R100-R60

Gantrail Re-levelling & Re-alignment System

A world of crane
rail expertise.
www.gantrail.com UK Patent Application number GB1513369.7
 R100-R60
Gantrail
Re-levelling &
Re-alignment System

The Gantrail fully adjustable re-levelling and re-alignment crane rail

system has been designed for all situations where post-installation
vertical and horizontal settlements/movements of the foundation are
expected in both the short and long term.

With the ever increasing demands for space to build new or expand container port
COMPONENTS backup yards, reclaiming land has become commonplace but with this comes
many challenges for the designers, not least is the issue of foundation settlement
and how to deal with it.
1
With many construction projects now taking the form of Engineering, Procurement,
and Construction (EPC) or Design and Build, it is the Contractor’s responsibility
to develop the most cost effective solution that meets the client’s performance
specification.
2
To design a foundation that will not move is unrealistic and ultimately not cost
3
effective. The Gantrail re-levelling and re-alignment system offers designers an
economical solution that allows significant cost reductions in foundation design by
4 allowing reasonable amounts of settlement to occur post installation.

If the crane rail system begins to move outside of operational tolerances, it can be
5 re-levelled or re-aligned with minimal downtime.

This makes concrete beam type construction a more viable option and serious
alternative to traditional concrete sleeper and ballast systems that require regular
annual maintenance and associated downtime.
6

7 SPECIFICATIONS: ADJUSTMENT:

RECOMMENDED MAX VERTICAL LOAD; 100mm VERTICAL RAIL ADJUSTMENT

8 R100-R60-165 = 350 kN 60mm HORIZONTAL RAIL ADJUSTMENT
R100-R60-220 = 500 kN
9 RECOMMENDED MAX HORIZONTAL LOAD = 120kN

10
DIMENSIONS (mm):
11
REF NO. X Y WEIGHT (KG)
R100/R60/165 420 165 16.3
12 R100/R60/220 420 220 20.9

1. Rail FEATURES:
2. Gantrail MK10 pad
3. Locking nut • 100mm vertical adjustment via introduction of shim plates
4. Gantrail 1120-21 clip caps
5. Top plate • 60mm horizontal adjustment via slotted holes
6. Packing plate(s) (When required) • Interchangeable hex head bolts to allow for variations in vertical settlements
7. Slot cover
8. Assembly bolt • Integral re-levelling and re-alignment system for ease of adjustment
9. Nut • Alignment markings to aid installation.
10. Washer
11. Bottom plate
12. Holding down bolt
THE R100-R60 SYSTEM COMPRISES;
420
420 280
280

220
165
R100-R60-165 PLAN
R100-R60-165 PLAN
HARD MOUNTED SYSTEM SOFT MOUNTED SYSTEM

RAIL
GANTRAIL MK10 PAD
GANTRAIL 1120/20 CLIP CAP
SHIM PLATE THICKNESS TO SUIT

30 30 CLIP & SOLEPLATE ASSEMBLY BOLT

MAXIMUM THICKNESS 100mm

GANTRAIL TOP SOLEPLATE

(R100/R55/***/T)
SHIM PLATE
ASSEMBLY BOLT COVER
GANTRAIL BOTTOM SOLEPLATE
(R100/R60/***/B)
15

30

GANTRAIL PLATE GROUT

HOLDING DOWN BOLT

GANTRAIL BOLT GROUT APPLICATIONS:
BOLT POCKET
CONCRETE FOUNDATION
• Container port backup yards
– ASC/RMG systems
• Stacker/Reclaimer systems
STAGGERED SECTION
• Automated Warehouses

Design Characteristics
The Gantrail fully adjustable re-levelling and re-alignment Regular surveys at specified intervals will determine
crane rail system comprises individual rail support whether the crane rail system is moving outside of
assemblies that are generally at even spacings along operational tolerances. This will identify any areas of the
the rail. These can be anywhere from 500 to 900mm rail that need vertical or horizontal adjustment.
providing rail stress and deflection remain within
acceptable limits. To adjust the system vertically, the nuts securing the
assembly bolts are loosened or removed. Nuts are
Each individual assembly consists of two plates that are inserted into the special apertures in the top plate to
fixed together with two standard hexagon head assembly create a unique levelling facility. Screws are inserted and
bolts. The bolts also act to fix the Gantrail rail clips which rotated to accurately raise the level of the top plate and
allows the use of their proven ‘double wedge’ design rail to the precise level required. Shim plates are then
to provide additional locking of the plates when lateral inserted between the top and bottom plates. If sufficient
loads are applied. The integral self-tightening Gantrail vertical adjustment cannot be achieved with the original
rail clips rigidly fix the rail from lateral movement whilst assembly bolts these can be interchanged easily with
allowing longitudinal movement resulting from thermal longer bolts.
variations. At the initial installation, the assembly bolts
are provided in a suitable length to allow an initial To adjust the system horizontally, this can initially be
amount of vertical adjustment whilst providing adequate achieved with 20mm of adjustment from the Gantrail
clearance to crane guide wheels and bogeys. Between rail clips without the need to adjust the complete plate
the top plate and underside of the rail is Gantrail MK10 assembly. However, if this is not sufficient, the nuts
that ensures an even distribution and transmission of securing the assembly bolts are loosened and the top
vertical loads into the plates and ultimately the concrete plate repositioned via the 40mm slotted holes in the
foundation. The bottom plate is fixed to the concrete bottom plate. Precise repositioning is made easy by
foundation by two holding down bolts. Once the precise inserting nuts into the special apertures in the bottom
final level of the rail is achieved, a layer of non-shrink plate to create a unique alignment facility. Screws are
epoxy grout is placed between the bottom plate and inserted and rotated to reposition the top plate and rail
concrete foundation. laterally to the precise alignment required.

Once all adjustments have been made, all nuts are re-
tightened to the specified torque.
R100-R60
Gantrail Re-levelling &
Re-alignment System
C

A
2. CLIP REFERENCE
F C A 1. CLIP REFERENCE FOR RAIL WITHOUT
F MM MM MM FOR RAIL WITH PAD PAD*
MRS 85 152.4 102.9 152.4 1120/21/45 1120/21/38
AS 86 150 101.6 152.46 1120/21/45 1120/21/38
MRS 87 A 152.4 101.4 152.4 1120/21/45 1120/21/38
MRS 87 B 152.4 102.2 152.4 1120/21/38 1120/21/38
QU 100 150 100 150 1120/21/38 1120/21/38
ISCR 100 150 100 150 1120/21/38 1120/21/38
UIC 60 150 72 172 1120/21/38 1120/21/38
SP 100 150 108 150 1120/21/38 1120/21/38
171 CR 152.4 102.9 152.4 1120/21/45 1120/21/38
175 CR 152.4 102.2 152.4 1120/21/38 1120/21/38
131 AREA 152.4 74.2 180 1120/21/38 1120/21/38
132 AREA 152.4 74.6 181 1120/21/38 1120/21/38
66 kg 152.4 75.1 181 1120/21/38 1120/21/38
68 kg 152.4 73.4 185.7 1120/21/38 1120/21/38
KP 100 150 100 150 1120/21/38 1120/21/38

This system is designed for rails with an approximate foot width (F) of 150mm, but can be used for a wider selection of rails than illustrated. This
may result in a loss of adjustment from the clips. Please contact GANTRAIL to discuss other possible rails.
GANTRAIL may change or improve their products and also alter specifications without notice.

INSTALLATION INSTRUCTIONS:
HOLD DOWN BOLT TIGHTENING TORQUE to suit project requirements
(typically 120Nm)
ASSEMBLY BOLT TIGHTENING TORQUE 475Nm (impact wrenches can be used)
Please contact GANTRAIL, for full installation instructions.

A world of crane rail expertise.

www.gantrail.com
Gantry Railing Ltd Gantrail (Middle East) Ltd
Sudmeadow Road P O Box 61428
Hempsted Jebel Ali Free Zone
Gloucester GL2 5HG Dubai
ENGLAND United Arab Emirates

Tel: +44 (0) 1452 300688 Tel: +971 4 8812 935

Fax: +44 (0) 1452 300198 Fax: +971 4 8812 936
E-mail: info@gantrail.com E-mail: gme@gantrail.com
R100-R60/ET/06/18