Grantex rail road spec.

8/10/2019 Grantex rail road spec.

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CRANE RAIL FASTENING SYSTEMS INSTALLATION & MAINTENANCE

GANTREX s.a . Gantrex_Rail Welding_Alumino_Spec Recommendation test&recording APR-4.doc -1 de 4 http://www.gantrex.com Rue du Commerce, 19 Tél. : 0032/67/88.80.30

BP 196 – 1400 Nivelles Fax : 0032/67/21.63.21

Belgique

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Ref : 06EP198-7 Spécifications

1. Scope

What does exist in terms of welding control and qualification standard for crane rail?

2. Preliminary consideration

At this moment, there is no standard dedicated to the welding of crane rail. In fact no

standard in point view of the qualification welders, qualification of procedures and control.

3. Alternative can be used

Strong by his proven and successful experience of crane rail aluminothermic welding,

Gantry considers some tests as relevant for the aluminothermic welding checking.

3.1. Mechanical test

At this moment, we consider the Gantrex/Railtech procedure for surface hardness

measurement as the only relevant method to qualify the weld regarding mechanical properties. This

procedure is enclosed.

The test result must be, as specified in the procedure, comprised between 260HB and 300HB for

normal steel grade and between 310HB and 350HB for 110CR-V grade.

3.2. Non destructive tests (NDT)

According with the state of the art and only for NDT tests, we can refer some items from

EN14730-2 and consider them only as guide line.

1. Visual surface examination

1.1. As cast iron

Following stripping and grinding the as-cast weld collar surface shall be visually examined

for soundness. For the process to be accepted:

-

There shall be no cracks with length of 2mm, or greater. Joints between weld collars and

rail and flashing and rail are not cracks.

-

There shall be no pores with a dimension greater than 3mm nor shall there be more than

three pores in the size range 2mm to 3mm per test.





BP 196 – 1400 Nivelles Fax : 0032/67/21.63.21

Belgique

- Slag or sand inclusions shall not exceed the limits.

Surface dimension (max) in mm: 10 15 20Depth (max) in mm: 3 2 1

No defect shall intrude into the rail cross section nor touch the edge of the weld

collar/rail intersection.

- The condition of the surface left by riser removal (other than that on the ground rail

head) shall conform to the requirements specified by Railtech process manual APR one

shot cresset.

1.2. Final ground weld surface

The head and the ground weld collar surface on either side of the rail head shall comply with

the following.

-

There shall be no cracks.- There shall be no defects (pore, slag sand inclusions, metal beads)

1.3. Visible heat affected

The visible heat affected zones on each side of the weld shall be measured on the rail

running surface centre line. Their widths shall be equal to +/-40mm (on the head of the rail).

The visible heat affected zone shall be nominally symmetrical about the longitudinal axis of

the rail and transverse axis of the weld. A mark can be made after rail cutting but before

welding, this mark will used as reference to check any movement of the rail during the

welding.

2. Magnetoscopic examination-MPI (according EN 1290)

There are 2 kinds of MPI tests, namely under UV light or without. We consider the process

using an UV light more relevant for the detection of the outlet cracks but it can be very

difficult to realize outside. The area of the web zone of the welding must be particularly

checked and no cracks. The controller must qualify to EN473 magnetoscopic control

cofrend 2 or 3.

3. Internal examination by ultrasonic test (according EN 1714)

The controller must qualify to EN473 US control cofrend 2 or 3. The step of the procedure

control is given below.

- A test of the head zone of the weld (non planar defect)

Reject level – any defect signals>= the signal a 5mm diameter flat-bottomed hole

- A test of the head zone of the weld (planar defects)

Reject level – any defect signals>= the signal from a 10mm diameter flat-bottomed hole

-

A test of the web zone of the weld (planar defects)

Reject level – any defects signals>= the signal from a 5mm diameter flat-bottomed hole

-

A test of the middle zone of the foot of the weld

Reject level – any defects signals>= the signal from a 5mm diameter flat-bottomed hole

-

A test of the ankle zone of the foot of the weld





BP 196 – 1400 Nivelles Fax : 0032/67/21.63.21

Belgique

Reject level – any defect signals>= the signal a 5mm diameter flat-bottomed hole

-

A test of the toe zone of the foot of the weldReject level – any defect signals>= the signal a 5mm diameter flat-bottomed hole

-

All vertical defaults are 100% rejected

- More than two acceptable defaults = reject of the weld

The extent and depth of any defect found shall be marked on the report supplied by the

controller.

4. Validation

According the standard, the validation of the welding is under the responsibility of thecontroller. Those 3 kinds of tests are always considered together by welding. We consider

other tests like x-ray examination or dye penetrate examination like extra tests.

4. Recording and tracing of the aluminothermic weld

Each aluminothermic welding must identified and reported, each report must be stored and

accessible on request. This identification report is fully making part of the welding process. In this

report (independent of control report) key information must be written like:

4.1. Identification of the responsible welder

- Name

-

Function

- Special accreditation

- Date and signed

4.2. Identification of client

- Name

- Responsible

- Phone

- Special demand

-

Date and signed for approval4.3. Identification of the welding

- Ident n°

-

Localisation

- Track name

- Time of realisation

-

Sate of the extremity rail

- Respect of the Railtech process APR manual

-

Railtech portion bag reference (using of the self-adhesive label from the portion bag)

- Preheat temperature

-

Global geometrical tolerances (gap and peak)

-

Observation





BP 196 – 1400 Nivelles Fax : 0032/67/21.63.21

Belgique

4.4. Identification of the works

-

Type of process- Number of welders

-

Objective

- New track or renovationµ

- Date Localisation

- Type of work

- Type of track

- Type of rail

- Local temperature

-

Local weather

Grantex rail road spec.

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