The importance of electric flashbutt welding in crane rail repair runway rail replacement can be an expensive project. The welding process uses large diameter electrodes 5 or 6 mm and a high current to fill the majority of the gap. Adhere to ufc 002 unified facilities guide specifications ufgs format standard when editing this guide specification or preparing. How to carry out a gap survey and rail adjusting on jointed. Around 2mm localized wear at hinge point with 45mm wear on trolley rail observed what looks like a structural weld crack on left girder between top flange and web june 2016 gantrex trolley rail services multiple crack repairs improper rail weld prone to failure battered joint stiffener cracks potential structural crack complimentary. By inspecting the crane and repairing all detected cracks, the envelope of crack frequency is effectively shifted down. As shown, however, as the crane ages, more cracks may appear for a given inspection. Wood cracking in a recent structure wood cracking in a recent structure jeepitou structural op. Boehler welding group maintenance and repair of switches with utp duration. Rail defects and bolted joints at plug rails or insulated joints are locations that require removal to create a track structure that requires less maintenance and is less stressful on rolling stock. But all concrete develops cracks eventually, and repairing surface cracks will always be part of your job as a professional installer.
This guide specification covers the requirements for welding of crane rail and railroad rail by a thermite process. The beam must be straight and the crack edges must be aligned before repairing the crack. Refurbishment could include new drives, an outreach extension, andor a crane raise. Actually, e7018 with a 300400 f local preheat of the rail should work fine. Visually inspect all bolt holes for cracks before welding. It is critical for the longevity of the complete crane rail system, that the welding of crane rail is completed to a. Normally clips or brackets are used for this type of application but the owner is looking to weld them instead these will be used as guide rails for a hydro trash rack, so loading will be occasional and relatively light. Crane rail welding process and crane rail welding procedure. Typically, major european rail networks remove s of discrete midrail defects each year.
This recommended practice establishes standards for the joining, repair, maintenance and inspection of rail welds, and the welding of related rail components. Remove the crack and prepare the weld joint by air carbon arc gouging followed by grinding. Frame repair on crane truck miller welding discussion forums. Scope this document recommends standards for the joining, repair, maintenance, inspection of rail welds, and related rail components. If on a double beam overhead crane for the trolley to run on, then the welding specification should be as per the manufacturers details. I would mt the welds when done to verify no cracking. On completion of the welding, the head of the rail is ground flush to ensure a smooth running surface on which the crane can run. To assess the effectiveness of various repair schemes for components of an overhead crane, weld repaired gusset specimens, several kinds of plate specimens with cracks repaired by welding, and.
Guidelines for inspecting overhead crane structures. Heavy bumps during transit also cause damage to other components and are unpleasant for the crane operators. Before starting work move the machine to a level surface, engage the parking brake, and stop the engine. Pdf the effect of cracks on stress state in crane wheel hard. The pictures below show an aft crane weld crack investigation on a 25ton knuckleboom crane with a 52foot boom radius. The process is to strike the arc on the rail ends and to melt the electrode and rail into a puddle of weld metal, which is covered with liquid slag, derived from the coating on the electrode. Ive got an older kenworth single axle cabover that spent nearly all of its life as a picker truck with an 8ton crane mounted just behind the cab. If on the crane runway beams, it is unusual for the crane manufacturer to specify the rail, and normally crane rail like railway rails, but usually smaller sections are used, clamped to the runway beam. Rail repair using wire feed welding rts 3733 issue b, revision 0 16 january 2009 1 introduction this standard establishes requirements for the repair of rail and crossings by qualified persons using approved wirefeed welding processes. Wire feed welding is a semiautomatic welding process, using selfshielding flux cored continuous wire. Of the three, cracks are by far the most detrimental.
Uit ultrasonic technology reduces pwht downtime, increases. Defects are either weld repaired or removed by renewing the rail, either as a short closure or in longer lengths. Weld new posts to crane rail beam above, and try make use of. The frame is cracked right around where the picker was bolted onto the frame. Topic welding industry metallurgy wear of rails overhead crane weld repair by quibo date 120920 12. Clean the area of any grease, dirt, paint, oil, rust, or other foreign material at least 2 inches 50 mm on either side of the repair. Bexon can also offer puddle arc welding, this method it is not as widely used, nor as common in australia, as in some other parts of the world. After applying ultrasonic technology uit, the company has experienced fewer cracks, fewer shutdowns, lower repair costs, and fewer headaches. American railway engineers and maintenance of way association arema, and. This article analyses the mechanism of the generation of vibra. Rail inspection is the practice of examining rail tracks for flaws that could lead to catastrophic failures. Cranes that are kept outside actually make the process of looking for cracks easier, because the steel exposed by a paint crack will start to rust in contact with rainwater or salt air. Crane rail systems specialty track solutions gantrex.
Recommended method for repairing fatigue cracking twi. Schematic of longitudinal weld termination crack and repair procedure. If you can get a scrap section of rail to try it on, that would be good. Preheating both ends of the track at the same time, preheating and interlayer temperature control between 300350 degrees. Read, understand, and heed all safety information found in your operators manual. Saw repair welding sub arc is a weld ing technique that allows on site repair of grooved rail profile wear bringing significant cost savings to. Repair welding can be carried out as a logical procedure that ensures the part is usable and safe.
One of the truly great injustices done to crane owners and insurance companies by the manufacturers, that is costing millions of dollars annually in unnecessary crane component replacement, is spreading the misconception that unless a repair or repair process to a crane is approved by an oem it is to be considered a modification. You can now repair cracks quickly and easily with crackweld, a fast concrete crack repair product that. Once the useful life of the crane is determined, other data is required for an economic assessment. Welded crane runway girderscauses and repair pro cedures. To obtain a crack free weld metal, the preheating temperature is most important, as is the interpass temperature. Gantry rail survey and repairs, gantry rail repair, gantry. Welding of gantry crane rail kingnero mechanical 10 may 17 11. Sts crane trolley rail weld repair starkon industrial.
Track welding rules and procedures the texas department of. It works from five locations and has invested heavily in new equipment and training cope with the new steels, shiffler says. The importance of electric flashbutt welding in crane. Thermit welding for high duty crane rails duration. Post weld heat treatment given to the pressure vessel during construction or repairs. The crane rail welding should follow the sequence of rail bottom, rail waist and rail head. Tighten the support on the rail and remove the preheat torch from the torch support.
Before you can add the epoxy to the inside of the tube you need to first find a way to keep the epoxy in the tube and not flow down and out of the tube through some other hole. Tack weld the runoff tab to the backing plate and clamp this assembly to the flange at the crack location. Weld cracking several types of discontinuities may occur in welds or heat affected zones. Welds may contain porosity, slag inclusions or cracks. If possible, the crane should be moved to an area that has good lighting, comfortable temperature, and is away. Track welding rules and proceduresfor inspecting, welding, and grinding of rail and track components, and.
Usually, the surveyors look for paint cracks, on the theory that paint will crack if the material underneath it moves, like a tiny earthquake. With systemic and repetitive cracking in the boom, propel structure, and other critical areas of their draglines, the client was used to spending considerable time and money to weld repair cracks. Repair welding of crane wheels in steelworks smederevo. Wood cracking in a recent structure wood design and. Where cracking occurs in or adjacent to welded joints, a satisfactory repair may be made by welding. Each completed weld shall have full penetration and complete fusion and be entirely free of cracks or fissures. Check the surfaces to be welded for cracking using magnetic particle inspection.
Welding needs to be done layer by layer, and finally repair the surrounding gap. The crane arms also carry the necessary cables on of the welder. For any organization there are multiple conditions that must be considered such as impact on cranes, structures and their operations as well as effects it may have on the product quality. Detailed analyses, based on the mechanical and chemical properties of the materials used for crane wheels, as well as for repair welding, were performed for the contact between the rail and wheel. If the crack and a small affected region beyond the crack are removed and the weld is repaired, the life of the detail starts over. We can weld in many locations including onshore or offshore, above or below ground. Design of the crane gives a lifting capacity of 4545 kg for the chem 110 and 7727 kg for the chem 180. Repair welding holland lp engineering rail solutions. The enclosed puddle arc welding process is a manual welding procedure specifically designed for the joining of crane rails of identical profile into one continuous length.
Whereas there are acceptable limits for slag inclusions and porosity in welds, cracks are never acceptable. Repair and maintenance of parts and components is a major activity in any process industry. It was developed and is maintained by the subcommittee on track welding. It can be applied in multiple layers without cracking, spalling or mushrooming. Cylinders may be lifted by a crane, derrick or hoist when a. Hardfacing alloys for railroad track components esab.
Repair welding involved the application of a welded layer to the crane wheel. A490 bolts allowable stress in lintels design for square bins and hoppers highstrength bolts and welds minimum length of thread on bolts special tolerances for cladding weathering steel high strength bolts. Repair and maintenance welding handbook serpantinas. A novel and semiautomatic weld repair technique for rail.
The crane has been removed and i want to use it as a farm flatdeckdump truck. Repair worn or damaged rail bound manganese turnout frogs. Recommended practices for the welding of rails and related. Wheco repairs and refurbishes all makes and types of cranes and is an approved repairer for manitowoc machines. Repair welding involved the application of a welded layer to the crane. My solution after the weld repair was done was to sleeve the inside of the tube with west systems 206 epoxy mixed with a filler for added strength. Corus rail technologies has developed a novel weld repair technique to improve the integrity of repairs to discrete defects. Pdf repair welding of crane wheels in steelworks smederevo. Useful data includes the cost estimate to repair the cracks and to refurbish and maintain the crane. Rail components for use by rail vehicles, but is included for informational purposes only. Rail welding and hoses for the safe operati crane a selfcontained twinarm articulating crane is provided to handle the welding head. A typical procedure for a welded crack repair includes crack removal, edge preparation, placement of root, intermediate and final weld passes, grinding of the weld reinforcement flush with the base metal and inspection of the completed weld using ultrasonic inspection technology. Cracks use the following instructions to repair structural cracks. Semipermanently mark a sequential weld number, rail temperature, and date on the rail immediately adjacent to the weld using.