Railway Earthing

CADWELD

Earthing Bonds and Earthing

Connections for Electrical Railways
2 Ph: 216-351-3060
www.erico.com
Introduction
Earthing Bonds
ERICO manufactures prefabricated earthing bonds to
customized specifications. These bonds are made
from galvanized or copper cables. The 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 iswelded on site to reinforcing bars,
flat steel strip or steel beams, whatever isspecified as
a conductor.
Low resistance to corrosion makes a permanently
welded CADWELD bond the best solution for con-
nections 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
methodsof 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.
FDB-16
How To
The connection is made to reinforcing bars prior to
pouring the concrete. The steel connection plate is
connected to the steel reinforcing bars by welding in
place. The earthing plate is temporarily bolted or
nailed to the internal surface of the formwork.
When the formwork is removed, only the contact
surface of the earthing plate appears. The earthing
plate is equipped with a threaded hole in order to
connect a standard cable lug of an earthing conduc-
tor. When the reinforcing bars are discontinued (for
example expansion joints), earthing bonds connect
them electrically by the use of prefabricated
jumpers, made from an insulated flexible cable
equipped with a standard cable lug on each end.
Benefits
Earthing Bonds (CADWELD - CADWELD) can be
custom manufactured according to your specifica-
tions
Earthing Bonds are available in 500 and 1000 mm
lengths, and in 70 and 95 mm
2
diameters
ERICO offers three styles of construction:
1. CADWELD - CADWELD Earthing Bond
2. CADWELD - Mechanically Crimped Earthing
Bond, earthing 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
WARNING
ERICO products shall be installed and used only as indicated in ERICOs product instruction sheets and training materials. Instruction sheets are available at
www.erico.com and from your ERICO customer service representative. Improper installation, misuse, misapplication or other failure to completely follow ERICOs
instructions and warnings may cause product malfunction, property damage, serious bodily injury and death.
WARRANTY
ERICO products are warranted to be free from defects in material and workmanship at the time of shipment. NO OTHER WARRANTY, WHETHER EXPRESS OR
IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), SHALL EXIST IN CONNECTION WITH THE
SALE OR USE OF ANY ERICO PRODUCTS. Claims for errors, shortages, defects or nonconformities ascertainable upon inspection must be made in writing within
5 days after Buyer's receipt of products. All other claims must be made in writing to ERICO within 6 months from the date of shipment or transport. Products
claimed to be nonconforming or defective must, upon ERICO's prior written approval in accordance with its standard terms and procedures governing returns,
promptly be returned to ERICO for inspection. Claims not made as provided above and within the applicable time period will be barred. ERICO shall in no event be
responsible if the products have not been stored or used in accordance with its specifications and recommended procedures. ERICO will, at its option, either repair
or replace nonconforming or defective products for which it is responsible or return the purchase price to the Buyer. THE FOREGOING STATES BUYERS EXCLU-
SIVE REMEDY FOR ANY BREACH OF ERICO WARRANTY AND FOR ANY CLAIM, WHETHER SOUNDING IN CONTRACT, TORT OR NEGLIGENCE, FOR
LOSS OR INJURY CAUSED BY THE SALE OR USE OF ANY PRODUCT.
LIMITATION OF LIABILITY
ERICO excludes all liability except such liability that is directly attributable to the willful or gross negligence of ERICO's employees. Should ERICO be held liable its
liability shall in no event exceed the total purchase price under the contract. ERICO SHALL IN NO EVENT BE RESPONSIBLE FOR ANY LOSS OF BUSINESS OR
PROFITS, DOWNTIME OR DELAY, LABOR, REPAIR OR MATERIAL COSTS OR ANY SIMILAR OR DISSIMILAR CONSEQUENTIAL LOSS OR DAMAGE
INCURRED BY BUYER.
3
1.1 Connection with the casing
Earthing plates DB-16 can be fastened to the form-
work as shown in the following. It has to be
ensured that the earthing plate and formwork are
connected as closely together as possible. This is
achieved by pressing the connection surface of the
earthing plate plane-parallel onto the formwork.
1.1.1 The formwork is drilled through and the
earthing plate is pulled tightly against the
formwork with a bolt M 16. Remove this
bolt before removing the formwork.
1.1.2 Connect the earthing plate to the back of
the formwork with nails using the three
indents. After removing the formwork, cut
off the nail spikes which are sticking out.
1.1.3 For an easy assembly, it is recommended to
use a threaded rod with a nut and, depend-
ing on the formwork material, with a
washer. At first, fasten the threaded rod by
hand to the earthing plate, then attach the
assembly to the formwork.
1.2. Connection with the reinforcement
The electrically connected conducting rods of the
reinforcement, designated as earthing conductor,
should have a minimum diameter of 16 mm. The
flat steel plates are connected to these rods by arc
welding. To avoid reduction of the cross sectional
area, the tracing dimension of the welded seam
must be at least 4 mm.
L + L > 90 mm
1. Assembly Instructions
4 Ph: 216-351-3060
www.erico.com
The following diagrams show a selection of the most common types. The code of each type is given on the
bottom right hand side.
Linear design, flexible
FDBS-16
FDBC-16
FDB-16
SDB-16
ADB-16
TDB-16
FDB-F
RDB-16
2. Summary of Types Information
5
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
Right angular design, flexible type WDB-16
WDB-16
6 Ph: 216-351-3060
www.erico.com
2.1 Design with solid conductor
The KDB 16 type 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, other lengths can also be supplied.
Design with flat steel band KDB-16
2.3 Special designs
With a few structures, (e.g. viaduct piers),
massproduced earthing bonds with several
outputs have proven themselves. For orders of
such types, drawings or sketches should be pro-
vided to ERICO with detailed information, such as
spacing, lengths, connection pieces and cable
cross section.
2.2 Standardized types Standard lengths 500 and 1000 mm
FDBC
This solid copper earthing point has a hollow core for cable insertion to factory-provide a crimped
connection according to DIN VDE 0220 part 2. The copper plated steel welding plate is as well a
crimped connection to the cable. This type of Earthing Bond is only available with straight designs.
FDBS The FDBS is a combination of a well-known CADWELD welded connection and the crimped
cable connection technique. The solid deep-drawn copper earthing point is welded to the cop-
per cable in the factory by means of a CADWELD welded electrical connection. The copper plat-
ed steel welding plate is a crimped connection to the copper cable.
FDBC-16
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8 Ph: 216-351-3060
www.erico.com
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 M 16x20
A4 ISO 4017
Alternative : CuNil. 5Si
Washer 18 DIN 126-Cu
Earthing bond
according to 4 Ebs. 15.03.17
Hex. head screw M 16x25
A4 ISO 4017
Alternative : CuNil. 5Si
Washer 18 DIN 126-Cu
Wire 10 DIN 43137-St 34
3 Ebs20.01.01
All screw connectionsare to be
tightly fastened with a wrench.
Earthing of railingsin the case of bridges Connection for current collector stop rail
Earthing connector
acc. to 4 Ebs15.03.17
Design
similar to
2Ebs15.01.09
L60x6
DIN 1028
Protection against unintentional
contact
Cap
Cap
Current collector stop rail
Detail Y Detail Y Cross section A-A
Detail Y in direction of arrow Detail Y in direction of arrow Cross section A-A in
direction of arrow
Earthing connector
acc. to 4 Ebs15.02.17
railway earthed
angular steel
L60x6
DIN 1028
Bridging of:
Bridge piers-
bridge decks
expansion joints,
concrete sections
Detail Z Detail Z in direction of arrow
Earthing connection
acc. to 4 Ebs15.03.17
Application Examples
9
Measures to be taken for earthing
when including slack reinforcement
Measures to be taken for earthing without
including untensioned reinforcement
Formwork panel
Wall thickness5-10mm
Formwork panel
Earthing plate DB 16
Earthing plate DB 16
Concrete Decks
Spacing inner-outer
reinforcement
CADWELD weld
sheathed with heat-shrink
sleeving
Plastic screw DBM 16
with break-off position
Cable NYY-0 1 x 70/95
Cable NYY-0 1 x 70/95
CADWELD

welds
sheathed with heat-shrink
sleeving
Steel plate 30x4 / 40x5
for building site connections.
A or E weldsconsidering
DIN 4099
Hex. head screwsM 16x40
DIN 933-St
Washer 18
Thisconnection applies
only to the fastening to form-
work panels. It isto be
removed before removing the
formwork.
Weld connection
The crosssectional area at
the root of the welding seam
must be at least 4 mm.
during the building phase.
Assembly information
Remove
label before
screwing on
a conductor
The fastening of the earthing platesto the formwork
panelscan also be made with nailsusing the
plate indents. After removal of the formwork, the
nail spikesthat stick out are to be removed.
The protective label placed to the front side of the earthing
platesservesasa thread protection during the construction
phase. It isto be removed before connecting a conductor.
Accompanying drawings:
2 Ebs02.05.19 3 Ebs02.05.34
2 Ebs15.01.09 4 Ebs15.03.17
3 Ebs20.01.01
Source of supply for earthing bonds:
ERICO Europe
Thisconnection appliesto reinforcement barswith a minimum diameter of 16 mm. For smaller bar diametersa longer steel welding plate hasto be selected
which hasthen to be welded to the smaller reinforcement barsmore often, asit isappropriate.
By the use of a formwork panel the seating of the earthing platesare to be determined accurately through control holes. Thisseating may not be obstructed by
reinforcement bars. When pressing on the reinforcement, sufficient space must remain for the earthing bonds.
The earthing plate hasto be fastened firmly
to the formwork panel with the plastic bolt
DSM 16. Thisbolt will not be removed until
removing the formwork. The bolt head can
easily be knocked off with a hammer, the
remaining part protectsthe thread from
subsequent damage and can finally be
removed with a hexagonal socket key.
When installing earthing bondsit hasto be
ensured by using spacersor by repositioning
the conductor cablesthat the bondsdo not
contact the formwork panel. Only a sufficient
concrete decking protectsagainst possible
damage due to corrosion.
The concrete vibratorsare to be handled
carefully during compacting of the concrete
near the earthing plates. Direct impact might
result in breaking off the plastic screw.
Usable for:
Overhead line regulations
2 Ebs 15.01.20
BZA Munich
Jan. 1992
Issue
Date
Scale
Dimensions
without reference
to tolerance DIN
1991 Date Name
Information about the arrangement
of railway earthing on buildings with
CADWELD type earthing bonds
Reviser 21.11. Stein
Checked 01.92
Standard
Sheet
1
Changes Date Name Orig. ERICO CD 101.143 Repl. for 2Ebs.15.01.20/05.85 Repl. by
Drawing revised 1.93
CD 101.179e
1 Sheet
10 Ph: 216-351-3060
www.erico.com
Construction a-d and g-h: Connection of componentsmade of steel/copper
1)
with steel/copper
1)
Construction e-f and i-j: Connection of componentsmade of steel/copper
1)
with rail
Construction k-l: Connection of componentsmade of aluminum with aluminum
Construction m-n: Connection of componentsmade of steel/copper
1)
with aluminum
Construction p-o: Connection of componentsmade of aluminum with rail
Construction q-r: Connection of rail with rail
Screws to be used: N 24 017, length as required
For components made of Al and Al alloys: A2
2)
made of Cu and Cu alloys: A2
2)
made of steel: 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
1 1 2 Cable lug 4 Ebs 15.13.22/b
1 1 2 Cable lug 4 Ebs 15.13.22/a
1 2 1 Cable lug DIN 46 235 12-70-S
1 2 1 Cable lug DIN 46 235 12-50-S
1 1 1 2 Cable lug DIN 46 235 16-70-S
1 1 1 2 Cable lug DIN 46 235 16-50-S
1 1 1 1 1 1 1 1 1 Cable N YY-0 1 x70mm
1 1 1 1 1 1 1 1 1 Cable N YY-0 1 x50 mm
Const. r q p o n m l k j i h g f e d c b a Component

6
6
0

5
7
1
6
6
0

5
7
0
6
6
0

5
6
7
6
6
0

5
6
5
6
6
0

5
6
4
6
6
0

5
6
2
6
6
6

8
5
4
6
6
6

8
5
3
6
6
6

8
5
2
6
6
6

8
5
1
6
6
0

5
7
3
6
6
0

5
7
2
6
6
0

5
7
5
6
6
0

5
7
4
6
6
0

5
6
9
6
6
0

5
6
8
The following drawingsand standardswere used when creating thisdocument:
- 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
Usable for:
Overhead line regulations
4 Ebs. 15.03.17
Halle
20.05.97
NGT 52
Issue
Date
Scale
Dimensions
without reference
to tolerance DIN
Date Name
Earthing Connectors
Reviser 19.05.97 Kurzbach
Checked
Standard
Sheet
Resp. Change Date Name Orig. Repl. for issue 09 95 Repl. by
Deutsche Bahn AG
Electrical and machine engineering
Overhead line
Sheet
Bem. with cross ref. to 03.00
3 Ebs 15.02.01 rem. Gla
Overhead Line
3. Reference
11
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.
Deutsche Bahn
Research and Technology Centre
Overhead lines
Theodor-Heuss-Allee 7
60486 Frankfurt am M ain
Publication: EBA Report 22
TEL Frankfurt/M ain
TEL 2 M unich
TZF 73 Frankfurt/M ain
ERICO GmbH
Technical Release
1. The present technical release applies to the company
ERICO GmbH
66851 Schwanenmhle
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/M ain, 05.09.2001
(Dipl.-Ing. Borgwardt)
Copyright 2002, 2009, 2010 ERICO International Corporation. All rights reserved.
CADDY, CADWELD, CRITEC, ERICO, ERIFLEX, ERITECH, and LENTON are registered trademarks of ERICO International Corporation. R407B-WWEN R1609LT09WWEN 02M1010
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