Pedoman instalasi dan perawatan wesel China Railway Shanhaiguan Bridge Group

EMT

Engineering Manual Track

PEDOMAN INSTALASI DAN PERAWATAN WESEL CHINA RAILWAY SHANHAIGUAN BRIDGE GROUP

VERSI 1.0 DITERBITKAN MEI 2013

Disclaimer  This document was prepared for use on the Bojonegoro – Surabaya Pasarturi Double Tracking Project only. BOJOSURO Project makes no warranties, express or implied, that compliance with the contents of this docume document nt shall be sufficient sufficient to ensure safe systems systems or work or operation. It is the the docum document ent user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by BOJOSURO Project. BOJOSURO Project accepts no liability whatsoever in relation to the use of this document by any party, and BOJOSURO Project excludes any liablility which arrises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without prior consent of BOJOSURO Project.

EMT

Turnout

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Rail product specifications Turnout is an important part of tracks. Its life is closely related to its own quality, laying quality, and maintenance quality. So, there are rules for the operation, laying, welding and maintenance to promote its life. 1 General requirements （1） At site handing and delivery shall follow laying guide； （2）Before laying, turnouts dismantling is not permitted except the packing between layers; （3）Special lifting tools are required for loading, unloading and transportation; （ 4 ） All components are not deformed, damaged or polluted during handing, storage and

transportation； 2 Delivery Delivery fo rm 2.1 2.1 Rail Rail co mponents packing Each switch packing unit includes two sets of switches (1 switches= 2 stock rails + 2 tongue rails) in two layers. If there is one set switches left, it is packed with itself. Each crossing packing unit includes two crossings in one layer. The guard rails are packed according to customer requirements. Each lead rail packing unit includes two sets lead rails. Packing form and lifting point refer to pictures from 1 to 4. 2.2 2.2 Rail Rail com ponents li fting requirements （1）The lifting cranes shall have enough lifting capacity. The crossing beam, soft nylon chains shall

meet lifting point requirements. Special notice: when the lifting point needs to be changed, it shall get the permission of site engineer. （2）When rail components are lifting, workers shall prevent turnover. 2.3

Rail Rail work ing requirements

（1）If the length of switch and stock rail components, and crossings are over 15m, large cranes shall

be used for lifting. The lifting point shall be around the gravity center or marked lifting point. Single point slinging is stricty prohibited. When handing, the speed shall be enough slow to prevent impact. it is difficute for using large crances. slide bars are used for unloading.but slide speed shall be well controlled.At the same tine ,There is cushion at the slide bar bottom to preventimpact rail components. （2）The components falling point shall be the components bottom surface, and component side surface falling will cause deformation. （3）Turnout main components shall be laid on the flat ground. No random laying is not allowed in case of quality problems. （4）switch rail and stock rail components are all well adjusted before delivery, so they shall be unloaded as a whole part to keep the quality. Large transportation machine shall be used for spare parts transportation and lifting. When manual （5） is used, there shall be enough workers to avoid accident or damages. Special attention shall be paid for  switch rail and stock rail components handling. Page 1 of 18 pages

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Picture 1 One One layer and and two layers packing struc ture of swit ches, and lifting po ints

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Picture 3

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High manganese steel steel frog packi ng

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Picture 3

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High manganese steel steel frog packi ng

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Picture 4

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Lead rail rail and guard rail packin g

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Picture 4

Lead rail rail and guard rail packin g

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（6）When turnout components need to be laid by multiple layers during transportation or storage, the sleepers

at the same layer shall be laid equally(3m distance is acceptable, within 4 meters). All the sleepers shall be in line either same layer or different layer. There shall be maximum 4 layers for switch rail and stock rail components, and movable-point frog. 2.4

Rail Rail compo nents lifting requirements

（1）The lifting point positions of stock rails,tonque rails and high manganese steel frogs are marked in the

packing list. （2）For load rail lifting,please refer to picture 5 ,the channel steal is used in packing to provent turn over.

1

2

1m ≤7m

L≤6m

L≤6m ≤25m

≤7m

（6）When turnout components need to be laid by multiple layers during transportation or storage, the sleepers

at the same layer shall be laid equally(3m distance is acceptable, within 4 meters). All the sleepers shall be in line either same layer or different layer. There shall be maximum 4 layers for switch rail and stock rail components, and movable-point frog. 2.4

Rail Rail compo nents lifting requirements

（1）The lifting point positions of stock rails,tonque rails and high manganese steel frogs are marked in the

packing list. （2）For load rail lifting,please refer to picture 5 ,the channel steal is used in packing to provent turn over.

1

2

1m ≤7m

L≤6m

L≤6m

≤7m

≤25m

Picture 5 Lead rails rails lift ing （3）For each single rail piece (length from 15m to 25m), the adjacent lifting points distance shall be within 6 meters. When each rail is lifted, the lifting point position refers to picture 6. The lifting point length at rail ends shall be within 8 meters. When lifting the switch rail, all the lifting points shall move 1m right. Fixed locking devices shall be used, and flexible ones are not allowed.

1

≤8m

2

≤6m

≤6m ≤25m

Picture 6

Lifting points position

≤8m

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When the rail length is over 25 meters, special flexible multiple points lifting devices with the length over 30 meters shall be use for loading and unloading. The adjacent lifting points distance shall be within 3 meters. The lifting position refers to picture 7.

1

......

2 3

A≤6m

L≤3m

L≤3m

L≤3m

L≤3m

L≤3m

L≤3m

L≤3m

L≤3m

L≤3m

A≤6m

≥25m

Picture 7 2.5

Long rail lifting points position

Storage requirements

（1）Turnout storage ground shall be smooth and hard. The flatness is not more than 10mm/10m. The yards

shall have anti-water measurements and drainage system. No stagnant water is allowed. （2）The turnout components is stored by the classification. Turnout storage shall be stable and easy lifting. There is enough room for lifting cranes or cars to travel. It shall prevent rain and rust too. （3）The storage of stock and tongue rails shall be 2 layers at most. Other rail components shall be within 4 layers. The buffering pad, wood block for example, shall be placed between component and ground. Each layer shall be flat placed by pads. Pads are placed vertically. Pads requirements refer to ex-workshop transportation plan. 2.6 Hand over and t ake over  （1） All turnout components shall be inspected at site. （2）The turnout type and quantity shall be inspected by delivery list. （3）switch rail close contact and straight switch rail alignment is important inspection items. Inspect packing,

fixing and no scratch is allowed. （4）fill the handover and take over report after delivery,three parties signature is needed . 3

assembly and laid

The construction company can do the assembly and laying according to its own custom. This manual only works as reference. 3.1

Bearers laying

acc ording to serial number. （1）Bearers are laid from front to end according （2）Choose the right direction. Fix the first bearer position and direction. （3） Adjust bearer distance, and use long ruler. No accumulated measurement is allowed. Specially take care of 

bearer distance at traction points and a nd the value shall be not less than the designing designin g geometry. Page 6 of 18 pages

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an d keep stable. The first bearer is the reference bearer, and laid at the same （4）Lay bearers in right position and time with item 3. Bearer’s position fixing shall refer to the first bearer bolt hole of straight direction of outside track. Because baseplates settings are different, the outside first bolt hole shall not be in line, so please take care of  when laying the bearers. For bearers well laid, two rulers are parallel, and use bearer distance to adjust. （5） Adjust height, and rough adjustment shall be done for obvious differences (20mm differences). （6）Check bearer distance, right position and total length. （7）Fix bearer in time. （8）Inspection and confirm. If the bearer laying is qualified, the following work shall begin. Bearer laying and adjustment refer to picture 8.

picture 8 3.2 3.2.1

Bearer Bearer laying and adjustment

Straight stock rail and curve tongue rail laying Indonesia 1:10 1:10 simple turnout straight s tock rail and curve tong ue rail laying

（1）Confirm heel end offset baseplate in good condition. （2）lay straight direction baseplates and guard plates until crossing end part. （3）Lay straight direction slide baseplates around the installation position for easy installation.

Take care of the lifting position po sition and methods of switch rail and stock rail components, and the speed shall be （4） slow. Single lifting point is not allowed. The bearer position shall be kept, and stable when operated by manual force.

（5）Fix stock rail front part position, and direction.

Please refer to picture 9 for straight stock rail and curve switch rail components adjustment. Page 7 of 18 pages

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Picture 9 Straight stock rail and curve switc h rail adjustment operation （6）Install slide baseplates on stock rail, and put baseplate on the right position. The switch rail shall not be dismantled if possible. The slide baseplate installation of Indonesia 1:10 turnouts: first put base plate on rails; second, put spring shim under slide base plate and fixed on the channel; last, knock dowel into base plate (no completed installed state, when whole set turnout is adjusted, then knock dowel completely into baseplate) and fix fasteners. Slide base plate installation refers to picture 10.

Install spring shim

Inco Incom m lete lete sta state te

picture 10 （7）Lay straight direction rails.

1:10 1:10 simple tur nout s lide baseplate installation

Please refer to picture 11 for straight stock rail and curve c urve switch rail laying. Straight stock rail and curve switch rail

picture 11 Laying of straight stock r ail and curve switch rail （8）Reconfirm stock rail direction and bearer in right state. （9）Confirm heel end offset baseplate in good condition; Connection slide baseplates and bearers.

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（10）Baseplates of straight stock rail is laid and installed until crossing end part.

Baseplate fasteners installation refer to picture 12.

Tightening in turn

picture 12 Pad Pad fastener in stallation Baseplate installation: first put rail into bearing channel; second, put T bolt into proper position; last put and fix buckle plate, double spring washer, washer, and nut. Install straight direction spike (first install 2 spikes of diagonal line). Make sure the stock rail direction, and bearer relative position, and bearer distance is right. Please refer to picture 13.

Diagonal line installation

picture 13 3.2.2

Spike pad diagrams diagrams of i nstallation

Indonesia 1:12 1:12 simple turnout straight s tock rail and curve switc h rail laying

The slide plate has been assembled on the stock rail and switch rail of No.12 turnout when lay straight stock and curve switch rail, the 3.2.1 steps (1) (2) (4) (5) (7) (8) (9) (10) shall be followed. 3.3

Curve stock rail and straight switch rail laying

Keep front part and straight stock rail stable and in right position, posi tion, and stability. Or keep the distance between straight tongue rail and curve switch rail within 2mm. Others refer to 3.2 installation process. Refer to picture 14 for curve stock rail and straight switch rail laying.

Curve stock rail and straight switch rail

picture 14

Laying of curve stock rail and straight switch rail Page 9 of 18 pages

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High Manganese Manganese steel steel cros sings laying

Take care of sudden falling. fall ing. （1）When assemble crossings, manual force shall be used. Take （2） Adjust and confirm position and distance of crossings and bearers. （3）Install straight direction baseplate fastening system. Check straight direction and turnout total length at this

period. Adjust or grinding if needed. （4）Make straight direction rail end as the reference to adjust crossing end geometry and direction. The location and direction refers to picture15。

picture 15 High manganese manganese crossing adjust ment opration （5）Measure straight direction turnout total length, and confirm crossing vertical position. （6）frog laying refers to picture 16.

High manganese steel frog

picture 16 Laying high manganese crossi ng （7）Check crossing outside fastening according to straight direction (adjustment is allowed). 3.5

Others

（1）Other baseplates laying and connection （2）Lead rail laying

Dismantle lead rail packing and keep packing materials well. Lay and fix lead rails according to laying drawing requirements. Please refer to picture 17 for lead rail laying.

picture 17

Laying lead rail

（3）Lead rail connection, fastener installation and fixing （4）connecting baseplate with bearers. （5）Lay check rail . Fixed nose protection has to be more than 1033mm, Free wheel passage has to be less

than 995mm,measure point is 20 to 40 mm section of switch rail。 Page 10 of 18 pages

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4  At si te adju ad ju stmen st mentt 4.1

Laying state adjustment

（1）Confirm turnout front part and direction. （2）Rough adjustment of the height, especially switches, crossings, and guard rail parts. （3）Gauge adjustment and close contact adjustment at switches part:

1） Confirm the installation state of curve and straight switch rails. If there is a problem, it shall be solved. 2） Adjust the dimension of stock rail two gauge lines according to picture 18. The dimension refers to gauge at switch rail front part, stock rail distance.；  e  g  u  a   k  g  c  o   l   t   i  s  a  r

 e  g  u  a   k  g  c  o   l   t   i  s  a  r

 e  g  u  a   k  g  c  o   l   t   i  s  a  r

 e  g  u  a   k  g  c  o   l   i   t  s  a  r

Tongue rail planing and cutting point

Picture18

Stock rail layout dimension

3） Confirm the gauge between straight tongue rail fixing end to heel end. Adjust switches direction. according to picture 19.   t  e  s   D   f   f  o

 e  g   A u  a  g

 e  g   B u  a  g

  t  e   C s   f   f  o

Picture19

offset detection

4） Adjust straight switch rail aligment； 5） Adjust straight and side direction gauge of the part after close contact. 6） Adjust close contact, offset and layout of straight stock rail and curveswitch rail. 7） Adjust the offset from the close contact part(curve stock rail and straight switch rail) to tongue rail heel part. Adjust the close contact of straight switch rail and curve stock rail with the reference adjustment of gauge and switch rail alignment. 8） Adjust straight and side direction gauge of the part after close contac 9） Tongue rail bottom and slide bed b ed plate meet requirements.

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（4）Offset and gauge adjustment

Offset adjustment is mainly upon stop block, distance block, offset baseplates and bearer position. Offset adjustment shall be adjusted at the same time with gauge adjustment. 1:10 simple turnout offset drawing refers to picture 20

picture 20

UIC54 rail 1:10simple turnout offset of switch stop

1:12 simple turnout offset drawing refers to picture pict ure 21

picture 21

UIC54 rail 1:12simple turnout offset of switch stop

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（5）Guard rail installation and adjustment: when guard rail flange way is not suitable, please use

adjustment shim between rail brace and guard rail. Refer to picture 22.

Guard rails adjustment

picture 22

Guard rails adjustment

（6）Level and direction adjustment. （7）Tongue rail close contact and all parts gauge adjustment meet requirements. （8）Fastener shall be well fastened. （9）Track system inspection, quality evaluation, and partial adjustment. （10）Electric transformation device installation and adjustment. （11） All items close contact, adjustment and electric system test. （12）Markings and at side cleaning. （13）If the turnout is laid on track, there shall no effects or minimum effects on turnouts caused by basic

construction. If the turnout is trial laid not on track, please take care of working process effects on turnout working state. Turnouts shall be re-examined and adjustment when laid on track. 4.2  Adju  Ad ju stmen st men t n otic ot ic e 4.2.1

Bearers

（1） Before installation, each bearer shall be marked by thread to mark the center line that is the reference

for bearer stable and in right direction. （2） Bearer top surface height shall be within ±20mm before rail connection. The rail top surface shall be at

the same level after rail connection. （3） Please take care of point machine installation for ballast laying that shall meet designing requirements. （4） Bearer, horizontal level, stable and right position, and distance shall be adjust as earlier as possible to

avoid do it again. 4.2.2

Rail Rail com ponents Take care of rail quality during installation and adjustment. Page 13 of 18 pages

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（1）The work of loading, unloading, transportation shall meet requirements. （2）In order to realize the successful assembly at site, there are strict requirements on bending(height and

horizontal level). The rail shall be inspected before using. If there is relatively big difference, the problem should be solved. There is at least 150T pressing machine at site. （3）We mentioned turnout front end position and stability during the assembly. If the two points are not strictly controlled, there will be much repeating work and not good laying condition. Base plate moves to the outside limited position, and the bolts are well driven. Then install and adjust gauge block. 4.2.3

Torsion adjustment 1）The spring washer of bolt -joint will be twisted to flat to satisfy with torsion reqarment. 2）the torsion of block ‘s bolts should be 600Nm。 3）the torsion of rail bracers’s bolts should be not less than 150 Nm。

4.2.4 Others The sub-grade and ballasted bed shall meet related technical requirements. The sub-grade shall be stable with good drainage system. Any loose, freeze and un-equal falling are not allowed.

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Maintenance

Turnout maintenance shall follow track maintenance regulation and technical pamphlet. Take care of the following contents. 5.1

Stock rail and switch rail maintenance

5.1.1 When stock rail and switch rail are laid on track, gauge, horizontal level, direction and height of all parts shall be inspected in time. 5.1.2 Early stage of laying: when there is 1mm fins on switch rail, please grind in time to avoid large size material tearing. 5.1.3 Early stage of laying: check the bolt fastening of the switches part. If the position limited device and bolts of distance block loose, measurements shall be taken such as fixing or replacing. 5.1.4 Take care of the close cont contact act of switch rail. If there is i s a problem, it shall be solved in time. 5.1.5 Remove the clamped items that affect the switch rail close contact. 5.1.6 Keep slide be plate clean. cle an. Repairing welding or replacing is needed if necessary. 5.1.7 Observation and maintenance of position limited device When the rail temperature is stable and the welding is finished, the relative position of position limited device shall not be adjust at random. When the temperature changes, the two sides gaps within the two parts of position limited device are not matched, or there is contact, it is acceptable. No adjustment is needed. If the movement of straight and curve stock rails is relatively longer and affects the working of point machine, adjustment is needed. 5.1.8 When the movement of the front part of switch rail is over tolerance, inspections shall be taken in time, such as whether the fastening part is loose or not, whether position limited device is damaged or  not, whether un-proper maintenance causes the release of stress force or not. If the problem is confirmed, measurements shall be taken to do the repairing, such as adjust switch rail and stock rail relative position in time, and fix position limited device location. 5.1.9 Inspect fastening part state frequently. If the problem is confirmed, measurements shall be taken in time. 5.1.10 During the high temperature seasons, observe the changes of the part before position limited device and part connecting track. If changes happen, please cool by pouring cold water. 5.2

Stock rail and switch rail maintenance

5.2.1 The switch rail needs to be repaired or replaced when the following phenomenon happens. 5.2.1.1 The close contact between tongue rail and stock rail is over tolerance. 5.2.1.2 switch rail is over bended switch and the the gauge can’t meet meet requirement. 5.2.1.3 For the part that switch rail section width is more than 35mm. That part rail top surface is higher  than stock rail surface. 5.2.1.4 For the part that switch rail section width equal or more than 50mm, and switch rail top surface is more than 1.5mm lower than the stock rail surface. 5.2.1.5 Damage reaches related standards. 5.2.2 The stock rail needs to be repaired or replaced when the following phenomenon happens. 5.2.2.1 Stock rail bending point position is wrong or bending dimension can’t meet requirements. 5.2.2.2 Stock rail vertical worn over 4mm in track. 5.2.3 There are two bolt missing or failing to work at the same part (or same distance block), and the turnout shall be removed from tracks. Page 15 of 18 pages

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5.2.4  All parts of switches shall be completed with good function. If there is any missing, please complete in time. When the following condition happens, please repair or replace. 5.2.4.1 Bolt, stop block, and distance block is damaged, deformed or failed to work. 5.2.4.2 Slide base plate is damaged, or deformed. Slide bed plate worn is over 2.5mm. 5.2.4.3 Pad is damaged or failed to work. 5.2.4.4 Brace is damaged, deformed or failed to work. 5.2.4.5 The welding crack appears on base plate. 5.2.4.6 All kinds of elastic fastenings is damaged or failed to work. 5.2.4.7 All 5.2.4.7 All kinds of gauge adjustment block is damaged or failed to work.. 5.3

High Manganese Manganese steel steel frog laying and maintaining notices

5.3.1 Laying and maintenance related records When crossings are laid on track, please fill usage records including type, time, location and serial number. frogs shall be well recorded throughout the whole life, such as problem occurring time, phenomenon, transportation capacity, maintenance record, remove time, reason, life transportation capacity, solving methods, results and etc. 5.3.2 Grind over fins  At the early stage of using, there will be over fins on the surface that trains pass. These fins shall be ground in time to reduce crack forming possibility. It is a must maintenance method for longer life and larger capacity. 5.3.3 Frequent ballast temping Promote and maintain the hardness and stability of ballast is one of the key methods for longer life and larger capacity. It can reduce the results of impact, and reduce crack happening possibility. The ballast at crossing part shall be well temped. The ballast shall be in good condition. At the beginning of  laying, please take care of observation. If any problem happens, please maintain in time. When the track goes to the stable period, the maintenance shall be done according to related requirements. Besides ballast bed stability, observations shall be done on the direction, smoothness. All these have relatively efforts on the crossing usage. The crossing life can be expanded if there is in time maintenance. 5.3.4 There is frequent observation at the early stage of crossing laying. The observation shall accord to related rules at the stable period.Frequent observation of crossings can help us to get quality information in time, so the problems can be solved in time. If the problem is solved at the early state, crossing life can be expanded. 5.3.5 Repair welding For all kinds of defects appearing during crossing usage, in time and effectively repairing measurements shall be taken according to related rules. According to American counterpart, the 200 million tons passing capacity is based on in time repairing welding. On track welding is also an international convention, including requirements in UIC standards. High manganese crossing, especially high solid manganese crossing, has solid layers in deep part. Thus provide the solid basis for the repairing welding, and guarantee the integrity and consistency for  the repaired parts. In conclusion, cracks and tearing shall be repaired in time.

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High Manganese Manganese steel steel cros sing welding repairing op eration rules

5.4.1 Welding material and equipment 5.4.1.1 KD-286 welding rods KD-286 welding rods are low carbon manganese steel formula. The electric arc is stable and second time welding is easy. Cinder removal is easy, and seam looks nice. 5.4.1.2 Light welding repairing equipment  AXQ1-200-3 light internal combustion arc welding generators and the matched 2V-0.36/7 internal combustion air pressing machine are both lighter and easy moving. 5.4.2 Welding repairing technique requirements 5.4.2.1 Before welding, take care of protection; remove the crack completely; remove the oxidize layer, oil damage, and rust until metal shining; when particle test is qualified, prepare welding. 5.4.2.2 No gas cutting or electric arc cutting is allowed, but use carbon gas gouging or sand grinder  gouging. When one piece carbon rod is used during carbon gouging, the gouging area temperature shall be cooled down below 60Ԩ immediately by water. The current of electric arc gouging is upon carbon rod diameter. When uses the most powerful current, the result will be best. The recommended current is as follows: a、 When the diameter is 4.8mm, the recommended current is 300A. b、 When the diameter is 6.4mm, the recommended current is 400A. Operation steps： (1) Before cutting, start the gas gouging gun. The gun can also be used for cutting area cooling. (2) Keep proper angle to make the metal scrap is removed from carbon rod back to forth by gas. The recommended angle is 40°. (3) If the gouging gun makes the airflow impact carbon rod from upper direction or front direction, metal can’t be removed and the cutting surface appears oxide layer. (4) The gouging depth and shape is upon carbon rod angle and welding speed. If the gouging is narrow and deep, the angle shall be sharp and the welding speed is slow. If the gouging is shallow, the angle shall be not sharp and the welding speed is fast. (5) The gouging width is upon carbon rod dimension. Usually, the gouging is 3.2mm larger than carbon rod diameter. (6) The welding speed shall be even. The proper speed makes good appearance without oxide. o xide. (7) During gouging, the cutting direction shall keep short arc operation with quick speed to remove metal. (8) Low or unstable voltage makes splashing, discontinuity and un-complete cutting. (9) If the welding speed is too slow, there will be un-regular gouging. (10) If the electrode is wrong, the electrode will become hot quickly and make electric arc splashing. (11) If there is any melted cinder on the cutting edge, that means the air pressure is too low. The cutting surface shall be ground. Oxide, cinder and other un-regular traces shall be removed. The finished cutting surface shall be clean and smooth. 5.4.2.3 The welding rods shall not be polluted and humidity. Rods shall be placed into sealed boxes for  use. If condition allowed, stay 1 hour in baking box with the temperature from 200Ԩ to 250Ԩ, and then adjust to about 100Ԩ for usage. 5.4.2.4 Strictly follow the following welding repairing technique principles: reverse connection of direct current, small current and short arc, different section, different layer, and skip welding. 5.4.3 Basic working Page 17 of 18 pages

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（1）Use small current if possible. If the current is too strong, the parent metal will have cracks

due to over heat. If the current is too weak, it will cause ca use incomplete melting and gas hole hol e easily. （2）Use short electric arc with the length around 2 meters. If the arch is too long, the parent metal will not fully melted, and cause gas hole, and un-smoothness on the welding surface. （3）The welding bead width is not over 16mm. The bead length is a rod welding length. The thickness is 2mm. The welding rod and welding part form an angle about 40°. The welding speed shall be equal, and melt completely. The rod welding traces likes crescent shape. The distance between rod and welding part is about 2 meters that higher or lower will cause arc burning out. If the welding bead is too narrow, the hardness value is high, and cause crack. If the welding bead is too long, there will be cracks too due to over heat. （4）Repair welding shall use different layer, different section, skipping, and reverse transition methods. The section shall be equally allocated, and it is better to use a chalk to mark. If the section is not equally allocated, there will be over heating and cause cracks. （5）The first layer welding rods shall be 286φ3.2. When the temperature falls to 50Ԩ below, use 286φ4.0 to do build up welding. When finish one section welding, the temperature falls to 60Ԩ below and then next welding continuous. If the repair welding area is too large, it is better to do water pouring for each layer for quick cooling. When finish the repair welding of one section, a hammer is used to beat lightly from the seam （6） end to front. Thus can release internal force, avoid crack, and improve metal structure. It shall be beaten slightly. appe ars. The arc starting shall （7）The welding groove shall be fulfilled, otherwise web crack will appears. not be started at the part lacking metal. If the bead is not completed molten, it will cause incomplete welding. （8）The steel wire shall be used to remove cinder, and use cotton pieces to keep clean. If the surface is not clean, there will be gas hole and slag inclusion. The second layer overlaps with the first layer about 1/3 to 1/2 to keep welding bead quality. （9）No preheating or post heating is recommended. （10）Reverse the direction of adjacent beads can reduce stress force. （11）The start or finish point of welding shall not at the edge part. （12）The bead had better higher than the parent materials to keep surface smoothness. （13）When the repair welding is operated at site, the temperature is not less than 5Ԩ , and the

rail temperature after train passing is not more than 300Ԩ. No repairing work during thunder, rain or  fog. 3. Grinding work （1）It shall be ground to required dimension and keep smooth after welding. （2）The hardness shall be tested and the value from HB180 to 200. （3）If there is a little deforming appears after welding, workers can do the build up welding at the opposite side to produce opposite deform. （4）Fill record report after inspection. （5）Grind flange way at internal to remove metal movement.

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