Several Points to Note When Installing the Gantry Crane Track

Gantry cranes are widely used in ports, yards, construction sites and other places, the quality of its track installation directly affects the operational safety and service life of the equipment. In the track installation process, you need to strictly follow the relevant standards and technical specifications to ensure the installation accuracy and construction quality. The following are the main points of attention of the gantry crane track installation:

1. Preparation of track foundation

Track foundation is the fundamental gantry crane track installation, must have enough bearing capacity and stability. Before installation, the foundation should be levelled to ensure that the bearing capacity of the foundation to meet the design requirements. If the foundation soil quality is poor, should consider taking reinforcement measures, such as laying concrete foundation or increase the reinforced concrete pad.

2. Selection of materials and pre-treatment of rails

The selection of rail should be in accordance with the design requirements, and usually adopts steel rails in accordance with national standards, such as 24kg/m, 38kg/m, 43kg/m and other models. The surface of the rails should be descaled, anticorrosive treated and coated with antirust oil. For places with special requirements, the choice of corrosion-resistant materials or coatings should also be considered.

3. Positioning and laying of track

Positioning of the track is the key link of track installation, and it must ensure that the level, straightness and parallelism of the track after laying are in accordance with the design requirements. The laying order of the track is usually to lay the two ends of the track first, and then gradually to the middle of the track, to avoid cumulative errors.

In the process of laying, the transverse and longitudinal level of the track should be strictly controlled, and a levelling instrument and a total station should be used for real-time monitoring. In the process of track laying, the track joints should be connected with standard joint plates, and ensure that the horizontal error at the joints does not exceed the design permissible range.

4. Fixing and adjustment of the track

After the track is laid, it should be fixed and adjusted in time. Usually, pre-buried bolts or nails are used to fix the track to ensure that the track will not shift or loosen in the process of use. When fixing, elastic bedding should be laid between the track and the foundation to reduce vibration and noise during operation.

The adjustment of the track is an important step to ensure the smooth operation of the gantry crane, mainly including horizontal adjustment and vertical adjustment. Horizontal adjustment should ensure that the lateral horizontal error of the track is within the permissible range, and vertical adjustment should ensure that the elevation error of the track meets the design requirements. In the process of adjustment, it is necessary to continuously measure and fine-tune until it reaches the design standard.

5. Seam treatment of the track

Seam treatment is also an important part of track installation, especially in the case of long track length, reasonable expansion joints must be set to cope with thermal expansion and contraction of the track caused by temperature changes. The design of expansion joints should be in line with the relevant standards, usually using the end of the track to leave a certain gap, and set the rail expansion device or expansion joints.

6. Testing and acceptance of the track

After the completion of track installation, comprehensive testing and acceptance must be carried out to ensure that the technical indicators of the track meet the design requirements. The main test content includes the level of the track, straightness, parallelism, seam processing and so on. In addition, the bearing capacity test of the track should also be carried out to verify the stability and safety of the track under the rated load.

During acceptance, the construction unit, supervisory unit and owner unit should be organised to participate in the inspection and record item by item in accordance with the design drawings and relevant standards, and the unqualified items should be rectified in a timely manner.

7. Maintenance and upkeep of the track

After the track is installed and put into use, it also needs regular maintenance and repair. Mainly includes track cleaning, anti-corrosion treatment, bolt fastening check, adjustment of expansion joints and so on. In addition, regularly check the wear and tear of the track, timely replacement of the track section with serious wear and tear, to ensure the safety of the gantry crane operation.

Track installation does not meet the requirements of the impact of the crane

Rail does not meet the technical requirements for installation or incorrect installation will cause the rail span tolerance and 2 rails of the same span elevation error exceeds the standard, which will lead to the crane operation nibble rail.

1. The quality of the track installation is not qualified, the track level of the bending is too large (the requirements of the side of the straightness error can not be greater than 2mm), more than the crane span tolerance, will produce nibbling rails, this nibbling rails in the fixed line segment.

2. When the track gauge is too large, the outer rim nibbles the rail; when the gauge is too small, the inner rim nibbles the rail.

3. The height difference of the rail surface on the same section of the two rails is too large (not more than 10mm at the column and not more than 15mm at other places), causing the gantry crane trolley to shift sideways, the outer side of the super-high side to bite the rail, and the inner side to bite the rail.

4. When running on a track with a large gauge at one end and a small gauge at the other end, and the parallelism of the two rails is out of tolerance, the gap between the wheel flange and the track becomes smaller and smaller until the inner wheel flange bites the rail.

5. The track installation pad is not compacted, the track remains horizontal when not loaded, and the track sinks when loaded, causing the track to bite.

In short, the installation of gantry crane rails is a complex and delicate process, which requires great attention to the construction quality of each link. Only through strict control and standardized operation can the safety and reliability of the gantry crane in use be ensured, providing a solid guarantee for the smooth progress of the project.

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