In industrial cranes the runway rail is the fundamental infrastructure that ensures correct and safe crane movement. Misaligned rails cause wheel wear on the bridge and trolley, derailment incidents and production stoppages. The Kale Vinç Sistemleri expert team carries out both new installation and existing rail replacement projects with precision.
Crane Rail Installation Stages
- 1Axis and level measurement: The rail axis and roof levels are determined with a laser level instrument.
- 2Support (runway beam) check: The load capacity of the existing steel structure is checked and reinforced if required.
- 3Rail selection: A rail profile suitable for the crane capacity and wheel type (A45, A55, A65, A75, A100 etc.) is selected.
- 4Rail laying and alignment: Rails are placed on supports and aligned to the axis with a laser; tolerance must not exceed ±2 mm.
- 5Connection: Rails are fixed to the supports by welding or by clamped (bolted) connection.
- 6Final check: Wheel-to-rail fit and clearances are measured and commissioning approval is given.
When Is Rail Removal Required?
- Facility relocation or reorganisation
- Rail replacement due to wear or fracture
- System overhaul due to bridge axis misalignment (wheel-rail mismatch)
- Replacing an under-capacity rail profile with a larger one
Frequently Asked Questions
What should the rail alignment tolerance be?
Per FEM 1.001 and ISO 12488, the height difference between two rails should be a maximum of 1 mm and lateral axis deviation ±1.5 mm. Exceeding these tolerances significantly shortens wheel and rail life.
How do you detect a misaligned rail?
Noise during bridge or trolley travel, abnormal wheel wear, a tendency to derail and difficulty in movement are the clearest signs of rail misalignment.