Method Statement for Installation of
Crane Track Installation
1. PURPOSE
2. SCOPE
3. REFERENCES
4. RESPONSIBILITY
5. MANPOWER CATEGORY
6. REQUIRED TOOLS
7. METHODOLOGY
8. QUALITY CONTROL AND ASSURANCE
9. SAFETY INSTRUCTIONS & PRECAUTIONS
1. PURPOSE
The purpose of this Method Statement is to serve as a guideline to carry out the Installation
of Crane Rail Track. This procedure will provide necessary requirements and responsibilities
relating to the installation, inspection and test of Cranes Rail Track. This specification gives a
set of recommendations allowing the realization of mounting and fastening of a crane track
on girders.
2. SCOPE
This method statement covers the installation works of Cranes Rail Track for Saline Water
Conversion Company – Ras Al-Khair, in accordance with applicable codes, standards for plants
and refineries.
3. REFERENCES
a. Specifications and Standards
• S-000-1520-101 Field QC Procedure
• S-000-1650-001 Safety Execution Plan
• S000-1351-002 Installation Marking Procedure
• S-000-3150-001 Installation of Static Equipment
• FWBS CODE (5000) Equipment Installation
• S-000-1520-103 Handling Procedure
• S000-1630-003 Material & Equipment Protection Program at work site
b. Industry Codes and Standards
• Steel Design Guide for Baseplate and Anchor Rod Design.
• AWS 01 .1 Structural Welding Code.
• PIP STS05130 Erection of Structural and Miscellaneous Steel Specification.
4. RESPONSIBILITY
Site Manager
Ensure full compliance by all Millwrights, Mechanical Foreman, Electrician and Labor
regarding
execution of work and implementation of HSE procedure in accordance with project
requirement and
specifications Confirm availability of all materials, tools, equipment and required
personnel who will
carry out the work.
Quality Control Inspector
Conduct inspection in accordance with this procedure. Monitor daily activities and
verify compliance to specifications. Prepares record and final acceptance
documentation where required.
Construction Manager
a. Pre-mobilization Inspection and color coding for all tools and equipment used on
site. Ensure that all safety requirements have been adequately addressed and the
work is carried out in accordance with project safety procedures.
b. Ensure relevant documentation and certifications are submitted for operators,
drivers, scaffolding and rigging.
Mechanical Supervisor
Prepare and submit method statement for review and approval. Provide latest revision
of OHC drawings, procedures, material specifications standards and technical
specifications. Provide latest as built drawings for every receive equipment.
Rigging Supervisor
To ensure that rigging and heavy lift activities are performed by certified rigger in a
safe and efficient manner. Rigging is engineered, performed and inspected to satisfy
the customer’s requirements in accordance with the issued project drawings and
specifications.
Safety Officer
Check the work areas and monitor from time to time in the implementation of safety
procedure and assuring that all safety equipment and tools are present at site and in
good working condition.
5. MANPOWER CATEGORY
• Foreman
• Welder
• Mechanical Fitter
• Fabricator
• Helper
• Scaffolder
• Surveyor
• Rigger
• Electrician
• Permit Receiver and other involved Manpower
• Mason
6. REQUIRED TOOLS
• Appropriate Crane for Specified Lift
• Slings/Non-Metallic Ropes/Soft Tag Lines
• Shackles/Seam Clamps
• Spreader Beam or Frame/Chain Hoist
• Welding Machine for Tacking of Liners/Wedges
• Wrenches/Leveling Tools/Feelers and Dial Gauges
• Precision Levels/Calibrated Gauge/Torque Wrench/Hand Tools
• Equipment/Survey Equipment
• Equipment shall be maintained and checked prior to use for safe work assurance
• All tools must be calibrated before using
7. METHODOLOGY
7.1 CONCRETE FOUNDATION AND SOLEPLATE
Crane rails cannot normally be directly mounted onto a concrete surface. The surface
of concrete is too soft and would be worn away by the movement of the crane and
rail. The upper surface of cast concrete tends to be weak as a result of the casting
process. It may also not be level to the accuracy required for the crane rail. Thus, it is
common to bed a steel plate onto the top surface of the concrete before the rail is
fixed. This then allows the Gant rail clips and pads to be accurately fixed as if the
installation was on steel. Typically, strong non-shrinking grout is used between the
embedded sole plate and the cast concrete.
STYLES OF SOLEPLATE FIXING
The most economical system is to fix the clip and the soleplate into position with the same
holding down bolts. This is only suitable for the lightest cranes. For heavier duty cranes the
holding down bolts and the clip fixing bolts are separated.
DISCONTINUOUS SOLEPLATE
The following decisions need to be made when designing an installation and specifying
suitable products and materials:
• Are clips to be on the holding down bolts or are the holding down bolts to be separate
from the clip fixing bolts?
• What number of holding down bolts will be required?
• Clip type? (Also covered in the clip selection chart)
• Pad or no pad? (Specified by the customer or covered in another note)
• Soleplate thickness?
• Soleplate width and lengths? (Also determined from Gant rail product data sheets and
covered in another note)
• Holding down bolt diameter and length for normal duty applications the arrangements
in the following table are recommended
Vertical Wheel Clips separate Number of HD Soleplate HD bolt diameter
Clips on HD bolts
Load kN from HD bolts bolts thickness (mm) (mm)
Up to 30 Preferred Possible 2 10 M12
30 – 50 Possible Preferred 2 12 M16
50 – 120 Not preferred Preferred 2 15 M16
120 – 250 Don’t use Preferred 2 or 4 20 or more M20
Above 250 Consider using a continuous soleplate unless the rail is very heavy and still or wheel load is light for rail
The Components in the Fastening System
The component parts in the rail system are shown in the figure. This shows only of the examples from the
above table.
HOLDING DOWN BOLT DIAMETER
The holding down bolt diameter is typically chosen to be the same as the bolt diameter for the clip to be
used. This is given by the third and fourth digit of the clip type e.g. 3116/10/32/13 has a 16 mm bolt and
would normally be used with a 16 mm holding down bolt. The exception to this is when Gant rail 9220
clips are to be used it is recommended that 24 mm diameter bolts are used.
The length of the holding down bolt needs to be determined on the basis of the horizontal and vertical
wheel loads and the required bolt tension. The horizontal wheel load is also needed to determine the
correct clip to use. If it is not given, it is assumed by Gantrail to be 15% of the vertical wheel load. The
subject is covered in another technical note. The horizontal load is used to check that there is sufficient
strength in the holding down bolts. The shear strength of the holding down bolt, when placed in high
strength grout is taken as equal to:
Vult = hef x do x fcm x 0.5 1000
Vult = ultimate shear load capacity of holding down bolt kN
hef = effective holding down bolt length mm
do = drilled hole diameter mm
fcm = minimum concrete compressive strength (normally assumed to be 30N/mm)2
0.5 = empirically derived factor
The working load should be less than the ultimate load by a factor of safety. This is normally taken as 3.
For most applications, Gant rail suggest the use of grade 4.6 holding down bolt of length to give a depth
into concrete as given in the following:
Safe Shear Strength
Depth of Drilled Hole in
Holding Down Bolt Assumed Drilled Hole on Basis of Above
Concrete (mm) Grade
Diameter (mm) Diameter (mm) Calculation Method
4.6 Bolts
(Force kN)
12 90 15 4.9
16 120 18 8.6
20 170 24 17.4
24 210 28 25.9
These are the lengths typically used in resin capsule anchoring systems. These typically give greater
strength than an anchor which is fixed by mixed and poured grout but the loading on soleplates for crane
rails is normally mainly in shear and not tension. Thus our application is less onerous than the normal
concrete anchor. It is assumed that the total horizontal load from one wheel will be applied to one
discontinuous soleplate assembly. When the holding down bolt is used to fix the clip, it is assumed that
the horizontal force will all be applied to one bolt. When separate holding down bolts and clip fixing bolts
are used, the force is assumed to be carried equally by the total number of holding down bolts fixing the
soleplate. Continuous soleplates offer a very strong solution and it is seldom necessary to carry out
detailed calculations to check their strength.
BOLT TIGHTENING
Bolt tension after tightening should not be more than 85% of bolt proof load. For simplicity Gant rail use
the following approach. The design strength for embedment of a bolt is 25 mm for each tons of load to be
carried. However, the first 25 mm is ignored as it is typically weaker in tension or bearing. The lengths in
the table above should be sufficient to allow this tension. When tightening bolts, care should be exercised
as the ultimate pullout load may be reached if they are over tightened. There should be a safety margin
on the calculated torque to ensure the bolt or grout is not damaged. Torque wrenches are sometimes
inaccurate and should not be relied upon unless correctly calibrated.
HIGH STRENGTH ANCHOR BOLTS
Grade 8.8 holding down bolts are approximately 2.5 times as strong in tension than grade 4.6. Thus in
some applications they may be preferable. If these are to be tightened to 85% of proof load the suggested
bolt depths in concrete are at least as follows. A factor of safety should be added and care should be
exercised to ensure that tightening does not damage them.
Bolts Size (Grade 8.8) Depth in Concrete (mm)
M12 125
M16 225
M20 325
M24 450
CONTINUOUS SOLEPLATES
Continuous soleplates are normally used in the heavier applications. It is seldom wise to use less than 20
mm thickness for continuous soleplate as it is too flexible. The width is dictated by the rail width and the
clip size. The following table gives a guide to thickness; however, this needs to be considered in relation to
the rail in use and the crane duty.
Continuous Soleplate
Wheel Load
Thickness (mm)
Up to 30 Tons 20
30 – 45 tons 25
Above 45 tons 25 or more
Holding down bolts should be fitted in pairs between the pairs of clips. They are typically specified as
Grade 4.6 material. Alternatively, Grade 8.8 material may be used. However, this is seldom necessary to
meet strength requirements unless there is a local uplift condition. The lengths of bolts are the same as
defined for discontinuous soleplate fixing.
7.2 Rail Track Installation
a. Prepare necessary work permit prior to conduct the activity.
b. Prepare all tools and equipment needed during installation.
c. Provide scaffolding access prior to installation and alignment of crane runway
rail & girder.
d. Offloading of Rail
• Rail will be off loaded by Mobile Crane
• Rails to be lifted in banded bundles. Lifting chains to be double wrapped
around rail bundle. Good communication between fork truck driver and
slinger/signaler must be maintained at all times.
• Rails to be lifted from lorry and lowered onto wooden bearers at floor level in
designated storage area. A minimum of three wooden bearers to be used per
rail length.
e. Installation and Assembly
i. Installation of Runway Girder, Runway Rail and End Stoppers
• After finishing the installation of rail support structures, crane rails
shall be installed in accordance with drawing and manufacturer’s
instruction. See (V-2155- 501-A-820) and runway girders shall be
fixed firmly.
• Align rails cross section with centerline of runway girders.
• Assemble the rails with fastening bolts. Smooth driving condition
shall be achieved by accurately aligning the elevation of each rail.
• Rail shall be seated on runway girders. Check that no rail junction is
corresponding to a clip position. The minimum distance between any
joint and an expansion joint shall be as per project
specification/Engineers’ requirements. If necessary, cut the rail.
• Shim plates shall be used to adjust the elevation of the runway rails
under the runway girders. Shims shall be smooth and free of foreign
material including rust and shall be lightly lubricated before final
assembly. When shims thickness is equal to or greater than 1.5mm,
no more than three shim pieces shall be used between each runway
girder and girder bracket. Shim plate installation shall be followed
according to the manufacturer’s recommendations. The shims
material shall be stainless steel unless otherwise noted on the
manufacturer’s instruction.
• Install the end stoppers at the end of crane runway. The front edges
of the end stops must be flush with each other and be at right angles
to the crane runway.
ii. Installation and Welding of Runway Rail Clips
• The centerline of the rail must be used as the reference. Identify the
theoretical axis of the rail using piano wire, laser beam or other
equipment
• Clips should be installed in opposing pairs. They should never be
staggered.
• Clip Installation Sequence
❖ Install the bolt heads in the clips lowers and push as far as
possible
❖ Install the clip upper part and push it against the rail
❖ Install the nuts and finger tight
❖ Once the clip upper part is in position, use an impact wrench to
torque the nut, while holding the upper in place.
• Welding should be completed prior to pad installation as excessive
heat could damage the pad.
• Welding shall be conducted in accordance with the special
requirements in drawing or manufacturers instruction.
• Welding of clip’s lower part shall be followed in accordance with
relevant codes and standards.
• Do not paint between clip components. Clip spacing, distance of weld
to the edge of the steel plate, as well as corrosion protection will
depend on application; otherwise consult to vendor’s manufacturers.
• Gap between crane rails and rail lower clip shall be assembled in
accordance with manufacturer’s recommendation.
• After proper spacing of rail clip to runway rail, tack welds the clip on
both ends and in the middle. The lower components of the clips are
welded to the support structure. The actual weld size is dictated by
design thrust and should be specified by the vendor drawing. Verify
again the gap between rail clip and runway rail after tack welding with
the approval of QC inspector. Then proceed to final welding. Weld
type shall be accordance to vendor drawing.
❖ Weld “Y” on the back and sides of the clip may be as large as
required to accommodate the imposed side thrust and to meet
governing code requirements.
❖ Welds “X” & Z on the side facing the rail may not exceed the
indicated values. This will avoid any interference with the
locating lug on the upper component or the rail.
❖ Weld Z on the side along the rail is not applicable if no pad is
used. The foot of the rail may touch the weld. If the weld size or
lengths are reduced, the full capacity of the clip might be
jeopardized.
• Bolt torquing for rail clips shall be performed in accordance with
manufacturer’s
• instruction
f. Tolerance for Alignment of Rail
• The maximum out of parallel horizontal alignment between rails on opposite
sides of Crane track tolerances shall be as per Manual recommendation.
• The maximum horizontal deviation from a specified straight line, from end to
end of the total length of rails on each side of runway or at any point within the
total length does not exceed ± 1 mm per 2m or otherwise specified by vendor’s
manufacturer’s manual.
• All rails shall be set level at the specified elevation within the maximum
deviation of ±3mm.
• Vertical alignment for runway rails shall be met the following requirements or
the requirements of the crane supplier. Height variance between two rails shall
be 0.15% of total span (max.10mm) between two rails.
• Height difference or length unevenness for a rail should not exceed to ±1 mm
per maximum length of 2 meter.
8. QUALITY CONTROL AND ASSURANCE
• Inspection shall be conducted and recorded in accordance with the Job
Specification Inspection and Test Plan.
9. SAFETY INSTRUCTIONS & PRECAUTIONS
• Make sure that all necessary work permits are issued.
• Check all lifting equipment prior to commencing lifting activities.
• Stay away from any suspended load/falling objects
• Wear full body harness when working at elevated platform.
• Install safety nets when necessary.
• Ensure that barricades and warning signs are properly installed.
• Ensure that there are no hazardous or combustible gases present in the work
area.
• Install flashing lights to traffic.
• Copy of approved JSA to be maintained at work site by Work Supervisor.
Conduct daily Tool Box Talk and discuss work methodology prior to
commencement of work.
• Implement and monitor safety instruction on site.
