Rapid Rail crane rail installation and safety line installation doc

Leaders in Height Safety Systems, Crane Rail & Crane Rail Lubrication

Paul Howard and Tony Sysum are the founding members of Rapid Rail Limited.

Both have worked in the crane rail industry for over 30 years. Paul and Tony started

their careers as installation technicians and progressively worked their way into

senior management.

Before forming Rapid Rail, Paul was sales manager for a leading product/installation

company and Tony was contracts manager. Having achieved their respective

positions, it became clear that their high levels of experience and knowledge could

be better served independent of product supply. Rapid Rail runs on a “hands on”

basis which enables skills and knowledge to be shared with all engineers, ensuring

the very best installation and service every time.

Rapid Rail design, supply, install and maintain crane rail safety and lubrication systems

Foreword For many years, a few dominant companies have served the crane rail industry,

motivated by the supply of products. The industry in which we had obtained

our knowledge and skills, was failing to provide the dedicated installation and

maintenance services required.

We decided to give something back to the industry by creating a company capable

of fulfilling these requirements. Rapid Rail Limited was founded in 1993 as a

truly independent company, offering design, supply, installation and maintenance

services to its customers. Since we formed Rapid Rail we have enjoyed a healthy yet

controlled growth, which has enabled us to re-invest in the company and our core

product, our engineers! By investing in the appropriate equipment and the training

needs of our engineers, we are able to respond to all our customers’ requirements

thereby offering security and peace of mind.

Our focus has and will always be to provide unequalled levels of service and quality

to our customers. Our commitment to you is to ensure that we are there whenever

you need us and to continuously provide the very best service and quality.

Company mission statement

Rapid Rail is a company

founded on a commitment

to excellence. We strive to

deliver the best value and

service to our customers.

Through a continuous learning

process and by investing in

people and technology, we

aim, not only to maintain

the high standards by which

we are already recognised

but to fulfil our ambition to

be recognised globally as

the best and most successful

company in our field.

Paul HowardTony Sysum

1

What do we do?

New applications• Design: full system design from

concept to completion

• Supply: all materials – rail, clips, pad, fastenings, base plates, grouts

• Install: installation of full crane rail systems – steelwork realignment/levelling and modifications

• Safety: Rapid Rail Safety Systems offers the complete safety solution – a range of Fall Protection Equipment, training and recommendations

• Crane wheel lubrication: Rapid Rail Lubrication System reduces crane rail wear by applying lubricant automatically at the precise point of contact between the crane wheel and rail

• Embedded rail: is a proven technology, set to revolutionise crane rail applications worldwide.

Existing applications• Repair: welding (both puddle

arc and Thermit welding processes) – replacement of damaged rail and fastenings

• Emergency repair: guaranteed response times for maintenance contracts/specified customers

• Maintain: maintenance contracts, material replacement, weld repairs, re-alignment

• Survey: visual survey through to full instrument survey supplying tabulated results together with cad drawings, report of findings and recommendations

• Installation: Rapid Rail can guarantee every installation due to using only Rapid Rail employed engineers.

Where do we do it?

As well as working extensively in the UK and Europe, Rapid Rail has successfully completed contracts in many locations throughout the world.

Our experience and knowledge of overseas working practices and market structures have enabled us to provide unequalled service and support to our customers.

America

Australia

Austria

Belgium

Egypt

Eire

Germany

Israel

Italy

Mexico

Oman

Spain

Switzerland

2

1 Safety 3

Rapid Rail Safety Systems Limited Offers a complete fall protection

equipment range

2 Crane Wheel Lubrication 7

Lubrication direct to the point of contact

3 Ports & Harbours 9

Introduction Specification – type of rail, clips,

spacing, standards/tolerances Technical – selection charts

4 Embedded Crane Rail 11

Rapid Rail supplies the latest technology in embedded rail

5 Steel & Non-Ferrous 13



6 Automated Warehouse Systems 17



7 Cement Manufacture 21



8 Power Generation 23



9 Water Treatment Works 25



10 Specialist Services & Repairs 27

Thermit Welding Puddle Arc Welding Diamond Drilling

11 Products 29

Introduction Rail – type of rail – selection charts Clips/Pad Fastenings Grouts Plates

2

Contents

2

As a result of over 20 years of safety critical experience at heights, Rapid Rail has developed the best available safety systems and products. They are appropriate for industry sectors such as construction, manufacturing, commercial property, ports, energy.

We offer systems that are appropriate, flexible and reliable. It is imperative to ensure safe working at heights when it’s not just a statistic but a human life at stake.

Safety 1

From the firm foundation of tried and tested industry expertise, Rapid Rail provides complete safety solutions – everything from equipment, recommendations and training.

3

Falls from height are the most common

cause of fatal injuries and the second

most common cause of major injury to

employees, accounting for 15% of all

such injuries.

4 5

Safety

Rapid Rail works with you to assess your needs and to make comprehensive recommendations and:

• site surveys and risk assessment

• computer generated specification

• a personal response to design the optimum system for you

• certificated installation using our experienced highly trained engineers

• staff training to optimise use, application and maintenance of systems

• regular servicing of systems and products – replacement where necessary.

LegislationThe law worldwide is increasing safety standards annually. It is now a legal imperative to ensure safety for those working at heights and to improve the statistics of fatalities and injury.

A safe environment is also a more productive, efficient and cost effective one.

The Personal Protective Equipment Regulations require:

• employers to maintain fall arrest equipment in good repair

• appropriate replacement

• inspection of equipment which is exposed to deterioration regularly and each time circumstances which might jeopardise safety have occurred

• marking of PPE against falls from height

• examination of components at least 12 monthly

• textile manufacturers recommend inspection more frequently.

Fall Protection EquipmentRapid Rail offers a flexible range of products. They go beyond the legal and quality requirements for proven fall protection equipment. Our products are:

• easy to use and install

• flexible

• quality assured

• industrially tried and tested

• permanent

• certified

• individually designed

• simple to maintain

• cost effective

• superior.

Horizontal Safety Lines*These give complete safety and working freedom. They travel easily with unrestricted movement and can support from one to ten users. For use in energy, warehouse, construction, applications.

• smooth operation

• hands free movement

• shock absorbing qualities

• adjustable, unobtrusive installation

• permanent

• customised design

• ensures maximum safety

• simple maintenance (annual service requirement)

• cost effective

• superior to all alternatives.

4 5* Full technical product specification available

Vertical Safety System*Designed to ensure safety in the horizontal, vertical or inclined planes. High tensile cables attach the user to the climbing area and safety is assured by automatic locking devices.

The right system for you, can be supplied quickly and easily:

• flexible lifelines

• different durability of product for different requirements

• smooth operation

• automatic release

• hands free movement

• maximum shock absorption

• temporary or permanent

• customised design

• ensures maximum safety

• manual rope adjuster

• cost effective

• automatic or manual versions

• superior to all alternatives.

Safety Harnesses*Designed for professionals combining functionality with comfort. For use in telecoms, construction, access machinery, rescue, any application requiring access or suspension.

• designed for professionals by professionals

• maximum safety

• flexibility

• multiple adjustments for perfect fit

• ultimate stretch and comfort

• adjustable function and movement

• lightweight but durable

• easy to use

• freedom of movement

• cost effective.

Lanyards*Maximum movement with no compromise on safety. Each lanyard can be supplied with various types of hooks and connectors. For use on towers, aerials, masts, wind generation farms, or any need for rope access or suspension:

• greater manoeuvrability

• highest standards of manufacture

• light but strong material

• maximum safety

• reduced risk of snagging, tripping or dragging

• reduced fall arrest forces

• heavy duty protection

• visible product warnings

• prolonged service life


• cost effective.

Retractable Fall Arrest Blocks*Maximum safety and compliance for: construction, warehouse, utility and confined space applications.

• maximum safety

• fall indicator

• easy to use

• swivel snap hook

• performance

• finest materials for durability


• lightweight blocks with webbing

• heavy duty with winch and galvanised cable.

Safety Harness Kits*The latest safety harness kits ensure compatibility and compliance of all components.

Kits include customised fall protection equipment eg harness, anchorage, lanyard, shock absorber, scaffold hook. An easy solution for construction, industry and specialist applications.

• maximum safety

• compliance

• easy and convenient

• ready for use

• performance

• choice of packaging

• readily portable

• choice of content

• cost effective.

6

2

Safety

* Full technical product specification available

Personal ProtectionEquipment*The best selection of products to ensure personal user safety in eye, ear, hand and foot protection. We can select, install and maintain the equipment you need for industry, public services, utilities, manufacturing:

• maximum safety

• staff satisfaction

• builds workplace confidence

• installation and training

• maintenance

• compliance

• comfortable

• quality

• practical, yet stylish

• performance

• choice

• cost effective.

Safety Training*Supply of the best available equipment is not enough to ensure worker safety. Training and advice in product usage, maintenance and application is a legal requirement. We supply training options to suit the customer daily facing risks and responsibilities of staff working at heights and provide the necessary consultancy to help you select, use and maintain all fall arrest and safety systems.

Rapid Rail ‘hands on approach’ to on-site training via customised workshops and seminars.

• managing height safety

• roof top safety

• inspection, care and maintenance of PPE

• industrial rope access

• cradles and platforms.

Rapid Rail – the completesafety solutionSafety and complacency do not mix – too much is at stake. Rapid Rail applies three decades of specialist industrial safety experience to your business application. Our experience and products are at your service. Rapid Rail – the ‘hands on approach’ to all aspects of safety consultancy:

• risk assessment• compliance• recommendations in systems

and practice• supply and installation of

products and kits• training and advice on use

and maintenance• ongoing monitoring and

inspection.

6

2Crane WheelLubrication

2

The automatic crane wheel lubrication system offered by Rapid Rail

7

**

** Authorised Distributor

LubricationThe close relationship that exists between Rapid Rail and our clients has driven us to pursue a solution to ease crane wheel and rail wear. To this end we are extending our range of products to include an

automatic rail wheel lubrication system. This will enable Rapid Rail to offer surveys, recommend supply and the installation of a clean, safe method of applying lubrication to a precise location.

8

Crane wheels are affected by crane loading, heat, cold, misalignment, settlement of buildings and hostile environments, especially in heavy industrial production areas i.e. steelworks, foundries and process industries. These can all accelerate wear, necessitating expensive repairs and replacements being undertaken to both rail and crane wheels, resulting in loss of production.

The rail/wheel lubrication system offered by Rapid Rail provides an automatic discharge of a specifically formulated lubricant into the inner surface of the wheel flange. This in turn is transferred to the point of contact on the rail head sides, thus reducing friction.

Due to the pre-set frequency and measured volume of the lubricant deposited, excessive build up of grease is avoided. This minimises cleaning and allows a more detailed examination of the rail and clips during routine maintenance checks. The amount of lubrication can be adjusted during each life cycle as required, enabling the end user to react to changing circumstances.

The system after initial installing and priming is maintenance free, until the cartridge requires replacing. The frequency of discharge can be 1, 3, 6 or 12 months or set individually, dependent on the users requirements.

Cartridge and batteries are always changed as a complete unit.

The motor drive has a proven minimum life of 8 cycles. For external use we can provide plastic caps for weather protection. The unit is mounted on the crane by a simple bracket fitted in a convenient position on the crane structure.

Some of the known advantages:

• Reduced wear resulting from metal/metal contact

• Reduced maintenance costs by increasing the life of crane wheels/rail

• Controlled use of specifically formulated lubricant

• Quick and easy installation and replacement on site

• No external power sources, fully automatic, maintenance free, electronic mechanical drives

• Safety proven. approved

• Waterproofed if required

• Widely used in Europe, UK and USA.

• If required, a computerised system of recording the installation and renewal of cartridges can be offered. This service depends on the delivery cycle being maintained

• A similar system can be offered for many engineering applications where lubrication is necessary to provide a smooth maintenance free operation.

Please phone or e-mail Rapid Rail with your requirements.

Crane Wheel Lubrication

8

Ports & Harbours 3

In a competitive and constantly changing business environment, a port must ensure it offers reliable and cost effective services.

Quayside cranes and rail mounted gantry cranes are the nucleus of port operations. Failure in these core areas directly affects productivity and profitability.

Rapid Rail has extensive experience of port installations and maintenance,

having worked for many years with some of the world’s largest port authorities.

Our reputation as reliable, credible and, above all, experts in our field has enabled us to assist these ports in their continuous improvement and development projects.

Today Rapid Rail is considered to be second to none in all rail mounted port installations.

Successful handling and management of world cargo relies upon the expertise and operating facilities of a port.

Rapid Rail clients include

all principal port authorities

worldwide.

9

10

Standards – TolerancesCrane rails are typically installed to tolerances set out in BS466 Appendix F (British standard specification for power driven overhead travelling cranes, Semi Goliath and Goliath cranes for general use). See page 14.

To ensure the optimum solution, attention must be paid to each individual application and agreement reached on the most appropriate tolerances.

FasteningsThere are two methods of fixing crane rails to concrete foundations. Continuous and discontinuous support. There is little doubt that continuous support is a better solution than discontinuous, but carries a higher cost. A designer must investigate the cost implications and, where operating criteria allows, give credence to discontinuous support.

Clips are generally installed in pairs opposite. The clip spacing may vary according to the rail type, wheel loads and duty cycle.

Trolley rails on overhead container handling cranes are generally installed to the normal overhead

crane tolerances. However, special attention must be taken at the hinged joints. Rapid Rail has extensive experience both home and overseas in this area and are frequently called upon to refurbish hinge rails.

Ports & Harbours

Rail Sections The following rail sections are commonly used on Ports & Harbours.

British Rails British Crane Rail British Bridge Rail

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION

SEC. 28BR 28.62 50 152 67 12 167 371 CES2

SEC. 56CR 56.81 76 171 101.5 35 836 702 CES2

SEC. 89CR 89.81 102 178 114 51 1502 1434 CES2

SEC. 101CR 100.38 100 165 155 45 3411 1266 CES2

SEC. 164CR 166.83 140 230 150 75 4784 5160 CES2

Continental Crane Rails A Sections S Sections


SEC. A55 31.8 55 150 65 31 178 337 DIN

SEC. A65 43.1 65 175 75 38 319 608 DIN

SEC. A75 56.2 75 200 85 45 531 1011 DIN

SEC. A100 74.3 100 200 95 60 856 1345 DIN

SEC. A120 100 120 220 105 72 1361 2350 DIN

Specification

lateral adjustment

2

1

4

3

5

7

6

8

KEY

1 stud/bolt fixing 2 adjustable clip 3 steel beam 4 resilient pad

5 epoxy resin/cementitious grout 6 levelling screw 7 soleplate 8 holding down bolt

10

4Embedded Crane Rail

Embedded crane rail is a proven technology, set to revolutionise crane rail applications worldwide.

Rapid Rail has formed a close working alliance with Edilon, world leaders in the development of embedded rail systems.

This ground breaking alliance means that Rapid Rail can now supply the latest technology with the Rapid Rail/Edilon Embedded Rail System.

11

12

Embedded Crane Rail

FeaturesThis embedded rail system means that traditional mechanical fastenings such as clips, anchors and base plates are no longer necessary. Embedded rails are connected to the underlying slab with continuous elastic rail support, which delivers flexibility and durability in one product.

The new crane rail can be precisely levelled and aligned into the completed chase in one operation after welding. A crane rail sealed into the jetty provides all the load bearing and functionality required at today’s modern port.

BenefitsThe added support means that the horizontal and vertical forces are more evenly distributed which reduces rail fractures and practically eliminates rail corrugation. Embedded rail offers maximum electrical insulation, a reduction in rail wear and important engineering advantages.

The advantages of the Rapid Rail /Edilon Embedded Rail System include:

• greatly reduced chase width

• potential for diamond drilling eliminated

• asphalt infill no longer required, reducing costs and routine maintenance

• greatly reduced site installation times

• rail is sealed preventing ingress of water, eliminating corrosion

• trapping and tripping hazards are reduced

• smoother passage for port traffic with greatly reduced impact on the embedded rail

• comparative initial costs with greatly reduced inspection costs through warranty periods

• full worldwide warranty available subject to terms and conditions.

Health, Safety and the EnvironmentThe Rapid Rail/Edilon Embedded Rail System is produced in compliance with the legislative requirements for health, safety and the environment. All Rapid Rail installation engineers are fully certified. Technical documents are produced regarding the use, effects, installation and removal of the systems.

A new embedded system highlights the reduced chase width

Traditional systems are more open to damage and loss of asphalt

12

5Steel & Non-Ferrous

Performance is key to ensure continued growth and development.

Cranes are paramount to successful and continual production. Renowned for their arduous duty cycles and extreme loading

necessitates continual maintenance and repairs to the crane rails.

Rapid Rail works closely with many companies to ensure continuous, uninterrupted operation of their production cranes.

The Steel & Non-Ferrous industry is a highly competitive global marketplace.

Rapid Rail clients include all major

Manufacturing and Process Plants

throughout the UK and overseas.

13

14 15

Specification

The most common types of cranes operating in steelworks are overhead gantry cranes, which are subjected to arduous working conditions and require frequent re-railing.

Standards/TolerancesOverhead crane rails are typically installed to tolerances set out in BS466 1984 Appendix F. (British standard specification for power driven overhead travelling cranes, Semi Goliath and Goliath cranes for general use).

It should be noted that gantry crane rails are generally only installed to tolerances for alignment and span. The level of the rail bearing structure determines the level of the rail.

The rail bearing structure should therefore be surveyed to ensure compliance with the required installation tolerances.

Steel & Non-Ferrous

Span Tolerances S

For spans less than or equal to15 metres S = 3mm.For every metre of crane span above15 metres (0.25mm) is added to the 3mm.Therefore a (20 metre) span crane the tolerance is as follows:

3 + (5 x 0.25) = 4.25mmup to a max of 15mm

Misalignment of Running Surfacein the Vertical Plane

H max 10mm

Permissible Deviation of Track Straightnessin Horizontal and Vertical Planes

Local vertical or horizontal deviation at any point of the track should not be greater than L/2000, measured over a length of not less than 2 metres on a line parallel to the theorectical datum as shown (right).NB To a max of 10mm.

1

2

3

H

'L'

10mm

10mm

'L'2000

S SPermissableinclination1 : 300

Track Tolerances (Top running cranes) derived from BS466 1984 Appendix F

14 15

Rail SectionsThe following rail sections are commonly used.



SEC. 56CR 56.81 76 171 101.5 35 836 702 CES2

SEC. 89CR 89.81 102 178 114 51 1502 1434 CES2

SEC. 101CR 100.38 100 165 155 45 3411 1266 CES2

SEC. 164CR 166.83 140 230 150 75 4784 5160 CES2

SEC. 28BR 28.62 50 152 67 12 167 371 CES2

SEC. 50BR 50.18 58.5 165 76 58.5 326 720 CES2



SEC. A45 22.1 45 125 55 24 90 170 DIN

SEC. A55 31.8 55 150 65 31 178 337 DIN

SEC. A65 43.1 65 175 75 38 319 608 DIN

SEC. A75 56.2 75 200 85 45 531 1011 DIN

SEC. A100 74.3 100 200 95 60 856 1345 DIN

SEC. A120 100 120 220 105 72 1361 2350 DIN

SEC. A150 150.3 150 220 150 80 4373 3850 DIN

FasteningsA rail fastening system should control vertical rail movement and secure the rail laterally.

There are several types of clips available. The two most common types of clips are:

1 a two part welded base clip incorporating its own bolt system

2 a single part clip which can incorporate the use of weld studs or bolts to secure.

Clips are generally installed in pairs opposite and are spaced along the rail according to the rail type, wheel loads, duty cycle and any other factors which can affect design.

adjustment

31

2 4

5 KEY

1 welded stud or bolt 2 adjustable single part clip 3 alternative adjustable welded base type clip with integral bolts 4 resilient pad 5 steel beam Diagram: Section through rail, clip and pad on beam

16

Steel & Non-Ferrous

Overhead crane rails provided by Rapid Rail at a new facility built for the production of Royal Navy vessels

16

6Automated Warehouse Systems

Fast moving goods, which require 100% selectivity, rely upon appropriate storage facilities and interfacing handling equipment.

Automated warehouse cranes are key to accurate and time effective handling. Accuracy is demanded in

the installation of the floor rails to ensure appropriate interaction of the crane and racking.

Rapid Rail has been selected time and time again as preferred installers capable of achieving the exacting standards required.

The world of logistics is often driven by time dependent customer demand.


manufacturers of storage and retrieval

system worldwide.

17

18 19

Specification

Standards – TolerancesNarrow aisle crane rails are typically installed to tolerances set out in FEM. 9.831 (Rules for the design of storage and retrieval machines. Tolerances and clearances in the high bay warehouse).

Installation tolerances for Crane Rails used for Storage & Retrieval generally in accordance with FEM 9.831

Floor RailAlignment tolerances with reference to vertical datum without tolerances, in the horizontal z–direction.

measured length total rail length 3.0mmmeasured length s/r machine wheel base 1.5mm

Rail heads of different dimensions shall be made flush by grinding the side guide surfaces in the joint area, levelness of the joints over a measured length of 200mm ≤0.5mm.

Level TolerancesLevel tolerances of H2 in the y–direction, with reference to a horizontal datum plane without tolerances in the vertical direction:

measured length 100m 2.0mm 100m 3.0mmmeasured length s/r machine wheel base 0.5mm.

Rail heads of different dimensions shall be made flush by grinding in the joint area: levelness of the rail and of the joints over a measured length of 100mm ≤0.1mm.

Travel CharacteristicsThe travel characteristics of the s/r machine can be influenced by the unevenness of the top and side guide surfaces of the rail. These surfaces must be even ie: there must be no pitting resulting from rust or rolling.

Dimensioning and AnchoringDimensioning and anchoring of the floor rail is the responsibility of the equipment manufacturer in conjunction with the civil engineer and the installer of the rail.

It is not unusual for these types of rails to be installed to greater tolerances than those specified in FEM 9.831. Each application is reviewed and agreement reached on the most appropriate tolerances.

Automated Warehouse Systems

18 19

FasteningsThere are various factors to be considered when designing a storage and retrieval floor rail system.

In addition to the normal design parameters, consideration should also be given to:

• the required installation tolerance

• limiting deflection to within the required parameters

• control of loading on concrete floor.

There are varying system designs, which accommodate specific application requirements.

Clips are generally installed in pairs opposite. For this type of application, it is common for the clip spacing to be a division of the machine wheelbase. This may vary according to the rail type, wheel loads, duty cycle and any other factors, which may affect the design.

Rail SectionsThe following rail sections are commonly used in storage and retrieval systems.



SEC. 50 ’O’ 24.82 52.39 100.01 100.01 10.32 424 105 BS11

SEC. 60 ‘R’ 29.85 57.15 109.54 114.3 11.11 682 148 BS11

SEC. 75 ‘R’ 37.09 61.91 122.24 128.58 13.1 1064 223 BS11

SEC. 80 ‘O’ 39.74 63.5 127 127 13.89 1101 276 BS11

Continental Rails A Sections S Sections


SEC. S30 30.03 60.3 108 108 12.3 606 DIN

SEC. S33 33.47 58 105 134 11 1040 154 DIN

SEC. S41–10 41 67 125 138 12 1382 260 DIN

SEC. S41–14 41 67 125 138 12 1367 260 DIN

SEC. S49 49.38 67 125 149 14 1816 320 DIN

Installations have been completed using HEA and IPN sections.

KEY

1 holding down bolt 2 levelling nut 3 pad 4 clip bolt (multi hole plate)

5 soleplate 6 epoxy resin/cementitious grout 7 adjustable clip 8 reinforcing bars

41

2

3

5

6

7

8

20

Automated Warehouse Systems

20

Cement Manufacture 7

There are various handling systems utilised within the cement processing industry.

From circular slurry tanks and general handling cranes, through to conveyer systems.

As with all manufacturing processes the need for effective and maintenance free plant is crucial.

The diversity of handling systems utilised within the cement industry

requires maintenance by engineers with equally diverse skills.

At Rapid Rail, we have the skills and experience necessary to enable us to service these requirements in a thorough and cost effective manner.


manufacturers of cement and cement

products.

21

22


To ensure the optimum solution attention must be paid to each application individually and agreement reached on the most appropriate tolerances.

FasteningsWhilst there are applications which would require a welded base type of fastening, it is reasonably common to use a single part clip utilising a through bolt/weld stud fixing.

There are varying system designs, which accommodate specific application requirements.

Clips are generally installed in pairs opposite. The clip spacing along the rails may vary according to the rail

type, wheel loads, duty cycle and any other factors, which may affect the design.

Cement Manufacture

Rail SectionsThe following rail sections are commonly used in the cement manufacture & processing industry.



SEC. 28BR 28.62 50 152 67 12 167 371 CES2

SEC. 50BR 50.18 58.5 165 76 58.5 326 720 CES2

SEC. 56CR 56.81 76 171 101.5 35 836 702 CES2

SEC. 89CR 89.81 102 178 114 51 1502 1434 CES2

SEC. 101CR 100.38 100 165 155 45 3411 1266 CES2

SEC. 164CR 166.83 140 230 150 75 4784 5160 CES2



SEC. A55 31.8 55 150 65 31 178 337 DIN

SEC. A65 43.1 65 175 75 38 319 608 DIN

SEC. A75 56.2 75 200 85 45 531 1011 DIN

SEC. A100 74.3 100 200 95 60 856 1345 DIN

SEC. A120 100 120 220 105 72 1361 2350 DIN

lateral adjustment

2

1

4

3

5

7

6

8

KEY



Specification

22

8Power Generation

There are many different power producing operations such as coal, combined heat and power (chp), gas, hydro and nuclear, all having varying and demanding methods of production.

All power producing companies aim to maximise the production and distribution of their power generation. Allied to this are their obligations and commitments to environmental and social issues.

Maintaining and upgrading production facilities contribute towards lower emissions and increased generation.

The diversity and depth of experience gained within power generating companies have enabled Rapid Rail to become a leading partner in power generation.

Power Generation a very demandingworking environment.

Rapid Rail clients include

Power Generating Plants

throughout the UK.

23

24

Power Generation

Rail Sections The following rail sections are commonly used in the power generating plants.



SEC. 28BR 28.62 50 152 67 12 167 371 CES2

SEC. 56CR 56.81 76 171 101.5 35 836 702 CES2

SEC. 89CR 89.81 102 178 114 51 1502 1434 CES2

SEC. 101CR 100.38 100 165 155 45 3411 1266 CES2

SEC. 164CR 166.83 140 230 150 75 4784 5160 CES2



SEC. A65 43.1 65 175 75 38 319 608 DIN

SEC. A75 56.2 75 200 85 45 531 1011 DIN

SEC. A100 74.3 100 200 95 60 856 1345 DIN

SEC. A120 100 120 220 105 72 1361 2350 DIN

SEC. A150 150.3 150 220 150 80 4373 3850 DIN

Specification


FasteningsCrane tracks in power generation plants can be either overhead or ground tracks and are all fixed using fully adjustable rail clips.

There are several types of clips available. The two most common types of clips are:

1 a two part welded base clip incorporating its own bolt system

2 a single part clip which can be secured by either weld studs or bolts.

Clips are generally installed in pairs opposite. The clip spacing may vary according to the rail type, wheel loads, duty cycle and any other factors, which may affect the design.

lateral adjustment

2

1

4

3

5

7

6

8

KEY



24

9Water Treatment Works

Privatisation of utility services has enhanced public accountability and brought about a drive for greater efficiencies and value for money. Efficient operation of plant and equipment has become the focus, resulting in a vast number of refurbishment schemes and new build projects.

Problematic areas in many water treatment works are the rails upon

which the distributors and scrapers operate.

Existing design parameters and varying drive systems create a challenging yet fulfilling project.

Rapid Rail has completed many refurbishment and new build projects in the water treatment industry and is considered to be the leading Installation Company.

Water Treatment Works – an environmentally sensitive area where standards are strictly controlled.

Rapid Rail clients – main utilities

and their suppliers.

25

26

Water Treatment Works

Rail Sections The following rail sections are commonly used in water treatment works.



SEC. 28BR 28.62 50 152 67 12 167 371 CES2

SEC. 40 ’M’ 18.89 45.64 80.57 88.11 12.3 246 51 BS11

SEC. 50 ‘O’ 24.82 52.39 100.01 100.01 10.32 424 105 BS11



SEC. S18 18.3 43 82 93 10 271 47 DIN

SEC. S20 19.8 44 82 100 10 346 53 DIN

Specification

Standards – TolerancesDistributor/Scraper rails are typically installed to tolerances set out in BS466 Appendix F (British standard specification for power driven overhead travelling cranes, Semi Goliath and Goliath cranes for general use). See page 14.

FasteningsThere are two methods of fixing crane rails to concrete foundations, continuous and discontinuous support. There is little doubt that continuous support is a better solution than discontinuous, but carries a higher cost. A designer must investigate the cost implications and where operating criteria allows, give credence to discontinuous support.

Clips are generally installed in pairs opposite. For this type of application, it is common for the clip spacing to be a division of the machine wheelbase. This may vary according to the rail type, wheel loads, duty cycle and any other factors, which may affect the design.

Steelwork finishes are generally soleplates and clips – galvanised fastenings – stainless steel,rail – self colour.

lateral adjustment

2

1

4

3

5

7

6

8

KEY



26

10Specialist Services & Repairs

Thermit Welding®

The Thermit® compound is a mixture of metal oxides, alloying elements and a reducing agent. These react to form the metal; simultaneously liberating intense heat to produce superheated molten steel, which forms the weld.

The rails to be joined together are aligned, leaving a prescribed gap between their ends. Preformed refractory moulds are fitted around the recommended gap at the junction of the two rails.

Thermit Welding® is a specialist welding process for the joining of rail steels.

27

28

Puddle Arc Welding

MMA Puddle Arc Welding is the process of joining carbon steel crane rails.

PreparationThe rails to be joined together are aligned, leaving a prescribed gap between their ends. Rail ends shall be smooth and free from defects and grease. The rails are set with a slight camber at the joint to allow for weld contraction and copper moulds are placed around and under the joint.

Heat TreatmentJoints are preheated to a prescribed temperature and confirmed using a temperature indicator prior to welding.

WeldingA mild steel strip is placed at the bottom of the joint on top of the copper strip (This will form part of the weld).

Welding is carried out using low hydrogen electrodes. Electrodes are held perpendicularly and short rectangular movements are used with the tip of the electrode. Copper moulds are placed around the outer profile of the rail joint as welding progresses. This process is continued until weld metal is within 12mm of the rail-running surface and is allowed to cool for five minutes. The weld is de-slagged and welding is continued to the top of the running surface.

Following an appropriate cooling period, the rail head is ground to profile and the rails aligned and fastened.

This is only a process guide. If you require further details, please contact us and ask for a full weld procedure.

Diamond Drilling

Diamond drilling is a process used to drill through steel reinforcing in concrete using cylindrical core bits. These core bits are set with diamonds, usually in a tungsten carbide alloy crown. Rotative boring in the concrete with a hollow cylindrical bit set with diamonds allows the steel to be penetrated and the resultant core extracted, which can be used as verification of quantity of steel removed.

When site drilling concrete contractors run the risk of hitting steel reinforcing, Rapid Rail engineers carry diamond drilling rigs as part of the site establishment for ground tracks. If steel is unavoidable, with experienced operators downtimes and costs can be minimised.

Specialist Services & Repairs

PreheatUsing a specially designed burner, the moulds and the enclosed rail ends are preheated for a time, dependent upon the rail section, to achieve the correct welding temperature of 900/1000˚C.

IgnitionWhen the correct degree of preheat has been achieved, reaction is initiated in the crucible using a special igniter. Superheated molten steel is produced by an alimino thermic reaction (The Thermit® reaction).

Weld formingAt the correct time, the tapping system at the base of the crucible discharges the superheated molten Thermit® steel into moulds via the pouring cup.

After solidification, surplus Thermit® steel is removed from the rail head using a pneumatic chisel. Following an appropriate cooling period, the rail head is ground to profile and the rail aligned and fastened.

28

11Products

GeneralAs an independent installation specialist, we are able to draw on the expertise and resources of the best of industry supply.

This unique position enables us to offer the most appropriate and cost effective solution for all rail-mounted applications.

All products supplied are from quality approved suppliers and are backed by full product guarantees. This, coupled with our installation

warranty/guarantee, creates the most reassuring solution.

We guarantee to supply materials consistently:

• to the right specification• of the right quality• of the right quantity• at a competitive price• and at the right time.

The diagram above represents a typical fastening arrangement showing the products we supply.

lateral adjustment

2

1

4

3

5

7

6

8

KEY



Correct material selection is critical to ensure integrity and longevity of the track system.

Diagram: Crane rail fastening arrangement for use on concrete base and steel beam

29

30 31

RailSteel mills have been producing rail steels for over a century. During this time their designs have changed reflecting the diversity of applications, none more so than the crane rail industry.

Every application is different and must be engineered to maximise efficiency and lifespan. Selection of the correct rail is critical to achieving this end.

Rapid Rail is able to offer rails in:a various lengths to suit your

applicationb normal or high grade steelsc mitre cut to specific design

and sized curved rail (such as circular

tanks as seen at water treatment works and cement works)

e drilled or undrilledf modified to any design within

the limitations of the sections.

Rail supply is an important element to sucessful installation and working life of the installed track

system. It is necessary that all rail is supplied with full mill certification thus ensuring that correct installation procedures can be programmed and guaranteed.

All rail supplied by Rapid Rail is sourced from reputable rolling mills with full certification.

The table below represents some of the most commonly used rail sections. It is by no means exhaustive. Other rail sections are available. Please contact us for further details.

Products

Rail Sections

British Rails B r i d g e R a i l s


13 BR 13.31 36 92 48 7.5 3.9 74.4 CES2

16 BR 16.06 44.5 108 54 11 65 117 CES2

20 BR 19.86 50 127 55.5 10.5 82 193 CES2

28 BR 28.62 50 152 67 12 167 371 CES2

50 BR 50.18 58.5 165 76 58.5 326 720 CES2

C r a n e R a i l s

56 CR 56.81 76 171 101.5 35 836 702 CES2

89 CR 89.81 102 178 114 51 1502 1434 CES2

101 CR 100.38 100 165 155 45 3411 1266 CES2

164 CR 166.83 140 230 150 75 4784 5160 CES2

F l a t B o t t o m e d R a i l s

50 ‘O’ 24.82 52.39 100.01 100.01 10.32 424 105 BS11

60 ‘A’ 30.62 57.15 109.54 114.3 11.11 696 150 BS11

60 ‘R’ 29.85 57.15 109.54 114.3 11.11 682 148 BS11

75 ‘R’ 37.09 61.91 122.24 128.58 13.1 1064 223 BS11

80 ‘O’ 39.74 63.5 127 127 13.89 1101 276 BS11

110 ‘A’ 54.52 69.85 139.7 158.75 15.87 2323 418 BS11

113 ‘A’ 56.22 69.85 139.7 157.75 20 2318 418 BS11

M i n e R a i l s

30 ‘M’ 14.79 38.1 69.85 75.41 9.13 139 33

40 ‘M’ 18.89 45.64 80.57 88.11 12.3 246 51

Continental Rails F l a t B o t t o m e d R a i l s


A45 22.1 45 125 55 24 90 170 DIN

A55 31.8 55 150 65 31 178 337 DIN

30 31

Continental Rails continued F l a t B o t t o m e d R a i l s


A65 43.1 65 175 75 38 319 608 DIN

A75 56.2 75 200 85 45 531 1011 DIN

A100 74.3 100 200 95 60 856 1345 DIN

A120 100 120 220 105 72 1361 2350 DIN

A150 150.3 150 220 150 80 4373 3850 DIN

UIC60 60.3 74.3 150 172 16.5 3055 513 UIC

T a l l R a i l s

S18 18.3 43 82 93 10 271 47 DIN

S20 19.8 44 82 100 10 346 53 DIN

S30 30.03 60.3 108 108 12.3 606 DIN

S33 33.47 58 105 134 11 1040 154 DIN

S41-10 41 67 125 138 12 1382 260 DIN

S41-14 41 67 125 138 12 1367 260 DIN

S49 49.38 67 125 149 14 1816 320 DIN

Examples of other rails supplied R a i l s


MRS87A 86.8 101.6 152.4 152.4 34.9 3068 975 ASTM

MRS87B 86.8 102.4 152.4 152.4 38.1 2922.7 901 ASTM

ASCE80 39.8 63.5 127 127 13.9 1098 ASCE

ASCE85 42.2 65.1 131.8 131.8 14.3 1252 ASCE

CR 73 73 100 140 135 32 2000 719

CR 100 100 120 155 150 39 3270 1360

73 kg BHP 73 69.9 146 157 2660 671.2

86 kg BHP 86 102 165 102 1082

Note: Engineers must check the accuracy of the data before relying upon it. Not all rail sections produced are readily available, some may not have been produced and some may have been removed from production.

FasteningsThere are many ways in which a rail can be secured, i.e. bolted, riveted, welded. Undoubtedly the one recommended by Rapid Rail is the fully adjustable clipped system which offers the most cost effective long term advantages.

It allows full rail adjustment to achieve design tolerances, easy replacement of worn rails, with minimum downtime necessary in high production areas.

With continuously welded rails, the clip allows controlled vertical and longitudinal movement which occurs with thermal expansion and

“Bow wave” effect in the rail which precedes each pass of the crane wheel.

Introducing a rail pad between the crane rail and the supporting structure will:

• accommodate unevenness in the supporting structure

• help to distribute wheel loads over a larger surface area

• re-centre loads – for rail mounted on steel girder

• reduce wear to the rail and the supporting structure

• reduce fretting between the rail and supporting structure.

There are several rail fastening arrangements available which fit this criterion.

Drawing on our resources and optimising our wealth of experience, we are able to bring together the best of the industry’s quality materials, thus offering the most appropriate and cost effective solution.

32

Products

adjustment

Note: adjustable weld basetype clip (not shown)

KEY

1 welded stud or bolt2 adjustable rail clip3 alternative welded base type clip with integral bolts4 resilient pad5 steel beam

Diagram 1: Section through rail, clip and pad on beam

Diagram 2: Section through ground track

Diagram 3: Section through embedded rail

3

12

45

41

2

3

5

6

7

8

1

2

3

KEY

1 holding down bolt2 levelling nut3 pad4 clip bolt (multi hole plate)5 soleplate6 epoxy resin/ cementitious grout7 adjustable clip8 reinforcing bars

KEY

1 corkelast® embedding polymer2 reinforcing bars in terminal quay3 terminal quay & recess

As is seen in diagrams 1, 2 & 3 there are various fixing configurations, each fixing arrangement selected according to the system criteria.

Clips – fully adjustable• Weldable base type clip

comprising cap & base with integral bolts

• Single part clip secured by either welded studs or grade 8.8 bolts through the structure.

Rail Pad• Continuous with lateral restraint• Lipped pad for individual

soleplates.

Bolts & holding down bolts • All sizes to suit application in

grades 4.6 and 8.8.

Soleplates • Continuous in mill lengths• Individual 2, 4 or 6 hole fixings.

GroutYears of experience and co-operation have led to the formulation of high quality grouts, designed specifically for crane track applications.

There are three basic types of grout.

• Polyester resin anchor grout used in most cases for the fixing of holding down bolts.

• Cementitious grout used for base plate grouting. A preferred option in suitable cases due to reduced costs.

• Epoxy grout used for base plate grouting continuous or individual generally recommended for all applications.

FinishesIn corrosive environments clips and soleplates can be supplied galvanised, bolts and HD bolts can be supplied galvanised, BZP or stainless steel.

Embedded RailRapid Rail supplies the latest technology in embedded rail, the

Rapid Rail/Edilon Embedded Rail System. Traditional mechanical fastenings are no longer necessary and continuous elastic rail support delivers flexibility, durability and cost savings through reduced rail fractures and rail wear. Embedded rail offers maximum electrical installation and considerable engineering advantage.

FacilitiesRapid Rail has the in-house manufacturing capacity i.e. cutting, profiling, drilling, welding to cover all installation requirements.

Items required outside our manu-facturing capacity are sourced from specialist suppliers with full warranties.

Notes

Legislation is constantly being reviewed. The information in this brochure is for guidance only, please contact Rapid Rail for specific details on specifications, latest updates and product supply.

Desi

gned

by

Litc

hfiel

d M

orri

s, G

louc

este

r 0

1452

733

955

If you would like any further

information or would like to

discuss any particular points,

please do not hesitate to

contact us.

Documents

Rapid Rail crane rail installation and safety line installation doc