Track: Emma Selén

Uploaded by

Copyright:

Available Formats

1(10)

Traffic administration TECHNICAL PROVISION Case/Doc. Id..