What is the maximum out-of-square tolerance for rail ends after saw cutting?

The maximum out-of-square tolerance for rail ends after saw cutting is established to ensure that when the rails are joined, they fit together properly without excessive gaps or misalignment. A tolerance of 1/8" reflects a standard that is tight enough to maintain structural integrity and aesthetic alignment, while still allowing for some minor variances that can occur during cutting.

This tolerance level helps to facilitate effective thermite welding by ensuring that the ends of the rails are sufficiently aligned for the welding process. A more stringent tolerance, like 1/16", might be overly challenging to achieve consistently during cutting operations, while a looser tolerance, such as 1/4" or 3/8", could lead to mechanical issues upon reassembly, reducing the quality and strength of the welded joint. Therefore, maintaining a maximum out-of-square tolerance of 1/8" strikes a balance between precision and practical feasibility in rail cutting operations.