Crane Rail TechnologyH

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SINGAPOREMHE-Demag (S) Pte Ltd33 Gul Circle, 629570 SingaporePhone: +65 6305 3500Fax: +65 6862 1933Service Hotline: +65 6862 1123

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Contents

On the Right Track

Heavy duty crane rail systems are used as load transfer and to handle the weight and balance of cranes and similar machinery. Thus, they are used in a host of industries and applications.

In ports rails sustain the enormous tonnages of ship-to-shore cranes and gantry cranes of the container depots, while in shipyards rails are used for shiplift that set vessels afloat. Supporting stacker reclaimer and ship unloader rails also play an important role in bulk material handling, e.g. in mines, while in steel production and cement works rails carry the weight of the raw materials. In the energy industry rails shoulder gigantic turbines in power stations and guarantee steady handling of fuel rods in nuclear reprocessing plants. In automated high bay warehouses rails carry pallets. The applications are as diverse as the industries, but one constant remains: our fixation system keeps them all on the right track!

03040506070809

Families of Crane Rails

Rail Support Systems

Flexibly Mounted System

Grout and In-fill

Rail Joining

360 Customer Care

Quality Control

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MRS, CR and QU profiles have taller and thinner webs. This enables them to cope with higher bending stress (Ixx cm4) when bridging over discontinued support. A common application is yard cranes.

A profiles have a low height, very thick web and very wide base ensure straightness. These rails are usually used with continuous support system, e.g. for overhead cranes, gantry cranes on full runway beams.

Families of Crane Rails Rail Support SystemsDepending on the application, continuous or discontinuous support systems are used to support crane rails.

MRS Profile(Luxembourg standard)

CR Profile(Japanese JIS standard)

QU Profile(Chinese standard)

A Profile(German DIN standard)

C

B

WH

C

B

H W

Continuous Support SystemOn concrete This system is suitable for heavy duty applications. The rails are usually resting on a continuous steel soleplate with level grouting below. Clip spacing usually range from 500 mm to 750 mm c/c. Commonly weldable clips are used for this system.

On structural steel Rails are fastened directly onto steel beams with or without rubber pads. Weldable or bolted clips are commonly used for such construction.

Discontinuous Support SystemOn concrete This system is suitable for light duty applications. Each support plate is grouted separately. The clip spacing could be up to 1000 mm c/c.

Ballast The rails are mounted onto floating sleepers with clips and steel plates. This system is often used for container yard cranes in ports and railworks in the mining industry.

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Grout Options Non-shrink cementitious grout is cost-

effective and provides good flowability and working time.

Non-shrink epoxy grout provides higher compressive strength, fast curing and excellent long-term performance.

In-fill Options Asphalt/bitumen is affordable and readily

available. Cement based is time consuming to remove. Rubber/plastic requires adequate trench

drainage.

Flexibly Mounted System Grout and In-fill

Clips The adjustable clips are either one-part boltable or two-parts weldable type, galvanized or self-colour, supported by bolts size M16, M20 or M24 in grade 8.8, suitable for use with or without rubber pad. They are made by cast or forged steel bonded with nitrile rubber noses via vulcanisation process. All clips are witness-tested by respected Lloyds Register of Shipping.

Pads The pads are either continuous type, reinforced with steel strip, or individual type. The pads positioned beneath the rail to provide a flexible bearing between rail and soleplate or structural steel. The distinct advantages are reduction in noise and vibration, compensation for uneven surfaces, even distribution of load, and prevention of fretting between rail and structure.

Soleplates Rails are supported on steel soleplates that are used for levelling the rails, spreading the load and for mounting clips. Thickness of plates ranges from 10 mm to 30 mm.

Anchor bolts To secure soleplates to the concrete ground beams. The common methods are using cast-in J-bolts or by drilled holes in concrete.

Levelling systems The preferred options are (i) levelling nut with rubber washer under soleplates (ii) levelling screw through threaded holes on soleplates.

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Rail Joining Quality Control

One of the most crucial processes to ensure that cranes do not derail is proper rail joining. The higher the weight the rails have to sustain, the more crucial it is to make the joining sections as steady and sturdy as possible. The most common rail joints are fishplates, puddle arc welds, flash butt welds and thermite welds.

Fishplates, also called splice or joint bars, are metal bars bolted to the rail ends to align them. As the rails are not merged but merely held together, this is only suitable for light applications.

Puddle arc welding is the most common rail joining method. However, as this method entrains some slag and a slight lack of fusion or undercut of the joint, the result is never perfect.

Flash butt welding requires very high current and hence heavy equipment. While commonly used for traffic railways and high-speed railways, it is uncommon for installation of heavy duty crane rails.

Thermite welding creates welds with a supreme metal integrity, while also being the fastest welding method. Also known as exothermic or aluminothermic welding, it requires a special certification.

To tackle excessive differential movement between new and old wharfs we provide design and installation of wharf expansion joints.

Installation & SupervisionWe employ a trained and competent workforce that includes experienced supervisors, as well as certified welders and operators for the complete site installation. Rigorous safety and quality checks ensure the optimum performance of the cranes and structures.

Inspection & AuditWhether a new or existing installation, our qualified technicians are able to conduct on site surveys such as measuring of track alignment, level and condition of rails and fastening systems. All measurements are detailed and comprehensive.

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For us, customer care never ends with the handover To ensure your operations can always continue smoothly we offer you complete preventive maintenance and repair services.

Moreover, we can also service you beyond the tracks and look after your gantry and EOT cranes as well. From spare parts, repairs and refurbishment, to audits and preventive maintenance, or technical and operational training we can fulfil all requirements. Also when it comes to crane accessories such as wheels and drives, bus bar and cable reels, eRTG electrification, etc. we can offer you the equipment needed to optimise your operations.

360 Customer Care

Choosing MHE-Demag for your heavy duty rail project will give you the best consultancy and engineering you will find in this field. Being the exclusive agent for Gantry Railing Ltd (Gantrail) in South East Asia since 1991, we have embarked on numerous projects and steadily refined our expertise along the way. Likewise, our British principal Gantrail has established itself as the worlds market leader for crane rail technology since 1965, with projects all around the globe.

Some of our key references include Jurong Port in Singapore, Westport, Northport and PTP in Malaysia, Teluk Lamong Port in Indonesia, Laemchabang Terminals in Thailand, as well as Saigon International Terminal Vietnam. We are certainly not only present in ports, but also in other areas where heavy duty rails are required. At the Singapore Sports Hub, for example, MHE-Demag built the retractable roof for the stadium, where our rails sustain the

synchronized opening and closing of the 2,200 tonnes roof structure at a height of 82 m. This kind of engineering expertise, also gained in over 20,000 industrial crane installations in the region, ensures that your project can be fulfilled to the optimum from the early planning stages all the way to our service long after the project execution.