RailEng PDF

BEMO RAIL BVDebbemeerweg 591749 DK WARMENHUIZENThe Netherlands

Tel: +31 (0)226 425300Fax: +31 (0)226 [email protected]

CCI Alkmaar: 37044577

INTRODUCTION

Since its foundation in 1970 Bemo Rail has grown significantly and developed into an expert with world-wide recognition in the field of rail-related internal means of transport, rail and crane-track technology.

Started as a trading company, Bemo Rail - after much demand from the market - decided to develop andbuild its own shunting systems in 1984. Six years later the production activities were expanded with theassembly of crane tracks. Since that moment until now Bemo Rail has consisted of two departments: Rail Technology and Shunting Technology.

In 2006 the company moved to new and larger premises. A modern office, in combination with logistically well-equipped storage and production halls facilitate the development of our products andthe execution of our services qualitatively, efficiently and quickly.

Mission StatementBemo Rail is the expert in the field of rail systems and rail-related means of transport for industry, storage and transfer companies. Together we successfully translate the customer’s questions into practical solutions.

Vision• Render durable and customer-specific services by professional and multi-purpose teams.• Remain prominent in the market for rail constructions.• Remain involved in the initial stage of projects, which results in qualitative, price-conscious and

practical solutions.• Become market leader for shunting systems, with functionality optimally related to price.• Be distinctive in upgrading and modernizing existing locomotives.• Using sustainable materials and methods is embraced as a principle by Bemo Rail.

More questions after reading the information? You will find the answers on our websitewww.bemorail.com and otherwise you can always contact us by telephone: +31 (0)226 – 425300.

We are ready to help you further!

Kind Regards,

Team Bemo Rail

TABLE OF CONTENTS RAIL TECHNOLOGY

SYSTEMS 6Concrete 6• Crane track on concrete - continuously supported 6• Crane track on concrete - discontinuously supported 7

Steel 7• Crane track on a steel girder 7

Ballast 8• Crane track on concrete sleepers 8• Crane track on wooden sleepers 9• Track on sleepers 9

Special systems 9

PRODUCTS 10Rails 10Clips 13Sole plates 23Sleepers 24Elastic pad 26Fastening material 27Grouting 29Buffers 30Recess filling 31Specials 31

SERVICES 34Consultancy and engineering 34Measuring and inspection 34Handling 34Assembly and supervision 35Welding and grinding 35Maintenance and repair 36

Information on Shunting Technology you will find on the other side.

RAIL TECHNOLOGY | 54 | RAIL TECHNOLOGY


SYSTEMS

Crane track on concrete, continuously supported, Eurogate Terminal in Germany.

Concrete

Crane track on concrete - continuously supportedA continuously supported crane track is characterized by rail mounted on a continuoussteel sole plate with continuous grouting, either ornot mounted in a concrete recess. This rail systemis particularly well suited for high dynamic wheelload.

If the wheel load is 50% of the maximally admittedwheel load on the rail, the steel sole plate may beleft out. Then the rail is anchored on concrete bymeans of anchor bolts through the rail foot. Characteristic are the holes in the rail foot and thecontinuous grouting.This system is only applicable to crane rail with a wide foot (type A).

Crane track on concrete - discontinuously supportedA discontinuously supported crane track is characterized by rail - either or not mounted in a concrete recess - on steel support plates or railchairs, with a centre-to-centre distance of ca. 500 – 1000 mm. Each support plate is grouted separately. Rail chairs can be integrated directlywith the reinforcement in the concrete.This system is suitable if continuous support is notnecessary or not possible.

Steel

Crane track on a steel girderCharacteristic for a crane track on a steel girder is the rail often being fastened onto profile steel, with adjustable clips and either or not with elastic pad. With such constructions mostly weldable clips are used. These clips can mostly be pre-constructed.

Rail chair


Ballast

Crane track on concrete sleepersBemo Rail has its own concrete sleeper for crane-rail constructions with heavy wheel loads.The rail is mounted onto a sleeper with a strongspring clip and an elastic sole plate. The sleepercan be installed very precisely in a gravel bed,

on sand-cement stabilization, or in repak. The entire rail construction can, if required, be applied in combination with hardening (asphalt, concrete slabs or paving). It is importantthat the foundation is solidly compact.

Crane track and track on concrete sleepers, Euromax, Rotterdam.

Crane track on wooden sleepersBesides the concrete sleepers Bemo Rail uses hardwood sleepers, provided with a support plate and rail-fastening material. These sleepers are installed in the same way as the concrete sleepers.

Track on sleepersLike crane tracks, industry track can be built on various types of concrete or wooden sleepers. The trackrail on the sleepers can be built like railway, tram or metro.

Special systems

Many years of experience in rail systems have enabled Bemo Rail to design and supply specialcustom-made rail systems. Among whichearthquake-resistant constructions. The rail in these transfer constructions does not break andconsequently remains intact. Also a crossings fieldfor the heavy industry (e.g. shipyards and windmillproduction) is specifically designed. Furthermorerail constructions are designed for very sensitivemachines and research basins for the maritimesector. The objective is to reach a very high degreeof accuracy (+/- 0.1 mm) of the rail, even the railhead of which is machined.


PRODUCTS

Rails

Low web crane rail

Rail Mass G Height H Foot B Head K Web W Neutral Admitted Factory Min.section (kg/m) (mm) (mm) (mm) (mm) axis wheel stock tensile

e (mm) load (m) strength(Kn) (N/mm2)

A 45 22.10 55 125 45 24 33.30 90 10/12/15 690

A 55 31.80 65 150 55 31 39 135 10/12/15 690

A 65 43.10 75 175 65 38 44.70 200 10/12/15 690

A 75 56.20 85 200 75 45 50.40 315 10/12/15 690

A 100 74.30 95 200 100 60 52.90 450 10/12/15 690

A 120 100.00 105 220 120 72 57.90 650 10/12/15 690

A 150 150.30 150 220 150 80 77.30 1050 12/15 690

MRS 86 85.53 102 165 102 80.30 54.49 470 12/15 690

The admitted wheel load in the rail table is based on the steel grade of the rail, the rail system applied and the normal service factor as defined in the DIN 15070.

When optimizing these factors the maximum wheel load can be increased by approximately 35%.



AS86 85.88 152.46 150 101.60 35 68.10 460 12/15 690

MRS 73 73.63 157 146 70 32 89 320 12/15 690

MRS 87aPRI 85r 86.80 152.40 152.40 101.60 34.90 76.83 460 12/15 690

BSC 101 100.38 155 165 100 45 81 455 12/15 690

MRS 125 125 180 180 120 40 91.40 725 12/15 690

104-lb CR 51.60 127 127 63.50 25.40 66.38 255 12/15 690

105-lb CR 52.08 131.75 131.76 65.09 23.81 66.45 275 12/15 690

135-lb CR 67 146.05 131.76 76.20 31.75 85.93 225 12/15 690

171-lb CR 84.80 152.40 152.40 101.60 31.75 108.70 460 12/15 690

175-lb CR 86.80 152.40 152.40 101.60 38.10 110.64 460 12/15 690

ISCR50 29.80 90 90 50 20 46.80 150 12/15/18 690

ISCR60 40 105 105 60 24 56.70 205 12/15/18 690

ISCR70 52.80 120 120 70 28 60.70 270 12/15/18 690

ISCR80 64.20 130 130 80 32 65.30 330 12/15/18 690

ISCR100 89 150 150 100 38 73.70 430 12/15/18 690

ISCR120 118 170 170 120 44 83.10 650 12/15/18 690

ISCR140 147 170 170 140 60 82.50 800 12/15/18 690

QU70 52.80 120 120 70 28 60.70 270 12/15/18 690

QU80 63.69 130 130 80 32 65.30 330 12/15/18 690

QU100 88.96 150 150 100 38 73.70 430 12/15/18 690

QU120 118.10 170 170 120 44 83.10 650 12/15/18 690

High web crane rail



Steel Tensile Yield Elongation Hardnessgrade strenght strength (%) (HB)

Rm min. Re min.(N/mm2) (N/mm2)

70 690 355 12 200

80 780 390 10 230

90 880 440 8 260

70 Va 690 450 15 200

80 Va 780 490 12 230

90 Va 880 540 10 260

100 Cr-Va 980 590 8 290

110 Cr-Va 1080 640 7 320

Steel Tensile Yield Elongation Hardnessgrade strength strength (%) (HB)


70 690 355 12 200

80 780 390 10 230

90 880 440 8 260

70 Va 690 450 15 200

80 Va 780 490 12 230

90 Va 880 540 10 260

100 Cr-Va 980 590 8 290

110 Cr-Va 1080 640 7 320




S7 6.75 65 50 25 5 33.95 28 5/6 540S10 10 70 58 32 6 35.12 45 6/8/10/12 540S14 14 80 70 38 9 41.80 64 6/8/10/12 690S18 18.30 93 82 43 10 47.90 82 6/8/10/12 540S20 19.80 100 82 44 10 51.80 86 6/8/10/12 690S24 24.43 115 90 53 10 58.52 125 6/8/10/12 690

30E1 30.13 108 108 60.30 12.30 55.88 140 15/12 690S30

33E1 33.47 134 105 58 11 67.33 150 15/12 690S33

41E1S41 r =10mm 41.24 138 125 67 12 69.34 220 15/12 69040E1

S41 r =14mm 40.95 138 125 67 12 69.80 210 15/12 69049E1S49 49.39 149 125 67 14 75.77 225 12/15/18 690

54E3 54.54 154 125 67 16 79.12 245 12/15/18 690S54

46E3NP46 46.66 142 120 73.72 14 71.70 265 15/12 69050E2

EB 50T 49.97 151 140 72 15 80.20 280 15/12 690EB 63 62.95 151 140 72 30 82.55 320 15/12 69054E1

UIC54 54.77 159 140 70 16 84.03 280 12/15/18 88060E1

UIC60 60.21 172 150 72 16.50 91.10 295 12/15/18 880UIC54A 65.39 159 140 70 28 86.33 310 12/15/18 880UIC60A 61.11 142 150 72 28 76.57 320 12/15/18 880ASCE 60 30.03 107.95 107.95 60.33 12.30 55.88 140 12/15/18 690ASCE 85 42.20 131.76 131.76 65.09 14.29 68.88 190 15/12 690

Vignola rail

Steel Tensile Yield Elongation Hardnessgrade strength strength (%) (HB)


70 690 355 12 20080 780 390 10 23090 880 440 8 260

70 Va 690 450 15 20080 Va 780 490 12 23090 Va 880 540 10 260

100 Cr-Va 980 590 8 290110 Cr-Va 1080 640 7 320



Clips

STANDARD RAIL CLIP FM16

1. RAIL WITHOUT PAD 2. PAD MOUNTED RAIL

Distance between stud bolts M16 P Rail base + 29 mm

Minimum assembly width clips W Rail base + 72 mm

F C A 1. RAIL WITHOUT PAD 2. PAD MOUNTED RAILmm mm mm

A45 125 45 55 FM16 H18 FM16 H24A55 150 55 65 FM16 H18 FM16 H24A65 175 65 75 FM16 H18 FM16 H24

30E1 (S30) 108 60.3 108 FM16 H18 FM16 H2433E1 (S33) 105 58 134 FM16 H18 FM16 H24

40E1 (S41- R14) 125 67 138 FM16 H18 FM16 H2441E1 (S41- R10) 125 67 138 FM16 H18 FM16 H24

ASCE60 108 60.3 108 FM16 H18 FM16 H24ASCE85 131.8 65.1 131.8 FM16 H18 FM16 H24

Specification Grade 5.8 stud bolts Grade 8.8 stud bolts

Maximum side load 23 kN 38 kN

Tightening torque 125 Nm 200 Nm







A55 150 55 65 FM20 H22 FM20 H28A65 175 65 75 FM20 H22 FM20 H28A75 200 75 85 FM20 H25 FM20 H31

A100 200 100 95 FM20 H25 FM20 H31A120 220 120 105 FM20 H25 FM20 H31

AS86 150 101.6 152.4 FM20 H31 FM20 H37PRI85r 152.4 101.6 152.4 FM20 H31 FM20 H37MRS51 127 64 127 FM20 H28 FM20 H34MRS67 132 76 146 FM20 H25 FM20 H31MRS73 146 70 157 FM20 H31 FM20 H37

MRS87A 152.4 101.6 152.4 FM20 H31 FM20 H37BSC101 165 100 155 FM20 H31 FM20 H37

ISCR70 120 70 120 FM20 H25 FM20 H31ISCR80 130 80 130 FM20 H25 FM20 H31

ISCR100 150 100 150 FM20 H25 FM20 H31ISCR120 170 120 170 FM20 H28 FM20 H34

QU70 120 70 120 FM20 H25 FM20 H31QU80 130 80 130 FM20 H25 FM20 H31


30E1 (S30) 108 60 108 FM20 H22 FM20 H2833E1 (S33) 105 58 134 FM20 H22 FM20 H28

40E1 (S41-R14) 125 67 138 FM20 H22 FM20 H2841E1 (S41-R10) 125 67 138 FM20 H22 FM20 H28

49E1 (S49) 125 67 149 FM20 H25 FM20 H3154E1 (S54) 125 67 154 FM20 H25 FM20 H31

46E3 (NP46) 120 72 142 FM20 H25 FM20 H3150E2 (EB50T) 140 67 151 FM20 H25 FM20 H31

EB63 140 72 151 FM20 H28 FM20 H3454E1 (UIC54) 140 70 159 FM20 H25 FM20 H3160E1 (UIC60) 150 72 172 FM20 H25 FM20 H31

ASCE85 131.8 65.1 131.8 FM20 H22 FM20 H28








F C A 1. RAIL WITHOUT PAD 2. PAD MOUNTED RAIL mm mm mm

A120 220 120 105 FM24 H31 FM24 H37A150 220 150 150 FM24 H34 FM24 H40

AS86 150 101.6 152.4 FM24 H34 FM24 H40PRI85r 152.4 101.6 152.4 FM24 H34 FM24 H40

MRS87A 152.4 101.6 152.4 FM24 H34 FM24 H40MRS125 180 120 180 FM24 H40 FM24 H46BSC101 165 100 155 FM24 H34 FM24 H40

ISCR100 150 100 150 FM24 H31 FM24 H37ISCR120 170 120 170 FM24 H34 FM24 H40ISCR140 170 140 170 FM24 H40 FM24 H46






ADJUSTABLE RAIL CLIP AM16





A45 125 45 55 AM16 H15 AM16 H21A55 150 55 65 AM16 H15 AM16 H21A65 175 65 75 AM16 H15 AM16 H21

30E1 (S30) 108 60.3 108 AM16 H15 AM16 H2133E1 (S33) 105 58 134 AM16 H15 AM16 H21

40E1 (S41- R14) 125 67 138 AM16 H15 AM16 H2141E1 (S41- R10) 125 67 138 AM16 H15 AM16 H21

ASCE60 108 60.3 108 AM16 H15 AM16 H21ASCE85 131.8 65.1 131.8 AM16 H15 AM16 H21









A55 150 55 65 AM20 H13 AM20 H19A65 175 65 75 AM20 H13 AM20 H19A75 200 75 85 AM20 H16 AM20 H22

A100 200 100 95 AM20 H16 AM20 H22A120 220 120 105 AM20 H16 AM20 H22

AS86 150 101.6 152.4 AM20 H22 AM20 H28PRI85r 152.4 101.6 152.4 AM20 H22 AM20 H28MRS51 127 64 127 AM20 H19 AM20 H25MRS67 132 76 146 AM20 H16 AM20 H22MRS73 146 70 157 AM20 H22 AM20 H28

MRS87A 152.4 101.6 152.4 AM20 H22 AM20 H28BSC101 165 100 155 AM20 H22 AM20 H28

ISCR70 120 70 120 AM20 H16 AM20 H22ISCR80 130 80 130 AM20 H16 AM20 H22

ISCR100 150 100 150 AM20 H16 AM20 H22ISCR120 170 120 170 AM20 H19 AM20 H25

QU70 120 70 120 AM20 H16 AM20 H22QU80 130 80 130 AM20 H16 AM20 H22


30E1 (S30) 108 60 108 AM20 H13 AM20 H1933E1 (S33) 105 58 134 AM20 H13 AM20 H19

40E1 (S41-R14) 125 67 138 AM20 H13 AM20 H1941E1 (S41-R10) 125 67 138 AM20 H13 AM20 H19

49E1 (S49) 125 67 149 AM20 H16 AM20 H2254E1 (S54) 125 67 154 AM20 H16 AM20 H22

46E3 (NP46) 120 72 142 AM20 H16 AM20 H2250E2 (EB50T) 140 67 151 AM20 H16 AM20 H22

EB63 140 72 151 AM20 H19 AM20 H2554E1 (UIC54) 140 70 159 AM20 H16 AM20 H2260E1 (UIC60) 150 72 172 AM20 H16 AM20 H22

ASCE85 131.8 65.1 131.8 AM20 H13 AM20 H19










A120 220 120 105 AM24 H24 AM24 H30A150 220 150 150 AM24 H27 AM24 H33

AS86 150 101.6 152.4 AM24 H27 AM24 H33PRI85r 152.4 101.6 152.4 AM24 H27 AM24 H33

MRS87A 152.4 101.6 152.4 AM24 H27 AM24 H33MRS125 180 120 180 AM24 H33 AM24 H39BSC101 165 100 155 AM24 H27 AM24 H33

ISCR100 150 100 150 AM24 H24 AM24 H30ISCR120 170 120 170 AM24 H27 AM24 H33ISCR140 170 140 170 AM24 H33 AM24 H39





ADJUSTABLE WELDABLE DOUBLE RAIL CLIP WDM16


Inside distance between base plates V Rail base + 10 mm

Distance between bolts M16 P Rail base + 45 mm

Minimum width sole plate W Rail base + 100 mm


A75 200 75 85 WDM16 N20 WDM16 N14A100 200 100 95 WDM16 N20 WDM16 N14A120 220 120 105 WDM16 N16 WDM16 N10

MRS51 127 64 127 WDM16 N18 WDM16 N12MRS67 132 76 146 WDM16 N28 WDM16 N12

ISCR70 120 70 120 WDM16 N20 WDM16 N14 ISCR80 130 80 130 WDM16 N20 WDM16 N14

ISCR100 150 100 150 WDM16 N18 WDM16 N12ISCR120 170 120 170 WDM16 N16 WDM16 N10

QU70 120 70 120 WDM16 N20 WDM16 N14QU80 130 80 130 WDM16 N20 WDM16 N14

QU100 150 100 150 WDM16 N18 WDM16 N12QU120 170 120 170 WDM16 N16 WDM16 N10

49E1 (S49) 125 67 149 WDM16 N20 WDM16 N1454E1 (S54) 125 67 154 WDM16 N20 WDM16 N14

46E3 (NP46) 120 72 142 WDM16 N20 WDM16 N1450E2 (EB50T) 140 67 151 WDM16 N20 WDM16 N14

EB63 140 72 151 WDM16 N18 WDM16 N1254E1 (UIC54) 140 70 159 WDM16 N20 WDM16 N1460E1 (UIC60) 150 72 172 WDM16 N20 WDM16 N14

Specification Grade 8.8 Hex. Bolt

Maximum side load 170 kN

Tightening torque 130 Nm

Welding: Inside Fillet welding 3Other 3 sides Fillet welding 4

Fixing Hexagon head screws ISO4017 / DIN933bolts: Steel grade 8.8 HDG.


ADJUSTABLE WELDABLE RAIL CLIP WM20






A75 200 75 85 WM20 N25 WM20 N19A100 200 100 95 WM20 N25 WM20 N19A120 220 120 105 WM20 N21 WM20 N15

AS86 150 101.6 152.4 WM20 N19 WM20 N13PRI85r 152.4 101.6 152.4 WM20 N19 WM20 N13MRS51 127 64 127 WM20 N23 WM20 N17MRS67 132 76 146 WM20 N23 WM20 N17

MRS87A 152.4 101.6 152.4 WM20 N19 WM20 N13

ISCR70 120 70 120 WM20 N25 WM20 N19ISCR80 130 80 130 WM20 N25 WM20 N19

ISCR100 150 100 150 WM20 N23 WM20 N17ISCR120 170 120 170 WM20 N21 WM20 N15

QU70 120 70 120 WM20 N25 WM20 N19QU80 130 80 130 WM20 N25 WM20 N19


49E1 (S49) 125 67 149 WM20 N25 WM20 N1954E1 (S54) 125 67 154 WM20 N25 WM20 N19

46E3 (NP46) 120 72 142 WM20 N25 WM20 N1950E2 (EB50T) 140 67 151 WM20 N25 WM20 N19

EB63 140 72 151 WM20 N21 WM20 N1554E1 (UIC54) 140 70 159 WM20 N25 WM20 N1960E1 (UIC60) 150 72 172 WM20 N25 WM20 N19






ADJUSTABLE WELDABLE RAIL CLIP WM24






A120 220 120 105 WM24 N24 WM24 N18A150 220 150 150 WM24 N22 WM24 N16

AS86 150 101.6 152.4 WM24 N22 WM24 N16PRI85r 152.4 101.6 152.4 WM24 N22 WM24 N16

MRS87A 152.4 101.6 152.4 WM24 N22 WM24 N16MRS125 180 120 180 WM24 N16 WM24 N10BSC101 165 100 155 WM24 N20 WM24 N14

ISCR100 150 100 150 WM24 N26 WM24 N20ISCR120 170 120 170 WM24 N22 WM24 N16ISCR140 170 140 170 WM24 N18 WM24 N12








Track clipsClip type ‘KPO 3’ is mainly applied to a ribbed base plate.Tightening torque nominal: 240 Nm.Material: S235JR.Preservation: black / hot dip galvanized.Mass = 0.627 kg.

Sole plates

Continuous sole platesLength: Standard 5980 mm.Width: Varying between 150 and 500 mm.Thickness: Varying between 12 and 50 mm.Material: S235JR, S275JR, S355J0.Preservation: Black, coating, hot dip galvanized, duplex system.

Clip type ‘KPO 6’ is also mainly applied to a ribbedbase plate.Tightening torque nominal: 240 Nm.Material: S235JR.Preservation: black / hot dip galvanized.Mass = 0.523 kg.

Spring clipsSpring clip type ‘SKL 1 extra strong’ possesses highpermanent clip strength.Diameter material d = 14 mm.Tightening torque nominal: 250 Nm.Material: Spring steel.Preservation: lacquered / dacromet.Mass: 0.7 kg.

Spring clip type ‘SKL 3’ also possesses high permanent clip strength.Diameter material d = 13 mm.Tightening torque nominal: 200 Nm.Material: Spring steel.Preservation: lacquered / dacromet.Mass: 0.523 kg.

Bemo Rail also supplies weldable and adjustable clips, provided with a rubber nose.

Discontinuous sole platesLength: Varying between 150 and 300 mm.Width: Varying between 150 and 500 mm.Thickness: Varying between 12 and 50 mm.Material: S235JR, S275JR, S355J0.Preservation: Black, coating, hot dip galvanized, duplex system.

Bemo Rail supplies the standard sole platesand also its own forged ribbed base plates.


Sleepers

Crane-track sleepers – ConcreteCharacteristics of pre-fabricated concrete crane-track sleepers:• Manufactured of high-quality pre-stressed

concrete.• Suitable for maximum wheel load of 500 kN.• Minimum life approx. 40 years.• Relatively low installation cost.• Simply adjustable after settling.• Can be moved or removed easily after use.

Track sleepers - ConcreteCharacteristics of pre-fabricated concrete tracksleepers:• Manufactured of high-quality pre-stressed

concrete C 50/60.• Track gauge 1435 mm.• Applicable for different rail types and fastenings.• Minimum life approx. 40 years.• Relatively low installation cost.• Simply adjustable after settling.• Available new or used.

Crane-track sleepers - WoodCharacteristics of wooden crane-track sleepers:• Mainly manufactured of Azobe hardwood.• Suitable for maximum wheel load of 450 kN.• Minimum life approx. 20 years.• Relatively low installation cost.• Simply adjustable after settling.

Track sleepers - WoodCharacteristics of wooden track sleepers:• Mainly manufactured of Azobe hardwood. Other types of wood are possible.• Track gauge nominal 1435 mm. Other gauges on request.• Applicable to various ribbed (tie) plates.• Applicable for different rail types and fastenings.• Life ca. 20 years.• Relatively low installation cost.• Simply adjustable after settling.• Available new or used.


Elastic pad

Elastic pad, manufactured from ethylene vinyl acetate (EVA) copolymer, is mounted between the rail footand the steel sole plate.

FunctionsThe most important functions of elastic pad are:1. Distribution of the load over a larger surface.2. Elimination of point load and the fatigue ensuing from it.3. Absorption of contact inequalities between the rail and the supporting constructions.4. Reduction of noise and vibration.5. Reduction of wear of the rail and the sole plate.

Thanks to a better distribution of pressure using the elastic pad is economically advantageous when de-termining the sizes of the support for the crane track. Moreover one may expect a load reduction for thesupporting construction of at least 25% (DIN 4132 and CTICM recommendations).

Because of the excellent quality and our favourable experience Bemo Rail uses the following types:- 14003: For standard applications.- 07002: For heavy rail constructions (for greater tensile strength: see rail table on pages 10 and 11).

SizesLength: 12 metres on roll.Width: Any desired width.Thickness: 6 mm.

Single plate:In any desired size. Two sides can beprovided with rubber noses.Standard thickness: 6 mm. Otherthickness possible.

Product specifications

14003 7002 Unit Test method

MFI (@190gr C; 2,16 kg) 3 2 g/10min ISO 1133

Density (@20 gr C) 0.934 0.925 g/cm3 DIN EN iso 183-1

VA content 14 7 %w/w FTIR

Vicat-softening-temperature 65 72 °C ISO 306 Method A

Hardness Shore A 91 95 ISO 868

Hardness Shore D 35 42 ISO 868

Strength (@50% elongation) 4,3 6 Mpa ISO 527

Tensile strength 19 17 Mpa ISO 527

Elongation (@break) >750 >700 % ISO 527

Processing recommendation 100-150 100-150 °C

Bemo Rail also supplies elastic pad with steel inlay type MKVII and MK6.

Fastening material

Anchor bolts

Type Diameter (mm) Length (mm) Quality

M16 x 200 M16 200 5.8 / THV

M20 x 250 M20 250 5.8 / THV

M20 x 300 M20 300 5.8 / THV

M24 x 300 M24 300 5.8 / THV

Type Definition External Internal Thickness Max.diameter diameter (mm) height

(mm) (mm) (mm)

Fe 6 Double 47 25 6 22spring washer

Fe 7 Single 45 25 6 14spring washer

Spring washers

T-headed bolts

Type Size Weight (Kg / piece)

HS 26/65 S M22 x 65/45 0.475Mu M22, Mh 20, SW 39

HS 26/90 S M22 x 90/45 0.549Mu M22, Mh 20, SW 39

HS 32/65 S M22 x 65/45 0.503Mu M22, Mh 20, SW 39

HS 32/90 S M22 x 90/45 0.577Mu M22, Mh 20, SW 39

HS 27/75 S M22 x 80/40 0.512Mu M22, Mh 20, SW 39


Type Size

HS 40W 22/80 S M22 x 80/40Mu M22, Mh 20, SW 39

HS 40W 22/90 S M22 x 90/40Mu M22, Mh 20, SW 39

HS 40W 22/100 S M22 x 100/40Mu M22, Mh 20, SW 39

HS 40W 22/110 S M22 x 110/40Mu M22, Mh 20, SW 39

HS 40W 22/120 S M22 x 120/40Mu M22, Mh 20, SW 39

HS 40W 22/140 S M22 x 140/40Mu M22, Mh 20, SW 39

HS 40W 22/160 S M22 x 160/40Mu M22, Mh 20, SW 39

T-headed bolts Sleeper screws

Fish plates

Type Railtype Length (mm) A (mm) B (mm) C (mm) Weight kg/pair

FL 7 S 7 280 70 70 35 1.19

FL 10 S 10 300 75 75 37.5 1.36

FL 14 S 14 330 75 90 37.5 2.6

FL 18 S 18 330 75 90 37.5 3.1

FL 20 S 20 330 75 90 37.5 3.2

FL 30 S 30 530 128.6 127 73.7 9.5

FL 33 S33 530 130 120 80 12.69

FL 41/49 S 41 / S 49 580 100 165 75 17.44

FL 14a S 49 / S 54 630 100 165 10 25.52

FL 54E1 54E1

UIC54 670 130 200 70 30.40

FL 46E3 46E3

NP46 700 130 200 85 12.40

Type Size Weight (Kg / piece)

Ss 1/120 22 x 120 0.438

Ss 1/130 22 x 130 0.451

Ss 1B/130 22 x 130 0.472

Ss 1/150 22 x 150 0.478

Ss 1/160 22 x 160 0.556

Ss 8/140 24 x 140 0.528

Ss 8/150 24 x 150 0.548

Ss 8/160 24 x 160 0.568

Grouting

Bemo Rail supplies high-quality non-shrinkable cement-based grouting mortars. This is applied for thegrouting of rail constructions. With the grain structures of 0 -1, 0 - 4 and 0 - 8 heights of 10 to 150 mm canbe grouted. The material can be handled in moist circumstances and can also be pumped easily.The compressive strength of the mortars mentioned is 90 N/mm2, which is reached after a hardening period of 28 days. Depending on the temperature the material can be loaded already after 24 to 48 hours.

Bemo Rail also supplies high-quality high-flow epoxy grout, which can be used for grouting rail constructions and for gluing-in anchor bolts. The material is suitable for grouting heights between 20 and 80 mm and handling has to take place in dry circumstances.The compressive strength of 90 N/mm2 is reached after 28 days. With a hardening temperature of 10°Cthe material can be loaded after approx. 18 hours. With 20°C loading can take place already after approx.10 hours.

For gluing-in anchor bolts Bemo Rail supplies non-shrinkable cement-basedmortar with a grain structure of 0 - 0.3 mm.Also this material can be handled in moistcircumstances.The compressive strength of 70 N/mm2 isreached after 28 days. Depending on thetemperature the material can be loaded already after 24 hours.


Buffers

For safety reasons it is recommended to assemblebuffers at the end of the crane track. Bemo Rail has much experience in calculating, designing,manufacturing and assembling buffers. Calculations are made in conformity with DIN 15018 4.3.2.All buffers are made to measure.

Types:1. Rail buffer. Buffers are clamped to the rails by

special clips.2. Concrete buffer. Buffers are mounted on the

concrete construction with anchor bolts.

Energy absorbers:To eliminate the crane’s energy there are three methods:A. Rubber buffer, or Cellular-plastic buffer.B. Hydraulic cylinder.C. None. With sufficient energy absorbers on

the crane.

Design data:To design a buffer the following data are needed:

Energy absorber:H = the height from the heart of centre of the contact point of the crane to the top of the railhead.P = Pushing power in kN.If P is not known, we calculate it on the basis ofmass and speed of the crane.M = mass of the crane.V = maximum speed.

Besides buffers for crane tracks, Bemo Rail can alsosupply buffer frames for railway tracks.

Specials

For the solution of diverse deviating logistic transportation problems, Bemo Rail designs, manufactures and supplies the following specialcomponents:

CrossingsFor crossings of rails, e.g. traverse platforms on shipyards, Bemo Rails produces special constructions.

Versions:• Construction steel.• Cast steel.

Recess filling

With rail constructions in a recess it is often desirable to fill up the spaces between the rail and concretesafely with (frost resistant) material that keeps the recess dirt and water free. The qualities of the rail construction have to be maintained and the crane wheels must not be obstructed by it. In total it must be safe and may not cause stumbling danger.Traditionally the spaces in the recess can be filled up with lean concrete or mastic asphalt. However, neither system functions optimally under all circumstances. Bemo Rail has developed material on the basis of rubber liquid-mortar. This rubber liquid-mortar is elastic, non-shrinkable and remains compressible. It consists of rubber granulates and a two-component liquid mass, on the basis of reactivepolymers. The upper 25 mm of the rubber liquid can be applied in a different ratio, so that a denser, watertight structure is developed that also adheres very well to steel and concrete.


Hinging level crossingsBemo Rail designs, manufactures and supplies hinging level crossings. These crossings can be found e.g. with transitions from a platform to a ship lift on shipyards.

Crane-rail switchA switch piece to move the crane on a different track, is called a crane rail switch.

Curved railsCurved rails are bentrails. E.g. a crane trackwith a bend in it, or rail on silos.

10-metre high work ofart ‘Heartbeat’ The Netherlands.

Bridge piecesA bridge piece is a movable rail crossing.

Crossings field on shipyard Stralsund, Germany. Hinging level crossings on shipyard Stralsund, Germany.


SERVICES

Consultancy and engineering

Bemo Rail can advise you on all sorts ofcrane-rail constructions for industry,production companies and storage andtransfer companies. Our engineeringdepartment designs custom madefrom our supply programme, in accordance with international standards, like ISO, ASTM and DIN.

Measuring and inspection

Our team of surveyors carries outmeasuring of existing situations in anyfield related to crane rail constructions. We carry out measurements for customers from diverse sectors like the concrete industry, the steel branch, shipyards,bulk-transfer companies, container-transfer companies, project developers and constructors. Bemo Rail guarantees accuracy duringthe measuring. All measurements are elaborated in detailed and reliable reports together with an elaborate advice. Use is made of precision measuring instruments, like total stations and accurate level-measuringinstruments.

Handling

Bemo Rail uses large modern CNC drilling and milling machines. Besides we have heavy sawing machines, among which an automatic one. With our adequate equipment we are capable of handling ourproducts, like sole plates, foot-drilled rail, clips and drilled strips at high speed. With our automatic saw wecan saw these products or other pieces of steel efficiently into high-quality finished products.

Furthermore we also have a framing machine, a cutting machine and a milling machine. For these machines we can also make a quotation for non-rail-related products.

Assembly and supervision

Besides supplying complete rail constructions, Bemo Rail assembles these constructions all over theworld. All our machines have especially been developed for the assembly of crane tracks. Besides goodequipment we employ enthusiastic skilled workers, who deliver a project in accordance with the accepted international standards, like FEM 9831, VDI 3576, SEB 664035, NEN 2019.Moreover we have a team of experienced managers, who can supervise local skilled workers.

Welding and grinding

Bemo Rail is specialized in rail welding. Nowadaysvirtually all rail is welded. As a result there are nomore joints and the rail will not shift anymore. Also wear and consequently rail and wheel repairwill decrease.

Rail can be welded in 3 ways:• Puddle arc welding.• Thermite welding.• Electric flash butt welding.

Grinding machine in operation.

Thermite weldingHydraulic precision power wrench

36 | RAIL TECHNOLOGY

Bemo Rail welds in accordance with the ISO-3834standard. The ISO-3834 standard is the standard forquality guarantee and qualitycontrol for welding. This standard consists of 3 different levels. Since June 1,2005, Bemo Rail has been certified for the most elaborate level: ISO 3834-2.The certification means thatwe weld in accordance withcertified procedures and withcertified technicians. This means quality guarantee foryour product.

Bemo Rail can measure thepossibilities for a crane trackin various ways. Checking theadmissible tolerances for yourcrane track is done by meansof measuring. We check yourwelds by means of NDR; Non-Destructive Research.This is divided into ultrasonicand magnetic research.

Maintenance and repair

If your crane track shows subsidence, shifting, rail breaches or other problems, we can solve them.A damaged rail can keep yourcrane out of service, whichhas annoying consequencesand must be solved. Besideswe can also maintain your railconstruction periodically.

The underpinning machine in operation to adjust rail on ballast to the right height andto compress the ballast.

Rail cutter in operation.

SHUNTING TECHNOLOGY

Information on Shunting Technology you will find on the other side.

RailEng PDF

Documents

Transcript of RailEng PDF