Presentation on
crane rail
erection of sms2
Presented by-Vikram Singh
Management
Trainee(Mechanical)
[Link]-5337
Crane rail introduction Rail
being a key component of the
crane support system.
Assists crane & provide a safe and
suitable runway for the cranes.
Must satisfy criterion such as
reliability, economy and life
expectancy .
Selection of rail characteristics is
such that to meet the specific design
parameters.
List of sizes of crane rails in different bays
of sms-2
Raw
Melting
materia Bay-(Cl
D)
storage
Bay-(CC)
Alloy
feeding
Bay-(DE)
Refining
Bay-(EF)
Casting
Bay-(FG)
Billet
Bay#1(G-H)
Billet
Bay#2(H-I)
SIZECR-80
CR-120
CR-80
CR-120
CR-100
CR-80
CR-80
SPAN21.8 m
26.6 m
12.4 m
26.6 m
26.6 m
31.6 m
25.15 m
RAIL
HEIGHT12 m
26 m
36.8 m
26 m
26 m
16 m
12 m
BAY
LENGTH126 m
192 m
192 m
192 m
192 m
192 m
192 m
CRANE
CAPACIT
Y-10 ton
90(175) /35 10 ton
/10 ton
160/40 ton 160/40 ton 60/20 ton
60/20 ton
General Requirements for the supply
of material
Designation-Crane
rail sections
confirming to Indian standards
IS:1387-1967 are designated bi the
letters ISCR followed by the head
width
PROFILE in millimeters.
SECTIONAL
STANDARD
WEIGHT (kg/m)
LENGTH
(m)
CR-80
64.2
12-13 m
CR-60
40
12-13 m
CR-100
89
12-13 m
CR-120
118
12-13 m
DESIRABLE PROPERTIES OF CRANE
RAILS:CRANE
RAILS
C%
Mn %
P max
S max
Si%
H2
0.650.75
1-1.3
0.04
0.04
0.1-0.5
Less
than 3
ppm
Ultimate tensile strength-850 MPA minimum
Elongation-8% minimum
Hardness-250 BHN minimum
Micro-structure- Pearlite
Crane rail fastening
systems: Crane
rail mounting methods are
developed in an effort to reduce the
all too frequent problems associated
with crane rail installations.
Todays line of crane rail clamps/clips
and use of fish plate ,splice plate for
joining of rails have been found easy
to install ,resulting in reduced
mechanical wear ,lower impact force
from shock loading & a quieter
Rail clamps:-
All clamp types can be used ,the choice between
bolt-able or weld-able clips is dependent on-:
Horizontal
wheel loads
Availability of free space on the girder width & the
chosen rail.
The accessibility
Possibility of work preparation in workshop
The type of work to carry on:new track or
reimbursement.
Weld-able clamps have been used in crane rail
erection of sms-2
Rail clamp:-
Rail clamp arrangement:-
Stop plate :-
Plan showing spacing of
clamps and stopper:-
Standards for crane rail
preparation & erection : Metal
arc welding of crane rails of same
designation
Preparation of faces to be welded1)Preparation of surfaces shall be done as
per above referred drawings by using a
power cutter hacksaw & use of grinder.
2)The rail ends should be cleaned of dirt,
rust,scale,grease [Link] to welding as
necessary.
Alignment of rail before
welding: This
shall be done as per drawing.
Use
of theodolite station is made for checking the
alignment of rails (northing, easting and level
readings of a TS machine),gives the degree of
closeness with the actual mentioned as per
drawing,& hence any correction if required in the
span or level of rails is done prior to welding.
Any
difference in width of rail heads shall always
be kept on non-collar side of crane wheels by
correctly aligning the rails.
Choice of electrode & its
specific location of use:
Low hydrogen type electrodes of 6.0mm &
5.0mm diameter shall be used from foot to head,
leaving a gap of about 6 mm at the top(other type of
electrode ) to be used there, of rail.
Electrode to confirm E616xxx as per IS815-74 &
classified against class D of IRS M-28-76.
low hydrogen electrode to be used ,shall be dried at
about 150-200^c for at least one hour before use
.shortest possible arc shall be maintained and
weaving of electrode shall be avoided as far as
possible.
Continued.
Hard facing electrodes are to be used for welding of 6 mm
gap at the top of rail head section for matching the
hardness of weld deposit with that of rail head.
The electrode to confirm IRS M-20-76 class H
Welding of rail ends-
The rail foot & the surrounding material up to about 10cm at
both the sides of the joints shall be preheated to
approximately 250^c either by oxy-acetylene flame or by air
petrol burner or any other suitable means like electric oven.
The magnetic field around the rail joint to be welded, if any,
shall be completely neutralized with the help of suitably
designed electromagnets having current variable control.
Revised method of erection of
crane rails as per new drawing: As
per the revised procedure of rail
mounting & erection ,the joints
between the two rails with v-section
cut on the faces has been replaced
by the method of bolting with the
support of splice plate the section of
splice plate ,fish plate, arrangement
of clamps, stoppers has already been
depicted.
Splicing joint detail:-
To sum up the entire erection
process of crane rail : Crane
rails of respective sections CR-80,CR-100 & CR-120 according to their
assigned bay.
Drilling
is carried out at both the ends of rail at a distance of 120 mm &
similar splice plate is prepared as per the drawing.
Pre
manufactured rail clamps confirming to the mentioned dimensions .
Rails are mounted on the top of crane girder with the help of a mobile
crane.
Spacing and alignment of crane rails is done as per drawing and affixed to
their aligned positions with a temporary joint with a stopper.
Alignment of rails is then checked with the help of a TS machine and
appropriate correction(if any) is done prior to welding of clamps and stopper
plates.
Finally welding is done with the use of proper electrodes & method already
mentioned.
Spring washer, plain washer ,and fish plate are fixed at their respective
positions and are tightened.
Thank you..
