Leaders in Height Safety Systems, Crane Rail & Crane Rail Lubrication
Rapid Rail design, supply, install
Company mission statement
Rapid Rail is a company
founded on a commitment
to excellence. We strive to
deliver the best value and
service to our customers.
Through a continuous learning
process and by investing in
people and technology, we
aim, not only to maintain
the high standards by which
we are already recognised
but to fulfil our ambition to
be recognised globally as
the best and most successful
company in our field.
and maintain crane rail safety and
lubrication systems
Paul Howard and Tony Sysum are the founding members of Rapid Rail Limited.
Both have worked in the crane rail industry for over 30 years. Paul and Tony started
their careers as installation technicians and progressively worked their way into
senior management.
Before forming Rapid Rail, Paul was sales manager for a leading product/installation
company and Tony was contracts manager. Having achieved their respective
positions, it became clear that their high levels of experience and knowledge could
be better served independent of product supply. Rapid Rail runs on a “hands on”
basis which enables skills and knowledge to be shared with all engineers, ensuring
the very best installation and service every time.
Tony Sysum Paul Howard
Foreword
For many years, a few dominant companies have served the crane rail industry,
motivated by the supply of products. The industry in which we had obtained
our knowledge and skills, was failing to provide the dedicated installation and
maintenance services required.
We decided to give something back to the industry by creating a company capable
of fulfilling these requirements. Rapid Rail Limited was founded in 1993 as a
truly independent company, offering design, supply, installation and maintenance
services to its customers. Since we formed Rapid Rail we have enjoyed a healthy yet
controlled growth, which has enabled us to re-invest in the company and our core
product, our engineers! By investing in the appropriate equipment and the training
needs of our engineers, we are able to respond to all our customers’ requirements
thereby offering security and peace of mind.
Our focus has and will always be to provide unequalled levels of service and quality
to our customers. Our commitment to you is to ensure that we are there whenever
you need us and to continuously provide the very best service and quality.
What do we do?
New applications
• Design: full system design from
concept to completion
• Supply: all materials –
rail, clips, pad, fastenings,
base plates, grouts
• Install: installation of full
crane rail systems – steelwork
realignment/levelling and
modifications
• Safety: Rapid Rail Safety
Systems offers the complete
safety solution – a range of Fall
Protection Equipment, training
and recommendations
• Crane wheel lubrication:
Rapid Rail Lubrication System
reduces crane rail wear by
applying lubricant automatically
at the precise point of contact
between the crane wheel and rail
• Embedded rail: is a proven
technology, set to revolutionise
crane rail applications worldwide.
Austria
Belgium
Egypt
Eire
Germany
Israel
Italy
Existing applications
• Repair: welding (both puddle
arc and Thermit welding
processes) – replacement of
damaged rail and fastenings
• Emergency repair: guaranteed
response times for maintenance
contracts/specified customers
• Maintain: maintenance
Where do we do it?
contracts, material replacement,
weld repairs, re-alignment
As well as working extensively in
• Survey: visual survey through to the UK and Europe, Rapid Rail
full instrument survey supplying has successfully completed
tabulated results together with contracts in many locations
cad drawings, report of findings throughout the world.
and recommendations
Our experience and knowledge of
• Installation: Rapid Rail can overseas working practices and
guarantee every installation market structures have enabled us
due to using only Rapid Rail to provide unequalled service and
employed engineers. support to our customers.
America
Australia
Mexico
Oman
Spain
Switzerland
1
 Contents

1 Safety 3 7 Cement Manufacture 21

Rapid Rail Safety Systems Limited Introduction
Offers a complete fall protection Specification – type of rail, clips,
equipment range spacing, standards/tolerances
Technical – selection charts

2 Crane Wheel
Lubrication 7 8 Power Generation 23
Lubrication direct to the point Introduction
of contact Specification – type of rail, clips,
spacing, standards/tolerances
Technical – selection charts
3 Ports & Harbours 9
Introduction
9 Water Treatment
Specification – type of rail, clips,
Works 25
spacing, standards/tolerances
Technical – selection charts Introduction
Specification – type of rail, clips,
spacing, standards/tolerances
4 Embedded Crane Rail 11
Technical – selection charts
Rapid Rail supplies the latest
technology in embedded rail
10 Specialist Services
& Repairs 27
5 Steel & Non-Ferrous 13
Thermit Welding
Introduction Puddle Arc Welding
Specification – type of rail, clips, Diamond Drilling
spacing, standards/tolerances
Technical – selection charts
11 Products 29
Introduction
6 Automated Warehouse
Rail – type of rail – selection charts
Systems 17
Clips/Pad
Introduction Fastenings
Specification – type of rail, clips, Grouts
spacing, standards/tolerances Plates
Technical – selection charts

2
 2
Safety 1

From the firm foundation of tried and tested

industry expertise, Rapid Rail provides complete
safety solutions – everything from equipment,
recommendations and training.

Falls from height are the most common
cause of fatal injuries and the second
most common cause of major injury to
employees, accounting for 15% of all
such injuries.
As a result of over 20 years of
safety critical experience at heights,
Rapid Rail has developed the
best available safety systems and
products. They are appropriate
for industry sectors such as
construction, manufacturing,
commercial property, ports, energy.
We offer systems that are appropriate,
flexible and reliable. It is imperative
to ensure safe working at heights
when it’s not just a statistic but a
human life at stake.

3
 Safety
Rapid Rail works with you to
assess your needs and to make
comprehensive recommendations
and:
• site surveys and risk assessment
• computer generated specification
• a personal response to design
the optimum system for you
• certificated installation using
our experienced highly trained
engineers
• staff training to optimise use,
application and maintenance
of systems
• regular servicing of systems
and products – replacement
where necessary.
4
Legislation
The law worldwide is increasing
safety standards annually. It is now
a legal imperative to ensure safety
for those working at heights and to
improve the statistics of fatalities
and injury.
A safe environment is also a more
productive, efficient and cost
effective one.
The Personal Protective Equipment
Regulations require:
• employers to maintain fall arrest
equipment in good repair
• appropriate replacement
• inspection of equipment which
is exposed to deterioration
regularly and each time
circumstances which might
jeopardise safety have occurred
• marking of PPE against falls
from height
• examination of components at
least 12 monthly
• textile manufacturers recommend
inspection more frequently.
Fall Protection
Equipment
Rapid Rail offers a flexible range
of products. They go beyond the
legal and quality requirements for
proven fall protection equipment.
Our products are:
• easy to use and install
• flexible
• quality assured
• industrially tried and tested
• permanent
• certified
• individually designed
• simple to maintain
• cost effective
• superior.
Horizontal Safety Lines*
These give complete safety and
working freedom. They travel easily
with unrestricted movement and
can support from one to ten users.
For use in energy, warehouse,
construction, applications.
• smooth operation
• hands free movement
• shock absorbing qualities
• adjustable, unobtrusive installation
• permanent
• customised design
• ensures maximum safety
• simple maintenance
(annual service requirement)
• cost effective
• superior to all alternatives.
 Retractable Fall Arrest Blocks*
Maximum safety and compliance
for: construction, warehouse, utility
and confined space applications.

• maximum safety
• fall indicator
• easy to use
• swivel snap hook
• performance
Safety Harnesses* • finest materials for durability
Designed for professionals • freedom of movement
combining functionality with • lightweight blocks with webbing
comfort. For use in telecoms, • heavy duty with winch and
construction, access machinery, galvanised cable.
rescue, any application requiring
access or suspension.

• designed for professionals

by professionals
• maximum safety
• flexibility
• multiple adjustments for perfect fit
Vertical Safety System* • ultimate stretch and comfort
Designed to ensure safety in the • adjustable function and movement
horizontal, vertical or inclined • lightweight but durable Safety Harness Kits*
planes. High tensile cables attach • easy to use The latest safety harness kits ensure
the user to the climbing area and • freedom of movement compatibility and compliance of all
safety is assured by automatic • cost effective. components.
locking devices. Kits include customised fall
The right system for you, can be Lanyards* protection equipment eg harness,
supplied quickly and easily: Maximum movement with no anchorage, lanyard, shock absorber,
compromise on safety. Each lanyard scaffold hook. An easy solution for
• flexible lifelines
can be supplied with various types construction, industry and specialist
• different durability of product
of hooks and connectors. For use applications.
for different requirements
• smooth operation on towers, aerials, masts, wind • maximum safety
• automatic release generation farms, or any need for • compliance
• hands free movement rope access or suspension: • easy and convenient
• maximum shock absorption
• greater manoeuvrability • ready for use
• temporary or permanent
• highest standards of manufacture • performance
• customised design
• light but strong material • choice of packaging
• ensures maximum safety
• maximum safety • readily portable
• manual rope adjuster
• reduced risk of snagging, tripping • choice of content
• cost effective or dragging • cost effective.
• automatic or manual versions
• reduced fall arrest forces
• superior to all alternatives.
• heavy duty protection
• visible product warnings
• prolonged service life
• freedom of movement
• cost effective.

* Full technical product specification available 5

 Safety

Personal Protection
Equipment*
The best selection of products to
ensure personal user safety in eye,
ear, hand and foot protection.
We can select, install and maintain
the equipment you need for
industry, public services, utilities,
manufacturing:

• maximum safety
• staff satisfaction
• builds workplace confidence
• installation and training
• maintenance
• compliance
• comfortable
• quality
• practical, yet stylish
• performance Safety Training* Rapid Rail – the complete
• choice Supply of the best available safety solution
• cost effective. equipment is not enough to ensure Safety and complacency do not mix
worker safety. Training and advice – too much is at stake. Rapid Rail
in product usage, maintenance and applies three decades of specialist
application is a legal requirement. industrial safety experience to
We supply training options to suit your business application. Our
the customer daily facing risks and experience and products are at
responsibilities of staff working at your service. Rapid Rail – the
heights and provide the necessary ‘hands on approach’ to all aspects
consultancy to help you select, of safety consultancy:
use and maintain all fall arrest and
• risk assessment
safety systems.
• compliance
Rapid Rail ‘hands on approach’ • recommendations in systems
to on-site training via customised and practice
workshops and seminars. • supply and installation of
products and kits
• managing height safety
• roof top safety • training and advice on use
and maintenance
• inspection, care and maintenance
of PPE • ongoing monitoring and
inspection.
• industrial rope access
• cradles and platforms.

6 * Full technical product specification available

**
The automatic crane wheel lubrication
system offered by Rapid Rail
Lubrication
The close relationship that exists
between Rapid Rail and our clients
has driven us to pursue a solution
to ease crane wheel and rail wear.
To this end we are extending our
range of products to include an
** Authorised Distributor
Crane Wheel 2
Lubrication
automatic rail wheel lubrication
system. This will enable Rapid Rail
to offer surveys, recommend supply
and the installation of a clean, safe
method of applying lubrication to a
precise location.
7
 Crane Wheel Lubrication
Crane wheels are affected by crane
loading, heat, cold, misalignment,
settlement of buildings and
hostile environments, especially
in heavy industrial production
areas i.e. steelworks, foundries
and process industries. These can
all accelerate wear, necessitating
expensive repairs and replacements
being undertaken to both rail and
crane wheels, resulting in loss of
production.
The rail/wheel lubrication system
offered by Rapid Rail provides an
automatic discharge of a specifically
formulated lubricant into the inner
surface of the wheel flange. This in
turn is transferred to the point of
contact on the rail head sides, thus
reducing friction.
Due to the pre-set frequency and
measured volume of the lubricant
deposited, excessive build up of
grease is avoided. This minimises
cleaning and allows a more detailed
examination of the rail and clips
during routine maintenance checks.
The amount of lubrication can be
adjusted during each life cycle as
required, enabling the end user to
react to changing circumstances.
The system after initial installing
and priming is maintenance free,
until the cartridge requires replacing.
The frequency of discharge
can be 1, 3, 6 or 12 months
or set individually,
dependent on the users
requirements.
8
Cartridge and batteries are always
changed as a complete unit.
The motor drive has a proven
minimum life of 8 cycles.
For external use we can provide
plastic caps for weather protection.
The unit is mounted on the
crane by a simple bracket fitted
in a convenient position on the
crane structure.
Some of the known
advantages:
• Reduced wear resulting from
metal/metal contact
• Reduced maintenance costs
by increasing the life of crane
wheels/rail
• Controlled use of specifically
formulated lubricant
• Quick and easy installation and
replacement on site
• No external power sources,
fully automatic, maintenance
free, electronic mechanical
drives
• Safety proven. approved
• Waterproofed if required
• Widely used in Europe, • If required, a computerised
UK and USA. system of recording the
installation and renewal of
cartridges can be offered.
This service depends on the
delivery cycle being maintained
• A similar system can be
offered for many engineering
applications where lubrication
is necessary to provide a smooth
maintenance free operation.
Please phone or e-mail Rapid Rail
with your requirements.
 Ports & Harbours 3

Successful handling and management of world

cargo relies upon the expertise and operating
facilities of a port.

Rapid Rail clients include
all principal port authorities
worldwide.
In a competitive and constantly
changing business environment,
a port must ensure it offers reliable
and cost effective services.
Quayside cranes and rail mounted
gantry cranes are the nucleus of
port operations. Failure in these
core areas directly affects
productivity and profitability.
Rapid Rail has extensive experience of
port installations and maintenance,
having worked for many years
with some of the world’s largest
port authorities.
Our reputation as reliable, credible
and, above all, experts in our field
has enabled us to assist these ports
in their continuous improvement
and development projects.
Today Rapid Rail is considered to be
second to none in all rail mounted
port installations.

9
 Ports & Harbours

Specification
Rail Sections The following rail sections are commonly used on Ports & Harbours.

British Rails British Crane Rail British Bridge Rail

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. 28BR 28.62 50 152 67 12 167 371 CES2
SEC. 56CR 56.81 76 171 101.5 35 836 702 CES2
SEC. 89CR 89.81 102 178 114 51 1502 1434 CES2
SEC. 101CR 100.38 100 165 155 45 3411 1266 CES2
SEC. 164CR 166.83 140 230 150 75 4784 5160 CES2

Continental Crane Rails A Sections S Sections

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. A55 31.8 55 150 65 31 178 337 DIN
SEC. A65 43.1 65 175 75 38 319 608 DIN
SEC. A75 56.2 75 200 85 45 531 1011 DIN
SEC. A100 74.3 100 200 95 60 856 1345 DIN
SEC. A120 100 120 220 105 72 1361 2350 DIN

Standards – Tolerances
Crane rails are typically installed
to tolerances set out in BS466
Appendix F (British standard
specification for power driven
overhead travelling cranes, Semi
Goliath and Goliath cranes for
general use). See page 14.
To ensure the optimum solution,
attention must be paid to each
individual application and
agreement reached on the most
appropriate tolerances.
Clips are generally installed in pairs
opposite. The clip spacing may vary
according to the rail type, wheel
loads and duty cycle.
Trolley rails on overhead container
handling cranes are generally
installed to the normal overhead
1
2 6
crane tolerances. However, special
attention must be taken at the hinged
joints. Rapid Rail has extensive
experience both home and overseas
in this area and are frequently called
upon to refurbish hinge rails.
lateral adjustment

Fastenings 3 7
There are two methods of fixing
crane rails to concrete foundations.
4 8
Continuous and discontinuous
support. There is little doubt that
continuous support is a better 5
solution than discontinuous, but
carries a higher cost. A designer
KEY
must investigate the cost
1 stud/bolt fixing 5 epoxy resin/cementitious grout
implications and, where operating
2 adjustable clip 6 levelling screw
criteria allows, give credence to 3 steel beam 7 soleplate
discontinuous support. 4 resilient pad 8 holding down bolt

10
 Embedded Crane Rail 4

Embedded crane rail is a proven technology, set

to revolutionise crane rail applications worldwide.

Rapid Rail has formed a close This ground breaking alliance

working alliance with Edilon, means that Rapid Rail can now
world leaders in the development supply the latest technology with
of embedded rail systems. the Rapid Rail/Edilon Embedded
Rail System.

11
 Embedded Crane Rail
Features
This embedded rail system means
that traditional mechanical
fastenings such as clips, anchors
and base plates are no longer
necessary. Embedded rails are
connected to the underlying slab
with continuous elastic rail support,
which delivers flexibility and
durability in one product.
The new crane rail can be precisely
levelled and aligned into the
completed chase in one operation
after welding. A crane rail sealed
into the jetty provides all the load
bearing and functionality required
at today’s modern port.
12
Benefits
The added support means that
the horizontal and vertical forces
are more evenly distributed which
reduces rail fractures and practically
eliminates rail corrugation.
Embedded rail offers maximum
electrical insulation, a reduction
in rail wear and important
engineering advantages.
Traditional systems are more open to damage
and loss of asphalt
The advantages of the Rapid Rail
/Edilon Embedded Rail System
include:
• greatly reduced chase width
• potential for diamond drilling
eliminated
• asphalt infill no longer required,
reducing costs and routine
maintenance
• greatly reduced site installation
times
• rail is sealed preventing ingress
of water, eliminating corrosion
• trapping and tripping hazards
are reduced
• smoother passage for port traffic
with greatly reduced impact on
the embedded rail
• comparative initial costs with
greatly reduced inspection costs
through warranty periods
• full worldwide warranty
available subject to
terms and conditions.
Health, Safety
and the Environment
The Rapid Rail/Edilon Embedded
Rail System is produced in
compliance with the legislative
requirements for health, safety
and the environment. All Rapid
Rail installation engineers are fully
certified. Technical documents
are produced regarding the use,
effects, installation and removal
of the systems.
A new embedded system highlights the
reduced chase width
 Steel & Non-Ferrous 5

The Steel & Non-Ferrous industry is a highly

competitive global marketplace.

Rapid Rail clients include all major
Manufacturing and Process Plants
throughout the UK and overseas.
Performance is key to ensure
continued growth and development.
Cranes are paramount to successful
and continual production.
Renowned for their arduous duty
cycles and extreme loading
necessitates continual maintenance
and repairs to the crane rails.
Rapid Rail works closely with many
companies to ensure continuous,
uninterrupted operation of their
production cranes.

13
 Steel & Non-Ferrous

Specification Standards/Tolerances It should be noted that gantry crane

The most common types of cranes
operating in steelworks are overhead
gantry cranes, which are subjected
to arduous working conditions and
require frequent re-railing.
Overhead crane rails are typically
installed to tolerances set out in
BS466 1984 Appendix F. (British
standard specification for power
driven overhead travelling cranes,
Semi Goliath and Goliath cranes
for general use).
rails are generally only installed to
tolerances for alignment and span.
The level of the rail bearing structure
determines the level of the rail.
The rail bearing structure should
therefore be surveyed to ensure
compliance with the required
installation tolerances.

Track Tolerances (Top running cranes) derived from BS466 1984 Appendix F

1 Span Tolerances S S S
Permissable
For spans less than or equal to inclination
15 metres S = 3mm. 1 : 300
For every metre of crane span above H
15 metres (0.25mm) is added to the 3mm.
Therefore a (20 metre) span
crane the tolerance is as follows:
3 + (5 x 0.25) = 4.25mm
up to a max of 15mm

2 Misalignment of Running Surface

in the Vertical Plane

H max 10mm

3 Permissible Deviation of Track Straightness

in Horizontal and Vertical Planes

Local vertical or horizontal deviation at any point of

the track should not be greater than L/2000, measured 'L'
over a length of not less than 2 metres on a line
parallel to the theorectical datum as shown (right).
'L'
NB To a max of 10mm.
2000
10mm
10mm

14
Rail Sections
The following rail sections are commonly used.

British Rails British Crane Rail British Bridge Rail

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. 56CR 56.81 76 171 101.5 35 836 702 CES2
SEC. 89CR 89.81 102 178 114 51 1502 1434 CES2
SEC. 101CR 100.38 100 165 155 45 3411 1266 CES2
SEC. 164CR 166.83 140 230 150 75 4784 5160 CES2
SEC. 28BR 28.62 50 152 67 12 167 371 CES2
SEC. 50BR 50.18 58.5 165 76 58.5 326 720 CES2

Continental Crane Rails A Sections S Sections

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. A45 22.1 45 125 55 24 90 170 DIN
SEC. A55 31.8 55 150 65 31 178 337 DIN
SEC. A65 43.1 65 175 75 38 319 608 DIN
SEC. A75 56.2 75 200 85 45 531 1011 DIN
SEC. A100 74.3 100 200 95 60 856 1345 DIN
SEC. A120 100 120 220 105 72 1361 2350 DIN
SEC. A150 150.3 150 220 150 80 4373 3850 DIN

adjustment
Fastenings
A rail fastening system should
control vertical rail movement and
secure the rail laterally.
There are several types of clips
available. The two most common
types of clips are:
1 a two part welded base clip
incorporating its own bolt system
2 a single part clip which can 3
1
incorporate the use of weld
studs or bolts to secure.
2 4
Clips are generally installed in pairs
opposite and are spaced along the
rail according to the rail type, wheel 5
loads, duty cycle and any other KEY
factors which can affect design.
1 welded stud or bolt
2 adjustable single part clip
3 alternative adjustable welded base
type clip with integral bolts
4 resilient pad
5 steel beam Diagram: Section through rail, clip and pad on beam

15
 Steel & Non-Ferrous

Overhead crane rails provided by Rapid Rail

at a new facility built for the production of
Royal Navy vessels

16
 Automated Warehouse 6
Systems

The world of logistics is often driven

by time dependent customer demand.

Rapid Rail clients include all major
manufacturers of storage and retrieval
system worldwide.
Fast moving goods, which require
100% selectivity, rely upon
appropriate storage facilities and
interfacing handling equipment.
Automated warehouse cranes are
key to accurate and time effective
handling. Accuracy is demanded in
the installation of the floor rails to
ensure appropriate interaction of
the crane and racking.
Rapid Rail has been selected time
and time again as preferred
installers capable of achieving the
exacting standards required.

17
 Automated Warehouse Systems

Specification

Standards – Tolerances
Narrow aisle crane rails are
typically installed to tolerances
set out in FEM. 9.831 (Rules for
the design of storage and retrieval
machines. Tolerances and clearances
in the high bay warehouse).

Installation tolerances for

Crane Rails used for Storage
& Retrieval generally in
accordance with FEM 9.831
Floor Rail
Alignment tolerances with reference
to vertical datum without tolerances,
in the horizontal z–direction.
measured length 
total rail length 3.0mm
measured length 
s/r machine wheel base 1.5mm
Rail heads of different dimensions
shall be made flush by grinding the
side guide surfaces in the joint area,
levelness of the joints over a
measured length of 200mm ≤0.5mm.
Level Tolerances
Level tolerances of H2 in the
y–direction, with reference to a
horizontal datum plane without
tolerances in the vertical direction:
measured length  100m 2.0mm
100m 3.0mm
measured length 
s/r machine wheel base 0.5mm.
Rail heads of different dimensions
shall be made flush by grinding in
the joint area: levelness of the rail
and of the joints over a measured
length of 100mm ≤0.1mm.
Travel Characteristics
The travel characteristics of the
s/r machine can be influenced by
the unevenness of the top and side
guide surfaces of the rail. These
surfaces must be even ie: there
must be no pitting resulting from
rust or rolling.
Dimensioning and Anchoring
Dimensioning and anchoring of the
floor rail is the responsibility of the
equipment manufacturer in
conjunction with the civil engineer
and the installer of the rail.
It is not unusual for these types of
rails to be installed to greater
tolerances than those specified in
FEM 9.831. Each application is
reviewed and agreement reached on
the most appropriate tolerances.

18
Rail Sections
The following rail sections are commonly used in storage and retrieval systems.

British Rails British Crane Rail British Bridge Rail

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. 50 ’O’ 24.82 52.39 100.01 100.01 10.32 424 105 BS11
SEC. 60 ‘R’ 29.85 57.15 109.54 114.3 11.11 682 148 BS11
SEC. 75 ‘R’ 37.09 61.91 122.24 128.58 13.1 1064 223 BS11
SEC. 80 ‘O’ 39.74 63.5 127 127 13.89 1101 276 BS11

Continental Rails A Sections S Sections

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. S30 30.03 60.3 108 108 12.3 606 DIN
SEC. S33 33.47 58 105 134 11 1040 154 DIN
SEC. S41–10 41 67 125 138 12 1382 260 DIN
SEC. S41–14 41 67 125 138 12 1367 260 DIN
SEC. S49 49.38 67 125 149 14 1816 320 DIN
Installations have been completed using HEA and IPN sections.

Fastenings
There are various factors to be
considered when designing a storage
and retrieval floor rail system.
In addition to the normal design
parameters, consideration should
also be given to: 4
1
• the required installation tolerance
5
• limiting deflection to within
2
the required parameters
6
• control of loading on
3
concrete floor.
7
There are varying system designs,
which accommodate specific
8
application requirements.
Clips are generally installed in pairs
opposite. For this type of application,
it is common for the clip spacing
to be a division of the machine
KEY
wheelbase. This may vary according
1 holding down bolt 5 soleplate
to the rail type, wheel loads, duty
2 levelling nut 6 epoxy resin/cementitious grout
cycle and any other factors, which 3 pad 7 adjustable clip
may affect the design. 4 clip bolt (multi hole plate) 8 reinforcing bars

19
 Automated Warehouse Systems

20
 Cement Manufacture 7

There are various handling systems utilised

within the cement processing industry.

Rapid Rail clients include all major
manufacturers of cement and cement
products.
From circular slurry tanks and
general handling cranes, through to
conveyer systems.
As with all manufacturing processes
the need for effective and
maintenance free plant is crucial.
The diversity of handling systems
utilised within the cement industry
requires maintenance by engineers
with equally diverse skills.
At Rapid Rail, we have the skills and
experience necessary to enable us
to service these requirements
in a thorough and cost effective
manner.

21
 Cement Manufacture

Specification
Rail Sections
The following rail sections are commonly used in the cement manufacture & processing industry.

British Rails British Crane Rail British Bridge Rail

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. 28BR 28.62 50 152 67 12 167 371 CES2
SEC. 50BR 50.18 58.5 165 76 58.5 326 720 CES2
SEC. 56CR 56.81 76 171 101.5 35 836 702 CES2
SEC. 89CR 89.81 102 178 114 51 1502 1434 CES2
SEC. 101CR 100.38 100 165 155 45 3411 1266 CES2
SEC. 164CR 166.83 140 230 150 75 4784 5160 CES2

Continental Crane Rails A Sections S Sections

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. A55 31.8 55 150 65 31 178 337 DIN
SEC. A65 43.1 65 175 75 38 319 608 DIN
SEC. A75 56.2 75 200 85 45 531 1011 DIN
SEC. A100 74.3 100 200 95 60 856 1345 DIN
SEC. A120 100 120 220 105 72 1361 2350 DIN

Standards – Tolerances Clips are generally installed in pairs type, wheel loads, duty cycle and
Crane rails are typically installed opposite. The clip spacing along the any other factors, which may affect
to tolerances set out in BS466 rails may vary according to the rail the design.
Appendix F (British standard
specification for power driven
overhead travelling cranes, Semi
lateral adjustment
Goliath and Goliath cranes for
general use). See page 14.
1
To ensure the optimum solution
attention must be paid to each 2 6
application individually and
agreement reached on the most
appropriate tolerances.
3 7
Fastenings 8
Whilst there are applications which
4
would require a welded base type of
fastening, it is reasonably common 5
to use a single part clip utilising a
through bolt/weld stud fixing.
There are varying system designs, KEY
which accommodate specific 1 stud/bolt fixing 5 epoxy resin/cementitious grout
application requirements. 2 adjustable clip 6 levelling screw
3 steel beam 7 soleplate
4 resilient pad 8 holding down bolt

22
 Power Generation 8
Power Generation a very demanding
working environment.
Rapid Rail clients include There are many different power
Power Generating Plants producing operations such as coal,
throughout the UK. combined heat and power (chp),
gas, hydro and nuclear, all having
varying and demanding methods of
production.
All power producing companies aim
to maximise the production and
distribution of their power
generation. Allied to this are their
obligations and commitments to
environmental and social issues.
Maintaining and upgrading
production facilities contribute
towards lower emissions and
increased generation.
The diversity and depth of
experience gained within power
generating companies have enabled
Rapid Rail to become a leading
partner in power generation.
23
 Power Generation

Specification
Rail Sections The following rail sections are commonly used in the power generating plants.

British Rails British Crane Rail British Bridge Rail

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. 28BR 28.62 50 152 67 12 167 371 CES2
SEC. 56CR 56.81 76 171 101.5 35 836 702 CES2
SEC. 89CR 89.81 102 178 114 51 1502 1434 CES2
SEC. 101CR 100.38 100 165 155 45 3411 1266 CES2
SEC. 164CR 166.83 140 230 150 75 4784 5160 CES2

Continental Crane Rails A Sections S Sections

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. A65 43.1 65 175 75 38 319 608 DIN
SEC. A75 56.2 75 200 85 45 531 1011 DIN
SEC. A100 74.3 100 200 95 60 856 1345 DIN
SEC. A120 100 120 220 105 72 1361 2350 DIN
SEC. A150 150.3 150 220 150 80 4373 3850 DIN

Standards – Tolerances Clips are generally installed in pairs

Crane rails are typically installed opposite. The clip spacing may vary
to tolerances set out in BS466 according to the rail type, wheel
Appendix F (British standard loads, duty cycle and any other
specification for power driven factors, which may affect the design.
overhead travelling cranes, Semi
Goliath and Goliath cranes for
lateral adjustment
general use). See page 14.
1
Fastenings
Crane tracks in power generation
plants can be either overhead or
2 6
ground tracks and are all fixed
using fully adjustable rail clips. 3 7
There are several types of clips
available. The two most common
4 8
types of clips are:
1 a two part welded base clip
incorporating its own bolt system
5
2 a single part clip which can be
secured by either weld studs
or bolts. KEY
1 stud/bolt fixing 5 epoxy resin/cementitious grout
2 adjustable clip 6 levelling screw
3 steel beam 7 soleplate
4 resilient pad 8 holding down bolt

24
 Water Treatment 9
Works

Water Treatment Works – an environmentally

sensitive area where standards are strictly
controlled.

Rapid Rail clients – main utilities
and their suppliers.
Privatisation of utility services has
enhanced public accountability and
brought about a drive for greater
efficiencies and value for money.
Efficient operation of plant and
equipment has become the focus,
resulting in a vast number of
refurbishment schemes and new
build projects.
Problematic areas in many water
treatment works are the rails upon
which the distributors and scrapers
operate.
Existing design parameters and
varying drive systems create a
challenging yet fulfilling project.
Rapid Rail has completed many
refurbishment and new build
projects in the water treatment
industry and is considered to be
the leading Installation Company.

25
 Water Treatment Works

Specification
Rail Sections The following rail sections are commonly used in water treatment works.

British Rails British Crane Rail British Bridge Rail

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. 28BR 28.62 50 152 67 12 167 371 CES2
SEC. 40 ’M’ 18.89 45.64 80.57 88.11 12.3 246 51 BS11
SEC. 50 ‘O’ 24.82 52.39 100.01 100.01 10.32 424 105 BS11

Continental Crane Rails A Sections S Sections

RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD

TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
SEC. S18 18.3 43 82 93 10 271 47 DIN
SEC. S20 19.8 44 82 100 10 346 53 DIN

Standards – Tolerances
Distributor/Scraper rails are
typically installed to tolerances set
out in BS466 Appendix F (British
standard specification for power
driven overhead travelling cranes,
Semi Goliath and Goliath cranes for
general use). See page 14.
Clips are generally installed in pairs Steelwork finishes are generally
opposite. For this type of application, soleplates and clips – galvanised
it is common for the clip spacing to fastenings – stainless steel,
be a division of the machine rail – self colour.
wheelbase. This may vary according
to the rail type, wheel loads, duty
cycle and any other factors, which
may affect the design.

Fastenings
There are two methods of fixing
crane rails to concrete foundations,
continuous and discontinuous
lateral adjustment
support. There is little doubt that 1
continuous support is a better
solution than discontinuous, but
carries a higher cost. A designer 2 6
must investigate the cost
implications and where operating
criteria allows, give credence to
3 7
discontinuous support.
4 8

KEY
1 stud/bolt fixing 5 epoxy resin/cementitious grout
2 adjustable clip 6 levelling screw
3 steel beam 7 soleplate
4 resilient pad 8 holding down bolt

26
 Specialist Services 10
& Repairs

Thermit Welding® is a specialist welding

process for the joining of rail steels.

Thermit Welding®
The Thermit® compound is a
mixture of metal oxides, alloying
elements and a reducing agent.
These react to form the metal;
simultaneously liberating intense
heat to produce superheated molten
steel, which forms the weld.
The rails to be joined together are
aligned, leaving a prescribed gap
between their ends. Preformed
refractory moulds are fitted around
the recommended gap at the
junction of the two rails.

27
 Specialist Services & Repairs
Preheat
Using a specially designed burner,
the moulds and the enclosed rail
ends are preheated for a time,
dependent upon the rail section,
to achieve the correct welding
temperature of 900/1000˚C.
Puddle Arc Welding
MMA Puddle Arc Welding is the
process of joining carbon steel
crane rails.
Preparation
The rails to be joined together are
aligned, leaving a prescribed gap
between their ends. Rail ends shall
be smooth and free from defects
and grease. The rails are set with a
slight camber at the joint to allow
for weld contraction and copper
moulds are placed around and
under the joint.
Heat Treatment
Joints are preheated to a prescribed
temperature and confirmed using a
temperature indicator prior to welding.
Welding
A mild steel strip is placed at the
bottom of the joint on top of the
copper strip (This will form part of
the weld).
28
Ignition
When the correct degree of preheat
has been achieved, reaction is
initiated in the crucible using a
special igniter. Superheated molten
steel is produced by an alimino
thermic reaction (The Thermit®
reaction).
Welding is carried out using low
hydrogen electrodes. Electrodes
are held perpendicularly and
short rectangular movements are
used with the tip of the electrode.
Copper moulds are placed around
the outer profile of the rail joint as
welding progresses. This process
is continued until weld metal is
within 12mm of the rail-running
surface and is allowed to cool for
five minutes. The weld is de-slagged
and welding is continued to the top
of the running surface.
Following an appropriate cooling
period, the rail head is ground to
profile and the rails aligned and
fastened.
This is only a process guide. If you
require further details, please
contact us and ask for a full weld
procedure.
Weld forming
At the correct time, the tapping
system at the base of the crucible
discharges the superheated molten
Thermit® steel into moulds via the
pouring cup.
After solidification, surplus
Thermit® steel is removed from the
rail head using a pneumatic chisel.
Following an appropriate cooling
period, the rail head is ground to
profile and the rail aligned and
fastened.
Diamond Drilling
Diamond drilling is a process used
to drill through steel reinforcing
in concrete using cylindrical core
bits. These core bits are set with
diamonds, usually in a tungsten
carbide alloy crown. Rotative boring
in the concrete with a hollow
cylindrical bit set with diamonds
allows the steel to be penetrated
and the resultant core extracted,
which can be used as verification
of quantity of steel removed.
When site drilling concrete
contractors run the risk of hitting
steel reinforcing, Rapid Rail
engineers carry diamond drilling
rigs as part of the site establishment
for ground tracks. If steel is
unavoidable, with experienced
operators downtimes and costs can
be minimised.
 Products 11
lateral adjustment

2 6

3 7

4 8

KEY
1 stud/bolt fixing 5 epoxy resin/cementitious grout
2 adjustable clip 6 levelling screw
Diagram: Crane rail fastening arrangement 3 steel beam 7 soleplate
for use on concrete base and steel beam 4 resilient pad 8 holding down bolt

Correct material selection is critical to ensure

integrity and longevity of the track system.

General
As an independent installation
specialist, we are able to draw on
the expertise and resources of the
best of industry supply.
This unique position enables us
to offer the most appropriate and
cost effective solution for all rail-
mounted applications.
All products supplied are from
quality approved suppliers and are
backed by full product guarantees.
This, coupled with our installation
warranty/guarantee, creates the
most reassuring solution.
We guarantee to supply materials
consistently:
• to the right specification
• of the right quality
• of the right quantity
• at a competitive price
• and at the right time.
The diagram above represents
a typical fastening arrangement
showing the products we supply.

29
 Products

Rail
Steel mills have been producing rail
steels for over a century. During this
time their designs have changed
reflecting the diversity of applications,
none more so than the crane rail
industry.
Every application is different and
must be engineered to maximise
efficiency and lifespan. Selection
of the correct rail is critical to
achieving this end.
Rapid Rail is able to offer rails in:
a various lengths to suit your
application
b normal or high grade steels
c mitre cut to specific design
and size
d curved rail (such as circular
tanks as seen at water treatment
works and cement works)
e drilled or undrilled
f modified to any design within
the limitations of the sections.
Rail supply is an important element
to sucessful installation and
working life of the installed track
system. It is necessary that all
rail is supplied with full mill
certification thus ensuring that
correct installation procedures can
be programmed and guaranteed.
All rail supplied by Rapid Rail is
sourced from reputable rolling mills
with full certification.
The table below represents some
of the most commonly used
rail sections. It is by no means
exhaustive. Other rail sections are
available. Please contact us for
further details.

Rail Sections

British Rails
B r i d g e R a i l s
RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD
TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
13 BR 13.31 36 92 48 7.5 3.9 74.4 CES2
16 BR 16.06 44.5 108 54 11 65 117 CES2
20 BR 19.86 50 127 55.5 10.5 82 193 CES2
28 BR 28.62 50 152 67 12 167 371 CES2
50 BR 50.18 58.5 165 76 58.5 326 720 CES2
C r a n e R a i l s
56 CR 56.81 76 171 101.5 35 836 702 CES2
89 CR 89.81 102 178 114 51 1502 1434 CES2
101 CR 100.38 100 165 155 45 3411 1266 CES2
164 CR 166.83 140 230 150 75 4784 5160 CES2
F l a t B o t t o m e d R a i l s
50 ‘O’ 24.82 52.39 100.01 100.01 10.32 424 105 BS11
60 ‘A’ 30.62 57.15 109.54 114.3 11.11 696 150 BS11
60 ‘R’ 29.85 57.15 109.54 114.3 11.11 682 148 BS11
75 ‘R’ 37.09 61.91 122.24 128.58 13.1 1064 223 BS11
80 ‘O’ 39.74 63.5 127 127 13.89 1101 276 BS11
110 ‘A’ 54.52 69.85 139.7 158.75 15.87 2323 418 BS11
113 ‘A’ 56.22 69.85 139.7 157.75 20 2318 418 BS11
M i n e R a i l s
30 ‘M’ 14.79 38.1 69.85 75.41 9.13 139 33
40 ‘M’ 18.89 45.64 80.57 88.11 12.3 246 51

Continental Rails
F l a t B o t t o m e d R a i l s
RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD
TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
A45 22.1 45 125 55 24 90 170 DIN
A55 31.8 55 150 65 31 178 337 DIN

30
 Continental Rails continued
F l a t B o t t o m e d R a i l s
RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD
TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
A65 43.1 65 175 75 38 319 608 DIN
A75 56.2 75 200 85 45 531 1011 DIN
A100 74.3 100 200 95 60 856 1345 DIN
A120 100 120 220 105 72 1361 2350 DIN
A150 150.3 150 220 150 80 4373 3850 DIN
UIC60 60.3 74.3 150 172 16.5 3055 513 UIC
T a l l R a i l s
S18 18.3 43 82 93 10 271 47 DIN
S20 19.8 44 82 100 10 346 53 DIN
S30 30.03 60.3 108 108 12.3 606 DIN
S33 33.47 58 105 134 11 1040 154 DIN
S41-10 41 67 125 138 12 1382 260 DIN
S41-14 41 67 125 138 12 1367 260 DIN
S49 49.38 67 125 149 14 1816 320 DIN

Examples of other rails supplied

R a i l s
RAIL WEIGHT WIDTH WIDTH HEIGHT THICKNESS INERTIA INERTIA STANDARD
TYPE Kg/Mtr HEAD mm FOOT mm mm WEB mm Ixx cm4 Iyy cm4 SPECIFICATION
MRS87A 86.8 101.6 152.4 152.4 34.9 3068 975 ASTM
MRS87B 86.8 102.4 152.4 152.4 38.1 2922.7 901 ASTM
ASCE80 39.8 63.5 127 127 13.9 1098 ASCE
ASCE85 42.2 65.1 131.8 131.8 14.3 1252 ASCE
CR 73 73 100 140 135 32 2000 719
CR 100 100 120 155 150 39 3270 1360
73 kg BHP 73 69.9 146 157 2660 671.2
86 kg BHP 86 102 165 102 1082

Note: Engineers must check the accuracy of the data before relying upon it. Not all rail sections produced are readily available, some may
not have been produced and some may have been removed from production.

Fastenings
There are many ways in which
a rail can be secured, i.e. bolted,
riveted, welded. Undoubtedly the
one recommended by Rapid Rail is
the fully adjustable clipped system
which offers the most cost effective
long term advantages.
It allows full rail adjustment to
achieve design tolerances, easy
replacement of worn rails, with
minimum downtime necessary in
high production areas.
With continuously welded rails,
the clip allows controlled vertical
and longitudinal movement which
occurs with thermal expansion and
“Bow wave” effect in the rail There are several rail fastening
which precedes each pass of the arrangements available which fit
crane wheel. this criterion.
Introducing a rail pad between Drawing on our resources and
the crane rail and the supporting optimising our wealth of experience,
structure will: we are able to bring together the
best of the industry’s quality
• accommodate unevenness in
the supporting structure materials, thus offering the most
appropriate and cost effective
• help to distribute wheel loads
over a larger surface area solution.
• re-centre loads – for rail
mounted on steel girder
• reduce wear to the rail and
the supporting structure
• reduce fretting between the
rail and supporting structure.

31
 Products
As is seen in diagrams 1, 2 & 3 there
are various fixing configurations,
each fixing arrangement selected
according to the system criteria.
Clips – fully adjustable
• Weldable base type clip
comprising cap & base with
integral bolts
• Single part clip secured by either
welded studs or grade 8.8 bolts
through the structure.
Rail Pad
• Continuous with lateral restraint
• Lipped pad for individual
soleplates.
Bolts & holding down bolts
• All sizes to suit application in
grades 4.6 and 8.8.
Soleplates
• Continuous in mill lengths
• Individual 2, 4 or 6 hole fixings.
Grout
Years of experience and co-operation
have led to the formulation of high
quality grouts, designed specifically
for crane track applications.
There are three basic types of grout.
• Polyester resin anchor grout
used in most cases for the fixing
of holding down bolts.
• Cementitious grout used for
base plate grouting. A preferred
option in suitable cases due to
reduced costs.
• Epoxy grout used for base plate
grouting continuous or individual
generally recommended for all
applications.
Finishes
In corrosive environments clips
and soleplates can be supplied
galvanised, bolts and HD bolts can
be supplied galvanised, BZP or
stainless steel.
Embedded Rail
Rapid Rail supplies the latest
technology in embedded rail, the
32
KEY
1 welded stud or bolt
2 adjustable rail clip adjustment
3 alternative welded base type
clip with integral bolts
4 resilient pad
5 steel beam
3
1 4
2 5
Diagram 1: Section through rail, clip and pad on beam
KEY
1 holding down bolt
2 levelling nut
4
3 pad
4 clip bolt (multi hole plate) 1
5 soleplate 5
6 epoxy resin/
cementitious grout
2
7 adjustable clip 6
3
8 reinforcing bars
7
Note: adjustable weld base
type clip (not shown) 8
Diagram 2: Section through ground track
KEY
1 corkelast® embedding polymer
2 reinforcing bars in terminal quay
3 terminal quay & recess 3
1
2
Diagram 3: Section through embedded rail
Rapid Rail/Edilon Embedded Rail Facilities
System. Traditional mechanical Rapid Rail has the in-house
fastenings are no longer necessary manufacturing capacity i.e. cutting,
and continuous elastic rail support profiling, drilling, welding to cover
delivers flexibility, durability and all installation requirements.
cost savings through reduced rail Items required outside our manu-
fractures and rail wear. Embedded facturing capacity are sourced
rail offers maximum electrical from specialist suppliers with full
installation and considerable warranties.
engineering advantage.
Notes

Legislation is constantly being reviewed. The information in this brochure is

for guidance only, please contact Rapid Rail for specific details on specifications,
latest updates and product supply.
If you would like any further
information or would like to
discuss any particular points,
please do not hesitate to
contact us.

Designed by Litchfield Morris, Gloucester 01452 733955