Railway Earthing CADWELD® – Earthing Bonds and Earthing Connections for Electrical Railways
Introduction Earthing Bonds ERICO manufactures prefabricated Earthing Bonds to customized specifications. These bonds are made from galvanized or copper cables. The ERICO CADWELD exothermic connection process is employed to attach an earth plate on one end of the bond and a steel connection plate on the other end. The steel connection plate is welded on site to reinforcing bars or steel beams. Low resistance to corrosion makes a permanently welded CADWELD bond the best solution for connections inside concrete structures. The property of low resistance is important for earthing and cathodic protection of reinforcing bars and steel beams in bridges and tunnels. However, other acceptable methods of connections are to combine a CADWELD connection and a mechanically crimped connection, or a mechanically crimped connection on both ends of the Earthing Bond. An equipotential bond between all current carrying elements in a structure and earth is required for personnel safety in case of catenary failure. A cathodic protection system prevents damage to steel work due to corrosion and reduces expensive maintenance.
How To The connection is made to reinforcing bars prior to pouring the concrete. The steel connection plate is connected the steel reinforcing bars by welding in place. The earth plate is temporarily bolted or nailed to the internal surface of the formwork. When the formwork is removed only the connecting surface of the earth plate appears. The earth plate is equipped with a threaded hole in order to connect the standard lug of an earth cable. When the reinforcing bars are discontinuous (expansion joints for example), Earthing Bonds connect them electrically by means of prefabricated jumpers made from an insulated flexible cable equipped on each end with a standard lug.
Benefits •Earthing Bonds (CADWELD - CADWELD) can be custom manufactured according to your specifications. •Earthing Bonds are available in 500 and 1000 mm lengths, and in 70 and 95 mm ≤ diameters. •ERICO offers three styles of construction: 1. CADWELD - CADWELD Earthing Bond. 2. CADWELD - Mechanically Crimped Earthing Bond, earth plate welded with CADWELD, steel plate mechanically crimped. 3. Crimped -Crimped Earthing Bond, earth plate and steel plate both mechanically crimped. • Increased resistance to corrosion with the use of the earthing bonds. • Reduces expensive maintenance • The use of Earthing Bonds provides increased safety to personnel.
1. Assembly Instructions 1.1 Connection with the casing
1.2. Connection with the reinforcement
Earthing plates DB-16 can be fastened to the casing as shown in the following. It has to be ensured that the earthing plate and casing are connected as closely together as possible. This is achieved by pressing the connection surface of the earthing plate plane-parallel against the casing.
The electrically connected conducting rods of the reinforcement, designated as earthing conductor, should have a minimum diameter of 16 mm. The flat welding tongues are connected to these rods by arc welding. To avoid reduction of the cross sectional area, the root of the welding seam must be at least 4 mm.
1.1.1
The casing is bored through and the earthing plate is drawn tight against the casing with an M16 bolt. This bolt is removed before removing the casing.
1.1.2
The earthing plate is connected to the casing with nails in the three indents. After removing the casing the three nail spikes are to be removed.
1.1.3
For an easy assembly, it is recommended to use a threaded rod with a nut and, depending on the casing material, with a washer. First, screw the threaded rod into the blind hole of the earthing plate by hand.
L + L < 90 mm
2. Summary of Types – Information The following diagrams show a selection of the most common types. The identification of each type is given on the bottom right hand side.
Linear design, flexible
FDBS-16 FDBC-16 FDB-16
RDB-16
SDB-16
TDB-16
ADB-16
FDB-16
Right angular design, flexible type WDB-16
WDB-16 Design 1
WDB-16 Design 5
WDB-16 Design 2
WDB-16 Design 6
WDB-16 Design 3
WDB-16 Design 7
WDB-16 Design 4
WDB-16 Design 8
WDB-16 Design 8
2.1 Design with solid conductor
2.3 Special designs
This type, KDB 16, is to be used on such concrete structures where flexible connections are not necessary (e.g. sound protection walls etc.). The standard length of the steel band is 400 mm, if required varying lengths can also be supplied.
With a few structures, e.g. viaduct piers, massproduced earthing bonds with several outputs have proven themselves. For orders of this kind, drawings or sketches should be provided to ERICO with all necessary information, such as spacing, lengths and connection pieces.
Design with steel band KDB-16
2.2 Standardized types
Standardized lengths 500 and 1000 mm
FDBC The solid deep-drawn copper earthing point is opened by boring. This makes a compressed joint possible according to DIN VDE 0220 part 2 in the factory. The coppered steel welding tongue is compressed onto the copper cable. This variation is only possible with straight designs.
FDBS
The FDBS is a combination of the well-established CADWELD welding joint and the newly introduced compression technique. The solid deep-drawn copper earthing point is welded to the copper cable in the factory by means of a CADWELD welded electrical connection. The coppered steel welding tongue is compressed onto the copper cable.
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Application Examples
Cross section
View
Example of a connection with an earthing connector
Example of a connection with wire 10 DIN 43 137-St34
Hex. head screw M16x25 A4 ISO 4017 Alternative : CuNil. 5Si Washer 18 DIN 126-Cu
Hex. head screw M16x20 A4 ISO 4017 Alternative : CuNil. 5Si
Wire 10 DIN 43137-St 34
Washer 18 DIN 126-Cu
3 Ebs 20.01.01
Earthing bond
All screw connections are to be tightly fastened with a wrench and of the angular steel fitted to the protruding protection against unintentional contact, without protruding protection against unintentional contact and a spacing between the floor space and the Connection for current collector stop rail parts under voltage less than 5m.
according to 4 Ebs. 15.03.17
Earthing of railings in the case of bridges
Earthing connector acc. to 4 Ebs 15.03.17
Design similar to 2Ebs 15.01.09 L60x6 DIN 1028 Current collector stop rail Cap
Protection against unintentional Cap contact Detail Y
Detail Y
Cross section A-A
railway earthed angular steel Earthing connector acc. to 4 Ebs 15.02.17
L60x6 DIN 1028
Detail Y in direction of arrow
Detail Y in direction of arrow
Bridging of: Bridge piers bridge decks expansion joints, concrete sections
Detail Z
Earthing connection acc. to 4 Ebs 15.03.17
Detail Z in direction of arrow
Cross section A-A in direction of arrow
Measures to be taken for earthing when including slack reinforcement Concrete Decks
Measures to be taken for earthing without including slack reinforcement
Spacing inner-outer reinforcement
Switch panel
Switch panel
Wall thickness 5-10mm
Earthing plate DB 16
Earthing plate DB 16
CADWELD-Welding Plastic screw DBM 16
sheathed with heat-shrink sleeving
with break-off position
Cable NYY-0 1 x 70/95 Cable NYY-0 1 x 70/95
CADWELD-Welding sheathed with heat-shrink sleeving
Connecting tongue 30x4 for building site connections. A or E welds considering DIN 4099
6 screws M16x40
Weld connection
This connection applies only to the fastening to switch panels It is to be removed before removing the casing.
DIN 933-St
Washer 18
The cross sectional area at the root of the welding seam must be at least 4 mm. during the building phase.
Assembly information
The fastening of the earthing plates to the switch panels can also be made with nails in the nail inserts. After removal of the casing the nail spikes that stick out are to be removed.
Remove foil before screwing on a conductor
The protection foil stuck on the front side of the earthing plates serves as a protection to threads during the building phase. It is to be removed before screwing in a conductor.
Accompanying drawings: 2 Ebs 02.05.19 3 Ebs 02.05.34 2 Ebs 15.01.09 4 Ebs 15.03.17 3 Ebs 20.01.01 Source of supply for earthing bonds: ERICO GmbH, 66851 Schwanenmühle
This connection applies to rods with a minimum diameter of 10 mm. For smaller diameters a longer terminal lug is to be selected which is to be welded on more often, as is appropriate. By the use of a casing carriage the seating of the earthing plates is determined accurately by borings. This seating may not be obstructed by reinforcement rods. When pressing on the reinforcement, sufficient room must remain for the earthing bonds. The earthing plate is to be fastened firmly to the casing carriage with the plastic screw DSM16. This screw is not to be removed before removing the casing. The head is to be knocked off with a hammer, the remaining part protects the threaded hole from of the subsequent damage and can be removed with a hexagonal socket key. When fitting earthing bonds it has to be ensured through the use of spacers or transposition of conductors that the bonds do not contact the casing skin. Only an adequate concrete decking protects against consequential damage due to corrosion. The vibrators are to be handled carefully during compacting of the concrete near the earthing plates. If struck directly there is a danger of breaking the plastic screw.
Usable for:
2 Ebs 15.01.20
BZA Munich Jan. 1992
Overhead line regulations
Issue Date Scale
Dimensions without reference to tolerance DIN Drawing revised
1.93
1991 Date Reviser 21.11. Checked 01.92 Standard
Name Stein
Information about the arrangement of railway earthing on buildings with CADWELD type earthing bonds Sheet 1 1 Sheet
CD 101.179e Changes
Date
Name
Orig. ERICO CD 101.143
Repl. for 2Ebs.15.01.20/05.85
Repl. by
1
1 1
2 1
2 1
2
1
1
2
1
1
1 1
1 Const.
r –
1 1 q
p
1 1 o
1 n m
1 1
1 l
1 1 k
j
1 1 i
1 1 g
h
f
2 1
1 1 e
d
2 1
1 c
1 a
b
Cable lug 4 Ebs 15.13.22/b Cable lug 4 Ebs 15.13.22/a Cable lug DIN 46 235 12-70-S Cable lug DIN 46 235 12-50-S Cable lug DIN 46 235 16-70-S Cable lug DIN 46 235 16-50-S Cable N YY-0 1 x70mm Cable N YY-0 1 x50 mm Component
1 0 7 5 4 2 4 3 2 1 3 2 5 4 9 8 7 7 6 6 6 6 5 5 5 5 7 7 7 7 6 6 5 5 5 5 5 8 8 8 8 5 5 5 5 5 5 – 5 0 0 0 0 0 0 6 6 6 6 0 0 0 0 0 0 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
Construction a-d and g-h: Construction e-f and i-j: Construction k-l: Construction m-n: Construction p-o: Construction q-r:
Connection of components made of steel/copper1) with steel/copper1) Connection of components made of steel/copper1) with rail Connection of components made of aluminum with aluminum Connection of components made of steel/copper1) with aluminum Connection of components made of aluminum with rail Connection of rail with rail
Screws to be used: N 24 017, length as required For components made of Al and Al alloys: made of Cu and Cu alloys: made of steel:
A2 2) A2 2) coating DIN 267, part 10; tZn
1) on Cu components also cable lug DIN 46235 12/16-50/70 permissible 2) bare with lubricant 3) length as required 4) state length of cable with order Usable for:
4 Ebs. 15.03.17
Halle 20.05.97
Overhead line regulations NGT 52
Dimensions without reference to tolerance DIN Date Reviser 19.05.97 Checked Standard
Bem. with cross ref. to 3 Ebs 15.02.01 rem. Resp. Change
03.00 Date
Gla Name
Issue Date Scale
Overhead Line Name Kurzbach
Deutsche Bahn AG Electrical and machine engineering Overhead line Orig.
Earthing Connectors Sheet Sheet Repl. for issue 09 95
Repl. by
3. Reference The following drawings and standards were used when creating this document: - Technical release from 05.09.2001 - 3 Ebs. 15.03.19 BL.1
CADWELD - Earthing Bonds
- 2 Ebs. 15.01.20
Information about the arrangement of railway earthing on buildings with CADWELD type earthing bonds
- 4 Ebs .15.03.17
Earthing connectors
Deutsche Bahn Research and Technology Centre Overhead lines Theodor-Heuss-Allee 7 60486 Frankfurt am Main
Publication: EBA Report 22
TEL Frankfurt/Main TEL 2 Munich TZF 73 Frankfurt/Main ERICO GmbH
Technical Release 1. The present technical release applies to the company
ERICO GmbH 66851 Schwanenmühle 2. The technical release applies to the supply of the following equipment to the DB AG:
FDBC-16 earthing bonds FDBS-16 earthing bonds 3. The following documentation, test certificates and other details were checked, and form the basis of the technical release:
- EBA authorization for electronic systems no.: 201090/8 - Investigation of the short circuit behavior, Report no.: 98471638.000-HVL 99-1322, of the KEMA Netherlands B.V. - Separation testing by the company ERICO, Test report no.: PN0023T1 - Drawing 3 Ebs 15.03.19 Sht. 1 4. Additional condition: 5. The technical release presented is valid until revoked.
Frankfurt/Main, 05.09.2001
(Dipl.-Ing. Borgwardt)
We reserve the right to make changes to the information given in this brochure where we think that the changes are necessary or advantageous. This brochure gives only introductory information about products and services. It is not a constituent part of a contract. The company is not liable for loss or damage arising from non-compliance with the instructions or with different products.
www.erico.com
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