Rail Mounting Instructions for Hevi-Rail

July 07, 2011 - Rockford, IL  -  Posted by Tech Team

Hevi-Rail is typically used in applications which require moderate accuracy.  There are two common methods for installing Hevi-Rail rails:  Welding & Clamp Flanges. 

Welding

The preferred method of welding Hevi-Rail and Hevi- Rail Clamp Flanges is MIG Welding.  Please follow the guidelines listed below when MIG welding Hevi-Rail and Hevi- Rail Clamp Flanges to the frame of your assembly. 

1. Use a metal brush or grinder to remove rust or paint from surface to be welded.
2. Bevel joint edges on metals thicker than 3/8” to ensure the weld fully penetrates to the base of the metal.  (HVR-2, HVR-3, HVR-4, HVR-5 HVR-6, HVRI-08, HVRI-09, HVRI-10, HVRI-11.)
3. Ensure that grounding clamp is engaged in clean metal.
4. When welding HVR-S, HVR-0, HVR-1, HVRI-07 sections of Hevi-Rail it is recommended to use .03” diameter wire. A preferable grade wire for mild steel is  ER70S-3
5. When welding thick sections of Hevi-Rail, it is recommended to use .035”-.045” ER70S-3 wire. Weld at a higher heat level to obtain a deep penetration. This is recommended for HVR-2, HVR-3, HVR-4, HVR-5 HVR-6, HVRI-08, HVRI-09, HVRI-10, and HVRI-11.
6. A 75% Argon/25% Carbon Dioxide mix is a preferable general purpose shielding gas when welding mild steels like Hevi-Rail.
7. Know your load calculations, when it doubt meet with your structural or mechanical engineer.
8. Destructive testing facilities are recommended for testing weld strength.  Periodic destructive testing ensures that the welding equipment and welding practices are yielding safe and strong welds.
9. NEVER weld a mild steel Hevi-Rail product to a dissimilar metal such as cast iron, or stainless steel.

Clamp Flanges

When using bolts to hold a Clamp Flange to  Hevi-Rail HVR1, HVR-2, HVR-3, HVR-4, HVR-5 HVR-6, it is recommend to drill a detent in the top of the rail where the screw seats.  Many customers use a drill point smaller than the minor diameter of the tap diameter to put a point in the rail.  This is preferred in systems that have vibrations and harmonics in its environment.  Some customers use bolts to align and assemble the system, then weld the clamp to the rail.