Crane Track Material

8/12/2019 Crane Track Material

1/20

A

Innovative range.The crane track system.

ThyssenKrupp GfT Gleistechnik


2/20

02


3/20

03

04

09

13

14

15

1819

STEP BY STEP PROJECT RELIABILITY MINEX-SYSTEMMINEX-components MX-rail fasteners Accessories

AN UPLIFTING CONCEPT CRANE TRACK BEAMCrane track beam Quality Site logistics

RAILSCustomer focus with profile

SLEEPERSPrecisely tailored solutions

PLANNING, MEASURING, DETECTING RAILCONTROL CRANE TRACK MEASURING SYSTEMFunctions Areas of use

SERVICE

Your route to a crane track

THE CRANE TRACK BEAM ON THE BUCHARD QUAY IN HAMBURGProven references

Tracks for container cranes and other transport vehicles haverequirements all of their own. The reason? Crane tracks are

generally used to transport particularly heavy loads at relatively

low speeds. We have therefore created a special technological

all-round package for you which will meet all the special con-

ditions of your project superbly. The cranetrack system.

An all-round track package.The crane track system.


4/20

04

Step by step project reliability.

MINEX-system.MINEX stands for all the components relating to ourcrane track system. This gives our customers thecertainty that all the elements, from the foundationcasting component and pads to the rail fasteners,are part of a single system. So as far as you areconcerned, MINEX means project reliability.


5/20

05

We supply the following MINEX-components

for the crane track system:

MX-rail fasteners MINEX-rail pads

MINEX-grout, the precision cement-based

casting compound

MINEX-EP Grout, the 2-component casting compound

MINEX-PUR 880-6, the elastic casting compound

MINEX-cladding tubes

MINEX-groove filler sections

MINEX-rail end stops

MINEX-rail beds

Excellent experience.MINEX-components.

We have been developing and building tracksystems on ballastless tracks made of con-crete, steel, asphalt or gravel for more than30 years. Excellent experience which wasused in the development of the MINEX-systemcomponents.

2

3

1

1 First fully automatic

container block storagefacility in the world

2 Measuring track and

servicing building

3 Port crane track


6/20

06

We have developed two special fasteners

for our crane track system the MINEX-fastener system which is bolted to the

support plate and the MXA weld system.

Both solutions feature a guide plate

which holds the rail at the side without

clamping it. This prevents the displace-

ment of the rail caused by temperature

fluctuations and the transportation of

heavy loads having an adverse effect or

even damaging the fastening compo-

nents.

The flat design is sealed to prevent the

ingress of dirt into the system. The

push-through connection for the base

anchor consists of a zero play eccentric

component. This allows infinite lateral

adjustment.

Also available made of stainless steel.

Simply eccentric.MX-rail fasteners.

1 2

3

4

5

Sealed system

prevents the

ingress of dirt

Horizontal forces

only stress the bolt

for shearing

Held securely in

position by infinitely

laterally adjustable

eccentric component

Drop-forged

Free longitudinal

movement of the rail

Corner pressure

is prevented by

rounding the guide

plate

Particularly flat

design

1 Single bolt system (MINEX)

2 Double bolt system (MINEX)

3 Single weld system (MXA)

4 Double weld system (MXA)

5 Port crane track


7/20

07

Economy, durability and safety.Accessories.

MS-rail pad

Further assurance of the dura-bility of the complete system is

provided by the elastic crane rail

pad for installing between the

rail foot and the rail bed. The

material is made of ethylvinyl-

acetate and offers outstanding

damping properties. It allows

the low friction longitudinal

movement of the rail, thus redu-

cing peak stresses and vibra-

tion. It also prevents corrosive

processes between the twocomponents. The result is the

great economy of the crane

rail bed.

MINEX-anchors

MINEX-casting compound

MINEX-grout has proved to bean ideal casting compound for

making a full, positive connec-

tion between the foundation

and the rail bed. This precision

cement-based casting mortar

can be pumped, does not shrink,

is very strong and cures in a

very short time. This means

that it can withstand even high

and multiple loads. MINEX-grout

is supplied ready-mixed. It only

has to be mixed with water onthe site. We recommend MINEX-

EP grout for particularly high

bending tensile stresses. Steel

sections which no longer have

their original cross-section

can be restored using elastic,

vibration-damping MINEX-PUR

880-6 rail casting compound.

MINEX-cladding tubes

If the foundation is cast in con-crete, MINEX-cladding tubes are

essential for creating recesses

for installing the MINEX-base

anchors. The tube is profiles

both inside and outside. This

gives it a firm hold in the con-

crete. All diameters between

40 and 200 mm are available

including two matching plastic

covers for each tube.

1

2 3 4

MINEX-cladding tubeStone boltThreaded anchorFlat anchor

1 MINEX-pad

2 Cladding tube with twocover caps (left), top

cladding tube with cover

cap and bottom with

cover cap with nail edge

(centre)

3 MINEX-PUR 880-6

4 MINEX-grout precision

casting compound


8/20

08

MINEX-groove filler section

The MINEX-groove filler section offers plenty

of benefits. This innovation can be suppliedfor any form of rail and is easy to install and

maintain. When installed it prevents frost

damage, the gulley drain from blocking

and the rails and rail bed from floating in

aggressive water. But the system has also

proved to be superb from a safety point of

view. It guarantees safe crossing for road

vehicles and helps to prevent personnel

accidents.

MINEX-rail end stops

MINEX-rail end stops can be supplied in

standard form or in bespoke designs tomeet your requirements for all loads.

We can supply three different designs:

Crane track stops with baffle plates,

Crane track stops with cellulose buffers,

Crane track stops with hydraulic buffers.

We can also supply other products for

the construction of ballastless tracks, for

example in high bay shelving warehouses

or for working trench systems in railway

depots.

Economy, durability and safety.Accessories.

1

3

2

4

1 MINEX-end stop with cellulose

buffer, clamped

2 MINEX-end stop with hydraulic

buffer, clamped3 MINEX-filler section

4 MINEX-end stop with baffle plate


9/20

An uplifting concept.The crane track beam.

In areas in which heavy loads aretransported, experience has shownthat the foundations can suffer settle-ment. In conjunction with HHLA CTBautechnik we have developed apioneering crane track to prevent highcost repair work and long down times.The design of this innovation includesthe facility to raise the entire systemretrospectively. This offers our custo-mers massive time and therefore costsavings.

09


10/20

10

Raise, underpour, continue.Crane track beam.

Rising operating loads, rapidly increasing volumes of bulkgoods for loading and unloading and even larger and heaviercranes require crane tracks which guarantee good positionalstability and therefore high positioning accuracy. This meansthat foundation settlement must be detected early and com-pensated by a raising and levelling concept.

The technological answer to this

challenge is provided by a new

development which we havedeveloped in conjunction with

HHLA CT Bautechnik. The crane

track beam. The system con-

sists of monolithic longitudinal

concrete beams (comprising

reinforced prefabricated concrete

parts) on flat foundations and

connected by in-situ concrete

joints. A sophisticated raising

concept allows the rail to be

raised by up to 10 centimetres

after it has suffered settlement.

By raising and underpouring thelongitudinal beam it is possible

to raise the entire structure by a

further 2 times 10 centimetres,

making a total retrospective

adjustment capacity of 30 centi-

metres.

1

2 3

1 ThyssenKrupp crane

track beam in use

2 MRS87A

3 AS86


11/20

11

Born of experience and ideal for everyday use.Quality.

The development of the crane track system, which is reliableeven under heavy crane loads and high traffic frequency,was monitored by several well-known engineering agencies,companies and universities. It was also subjected to stringentpractical tests by specialists. In addition to a demonstrationof the raising concept, a major series of tests confirmed theload capacity of the system and went well beyond expectations.A system born of experience and ideal for everyday use.

Another element of our quality

concept is our certification toDIN EN ISO 9001. The docu-

mentation required for this

ensures full traceability of all

components is possible at any

time. Batch numbers mean that

every beam and all the compo-

nents in it can be traced back

precisely to the date of produc-

tion.

We will be delighted to advise

you with the planning and de-sign of your new crane track.

1 2

1 ThyssenKrupp crane track beam

2 Detailed photograph: MINEX-crane rail

fasteners


12/20

12

Smooth planning.Site logistics.

Prompt commissioning contributes to theeconomy of a project. With this in mind weensure very detailed plans for delivery andsite logistics during the construction work.

We prefabricate the concrete

elements at our plant. The

length of an element essentially

depends on the existing trans-

port capacities. Depending on

the terms of the project we alsoinstall all the necessary com-

ponents.

Whether it is direct to the instal-

lation crane or to a temporary

storage facility we deliver the

goods to correspond to the pro-

gress on site and always just in

time. That means that we canensure that everything runs

smoothly on site.

After completion After height correction using

compensating plates

Height correction by raising

and underpouring the beam

1

2 3

1 Installation

2 Final alignment

3 Production of the

planed subgrade


13/20

13

Customer focus with profile.Rails.

Every crane track project is different. As a systemsupplier we can therefore always supply you preciselythe rail section that your crane track project needs.Whether it is for heavy or lightweight loads, frequencyor rare traffic, high or low design heights, continuousor discontinuous mounting the requirements of yourproject decide the track type.

That is why we supply a particu-

larly wide range of sections:

A sections to DIN 536-1

Special sections

Flat-bottom sections

Field track rails

Grooved rails

Rectangular sections

and many other sections

as well.

Depending on the requirements

of your project we can also offerprecision machining. We manu-

facture the precise lengths you

require, complete all the step

and mite cuts that may be

needed, drill the holes required

for lugs, screw connections and

earth connections and bend

every rail precisely using the

planning specifications if neces-

sary.

60 x 40 A45 A100 30E1 49E1 60E1 RiPh37A AS86 MRS221

1

2 3

4

5

1 Step cut

2 90 cut

3 Angled cut

4 Bending plan

5 Flat-bottomed rails


14/20

14

Precisely tailored solutions.Sleepers.

We will use wooden or concrete

sleepers for your crane trackdepending on the terms of your

project. If heavy loads are likely,

the concrete sleeper is an ideal

component. If the main require-

ment is for elasticity, the wooden

sleeper is the better alternative.

In any event, to order we can

supply your sleepers including

plates for all conventional rail

sections.

We manufacture wooden slee-

pers (both impregnated anduntreated) at our own plant in

Gross Oesingen. We use a range

of timber types for this purpose,

including beech, oak, spruce,

ekki and mora, and process them

to produce precisely tailored

top quality products. They are

impregnated using the pressure

method and the WEI Type C

product.

1 3 4

5

2

1 Crane track on concrete sleepers

2 Impression crane track

3 Crane track on concrete sleepers

with system W

4 Wooden sleeper yard

5 Crane track on wooden sleepers

with system KS


15/20

15

Planning, measuring, detecting.The Railcontrol crane track measuring system.

The precise measurement of a crane track has become an integralpart of the overall crane track system. We use our Railcontrolmeasuring system during the acceptance procedure and as part

of our planning. Railcontrol has also proved to be very useful forresearching the causes of excessive wear. The early detection andrectification of defects helps to save massive costs.


16/20

16

Automatically precise.Functions.

The automated process developed by ThyssenKrupp

GfT Gleistechnik GmbH in conjunction with Vermes-sungsbro Hanack und Partner is suitable for a wide

range of tasks:

Checking compliance with the tolerances set

out in VDI 3576, ISO 12488-1, etc.

Measuring in laden (crane moving) and unladen

state (standstill). The difference can be used to

form conclusions about the movements as the

crane is moving.

Error analysis in the event of problems whilst the

crane is moving or if the track suffers excessive wear.

Monitoring by means of tachymetric measurements which integrates the results in a high

level coordinate network.

Ability to take measurements whilst operations

continue.

Tolerance deviations to regulations

1 2

1 Port crane track

2 Indoor crane track

3 Angled crane track

4 Intermodal terminal

5 High bay shelvingwarehouse

B C ES max

Position deviation Height deviation Level Gauge centre dimension

S min


17/20

17

Railcontrol can be used on any crane track. After being

placed on the rail it moves automatically using its owndrive unit. This enables it to take continuous, fast and

precise 3-D measurements.

The tachymeter records the gauge, position and height

of the rail with great precision along with the offset and

angle of the rail and plots all the data on evaluation gra-

phics using a special software package. This gives the

customer a plastic load picture. If these investigations

show that repair work is required, we can find a compe-

tent contractor for you.

Project phases in which we use Railcontrol:

Before commissioning new cranes on existing

crane tracks

To document the position and height of new

crane tracks

For damage assessment and evaluation

As part of preventive maintenance procedures

To assess the capacity use of an indoor construction

For quality assurance and wear reduction purposes

For health and safety procedures

For every phase.Areas of use.

4 5

3


18/20

18

Your route to a crane track.Service.

In addition to what we can offers in terms of the Rail-

control measuring system we also offer a wide rangeof other services. For example we can help you with

project and budget planning and can help you develop

a crane track system that is precisely tailored to your

needs.

We use a specially adapted crane track design program

for this purpose. Using a wide range of material and

load parameters we calculation the potential capacity

for you. To order we can supply all the verifiable static

calculations you will need.

The crane track configurator on our homepagewww.tkgftgleistechnik.de is an ideal tool to provide an

initial estimate. This allows you to compile all the crane

track components you need to suit your requirements.

We will be delighted to hold discussions with you on

the basis of these documents.

For further information go to

www.tkgftgleistechnik.de

1

2

3

1 Rail storage facility

2 Service vehicle

3 Advice

4 Railcontrol

measurement log

4


19/20

19

The Port of Hamburg occupies position 8 in the list of globalcontainer ports. During the 2005 financial year it exceededthe 8 million mark for the first time by handling a total of8.1 million containers. In 2006 its total handling numbersincreased to 8.9 million containers. This makes the port thefastest growing in Northern Europe. Plenty of reasons forHamburger Hafen und Logistik AG (HHLA) to extend itsBurchard Quay Container Terminal.

Proven references.The crane track beam at the Burchard Quay in Hamburg.

The port authority chose our crane track

beam as the rail system for its cranes. Inaddition to high requirements in terms of

quality, load capacity and economy, the

main reasons behind this decision were its

fast installation and the possibility to install

the system whilst port operations conti-

nued.

A triple rail mounted gantry (TRMG) was

installed. This system comprises two small

cranes on the inner rails and a large crane

on the outer ones. This solution provides a

great deal of flexibility in the stacking block.Some 29 of these blocks will be built by the

end of the project. Each block is around

375 metres long. Placed one after the

other, these crane tracks have an over-all

length of more than 40 km.

The project at the Burchard Quay Container

Terminal provides more impressive evidence

of what we can provide.

Photos: HHLA

Other references

Airbus ArcelorMittal Audi Bayer BWG

Deutsche Bahn AG Fraunhofer Institut Gottwald

HKM Honda Japan Liebherr Meyerwerft Rheinbraun RWE Sandvik Schweden Solvay Stelcon Unilever Stump Indonesien Vattenfall Volkswagen


20/20

SALES

Regional office

NorthVahrenwalder Str. 20530165 Hannover GermanyPhone:+49 511 6703-25Fax: +49 511 6703-37

WestHollestr. 7a

45127 Essen GermanyPhone: +49 201 844-563745Fax: +49 201 844-563750

EastRotherstr. 710245 Berlin GermanyPhone:+49 30 628901-15Fax: +49 30 628901-20/-21

SouthFrstenrieder Str. 26781377 Mnchen GermanyPhone:+49 89 7871-300Fax: +49 89 7871-343

South-West

Weilimdorfer Str. 74/ 270839 Gerlingen GermanyPhone: +49 7156 430730Fax: +49 7156 430740

EXPORT SALES

ExportHollestr. 7a45127 Essen GermanyPhone: +49 201 844-563764Fax: +49 201 844-563757

MANUFACTURING PLANT

HolzschwellenwerkAm Bahnhof 229393 Gro Oesingen GermanyPhone:+49 5838 9905-0Fax: +49 5838 9905-79

Location of sales

Waidmannstr. 2622769 Hamburg GermanyPhone:+49 40 85340-700Fax: +49 40 85340-701

An der Kreuzkirche 601067 Dresden GermanyPhone:+49 351 4902040Fax: +49 351 4902480

Dortmunder Str. 268219 Mannheim GermanyPhone:+49 621 8906-120/-121Fax: +49 621 8906-122

MRT Track &Services Co., Inc.270 Broad Street07003 Bloomfield NJ-USAPhone:+1 973 748-8899Fax: +1 973 748-9243

ThyssenKrupp WeichenbauObere Stahlindustrie 444793 Bochum GermanyPhone:+49 234 9114-343Fax: +49 234 9114-557

Humboldtstr. 304105 Leipzig GermanyPhone: +49 341 6017054Fax: +49 341 6017055

ThyssenKrupp

GfT Polska Sp. z o.o.

Al. Slowackiego 6630-004 Krakw PolandPhone: +48 12 6204130Fax: +48 12 2677548

Betrieb IndustrieweichenAm Wasserturm 3b06869 Coswig/Anhalt GermanyPhone: +49 34903 4741-0Fax: +49 34903 4741-20

VertriebsbereichWaggonausrstungRotherstr. 710245 Berlin GermanyPhone:+49 30 628901-15Fax: +49 30 628901-22

Betrieb SpannmittelAm Wasserturm 3b06869 Coswig/Anhalt GermanyPhone:+49 34903 4741-0Fax: +49 34903 4741-24

ThyssenKrupp LangschienenLadestr. 839175 Knigsborn GermanyPhone:+49 39292 6958-17Fax: +49 39292 6958-20

bjectto

alterations

09/2012e

ThyssenKrupp GfT Gleistechnik GmbH

Hollestr. 7a 45127 Essen Germany

Phone +49 201 844-563710 Fax +49 201 844-563714

www.tkgftgleistechnik.de [email protected]

Documents

Crane Track Material