GANTREX TROLLEY RAIL SOLUTIONS SHORT RAIL SYSTEMS AND SERVICES OFFERED JUNE 2016
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1 GANTREX TROLLEY RAIL SOLUTIONS SHORT RAIL SYSTEMS AND SERVICES OFFERED JUNE
2 SHORT RAILS Subject to high duty cycle due to trolley movements Discontinuity in rail a cause for shock and vibration 2 GANTREX TROLLEY RAIL SERVICES
3 SHORT RAIL OPTIONS Full Web Short Rail Standard Short Rail Standard Short Rail With Welded Stiffener 3 Gantrex Short Rail 3 GANTREX TROLLEY RAIL SERVICES
4 STANDARD SHORT RAILS Suggested material grade 110CrV 1,080 N/mm 2 Rail crack formation through web Extreme plastic defformation zone due to lack of railhead support 4 GANTREX TROLLEY RAIL SERVICES
5 STANDARD SHORT RAILS WITH WELDED STIFFENER Large localized wear causes shocks and vibrations Stiffener weld cracks appear within months of installation Stiffener weld cracks if left unchecked can propogate into the rail and cause rail cracks and failure 5 GANTREX TROLLEY RAIL SERVICES
6 FULL WEB SHORT RAIL Fabricated from larger rails to keep univorm web thickness, suggested material grade 110CrV Large localized wear causes shocks and vibrations More robust solution than Standard SR Eliminates Stiffener cracks 6 GANTREX TROLLEY RAIL SERVICES
7 TROLLEY RAIL SYSTEM Large impact loads and vibration at boom hinge All shock and vibration transffered into the trolley rail system and crane structure Increased wear and tear Accelerated fatigue Rail and weld cracks Stringer Structural Fatigue Cracks Failed Fixed Points and Loose Clips and Clamps, large localized wear 7 GANTREX TROLLEY RAIL SERVICES
8 GANTREX SHORT RAIL SOLUTION Railhead machined from larger rail sizes to fit existing profile, standard material grade 110CrV Vulcanized rubber layer between Railhead and Rail Foot Rail Foot machined as a cavity to fit the Railhead and to fit existing rail profile GANTREX TROLLEY RAIL SERVICES 8
9 GANTREX SHORT RAIL SOLUTION The Back end of the Railhead is machined to fit existing rail profile for welding Improved Clamping through Gantrex SR Clamps Steel Shim installed under the vulcanized rubber layer RailLok TM Pad Installed up to the vulcanized rubber layer Staggered Shear Blocks Improved lateral stability through Gantrex RailLok TM Style Clips 9 GANTREX TROLLEY RAIL SERVICES
10 GANTREX SHORT RAIL SOLUTION Ammortizes Shocks and Viabration Eliminates Stiffener Cracks Minimizes wear and tear Minimizes Localized Wear Minimizes Rail and Weld Cracks Minimizes Fatigue Failures 10 GANTREX TROLLEY RAIL SERVICES
11 GANTREX TROLLEY RAIL SERVICES Complimentary Short Rail and Stringer Analysis Detailed Survey, Inspection and Alignment Short Rail System Design Short Rail and Trolley Rail Material Supply Turnkey Short Rail System Replacement Turnkey Trolley Rail System Replacement 11 GANTREX TROLLEY RAIL SERVIECS
12 COMPLIMENTARY ANALYSIS EXAMPLE Battered Boom Hinge Joints with numerous weld repairs Stiffener cracks observed on all four rails Around 2mm localized wear at hinge point with 4-5mm wear on trolley rail Observed what looks like a structural weld crack on left girder between top flange and web Battered Joint Stiffener Cracks Potential Structural Crack Improper Rail Weld prone to failure Multiple crack repairs 12 GANTREX TROLLEY RAIL SERVICES
13 COMPLIMENTARY ANALYSIS EXAMPLE Extreme Vertical Shock at Joint around 5G Lateral Shock at Joint around 2G (Suggests some lateral misalignment) Constant lateral and vertical vibrations throughout the trolley rail length Substantial shocks at trolley rail welds 13 GANTREX TROLLEY RAIL SERVICES
14 COMPLIMENTARY ANALYSIS EXAMPLE 14 GANTREX TROLLEY RAIL SERVICES
15 SHORT RAIL SYSTEM DETAILING EXAMPLE 15 GANTREX TROLLEY RAIL SERVIECS
16 THE GANTREX SHORT RAIL SUPPLY GANTREX TROLLEY RAIL SERVIECS
17 INSTALLATION A good installation goes a long way, Gantrex has specialized teams that can provide installation services as per the latest best practices and to Gantrex Highest Quality Standards 17 GANTREX TROLLEY RAIL SERVIECS
18 GANTREX SCAFFOLDING SYSTEM Gantrex installs Modular Scaffolding systems for safe access to the trolley rail 18 GANTREX TROLLEY RAIL SERVIECS
19 GANTREX SCAFFOLDING SYSTEM Gantrex Scaffolding is load rated and OSHA certified Scaffolding Installation Time 4 6 hours with adequate trolley access 8 10 hours with no trolley access Scaffolding Removal Time 2 3 hours 19 GANTREX TROLLEY RAIL SERVIECS
20 INSTALLATION CLEAN UP Stringer top surface needs go be cleaned to bare metal to receive new material for proper alignment and installation of a more robust solution 20 GANTREX TROLLEY RAIL SERVIECS
21 INSTALLATION BED REPAIR Stringer top surface needs to be cleaned to bare metal to receive new material for proper alignment and installation of a more robust solution 21 GANTREX TROLLEY RAIL SERVIECS
22 INSTALLATION SERVICES New Short Rails, Transition Pieces, Clamps, Clips and fixed points are installed as per Gantrex Generated and client approved drawings 22 GANTREX TROLLEY RAIL SERVIECS
23 SURVEY AND ALIGNMENT 23 GANTREX TROLLEY RAIL SERVIECS
24 THE GANTREX DIFFERENCE Engineered Solutions Material and Layout improvements Improved installation techniques Reduced installation time (reduced crane down time) Cerified reusable scaffolding system Standard 1 year warranty on labor Gantrex Short Rail Amortizes shocks and vibration Minimizes localized wear Reduces maintenance to clips and clamps Minimizes fatigue related structural failures Improves driver comfort 24 GANTREX TROLLEY RAIL SERVIECS
25 NEED MORE INFORMATION? For more information please contact your Gantrex Trolley Rail Services Specialist: Steve Nikolayev Gantrex Trolley Rail Services Manager Mobile: GANTREX TROLLEY RAIL SERVIECS
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