TB 10461-2019Technical Regulations for Dynamic Acceptance for Mixed Passenger and Freight Railways Construction (English PDF)

3.5 in this edition and 3.5 in 2005 edition);

— MODIFY the inspection method (SEE Chapter 4 in this edition and

Chapter 4 in 2005 edition);

— CANCEL the impact test in the test method (SEE 4.6 in 2005 edition);

— MODIFY the inspection rules (SEE Chapter 5 in this edition and Chapter

3.1 Welding rail requirements

The new rails for thermit welding shall meet the requirements of Chapter 4 in

TB/T 1632.1-2014.

3.2 Welding material requirements

The materials for thermit welding of rails shall meet the requirements of TB/T

3322-2013.

3.3 Personnel requirements

Each welding operator shall hold a job training certificate issued by the technical

institution approved by the railway authority.

3.4 Process requirements

3.4.1 Welding process

3.4.1.1 The thermit welding process shall be implemented according to the

process manual provided by the supplier.

3.4.1.2 The supplier shall specify the required equipment, consumable

materials and detailed method of operation in the manual. The following

contents shall also be included.

a) number of main operators;

b) instructions for welding equipment;

c) flux corresponding to the rails of different grades and models;

d) preparation of rail ends and rail gap size;

e) detailed preheating parameters;

f) time range from the ignition of the flux to the casting of the molten steel;

g) the temperature at which the train is allowed to pass the welded joint;

h) requirements for welding environment (such as temperature, humidity, wind

power, etc.);

i) storage requirements and shelf lives of the flux and sand mold;

j) safety precautions.

3.4.2 Welding records

Welding operators shall document the welding process. REFER to Annex A for

the records. Records shall be retained for an overhaul period.

3.4.3 Joint marking

The welded joints (finished products) of each rail shall be marked. The markings

shall be 1m to 3m away from the welds. In addition, the markings shall be clear,

upright and identifiable for at least 5 years (or 1 overhaul cycle). The marking

method shall ensure that the welded joints (finished products) of each rail are

traceable based on the operation records.

3.5 Quality requirements

4.1 Appearance inspection

The methods for inspecting the flatness and surface quality shall meet the

requirements of Chapter 7 in TB/T 1632.1-2014.

4.2 Flaw detection

The flaw detection methods shall meet the requirements of Chapter 8 in TB/T

1632.1-2014.

4.3 Static bending test

The specimen requirements and test methods shall meet the requirements of

Chapter 10 in TB/T 1632.1-2014.The connector shall be loaded until it breaks.

4.4 Fatigue test

The specimen requirements and test methods shall meet the requirements of

Chapter 11 in TB/T 1632.1-2014.

4.5 Tensile test

The specimen requirements and test methods shall meet the requirements of

Chapter 12 in TB/T 1632.1-2014.

4.6 Hardness test

4.6.1 Weld hardness

The weld hardness test shall be carried out in a horizontal position at the weld

center on the top of rail (SEE Figure 2). TEST Brinell hardness at 3 points,

respectively. CALCULATE the average hardness value, recorded as the weld

hardness. TEST the 3 points on the parent metal on both sides of the weld

according to the positions shown in the figure, respectively. CALCULATE the

average hardness value, recorded as the average hardness of parent metal,

HP. The test methods shall meet the requirements of GB/T 231.1-2009.

welding production. The production inspection results shall meet the relevant

requirements of Chapter 3.Production shall be continued only after passing the

inspection.

5.3.5 The production inspection report shall include the following contents.

name of the rail welding organization, models and manufacturing plants of the

welding materials, names and job training certificate numbers of the main

welding operators, manufacturing plant of rails, rail shape, steel grade of rails,

delivery status of rails, inspection equipment, reasons for production inspection,

detailed inspection results, etc.

5.3.6 Re-inspection shall be carried out when one or more specimens fail to

pass the production inspection.

First re-inspection. DOUBLE the samples of non-conforming specimens for re-

inspection. After passing the inspection, it indicates that the production

inspection results are qualified. If one or more of the specimens fail, REPEAT

the inspection.

Second re-inspection. DOUBLE the samples of non-conforming specimens for

re-inspection. After passing the inspection, it indicates that the production

inspection results are qualified. If one or more of the specimens fail, the

production inspection results shall be determined to be unqualified.

5.4 R...

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