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ComponentCrane Rail and Fastening Systems
The wrong rail and the wrong fastening write the crane's entire fault history.
Choosing the rail profile
Rail profile is chosen based on wheel load and wheel diameter. A profile that's too small gets its head crushed quickly; an unnecessarily large one raises cost and the demand placed on the supporting girder.
Using square bar or railway rail is incorrect outside of light-duty, low-class applications: load distribution and wheel contact behave differently on those profiles.
Fastening method
Welding looks the cheapest, but it makes the rail unremovable, blocks thermal expansion, and leaves unwanted stress in the supporting girder. Realigning it afterwards is nearly impossible.
Bolted fastening is adjustable but prone to loosening from vibration and needs regular checking. Elastic clips allow lateral adjustment while also allowing for thermal expansion — the preferred method for permanent runways.
Comparing the methods
| Method | Advantage | Drawback |
|---|---|---|
| Welding | Cheap and fast | Unremovable, can't be realigned, leaves stress in the girder |
| Bolted | Adjustable | Prone to loosening, needs regular checking |
| Elastic clip | Adjustable, allows for expansion | Higher initial cost |
Technical terms
| Term | What it means |
|---|---|
| DIN 536 | The standard defining crane rail profiles (A-series). |
| Joint | The point where two rail sections meet. |
| Shim plate | A plate placed between the rail and the girder to correct a level difference. |
| Elastic clip | An adjustable fastener that holds the rail laterally while allowing for thermal expansion. |
Frequently asked questions
Can I get a new crane without replacing my existing rail?
The rail's profile and condition need to be measured. If the profile can't take the new crane's wheel load, or the rail head is already crushed, the new crane will run into the same problems quickly.
How should rail joints be made?
Joints should be made with a gap that allows for thermal expansion and no level difference. An impact sound at a joint is the clearest sign that adjustment is needed.