Crane rail welding and rail steels official partner of. Rapid rail supply welding engineers, supervision and or training in either mma puddle arc or thermitthermic welding. Flash butt welding is recommended whenever possible because of its proven durability. Thermit welding is an effective, highly mobile, method of joining heavy section steel structures such as rails. Aluminothermic rail welding process mrs 73 crane rail mrs 73 crane rail oxygen and propane preheat oneshot crucible stemming paste queensland 4110 acn 003 043 034 railtech australia limited po box 6211 acacia ridge dc australia telephone. The rails are set with a slight camber at the joint to allow for weld contraction and.
Process numbers according to en iso 4063 111 manual metal arc welding 5 mag welding with solid wire electrode. Welding of rails and related rail components for use by rail vehicles. The rail cross sections are large and the metallurgy. Typically rails may be welded into lengths of 300 metres or more with no expansion joint. Products welcome to railwel canada leader in rail welding. No mention made of the length of the rail sections, or the distance between supporting channels, but there is probably enough material in the rail s bottom flange to carry the load with little deflection, unless this is a really wide walk. Repair welding of crane wheels in steelworks smederevo. Design of the crane gives a lifting capacity of 4545 kg for the chem 110 and 7727 kg for the chem 180. Welding processes include shielded metal arc welding smaw, gas metal arc welding gmaw, flux cored arc. They are mostly used in heavy constructions and manufacturing of heavy equipment industries. The strip is fully melted in the welding process and becomes alloyed with the weld metal. The enclosed puddle arc welding process is a manual welding procedure specifically designed for the joining of crane rails of identical profile into one continuous length. This electrode is especially designed for the butt welding of rails with square preparation. In addition, there is a full glossary of rail and ndt terms.
Adhere to ufc 002 unified facilities guide specifications ufgs format standard when editing this guide specification or preparing new project specification. If on a double beam overhead crane for the trolley to run on, then the welding specification should be as per the manufacturers details. Topic welding industry technical discussions welding of crane rails by chguilford date 01052005 22. The enclosedwelding method wherein the molten welding deposit metal is filled in the gap between the rails and the excess metal is ground off and finished is a method that does not create any rail joint gap table 2. Rail welding and hoses for the safe operati crane a selfcontained twinarm articulating crane is provided to handle the welding head. Lonsdale metallurgical engineer conrail technical services laboratory altoona, pa 16601 abstract this paper provides a broad overview of thermite rail welding as information for. Enclosed arc puddle arc welding is widely used throughout the world for welding crane rails. Thus the composition of the strip is not important, providing it does not contain significant impurities. Crane is a powerful and heavy machine which is used for lifting, lowering of heavy objects, machinery etc with the help of cables and pulleys. Weld second hand rail according to the requirements of the arema manual, chapter 4, section 3. Should you require any further technical support on any of the areas covered below please contact our technical teams. Essentially a casting process, the high heat input and metallurgical properties of the thermit steel make the process ideal for welding high strength, high hardness steels such as those used for modern rails.
The nordco rail services and inspection technologies staff worked with railroad personnel and agencies around the world to identify major rail fl aw types. Essentially a casting process, the high heat input and metallurgical properties of the thermit steel make the process ideal for welding high strength, high hardness steels such as. The 1m straight edge must continuously touch the gauge face of the railhead. Part of what makes rail welding different from other welding is the composition of the rail. Bexon can offer our fully qualified specialist crane rail welding teams to complete the welding. I expect something suitable can be figured out and a welding proccess can be determined to join the tracks to. The process can be used on all crane rails including the a150 profile. The plasma welding consists only of the plasmaarc welding process which works with a transferred arc.
This project consists of the tearout and removal of the old crane rail system and the installation of a new gantrex rail system. If on the crane runway beams, it is unusual for the crane manufacturer to specify the rail, and normally crane rail like railway rails, but usually smaller sections are used, clamped to the runway beam. Rail ends shall be smooth and free from defects and grease. Top 12 different types of cranes used in construction works.
Rail wear limits for these alternative rail sizes should be determined during the process. The process employs an exothermic reaction of a thermite composition to heat the metal, and requires no external source of heat or current. The electrode is specially designed to enable good fusion to the side walls to take place without excessive slag interference. Way more information than you ever wanted on how to fell a tree. This guide specification covers the requirements for welding of crane rail and railroad rail by a thermite process. Our training team includes instructors, lead assessors and verifiers. It is our intention to offer the broadest level of service and support to all of our partners and clients worldwide. Specification for welding of industrial and mill cranes and. Track welding rules and proceduresfor inspecting, welding, and grinding of rail and track.
We offer a full range of rail welding kits to suit all rail sections including worn rail welding and wide gap welding. Gantrail employ skilled technicians who can do this work or can train other operatives. From limited knowledge and a more limited memory that doesnt sound like a recognized complete spec so i have some work there. However, as the time required for the onsite rail welding method is much longer than that of the bolt method and. The chemical reaction that produces the heat is an aluminothermic reaction. Track welding rules and procedures effective may 2, 2016 includes updates as of may 2, 2016 pb221 100. The information contained in this code of practice is applicable to the sks crane rail multipleuse and singleuse welding processes. Requirements are also included for modification, weld repair, and postweld treatments of new and existing weldments. Specification for welding of industrial and mill cranes. For the purposes of this document, rails include railroad rails, crane rails, guard rails, electrical contact rails, girder rails, and retarder rails.
Welding mostly mig and submerged is done with automatic or semiautomatic welding machines. The crane arms also carry the necessary cables on of the welder. The enclosed welding method wherein the molten welding deposit metal is filled in the gap between the rails and the excess metal is ground off and finished is a method that does not create any rail joint gap table 2. There are several types of cranes used in constructions depending on the type of work. History, process developments, current practices and outlook for the 21st century c. Welding processes addressed in this document include shielded metal arc welding smaw, gas metal arc welding gmaw, flux cored arc welding fcaw, flash welding fw, and thermite welding tw.
Crane wheel repair demands are primarily related to dimensions and. Crane rail welding is a specialist process that must be undertaken by fully trained and competent engineers. Adhere to ufc 002 unified facilities guide specifications ufgs format standard when editing this guide specification or preparing. The rail welding process is mainly divided into four steps, they are preweld preparation, crane rail welding, stress relief heat treatment and joint smoothing treatment. Crane rail welding process and crane rail welding procedure. In line with this, we have created a selection of technical guidance notes covering a broad range of topics. The cranes are assembled in special assembly jigs, which ensure the proper alignment of the crane. Cpts953 infrastructure management and principles outlines the processes, which shall be used to determine the acceptability of any new rail. Preweld preparation before welding the joint of crane rails, the oil, rust and other dirt on the end face should be carefully cleaned to facilitate the subsequent welding.
Recommended practices for the welding of rails and related rail components for use by rail vehicles. See annex a and the welding handbook, volumes 2 and 3, ninth edition for details on these processes. Crane rail systems specialty track solutions gantrex. Mar 31, 2017 crane rail aluminothermic welding gantrex team. Experience gained from user contact and welding training of crewmembers showed that. It can also be used for welding similar crosssections such as bars, thick plates, flanges, etc. Before welding, all material is carefully inspected and cleaned. The rail cap will now be in tension between the supports, and it may have cracks from its former use.
We also offer aluminothermic welding consumables from the european leaders in the industry. A crane rail is commonly considered to be a large and awkward section for welding, thus requiring a specialist to successfully complete the welding. On completion of the welding, the head of the rail is ground flush to ensure a smooth running surface on which the crane can run. Lonsdale metallurgical engineer conrail technical services laboratory altoona, pa 16601 abstract this paper provides a broad overview of. Rail welding processes gantry rail homepage gantry rail. Gantrail crane rail welding consumables for enclosed arc crane rail welding the benefits for continuously welded rail are considerable but they require the rail to be welded on site. Welding managers and supervisors, track managers and supervisors, track inspectors, track maintenance foremen, track welders and helpers and grinder operators must have a current copy of the track welding rules as described in this document. Welding of gantry crane rail kingnero mechanical 10 may 17 11. Pdf repair welding of crane wheels in steelworks smederevo. Optimal way of bridge crane track welding springerlink. The standard gap widths are 23 mm 1 mm and 25 mm 1 mm depending on the profile. Filler metal and welding procedure guidelines are recommended for the applicable base metals, which are limited to carbon and lowalloy steels. Puddle arc welding is widely used throughout the world for welding crane rails. Compared with arc welding, the welding process is largely independent of the user and has a greater degree of automation.
The purpose of the welding handbook for maritime welders is to provide guidance in modern welding and related processes and to provide the welder with a source of practical information on the right solution to specific onboard welding problems. We also cover nondestructive testing mptlpt, small plant, oxyfuel gas cutting and abrasive wheels. In this method the two rail ends to be joined are cut square, placed about 20 mm apart, preheated and then welded using special manual metal arc electrodes. The one shot crucible is tapped at the bottom, the molten steel flows into the mold, fusing with the rail. This document recommends standards for joining, repair, maintenance, inspection of rail welds, and related rail components. The rails to be joined together are aligned leaving a prescribed gap between their ends. Training thermit welding is fully approved by network rail to deliver courses in all approved aluminothermic welding processes, as well as in visual weld inspection. The most challenging issues with the project are the scheduling and working around the production of a paper mill. Rail is subjected to continually varying loads, forces and stresses, in all kinds of. Safety in welding, cutting, and allied processes, and applicable federal and state regulations see also annex e, safe practices.
Aluminothermic welding uses a refractory mould around the two square cut rails ends. The manufacturing of hooks is based on din 15401 for single hooks, din 15402 for double hooks and din 15404 for certification of hooks. Crane rail welding and rail steels the welding process striking on the copper. Detailed analyses, based on the mechanical and chemical properties of the materials used for crane wheels, as well as for repair welding, were performed for the contact between the rail and wheel. The crane rail should be continuous along the travel path of the cranes. Exothermic welding, also known as exothermic bonding, thermite welding tw, and thermit welding, is a welding process that employs molten metal to permanently join the conductors.
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