Gallant Engineering

METHOD STATEMENT FOR CRANE RAIL

INSTALLATION

Alumino-thermit welding of Crane rails.

Ø The CR100 Rails has to be placed on wooden blocks outside the trench.
Ø It has to be ensured that the rail ends are square, in case it is not square then it has to be cut or
grinded to make it to right angle.
Ø In case of any bend in the rails, the bended segment shall be cut and removed.
Ø A gap of 25mm has to be maintained between the rails.
Ø The 1 meter alignment scale shall be used to align the rail in position and gap gauge shall be used to
measure the gap between rails.
Ø The rail moulds has to be placed in position and luting paste shall be applied to cover the gaps.
Ø The preheating torch has to be placed in position and preheating shall be done for approximately
12 minutes.
Ø After the preheating process, the Crucible shall be placed in position and the metal portion shall be
filled into the crucible.
Ø The ignitor is placed inside the crucible and the molten metal flows into the mould and the rail joint
shall be formed.
Ø Excess metal shall be removed form the rail head and Profile grinding shall be done on the rail head
to achieve the required tolerance limits.

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Alignment using 1 meter scale for welding Fixing of moulds

Preheating of Rails Pouring of metal into mould from crucible

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Profile Grinding after completion of Weld

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Method Statement Submitted to : L&T, VIH VIZAG Project

EQUIPMENT AND CONSUMABLES REQUIRED FOR WELDING

The following welding equipment is required.A full set of specialist equipment is required to carry out
welding process.

• Rail space setting gauge

• DIN-straight edge, 1 metre
• Short and long wedges
• Mould files
• Universal clamp and mould clamps
• Crucible fork
• Slag pans
• Preheat burner and holding device
• Regulators, flash back arrestor and hoses for propane and oxygen
• Thermometer magnetic clamp
• Hot chisel.

The following consumables are required for AT Welding

• Welding portion in one shot crucible or multi shot crucible suitable for the crane rail profile and rail
grade.
• Welding mould suitable to the crane rail profile (three parts, one bottom and two sides).
• Paste or luting sand for sealing the moulds.
• Ignitor for starting the ignition of the portion.
• Sufficient oxygen and LPG for the preheating burner.