CONSTRUCTION OF COAL, CLINKER

& CEMENT TERMINAL

AT PORT QASIM, PAKISTAN

Specification for Crane Rail

DOCUMENT No.: 14S441-DD-GY-0001

CHINA HARBOR ENGINEERING CO., LTD.

2015.12

Rev.

DATE

First Issue
Prepared

Checked

Reviewed

Approved

Description

Update tracing table

Version Update

Project: Construction of Coal, Clinker & Cement Terminal at Port Qasim, Pakistan

CONTENT
CONTENT ................................................................................................................... I
1
GENERAL ....................................................................................................... 1
2
NATURAL CONDITIONS ................................................................................ 2
2.1
Rainfall and Visibility ............................................................................. 2
2.2
Wind...................................................................................................... 2
2.3
Temperature ......................................................................................... 2
2.4
Humidity ................................................................................................ 2
Humidity condensing 100%. ............................................................................ 2
2.5
Seismic Conditions ............................................................................... 2
3
CRANE RAILS ................................................................................................ 3
3.1
Crane Rail Sole Plates .......................................................................... 3
3.2
Crane Rail Sole Plate Grout.................................................................. 3
3.3
Crane Rail Resilient Bearing Pad ......................................................... 3
3.4
Crane Rail Fastening System ............................................................... 3
3.5
Crane Rail Earthing .............................................................................. 3
3.6
Crane Rail Welding ............................................................................... 4
3.7
Crane Rail Slot Asphalt Infill (If Required)............................................. 4
3.8
Crane Rail Steelwork ............................................................................ 4
3.9
Crane Rail Alignment, Levelling And Tolerances .................................. 4
4
ANNEX ............................................................................................................ 6

Project: Construction of Coal, Clinker & Cement Terminal at Port Qasim, Pakistan

GENERAL

1.1 This specification is described theCrane Rail with Accessories . The works
include supply,fabrication and installation of materials required and the provision of all
labour, plant and equipment and the control for the proper execution and completion
of the works.
1.2 The Contractor shall be responsible for executing the works strictly in accordance
with the relevant local regulations and by-laws that are current at the date of the
tender together with all amendments and addenda which are imposed as statutory
requirements in the course of the works.
1.3 The Contractor is required to install crane rail systems with all its components.
1.4 The crane rail system shall be installed and linked to the existing crane rails in
order to allow operation of the crane throughout the full length (existing and new
rails).
1.5 To indicate the scale of the cranes the main bullet points to the crane properties
are listed below.
1.6 The following table depicts detailed dimensions and capacities of the Crane
proposed:
Span (rail centre distance): 15,000 mm
Minimum number of wheels per corner: 8
Minimum number of individually driven wheels per corner: 50%
Gantry type:A120
Rail length: 423 m
Maxium wheel load500KN.
1.7 It is anticipated that the Contractor will employ a specialist installation company to
carry out this work. Any such company shall be subject to the prior approval of the
Engineer and will be required to show a proven record of satisfactory performance on
similar installations before being considered.
1.8 The installation is to be of continuously welded rail with flexible resilient pad
bearing on a sole plate which is supported on a high strength grout, as indicated on
the drawings.
1.9 Any standard that can be determined to be substantially equivalent to the
standards specified in this document may be used, but it is the Contractors
responsibility to show the equivalency of the alternate standard and its use must be
approved by Engineer.

Project: Construction of Coal, Clinker & Cement Terminal at Port Qasim, Pakistan

NATURAL CONDITIONS

1.1

Rainfall and Visibility

Rainfall is rare and expected only during the south-west monsoon. The annual
average is about 200 mm only, but intensity of rainfall can be severe. In July a mean
monthly rainfall of 94 mm in 24 hrs was recorded, but the extreme recorded rainfall
within 24 hrs was 278 mm in August 1953.
Commonly the number of rainy days stays from 15 to 20 days per annum, while there
are years practically without rain and extraordinary events as observed earlier in
2005.
Mean average rainfall: 195 mm/a.
2.1

Wind

The area is featured by two seasons:

SW monsoon from May to September with south-westerly winds up to 14 knots (4
Bft)
NE monsoon from November to March with north-easterly winds up to 9 knots (3 Bft)
Variable winds are occurring in April and October. In general wind speeds seldom
exceed 20 knots, not even during the stronger SW monsoon period. Cyclonic storms
are very seldom striking the coast of Pakistan and are rarely stronger than 8 Bft.
Max. operating wind speed 20 m/s.
Max. stowed speed 42 m/s.
2.2

Temperature

Temperature range 5 C to 40 C
Direct sun impact 50 C
For the design of all air-conditioning systems an ambient temperature of + 50 C
(desert type) shall be considered. The crane must be designed to operate with
minimum maintenance under the defined conditions. It must be made sure that the
electrical and mechanical equipment does not overheat, especially where exposed to
direct sunshine.
2.3

Humidity

Humidity condensing 100%.

2.4

Seismic Conditions

Special attention shall be given to the seismic effects in the port area. The crane
design shall conform to the requirement of Seismic Zone 2B, 0.16 to 0.24 g.

Project: Construction of Coal, Clinker & Cement Terminal at Port Qasim, Pakistan

CRANE RAILS

(1) Crane rails shall be flat bottom rail with the performance data indicated on the
drawings. The rail shall be subject to inspection.
(2)Rails when stored on site shall be properly and carefully stacked on suitably
spaced support blocks and only to a reasonable height in such a way as to avoid
distortion.
They shall be handled at all times with adequate care and with proper appliances.
Bent rails shall be straightened before laying by means of a proper rail straightening
screw. Kinked rails or rails distorted in a vertical plane shall be rejected.
3.1

Crane Rail Sole Plates

Sole plates shall be of steel to EN 10025, Grade Fe 430 A (Based on EN-alternative

S275-JR) drilled to suit the bolting requirements and with suitable attachments to
permit fine adjustments for levelling of the sole plate to within the requisite tolerances.
Where applicable, all levelling bolts shall be removed on completion and where
necessary coatings shall be applied to the bolts to facilitate removal.
3.2

Crane Rail Sole Plate Grout

(1) The sole plate and its holding down bolts shall be grouted in position using an
approved high strength pourable non-shrinkage grout material. Proposals for the use
of either cementitious or epoxy grout will be considered.
(2) It should be noted that thicker layers are required with the use of cementitious
grouts.
(3) The maximum grout thickness is 25mm deep.
3.3

Crane Rail Resilient Bearing Pad

A resilient bearing pad shall be provided between the rail and the sole plate. This
shall be of approved proprietary type, designed for use with this type of installation
and fitted to the size of rail proposed.
3.4

Crane Rail Fastening System

(1) Rail clips shall be provided to hold the rail in place on the sole plate. They shall
be of approved type, designed for use with this type of installation and fitted to the
size of rail proposed. They shall secure the rail against surge along its length,
sideways and uplift forces and shall be capable of adjustment; both for fine
adjustment during initial installation and subsequently to compensate for rail head
wear in service.
(2) Particular attention shall be paid to the corrosion resistance and long service life
of the clip and holdings down system and preference will be given to approved
systems in hot dip galvanised.
(3) The fastening system shall be capable to allow sideways rail adjustment of at
least 6 mm after installation of the sole plate.
3.5

Crane Rail Earthing

Project: Construction of Coal, Clinker & Cement Terminal at Port Qasim, Pakistan

(1) The crane rails shall be connected to earthing strips which shall be welded to the
reinforcement cage of the capping beams/crane rail beam. Earthing shall be provided
at the spacing shown on the drawings.
(2) Connection from rail to the earthing plates at the crane rail grooves shall be
galvanized mild steel strip 50 x 3.5 mm, if not indicated on the drawings, welded to
the rails and the earthing plates.
3.6

Crane Rail Welding

(1) Welding of lengths of crane rail to form a continuous length shall be carried out by
one of the following two methods:
a) Puddle Arc welding process
b) Thermit welding process
(2) Full details of the Contractor's welding proposals shall be submitted to the
Engineer for prior approval together with welder qualification.
(3) The Contractor shall show that the techniques proposed are satisfactory and that
his welders are suitably qualified and this may include a requirement to carry out
welding and/or welder qualification trials. The Contractor shall provide weather
protection during welding operations.
3.7

Crane Rail Slot Asphalt Infill (If Required)

(1) If required, the asphalt infill shall be 10 mm size close graded bitumen macadam
wearing course for Class B traffic with crushed rock or slag aggregate. The surface
shall be sealed with bituminous grit.
(2) The asphalt shall be hand laid and compacted with a hand roller to form a close
packed waterproof surface. The asphalt shall be worked in to fill the voids of the crane
rail clips and to fill the profile of the rail assembly.
3.8

Crane Rail Steelwork

All steelwork, welding, bolts, nuts etc., shall be in accordance with the requirements
of the European Standards.
3.9

Crane Rail Alignment, Levelling And Tolerances

(1) Rails shall be laid straight and true to the alignment and levels shown on the
drawings and as specified by the crane supplier. Rails shall be laid so that the leading
end from the rolls during manufacture is placed against the trailing edge of the
adjacent rail.
(2) The finished rail tolerances shall be in accordance with the F.E.M. 1.001, 3rd
Edition* but are subject to confirmation by the crane supplier. It shall be assumed as
follows:
a) Maximum variation for required cross level differences = 4 mm
b) Maximum gradient = 1:1000
c) Maximum deviation from required rail level = 2 mm
d) Gauge tolerance = 5 mm

Project: Construction of Coal, Clinker & Cement Terminal at Port Qasim, Pakistan

e) Maximum deviation from straight line = 1 mm in 2 m

f) Maximum deviation from required rail line = 3 mm
*) F.E.M. Federation Europeenne De La Manutention, Section I, Heavy Lifting
Appliances, Booklet 8, Test Loads and Tolerances

Project: Construction of Coal, Clinker & Cement Terminal at Port Qasim, Pakistan

ANNEX

Figure 1-1 Crane Rail (with Accessories)