Rail ends that exhibit any batter at ______ inch or more prior to cutting weld gap shall not be welded.

The guideline regarding rail ends indicates that if there is any batter greater than or equal to 1 inch at the weld gap prior to the cutting process, those rail ends should not be welded. This standard ensures structural integrity and the effectiveness of the weld. A batter of this magnitude can lead to misalignment and insufficient welding quality, as the surfaces won't adequately match during the welding process. Proper fit-up is crucial for a successful thermite weld; therefore, maintaining a maximum tolerance for batter allows for stronger, more reliable welds.

If the batter exceeds this threshold, it is likely to result in structural weaknesses and potential failures in the welded joints. Given these considerations, 1 inch is recognized as the critical limit for acceptable batter in this context.