53 QUAY CRANE RAILS

All rails and fastenings shall be new and perfect. Flanged bottom rails shall comply with
the tests and other requirements of GERMAN STANDARD DIN 536 AI50-880N/nun2
for the rail sections specified in the drawing.

Rails shall be fabricated as shown in the Drawings by a specialist manufacturer to be

approved by the Superintending Officer. The normal length in which rail sections (ie.
length of base plate) are fabricated shall be 12 metres but no section shall be less than 7
metres in length. Shop drawings shall be prepared by the specialist manufacturer and
submitted to the Superintending Officer for approval before fabrication commences.

The crane rails shall be accurately fabricated to the dimensions shown in the Drawings
and to the relevant British Standard.

54 Anchor Sockets, Jacking Pads & Buffer Stops

Anchor sockets and jacking pads shall be fabricated from mild steel to B.S. 4360, Grade
50. Fabrication generally shall conform to B.S. 5950.

P.V.C, WATERSTOP

55 Waterstop

Waterstop for use in pipe trenches at expansion joints shall be Expandite P.V.C.
Hydrofoil waterstop or other approved equivalent.

-".

SM/13
 104.4 APPARATUS FOR RECORDING, REDUCING AND DISPLAYING DATA

The signals from the transducers during the impact event, shall be transmitted to an
apparatus for recording, reducing and displaying data to allow determination of the force and
velocity versus time. The acceleration and displacement of the pile head, and the energy
)y the ",
transferred to the pile shall be determined. The apparatus shall include an oscilloscope or
oscillograph for displaying the force and velocity, a tape recorder for obtaining a record for future
analysis, and a means to reduce the data. The apparatus for recording, redncing, and displaying
:epted,i data shall have the capability of making an internal calibration check of force, velocity, and time
hall bet
scales. No error shall exceed 2 percent of the maximum signal expected.
of theS'1,
i Signals from the transducers shall be displayed by means of an apparatus on which the force and
,~
velocity versns time can be observed for each hannner blow such as an oscilloscope or
on the:"
oscillograph. Both the force and velocity data shall be reproduced for each blow and the
of th~:
apparatus shall be capable of holding and displaying the signal from each selected blow for a
ze and~ minimum period of 30 seconds.
medial,

104.5 DYNAMIC MEASUREMENTS

Dynamic properties shall be determined from a minimum of ten impact records during initial
driving. Soil resistance computations shall be determined from one or two representative blows at
the beginning of restriking. The force and velocity versus time signals shall be reduced by
computer or manually to calculate the developed force, velocity, acceleration, displacement, and
energy over the impact event. The number of impacts for a specific penetration, ram travel length,
and the number of blows per minute delivered by the hammer shall be recorded. For double
acting diesel hammers, the bounce pressure shall be measured and, for double acting steam or
compressed-air hammers, the steam or air pressure in the pressure line to the hammer shall be
measured. A series of force and velocity measurements shall be taken.

104.6 SUBMISSION OF TEST RECORDS

The Contractor shall submit two copies of all records of results and any other information to the
Superintending Officer on completion of test.

The Superintending Officer's interpretation and conclusion arrived at on the test results shall be
final.

STRUCTURAL STEELWORK

105 GENERALLY

Structural steelwork, such as bollard anchorage frames, ladders, crane buffer stops, fender
brackets, etc, if not to be fabricated in the Contractor's own works shall be supplied and fabricated
by a Sub-Contractor whose name and address and particulars of whose experience shall be
submitted for the Superintending Officer's approval.

Detailed design, fabrication, erection, etc, shall comply with all requirements of B.S. 449,
including amendments.
All like parts shall be interchangeable.

In general, shop joints shall be made by welding and site joints by bolting. Site welding will not
be permitted without the express approval of the Superintending Officer.

SW127
106 METHOD OF WELDING

Machine welding shall be carried out by approved machines efficiently supervised by qualified
operators and hand welding shall be executed in an efficient maimer by fully qualified workmen
equipped with plant suitable for the purpose.

107 MANIPULATORS

The manipulators and the sequence of welding shall be suitable for the work and the
Superintending Officer's approval to the same shall be obtained before welding is commenced,

108 SURFACES TO BE CLEANED

Surfaces to be welded shall be properly cleaned and prepared beforehand, all mill scale and
extraneous matter being removed and shall be kept clean and free from all such matters during
welding.

109 WELDS TO BE FINISHED FULL

All welds shall be finished full and made with the proper number of runs, the welds being' kept
free of slag intrusions and all adhering slag being carefully removed from the exposed surfaces
immediately after each run.

The Superintending Officer will carry out such tests of welding as are deemed necessary following
inspection. The Contractor shall cut out and replace at his own cost any portion of the structural
steelwork which the Superintending Officer shall decide is defective.

110 COST

The cost of welding, supply of electrodes, preparation of surfaces to be welded, removal of

adhering slag from exposed surfaces, testing and all oilier items of cost in connection with welding
shall be included in the rates and prices entered in the priced Breakdown of Tender Price and
Schedules.

111 AVAILABILITY OF STEEL WORK SECTION

In case the sizes of steel members shown in the Drawings are not available at the appropriate time
for incorporation in the Works, the Contractor shall substitute with an alternative size member
which shall be to the approval of the Snperintending Officer in all respects. Should the weight of
the alternative size member be less than that of the originally specified member, payment will be'
made for the alternative size member. Should the weight of the alternative size member be greater
than that of the originally specified member, payment will be made for the originally specified
member.

When tendering the Contractor shall take all measures necessary to ascertain the supply position
for steelwork and shall inclnde in the rates and prices entered in the priced Breakdown of Tender
Price and Schedules for all costs of whatsoever nature involved in complying with this Clause. Be
shall also make all due allowances in the time for completion quoted with the Tender.

SW128
 112 BOLLARDS

The anchorage system shall be proposed by the ballard supplier and the necessary calculation
fled
men ,,, sheets shall be submitted to the Superintending Officer for approval prior to manufacture.

The anchorage system will be supplied self-colour (uncoated) and will have a template plate
suitable for positioning the anchor bolts in the correct position. Installation of the bollard will be
undertaken by packing and levelling on steel shims followed by grouting with approximately
50mm of grout.
.-
the r The nut and washers shall be seated into the recess in the bollard base and any surplus length shall
be removed without damage to the threads:

The recess and bolt shall be covered with bitumen completely filling the bolt recess and leaving a
smooth surface.
md .
ring]
113 FENDERING

Before casting in bolt inserts for fender chain brackets, the Contractor shall make a full-scale trial
to check that the lengths of chain supplied and the positions of the bolt inserts specified are such
that when the mild steel brackets are pulled against the concrete faces there is a light tension on
the chains.

Fender chains shall be tensioned so that fenders hang uniformly in line. The Contractor shall
undertake any adjustments to chain tensions necessary after the fenders have been in use during
the maintenance period.

114 OUAY CRANE RAIL SYSTEM

The ends of rails to be jointed by fish plates shall be truly square and the rails shall be laid with
the appropriate gap for the prevailing ambient temperature as shown in the Drawings. The ends
of the rails adjacent to the expansion joint shall be accurately cut to the profile shown in the
Drawing to a tolerance of 0.80 mm.

Quay crane rails shall be laid to the tolerances as indicated in Appendix I.

the crane rails shall be held rigidly in position by means of temporary struts and wedges or other
approved means prior to concreting-in, which shall not be undertaken until approval has been
given by the Superintending Officer. The space between the base plate of the rails and the
structural concrete shall be completely filled with epoxy resin grout as shown in drawings to
ensure that the rails have a firm bearing throughout their length.

The Contractor is required to submit details of the rail clip, steel anchor bolts and reinforced
bearing pad for the installation of the crane rail in their tender submission for the Superintending
Officer's consideration. Manufacturer's test certificates from an independent testing house shall
be submitted by the Contractor. The Superintending Officer may require such further test
certificates to be submitted if he considers necessary. The technical specifications for rail
fastening system are given in Appendix II.

SW/29
us JOINTING OF CRANE RAILS

The Contractor is required to submit their proposed method of jointing the crane rails for th
Superintending Officer's consideration. Jointing of crane rails can either be by approved bU~
welding as specified in Appendix III or other approved process.

The various butt welding steps specified shall be strictly adhered to if applicable in other methods
of jointing of crane rails.

116 WARRANTY

The Contractor shall be required to warrant that the quay crane rail system installed shall be free
of defects for a period of ten (10) years after the issue of the certificate of Practical Completion.
The Deed of Warranty for the quay crane rail system shall be given in the format as provided in
the Tender Document.

117 REMOVABLE COVERS

Removable covers to valve pits, access openings, sumps etc. are to be hot-dip galvanised.

118 BITUMASTIC PAINTING OF NON-GALVANISED STEELWORK

Other items, such as crane bnffer stops and anchor socket, (other than for surfaces to be
cast into concrete) which have not been galvanised are to be thoroughly cleaned to remove all
dirt, rust, grease, mill scale, etc, by grit blasting or other approved mechanical means to leave
a clean metallic surface to B.S. 4232, second quality finish, all to the approval of the
Superintending Officer. The exposed surfaces shall then be given three coats of Bitumastic No 50
to build up a total film thickness of 12 mils (0.30 mm).

119 SAFETY OF EXISTING STRUCTURES

In carrying out dredging the Contractor shall ensure that the stability of the existing adjacent
structures are maintained. The Contractor shall submit his proposal for dredging accompanied by
sketches, drawings and calculations, etc for the approval of the Superintending Officer before
commencement of work. He shall carry out any other calculations required by the Superintending
Officer to confirm the stability of adjoining structures,

The Contractor shall be fully liable for any damages caused to the existing adjacent structures.
Any damages caused shall be made good to the satisfaction of the Superintending Officer at the
Contractor's expense.

Approval by the Superintending Officer .of the Contractor's proposal shall in no way relieve the
Contractor of his sole and entire responsibility for the safety of the adjoining structures.

SW/30
 APAPEIIDIX I

-
TOLERANCE OF TRAVEU ING RAIL
oCRMISSIBLE TOLERANCE FOR TRAVELLING RAIL FOR CONCRETE FOUNDATION
FOR BOTH RA IL SIDE
SH~~R LEGS

WHEN THE VALUE R~CHES THE MAINTENANCE TOLERANCE. RAILS SHOULD BE REPAIRED
WITHIN TOLERANCE AT INSTALLATION

To Ierance at I 'Mal ntenance

ChecK Item I Insta11 ati on I ChecK Method
I Tolerance
Strai qntness For Total Length .<>.-<b'~:
, Base Une
:S :t lOrrm By Transit s ± lOrrm
Max Left ! Inm
Value Right I }nm
Note (1) s± 2.8mm ChecK Every 2 metres
By Steel Tape s ± 2.8rrm
Span

Max
ill hD 11
l Oist~~ce
10m
(Sm):
Scale
(JIS Class)

Value c::::::J m/m )

, ~m/m
Height Difference For Whee 1 Base Soan *
Between Ra i1s Length By Transit s I x Span
I(Oi fference) c::J 5iiIT
~ Span x I
s a.3m
TIiilii .~ 12k Max Value
rrm s 6.3rrm

Bend orRai I Left For Total Length , 2m 2m 2m

and Ri ght s 10nm
For 2m s 1nm =1
bAE By Transit For 2m s Irrm

Base Lme
/span I Left c=Jrrm
I Value Ri ght c:Jrrm
Incl inati on s 1 s I
1000
For Total Length
s ± 10lllll I==:::P
CheCK Every
Max
Value
c=::J.m
Left
c=:Jrrm
By Transit
1000
For Total
Length
.s ± 10mm
Right

NOTE (1): THE SPAN SHOULD BE M~SUREO BY STEEL TAPE SCALE STRETCHING WITH IS KG. THE VALUE OF MARK* SHOWS IN.'
CASE OF INCLINATION OIFFERENCE FROM ~CH OTHER. I~ CASE OF SAME INCLINATION. THE VALUE OF MARK* IS
ALLOWED TW ICE OF IT.

5w131
 CRANE RAIL FASTENING SYSTEM

1.0 GENERAL

The crane fail fastening system described in this specification represents the minimum standard
acceptable in a system designed to fasten the crane rail to the support structure, ie. crane girder
concrete beam etc. '

The system shall consist basically of two components:

1 A steel-reinforced synthetic rubber pad to go under the rail.

2 Crane rails clips with a resilient compression block to constrain the rail in the vertical and
lateral planes while allowing movement in the longitudinal direction.

2.0 PAD

2.1 The pad shall be manufactured of synthetic rubber of suitable quality to resist deterioration from ],
oil and grease. It shall be reinforced with steel to ensure transverse rigidity.

2.2 The rubber shall have the following mechanical properties:

Shore hardness 75° + 5° shore A

Minimum tensile strength 12.5 N/mm
Elongation 250%
Permanent set 5%
Temperature range -25°C to + lOO°C
Rebound resilience 30%

2.3 Overall dimensions shall be as follows:-

Pad width- Rail width, plus 0, less 5 to 8mm

Pad thickness 75mm
Pad length 12m nominal lengths

2.4 The reinforcing shall be of steel with the following characteristics:

Minimum thickness O.4mm

Minimum width 60 % of the pad width
Tensile strength 690N/mm

2.5 The rubber shall be securely bonded to the steel by means of vulcanization process.

Rubber to steel bond strength Minimum 4.7 NImm

Width of bond from top and bottom surfaces of the pad with 180 peel.

SW/32
 3.0 RAlLCLIPS

3.1 The rail clips shall be made of steel with the following mechanical properties:

Minimum tensile strength 600 N/mm

Minimum yield strength 500 N/mm
Minimum elongation 17.5%
Hardness (Brinnell) 179
andard
girder, 3.2 The clips shall be designed to allow a lateral adjustment of at least 151mn and shall be self-locking,
self-tightening features.

3.3 The clips shall be able to withstand the lateral design loads imposed by the rail on the clip.

3.4 The vertical constraint on the rail shall be applied through a synthetic rubber compression block
securely bonded to the rail clip. The mechanical properties of the rubber block shall be similar to
al those of the pad. Shore hardness shall be 75 nominal.

1 from
'"

SW/33
 APPROVED BUTT WELDING METHOD

I PREPARATION

Previous to starting the welding procedure, each length of rail must be accurately aligned a!lll
firmly fastened to the steel support by means of clips, with the pad laid under the rail. On a length
of minimum 3 metres at each end of the rail length, the rail must be left unfastened in order to be
lifted (see Fig. I). Between each length of rail, a gap must be provided to enable the welding.
The gap should be minimum 20mm wide.

The two neighbouring rail ends must be lifted by a height approximately equal to the width of the
gap between them. This height is due to end up with a horizontal rail portion after welding, due
to differential shrinkage. A sheet of asbestos shall be laid on the pad to protect it against burning
during the welding. A IOmm thick plate made of electrolytic copper shall be laid under the rail
acting as a mould basis. If the abovementioned height is not achieved, add steel lugs to obtain tbe
desirable height (Fig. 2).

NOTE: The mentioned height is indicative.

The welder will appreciate himself the adequate height to provide and will adjust
after having checked the horizontality of the first rail joint.

The two end surfaces of the adjacent rail lengths shall be cleaned and all rust, scale and dirt
be carefully removed.

In the case of the ambient temperature being lower than + lOo e, the two rail ends should
preheated to ring them to a temperature of approximately 200 to 250 o e.

2 WELDING

Welding of the rail foot

Place the back side of the copper monld against the edge of the rail foot on each side to maintain
the melted metal in situ (Fig. 3). Start by welding a weld fillet at the bottom of each rail all along
the rail width as shown on Fig 4. Then proceed with the welding, going forward and backward
from one edge to the adler, until the web base is reached (Fig. 4). Remove carefully all the slags.
Grind off the excess of weld metal on the foot to enable the copper mould to be fixed accurately.

Welding of rail web and top

Place the two sections of copper mould on both sides of the rail as close as possible to the rail
(Fig. 5).

Proceed with welding as stated above up to the top of the rail.

NOTE: From time to time as occurs, displace one of the copper moulds and remove the excess
slag.

SW/34
 3 FINISHING

Once the welding is completed, grind off the excess welded metal on the top surface of the rail
and on the two top edges. This operation must be done progressively and very carefully in order
to obtain perfectly smooth surface on the top of the rail, at the rail joint eliminating shocks and
impacts when the crane wheels roll on the join. Remove copper mould and base plate BUT NOT
the asbestos sheet. After completion, it is recommended to cover the rail joint with layers of
asbestos to slow down the cooling of the joint.
led and(
a lengll(\
er to b~ 4 EQUIPMENT AND MATERIAL
elding ! "
Electrodes

1of the
~ Special electrodes must be used, such as (European Standards):
ng, dn~
ournin SOUDOMETAL TENASOUDO 75
he raij;
t?' . th PHILIPS PHILIPS 56R

KOBE STEEL LB-1l6

Usual diameter is 4mm.

Copper moulds must be made of pure electrolytic copper.

Their shape must fit the shape of each rail type profile (Fig. 5).

Welding Eqnipment

A 500 amp. power source is recommended (minimum 350 Amp.), Setting for welding should be
200 - 230 Amp.

5 QTHER WELDING PROCESS

The various butt welding steps specified above shall be strictly adhered to if applicable for other
methods of jointing of crane rails. ."

SW/35
 GAP "A"
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