Rails on Concrete

Crane Rails on Concrete

Many rails must be mounted on concrete. The components in such an installation are:

The rail
Gantrail Pad of a suitable type
Gantrail adjustable clips to fix the rail
Steel sole plates either continuous or discontinuous
Grout to bed the sole plate
Steel holding down bolts for fixing sole plates

Continuous Sole Plates

Continuous rail support on steel sole plates is the option for heavy duty applications with wheel loads of >30 tonnes. Sole plates are typically 6 meters in length and tend to be supplied with a thickness of 20mm or more. Sole plates are often galvanised for outdoor applications. When rail clips are to be welded this must be done before galvanising.

Holding down bolts

The most economical holding down bolts are made from fully threaded bar. These can have angle cut ends to help prevent rotation after installation.

Grouts are formulated for the two applications on site:
- Fixing the holding down bolts
- Filling the gap between the sole plate and the concrete supporting structure

Three formulations are routinely used when installing crane rails:
- Polyester – normally only used for fixing holding down bolts
- Epoxy – used for fixing holding down bolts and beneath the sole plate
- Cement based - used for fixing holding down bolts and beneath the sole plate

The choice will be dependent on the application and other local conditions

Gantrail Discontinuously mounted rail

The most economical system is to fix the clip and the soleplate into position with the same holding down bolts. This is only suitable for the lightest cranes. For heavier duty cranes the holding down bolts and the clip fixing bolts are separated. Four styles of soleplate are used. The choice is dependent on the horizontal force from the crane wheels.

Installation

Accurate installation is imperative, as the dynamic forces from the crane will be magnified with misaligned rails. There are a number of ways to achieve accurate level and rail alignment. The method chosen will have an influence on the cost of materials, the speed of installation and the skill level of the workforce required to complete the installation. Gantrail are always happy to provide a method statement and typical drawings.

Gantrail have prepared a series of Data Sheets showing a range of installation options.

Gantrail have prepared a guide to installation on concrete.