Corrosion Protection

Corrosion Protection

Crane rail is seldom protected from corrosion by painting and even more rarely protected by other means.  Paint on the top surface of rails can act as a lubricant and may not be acceptable for machine operational reasons.  Rails tend to have large cross sections and corrosion rates are normally less of a concern than wear of the head.  Many rails have seen service without problem of the 50-year design life suggested in some design codes.  Others are replaced due to wear or new developments at the facility.

Other components in a crane rail installation normally require corrosion protection if they are outdoors or not under cover.  The pad beneath the rail is not subject to corrosion as the steel is well embedded in the rubber.  Gantrail clips are reliant on a frictional resistance between the two components and should not be painted before installation.  Most installations are painted after completion.  If required parts can be supplied galvanised as can all bolts, nuts and other steel components for an installation.  In the most heavily corrosive atmospheres painting after galvanising is often specified.  Sole plates are often supplied in hot dip galvanised condition.  This must be undertaken with care as the heat of the process can cause distortion if not properly controlled.

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Crane Rails

Crane rails come in a wide range of shapes and sizes. The designs have been developed to meet individual countries requirements with some being squat and wide and others are taller and similar in shape to railway rails but they are all more robust. There are now only a few ‘families’ of rails with similar shapes and a range of sizes. Most crane rails range in head width from 45mm to 150mm. A common feature is a thick web to carry the load to the base. There are also a range of steel metallurgies. At their most basic they are made from high carbon manganese steel but some are more highly alloyed. They are all difficult to weld. Gantrail will normal comment on any chosen rail for a project or propose the most suitable choices.

Crane Rail Pads

It is an advantage if a rail can rotate a small amount around an axis along its length. This allows the rail to take up a position that matches the wheel and as a result reduces the compressive stresses in the tread of the wheel and the head of the rail. Gantrail supply steel reinforced crane rail pads that allow this. They have been proven in thousands of applications for over 50 years. They also eliminate the metal to metal contact and reduce corrosion between the rail and its support.

Crane Rail Fixing Clips

It is not practical to fasten crane rails rigidly to the support on which they are mounted. Rails need to be adjusted to the correct position and to be able to move small amounts along the support. They also need to be able to rotate about an axis along their length. But they should be fixed rigidly from significant sideways movement. Gantrail have developed a range of adjustable crane rail fixing clips for all sizes of rail. These can be fastened by means of bolting or by welding to a steel surface. Some in the range will resist the highest expected loads but other are compact and light and are for smaller applications.

Steel Soleplates & Bolts

Most sole plates look like simple plates of steel with many holes. But the challenge for the track system designer is to combine the requirements of the concrete foundations with its reinforcement and expansion joints with the needs of the rail system. Hole positioning is most important. There may be a need for rail fixed points and earthing. There is also a need for high accuracy sometimes combined with corrosion protection. Bolts for fixing sole plates need to be made such that they will not rotate on being tightened. Gantrail also supply more sophisticated system which allow for releveling a rail after installation.

Grout

The upper surface of poured concrete it very weak and will not support the loads imposed by a steel crane wheel. The surface needs to be cleared of soft material before the gap between the structural concrete and the steel sole plate.is filed with high strength grout. Gantrail supply two types of grout for the majority of applications. Some cases require the strength of an epoxy based system whereas others can accept special cement bases grouts. Smaller qualities of fast curing polyester grouts are used to secure bolts in premade holes in concrete.

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