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Innovative range. The crane track system.

ThyssenKrupp GfT Gleistechnik

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STEP BY STEP PROJECT RELIABILITY MINEX-SYSTEM

MINEX-components MX-rail fasteners Accessories

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AN UPLIFTING CONCEPT CRANE TRACK BEAM

Crane track beam Quality Site logistics

RAILS
Customer focus with profile

SLEEPERS
Precisely tailored solutions

PLANNING, MEASURING, DETECTING RAILCONTROL CRANE TRACK MEASURING SYSTEM

Functions Areas of use

SERVICE
Your route to a crane track

THE CRANE TRACK BEAM ON THE BUCHARD QUAY IN HAMBURG

Proven references

An all-round track package. The crane track system.

Tracks for container cranes and other transport vehicles have requirements all of their own. The reason? Crane tracks are generally used to transport particularly heavy loads at relatively low speeds. We have therefore created a special technological all-round package for you which will meet all the special conditions of your project superbly. The crane track system.

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Step by step project reliability. MINEX-system.

MINEX stands for all the components relating to our crane track system. This gives our customers the certainty that all the elements, from the foundation casting component and pads to the rail fasteners, are part of a single system. So as far as you are concerned, MINEX means project reliability.

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Excellent experience. MINEX-components.

1 First fully automatic container block storage facility in the world 2 Measuring track and servicing building 3 Port crane track

We have been developing and building track systems on ballastless tracks made of concrete, steel, asphalt or gravel for more than 30 years. Excellent experience which was used in the development of the MINEX-system components.

We supply the following MINEX-components for the crane track system: MX-rail fasteners MINEX-rail pads MINEX-grout, the precision cement-based casting compound MINEX-EP Grout, the 2-component casting compound MINEX-PUR 880-6, the elastic casting compound MINEX-cladding tubes MINEX-groove filler sections MINEX-rail end stops MINEX-rail beds

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Simply eccentric. MX-rail fasteners.

We have developed two special fasteners for our crane track system the MINEXfastener system which is bolted to the support plate and the MXA weld system. Both solutions feature a guide plate which holds the rail at the side without clamping it. This prevents the displacement of the rail caused by temperature fluctuations and the transportation of heavy loads having an adverse effect or even damaging the fastening components. The flat design is sealed to prevent the ingress of dirt into the system. The push-through connection for the base anchor consists of a zero play eccentric component. This allows infinite lateral adjustment. Also available made of stainless steel.

Corner pressure is prevented by rounding the guide plate

Particularly flat design Sealed system prevents the ingress of dirt

Horizontal forces only stress the bolt for shearing

Free longitudinal movement of the rail Drop-forged 1 2 3 4 5 Single bolt system (MINEX) Double bolt system (MINEX) Single weld system (MXA) Double weld system (MXA) Port crane track Held securely in position by infinitely laterally adjustable eccentric component

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Economy, durability and safety. Accessories.

MS-rail pad Further assurance of the durability of the complete system is provided by the elastic crane rail pad for installing between the rail foot and the rail bed. The material is made of ethylvinylacetate and offers outstanding damping properties. It allows the low friction longitudinal movement of the rail, thus reducing peak stresses and vibration. It also prevents corrosive processes between the two components. The result is the great economy of the crane rail bed.

MINEX-anchors

MINEX-casting compound MINEX-grout has proved to be an ideal casting compound for making a full, positive connection between the foundation and the rail bed. This precision cement-based casting mortar can be pumped, does not shrink, is very strong and cures in a very short time. This means that it can withstand even high and multiple loads. MINEX-grout is supplied ready-mixed. It only has to be mixed with water on the site. We recommend MINEXEP grout for particularly high bending tensile stresses. Steel sections which no longer have their original cross-section can be restored using elastic, vibration-damping MINEX-PUR 880-6 rail casting compound.

MINEX-cladding tubes If the foundation is cast in concrete, MINEX-cladding tubes are essential for creating recesses for installing the MINEX-base anchors. The tube is profiles both inside and outside. This gives it a firm hold in the concrete. All diameters between 40 and 200 mm are available including two matching plastic covers for each tube.

1 MINEX-pad 2 Cladding tube with two cover caps (left), top cladding tube with cover cap and bottom with cover cap with nail edge (centre) 3 MINEX-PUR 880-6 4 MINEX-grout precision casting compound

Flat anchor Threaded anchor Stone bolt

MINEX-cladding tube

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Economy, durability and safety. Accessories.

1 MINEX-end stop with cellulose buffer, clamped 2 MINEX-end stop with hydraulic buffer, clamped 3 MINEX-filler section 4 MINEX-end stop with baffle plate

MINEX-groove filler section The MINEX-groove filler section offers plenty of benefits. This innovation can be supplied for any form of rail and is easy to install and maintain. When installed it prevents frost damage, the gulley drain from blocking and the rails and rail bed from floating in aggressive water. But the system has also proved to be superb from a safety point of view. It guarantees safe crossing for road vehicles and helps to prevent personnel accidents.

MINEX-rail end stops MINEX-rail end stops can be supplied in standard form or in bespoke designs to meet your requirements for all loads. We can supply three different designs: Crane track stops with baffle plates, Crane track stops with cellulose buffers, Crane track stops with hydraulic buffers. We can also supply other products for the construction of ballastless tracks, for example in high bay shelving warehouses or for working trench systems in railway depots.

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An uplifting concept. The crane track beam.

In areas in which heavy loads are transported, experience has shown that the foundations can suffer settlement. In conjunction with HHLA CT Bautechnik we have developed a pioneering crane track to prevent high cost repair work and long down times. The design of this innovation includes the facility to raise the entire system retrospectively. This offers our customers massive time and therefore cost savings.

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Raise, underpour, continue. Crane track beam.

Rising operating loads, rapidly increasing volumes of bulk goods for loading and unloading and even larger and heavier cranes require crane tracks which guarantee good positional stability and therefore high positioning accuracy. This means that foundation settlement must be detected early and compensated by a raising and levelling concept.

The technological answer to this challenge is provided by a new development which we have developed in conjunction with HHLA CT Bautechnik. The crane track beam. The system consists of monolithic longitudinal concrete beams (comprising reinforced prefabricated concrete parts) on flat foundations and connected by in-situ concrete joints. A sophisticated raising concept allows the rail to be

raised by up to 10 centimetres after it has suffered settlement. By raising and underpouring the longitudinal beam it is possible to raise the entire structure by a further 2 times 10 centimetres, making a total retrospective adjustment capacity of 30 centimetres.

1 ThyssenKrupp crane track beam in use 2 MRS87A 3 AS86

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Born of experience and ideal for everyday use. Quality.

The development of the crane track system, which is reliable even under heavy crane loads and high traffic frequency, was monitored by several well-known engineering agencies, companies and universities. It was also subjected to stringent practical tests by specialists. In addition to a demonstration of the raising concept, a major series of tests confirmed the load capacity of the system and went well beyond expectations. A system born of experience and ideal for everyday use.

Another element of our quality concept is our certification to DIN EN ISO 9001. The documentation required for this ensures full traceability of all components is possible at any time. Batch numbers mean that every beam and all the components in it can be traced back precisely to the date of production. We will be delighted to advise you with the planning and design of your new crane track.

1 ThyssenKrupp crane track beam 2 Detailed photograph: MINEX-crane rail fasteners

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Smooth planning. Site logistics.

Prompt commissioning contributes to the economy of a project. With this in mind we ensure very detailed plans for delivery and site logistics during the construction work.

We prefabricate the concrete elements at our plant. The length of an element essentially depends on the existing transport capacities. Depending on the terms of the project we also install all the necessary components.

Whether it is direct to the installation crane or to a temporary storage facility we deliver the goods to correspond to the progress on site and always just in time. That means that we can ensure that everything runs smoothly on site.

1 Installation 2 Final alignment 3 Production of the planed subgrade

After completion

After height correction using compensating plates

Height correction by raising and underpouring the beam

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Customer focus with profile. Rails.

Every crane track project is different. As a system supplier we can therefore always supply you precisely the rail section that your crane track project needs. Whether it is for heavy or lightweight loads, frequency or rare traffic, high or low design heights, continuous or discontinuous mounting the requirements of your project decide the track type.

That is why we supply a particularly wide range of sections: A sections to DIN 536-1 Special sections Flat-bottom sections Field track rails Grooved rails Rectangular sections and many other sections as well.

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Step cut 90 cut Angled cut Bending plan Flat-bottomed rails

Depending on the requirements of your project we can also offer precision machining. We manufacture the precise lengths you require, complete all the step and mite cuts that may be needed, drill the holes required for lugs, screw connections and earth connections and bend every rail precisely using the planning specifications if necessary.

60 x 40

A45

A100

30E1

49E1

60E1

RiPh37A

AS86

MRS221

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Precisely tailored solutions. Sleepers.

1 Crane track on concrete sleepers 2 Impression crane track 3 Crane track on concrete sleepers with system W 4 Wooden sleeper yard 5 Crane track on wooden sleepers with system KS

We will use wooden or concrete sleepers for your crane track depending on the terms of your project. If heavy loads are likely, the concrete sleeper is an ideal component. If the main requirement is for elasticity, the wooden sleeper is the better alternative. In any event, to order we can supply your sleepers including plates for all conventional rail sections.

We manufacture wooden sleepers (both impregnated and untreated) at our own plant in Gross Oesingen. We use a range of timber types for this purpose, including beech, oak, spruce, ekki and mora, and process them to produce precisely tailored top quality products. They are impregnated using the pressure method and the WEI Type C product.

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Planning, measuring, detecting. The Railcontrol crane track measuring system.

The precise measurement of a crane track has become an integral part of the overall crane track system. We use our Railcontrol measuring system during the acceptance procedure and as part of our planning. Railcontrol has also proved to be very useful for researching the causes of excessive wear. The early detection and rectification of defects helps to save massive costs.

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Automatically precise. Functions.

The automated process developed by ThyssenKrupp GfT Gleistechnik GmbH in conjunction with Vermessungsbro Hanack und Partner is suitable for a wide range of tasks: Checking compliance with the tolerances set out in VDI 3576, ISO 12488-1, etc. Measuring in laden (crane moving) and unladen state (standstill). The difference can be used to form conclusions about the movements as the crane is moving. Error analysis in the event of problems whilst the crane is moving or if the track suffers excessive wear. Monitoring by means of tachymetric measurements which integrates the results in a high level coordinate network. Ability to take measurements whilst operations continue.

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Port crane track Indoor crane track Angled crane track Intermodal terminal High bay shelving warehouse

Tolerance deviations to regulations

Position deviation Height deviation Level Gauge centre dimension

S max

S min

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For every phase. Areas of use.

Railcontrol can be used on any crane track. After being placed on the rail it moves automatically using its own drive unit. This enables it to take continuous, fast and precise 3-D measurements. The tachymeter records the gauge, position and height of the rail with great precision along with the offset and angle of the rail and plots all the data on evaluation graphics using a special software package. This gives the customer a plastic load picture. If these investigations show that repair work is required, we can find a competent contractor for you.

Project phases in which we use Railcontrol: Before commissioning new cranes on existing crane tracks To document the position and height of new crane tracks For damage assessment and evaluation As part of preventive maintenance procedures To assess the capacity use of an indoor construction For quality assurance and wear reduction purposes For health and safety procedures

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Your route to a crane track. Service.

In addition to what we can offers in terms of the Railcontrol measuring system we also offer a wide range of other services. For example we can help you with project and budget planning and can help you develop a crane track system that is precisely tailored to your needs. We use a specially adapted crane track design program for this purpose. Using a wide range of material and load parameters we calculation the potential capacity for you. To order we can supply all the verifiable static calculations you will need. The crane track configurator on our homepage www.tkgftgleistechnik.de is an ideal tool to provide an initial estimate. This allows you to compile all the crane track components you need to suit your requirements. We will be delighted to hold discussions with you on the basis of these documents.

For further information go to

www.tkgftgleistechnik.de

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Rail storage facility Service vehicle Advice Railcontrol measurement log

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Proven references. The crane track beam at the Burchard Quay in Hamburg.

Photos: HHLA

The Port of Hamburg occupies position 8 in the list of global container ports. During the 2005 financial year it exceeded the 8 million mark for the first time by handling a total of 8.1 million containers. In 2006 its total handling numbers increased to 8.9 million containers. This makes the port the fastest growing in Northern Europe. Plenty of reasons for Hamburger Hafen und Logistik AG (HHLA) to extend its Burchard Quay Container Terminal.

The port authority chose our crane track beam as the rail system for its cranes. In addition to high requirements in terms of quality, load capacity and economy, the main reasons behind this decision were its fast installation and the possibility to install the system whilst port operations continued. A triple rail mounted gantry (TRMG) was installed. This system comprises two small cranes on the inner rails and a large crane on the outer ones. This solution provides a great deal of flexibility in the stacking block. Some 29 of these blocks will be built by the end of the project. Each block is around 375 metres long. Placed one after the other, these crane tracks have an over-all length of more than 40 km. The project at the Burchard Quay Container Terminal provides more impressive evidence of what we can provide.

Other references Airbus ArcelorMittal Audi Bayer BWG Deutsche Bahn AG Fraunhofer Institut Gottwald HKM Honda Japan Liebherr Meyerwerft Rheinbraun RWE Sandvik Schweden Solvay Stelcon Unilever Stump Indonesien Vattenfall Volkswagen

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MANUFACTURING PLANT Holzschwellenwerk Am Bahnhof 2 29393 Gro Oesingen Germany Phone: +49 5838 9905-0 Fax: +49 5838 9905-79 ThyssenKrupp Weichenbau Obere Stahlindustrie 4 44793 Bochum Germany Phone: +49 234 9114-343 Fax: +49 234 9114-557 Betrieb Industrieweichen Am Wasserturm 3b 06869 Coswig/Anhalt Germany Phone: +49 34903 4741-0 Fax: +49 34903 4741-20 Betrieb Spannmittel Am Wasserturm 3b 06869 Coswig/Anhalt Germany Phone: +49 34903 4741-0 Fax: +49 34903 4741-24 ThyssenKrupp Langschienen Ladestr. 8 39175 Knigsborn Germany Phone: +49 39292 6958-17 Fax: +49 39292 6958-20

ThyssenKrupp GfT Gleistechnik GmbH Hollestr. 7a 45127 Essen Germany Phone +49 201 844-563710 Fax +49 201 844-563714 www.tkgftgleistechnik.de gleistechnik@thyssenkrupp.com

Subject to alterations 09/2012 e