Safety Notice for Crane Rail Installation

Safety Notice

When a crane or trolley applies brakes during operation, longitudinal or lateral forces are generated. If both the crane and trolley brakes engage simultaneously, a combined braking force is produced, resulting in diagonal thrust on the track. In installations where the track is positioned with one side higher than the other, the crane will tend to move toward the lower side, increasing the lateral forces exerted on the track. To address this, effective measures must be implemented to secure the track reliably.

For outdoor cranes, in particular, it is essential to prevent them from being displaced or tipping over due to wind. Therefore, rail clamps should be used to secure the track when the crane is not in operation. The reliability of track installation is critical to ensure the crane remains stable and functional.

In addition to reliability, track installation should also facilitate ease of replacement, particularly in areas with continuous production. Permanent connection methods, such as riveting or welding, are not recommended for this reason.

Types of Rail Beams

Two commonly used types of rail beams for crane track installations include:

• Steel Structural Beams

• Precast Concrete Beams

Precast concrete beams should be designed with pre-embedded openings to accommodate anchor bolts during installation.

Methods of Fixing Crane Rails

Several methods are used to secure crane rails effectively:

• Rail Clips

Rail clips are commonly used to fix steel rails. These clips may include pressure clips, which secure the rails and allow for horizontal and vertical adjustments. Horizontal adjustments are made by elongating the holes in the plate, while vertical adjustments are possible by adding pads beneath the rail. This method is simple and reliable but requires the use of a sufficient number of adjustment shims of varying thickness to prevent lateral displacement during use. The design of track clips should ensure adequate rigidity, and plates may include single or double holes depending on the applied forces.

• Hook-Shaped Screws

In this method, holes are drilled into the waist of the steel rail, and hook-shaped screws are used to connect the rail to the support.

• Welding and Bolts

This method involves welding pads with long holes to the underside of the steel or square rail. The rail is then lifted to the anchor bolts on the support beam for fixation. Precise installation of anchor bolts and proper welding of pads are critical to prevent misalignment of holes and bolts, which can complicate installation.

Regardless of the method used, it is essential that each rail joint is tightly secured, and the two rail ends must be connected using standard fishplates.

Steel Rail Specifications

The specifications for steel rails are determined by the maximum wheel pressure exerted by the crane and the structure of the rail support beam. Specific details regarding rail varieties and specifications can be found in the relevant manuals.

Inspection and Maintenance

The results of the final inspection for newly installed tracks should be documented in detail in the "equipment file card" maintained by the user. This will serve as a reference for future inspections and recalibrations. Periodically, it is necessary to check the foundation for settling, ensure that connection parts are secure, and verify that the track remains aligned. Any issues identified should be addressed promptly.

Grounding of Crane Tracks

It is crucial that crane tracks are reliably grounded. Cranes operating on tracks are generally grounded through their wheels and the track itself. The grounding resistance of both the crane track and any point on the crane should not exceed 4 ohms.