guide to installation and fastening 7 WELDING PROCEDURES 7.1. STUD WELDING GWS - 01 SPECIFICATION FOR WELDING STUDS PROCEDURE NO. GWS.01 ‘SCOPE: This Procedure covers the requirements for welding studs in the size range M16 to M24 to structural steel members to which crane rails are to be fixed PLANT: Electric arc welding sets, AC or DC with a capacity of, or in excess of 250 amps. WELDING CONSUMABLES: Low hydrogen electrodes are to be used. They are to be from sealed packets or are to be re- baked in accordance with the makers instructions. Classification AWS AS,1-91:£7000 HAN EN 499-94:EN42 4 B53 HS PREPARATION: 1. The posttion for the studs to be fixed shall be marked out and a deep centre ‘punch mark shall be made according to the contract requirements. 2. Check that the supporting steel is clean andi tree from paint, rust, oll, grease or other contaminants. If tis contaminated it shal be ground to bare metal but without removing the centre punch mark. The area shail be ary. 8. For plato thickness of more than 25mm and less than 50mm, pre-heating is required. An area of radius 4.x the plate thickness shall be heated to 100°C minimum, Check with tempstick For plate thickness above 50mm or where otherwise directed by the customer a higher preheat temperature shall be used. This shail be determined using local codes of good practice. 4. When the ambient temperature is befow 5°C, when there has been recent rain or When there is the possibilty of condensation ‘on the steal work, the stee! shall be preheated as in 3 above. 5. Welding shal not be undertaken in rain. WELDING: 1. Tack weld the stud into position with two tacks, 2. Complete the fillet weld around the stud according to the requirements of he clip as set out below or as they may be varied for the purpose, 8. De-slag the weld. Welding Details Stud Size Weld Dimension mm Electrode Welding Current ‘Throat Thickness —_Leg Length ‘size mm Mi6 3 42 32 115 M20) 4 568 165 M24 48 63 5 180 INSPECTION: Visually examine welds, cracks, porosity, slag inclusion and porosity are not acceptable. Undercut shall not exceed 0.5mm. ‘Approved: _. 6 Date“©.Gairy Rang Lied 2004 guide to installation and fastening "aN Space 7.2 BASE WELDING GWS - 02 PREPARATION: SPECIFICATION FOR WELDING 1. The position for the olip bases to be GANTRAIL TYPE 9 CLIP BASES ‘xed shall be marked out according to the PROCEDURE No. GWS.02 contract requirements. ‘SCOPE: 2. Check that the supporting steel is clean and This Procedure covers the requirements ‘fee from paint, rust, ol, grease or other for welding Gantrail type 9 Clip Bases to contaminants. itt is contaminated it shall be structural steel members to which crane rails, {ground to bare metal but without removing are to be fixed. the centre punch mark. The area shall be dy. PLANT: Electric arc welding set, AC or DC with a capacity of, or in excess of 260 amps. 8. For plate thickness of more than 25mm and less than 50mm, pre-heating is required. An area equal to the clip bases plus two imes the plate thickness around the base WELDING CONSUMABLES: shall be heated to 100°C minimum. Low hydrogen electrodes are to be used. Check with ternpstick. They are to be from sealed packets or are to be For plate thickness above 50mm or re-baked in accordance with the makers. Where otherwise directed by the customer a instructions. higher preheat temperature shall be used. Classification This shall be determined using local codes of 00d practice. AWS AS. 1-91:£7028 HAR EN 4y9-94rENa? 4 Bod Ho Welding Details CLIP TYPE | WELDING METHOD. 9116/08 | Weld all around the base except side next to and parallel with rail with 4mm throat thickness fillet weld. 9116/10 | Weld all around the base except side next to and parallel with rail with mm throat thickness fillet weld. 9120/15 | Weld all around the base except side next to and parallel with rail with 4mm throat thickness fillet weld. 9124/20 | Weld all around the base except side next to and parallel with rail with Smm throat thickness fillet weld. 9216/08 | Weld along back and sides of clip base to be 4mm and in ‘V" next to rail 3mm throat thickness fillet weld, (9220/18 | Weld along back and sides of clip base to be 5mm and in ‘V" next to rail 3mm throat thickness fillet weld. 9220/20 | Weld along back and sides of clip base to be Smm and in ‘V’ next to rail 3mm, throat thickness fillet weld. "Note: Whon te epesttoaton cas for ter to be no stop eta positon onthe comptes weld 16 accaptable to wold long the sdbe which oret haves weld specttacin the tabla above, Censut Gaal fr deals. INSPECTION: Visually examine welds, cracks, slag inclusion and porosity are not acceptable. Undercut shall not exceed 0.5mm. Approved: _. Dateguide to installation and fastening 4, When the ambient temperature is below 5°C, when there has been recent rain or when thera is the possibilty of condensation on the steel work, the stee! shall be preheated as in above. 5. Welding shall not be undertaken in rain. WELDING: 1. Tack weld the cllp base into position with two tacks, 2. Complete the filet weld around the base according to the requirements for the lip ae set out below or as they may be varied for the purpose. 3. De-slag the weld, (previous page) 7.8 JOINT WELDING (WITHOUT PAD) Gws - 05 WELDING PROCEDURE FOR WELDING OF CRANE RAILS BY THE ENCLOSED OR PUDDLE ARG METHOD PROCEDURE NO. GWS.05 SCOPE: This Specification covers the site welding of steel crane rails, items covered include welding process, technique, pre and post heating equipment requirements, filler materials and inspection requirements. CRANE RAIL MATERIAL: It is essential to know the composition and particularly the carbon content of crane rails. They shall only be welded after study of their relevant materials certificate. WELD PREPARATIONS: 1. Weld preparations for butt welding shall be [produced by sawing square the rail ends, Flame cut rails ends are only acceptable by prior agreement. They shall be clean and tree from defects, grease or paint and shall be free from rust and scale for a distance of 150mm either end thom the side of the weld. They shall be aly. 2. The butt weld preparation shall be square butt with a nominal 16mm gap between adjacent rail enas. a JOINT ASSEMBLY: AA joints shall be assembled on site and held together by the clipping of track to the rail ‘support. The rails are set with a slight camber at the joint to allow for weld contraction. The ‘amount of this shall be determined by test or shall be based on experience. Copper moulds will be placed around and under joint. Welding of the bottom flange is to be carried out prior to inserting of copper in the web area of the rail HEAT TREATMENT: PRE-HEAT TREATMENT ‘The rails shall be pre-heated for a distance of 150mm either side of the joint. The temperature is to be maintained throughout welding. The pre-heat ternperature shall be dependant on the carbon content of the rail as follows: Carbon Content —_—Pre-Heat Temperature up to 0.5% 200°C 0.5% - 0.7% 300°C 0.7% - 0.8% 360°C Above 0.8% Consult Project, Engineer and/or Gantrail WELDING PROCEDURE AND TECHNIQUE: 1. Butt weld shall be caried out using the ‘enclosed welding method. This uses a ‘modified manual metal arc process. The welding supply rector or generator shall be of the direct current type with the electrode ‘connected to the positive terminal, 2, Weloing electrodes shall be proprietary rail welding type. Currents shall be 2 specitied by the electrode maker for the size of rod in use. The base of the rail shall be welded with 3.2mm electrodes. Subsequent passes may use Smm or 6mm electrodes. 8. Before the copper mould pieces are placed in position any pad below the rail must be protected using a refractory insulated tyoe sheet. A mild steel strip (@mm x 15mm x the rail foot width) shall be placed at the bottom of the joint on top of the copper plate. This will become part of the joint.“©.Gairy Rang Lied 2004 guide to installation and fastening oF GANTRAII The weld formed by the side of the rail foot is contained on both sides with the aid of copper biocks. A gap of 1.6mm is allowed between the rail and the copper blocks. On completion of the welding at the base of the rail t shall be de-slagged. Copper moulding pieces are placed on the foot and an both sides of the web in such @ Way that @ gap approximately 1.5mm is left between the wen of the rail, The web of the rail is then welded. On completion, the moulds are put into place against the web of the rail ensuring a gap of 1.5mm is maintained between the rail and the copper block. The electrode is held perpendicularly and short rectangular movements are desenibed with the tip of the electrode. A short arc is required throughout the process. The welding {s continued until the weld metal is above the rail surface, The weld Is then de-slagged. On completion, tho wold io ground to tho profilo. of the head Where welding is halted for more than a fow seconds due to placements of additional copper moulds, or other reasons, slag shall be removed and the weld wire-brushed before recommencement of welding. The pre-heat temperature shall be checked. POST-HEAT TREATMENT: This is dependant on rail carbon content. Up to 0.6% air cool but protect from rain, wind, ete above 0.6% insulate with refractors thermal blanket of 25mm thickness. This to be left in place for at least 4 hours. WELDING CYCLE: The welding cycle, when necessary, will be maintained by the utilisation of two welders producing as near as possible continuous welding throughout, WELDING CONSUMABLES: 1, Electrodes for the process shall be as follows: al Mowing Soe For rail composition up to 0.6%, carbon Metrode Rairod, Philips EW or Filarc R56. For rail compositions with up to 0.8%, carbon ‘Metrode Rairod. 2. Electrodes shail be kept in a heated quiver prior to use, Open packets shall be ra-baked if they have been open for more than 24 hours in accordance with the manufacturers instructions. Damaged electrodes or those that have been wet shall be discarded. INSPECTION AND WELDING: ‘All welds shall be subject to close visual examination and shall be free from the following detects: Surface lack of fusion Cracking Underout hal not excoed 0.6mm Surface breaking porosity When non-destructive testing is called for, the defect levels shall be agreed before welding and testing is commenced. Standards shall be based on achievable quality in sample and production welds. Approved: Date: 7.4 JOINT WELDING (WITH PAD) GWS - 08 WELDING PROCEDURE FOR WELDING OF CRANE RAILS BY THE ENCLOSED OR PUDDLE ARC METHOD PROCEDURE NO. GWS.08 (For rails mounted on a resilient pad only) SCOPE: ‘This Specification covers the site welding of steel crane rails, items covered include welding process, technique, pre heating, post weld heat treatment, equipment requirements, filer materials and inspection requirements,guide to installation and fastening CRANE RAIL MATERIAL It is essential to know the composition and particularly the carbon content of crane rails. ‘They shall only be welded after study of their relevant materials certificate. WELD PREPARATIONS: 1. Weld preparations for butt welaing shall be produced by sawing square the rail ends. Flame cut rails ends are not acceptable. They shall be clean and free from defects, grease Or paint and shail be free from rust and scale for @ distance of 150mm either end from the side of the weld. They shall be cry 2. The butt weld preparation shall be square butt with @ nominal 15mm gap between adjacent rail ends. JOINT ASSEMBLY: Al joints shall be assembled on site and held together by the clipping of track to the rail support, The rails are set with a slight camber at the joint to allow for weld contraction. The ‘amount of this shall be determined by test or shall be based on experience. Copper moulds will be placed around and under joint. Welding of the bottom flange is to be carried out prior to inserting of copper in the web area of the rail HEAT TREATMENT: PRE-HEAT TREATMENT The rails shall be pre-heated for a distance of 150mm either side of the joint. The temperature is to be maintained throughout welding. The pre-heat temperature shall be dependant on. the carbon content of the rail as follows: Carbon Content —_Pre-Heat Temperature up to 0.5% 200°C 0.5% - 0.7% 300°C 0.7% - 0.8% 360°C Above 0.8% Consult Project Engineer and/or Gantrall WELDING PROCEDURE AND TECHNIQUE: Butt welding shall be cartied out using the enclosed welding method. This uses 2 2 ‘modified manual metal arc process. The welding supply rectitier or generator shal bo of the direct current type with the electrode connected to the positive terminal. Welding electrodes shall be proprietary rail welding type. Currents shail be as specified by the electrode maker for the size of rod in use. The base of the rail shall be welded with 8.2mm electrodes. Subsequent passes may use Smm or 6mm electrodes. Before the copper mouid pieces are placed in position any pad below the rail must be protected using a refractory insulated type sheet. A mild steel strip (6mm x 50mm x the rail foot width) shall be placed beneath the Joint on top of the copper plate. This will become part of the joint. The weld formed by the side of the rail foot is carried out using a Manual Metal Arc welding technique. The weld sequence is shown on the attached schematic drawing. ‘Copper mould pieces are placed an the foot and on both sides of the web in such a way that a gap approximately 1.5mm is left between the web of the rail. The web of the rail is then welded. On completion, the moulds are put into place against the web of the rail ensuring a gap of 1.5mm is maintained between the rail and the copper block. The electrode Is held perpendicularly and short rectangular movements are described With the tip of the electrode. A short arc is required throughout the process. The welding ‘is continued untl the weld metal is above the rail surface, The weld is then de-slagged. On ‘completion, the weld is ground to the profile of the head. Where welding is halted for more than a few ‘seconds due fo placements of additional copper moulds, or other reasons, slag shall be removed and the weld wire-brushed before recommencement of welding. The pre-heat temperature shall be checked.guide to installation and fastening al Mowing Soe POST WELD-HEAT TREATMENT: This is dependant on rail carbon content. Up to 0.6% _ air cool but protect from rain, wind, etc above 0.6% insulate with refractory thermal blanket of 25mm thickness. This to be left in place for at least 4 hours. WELDING CYCLE: The welding cycle, when necessary, will be maintained by the utilisation of two welders producing as near as possible continuous welding throughout. WELDING CONSUMABLES: 1, Electrodes for the process shall be as foliows: For rail composition up to 0.6% carbon- ‘Metrode Railrod, Philips EWG or Filarc R56. For rail compositions with up to 0.8% carbon- Metrode Ralrod, 2. Flectronies shall be kept in a heated quiver prior to use. Open packets shall be re-baked if they have been open for more than 24 hours in accordance with the manufacturers instructions. Damaged electrodes or those that have been wet shall be discarded. INSPECTION AND WELDING: All welds shall be subject to close visual ‘examination and shall be free from the following defects: Surface lack of fusion Cracking Undercut shal not exosed 0.5mm Surface breaking porosity When non-destructive testing is called for, the defect levels shall be agreed before welding and testing is commenced. Standards shall be A based on achievable qualy in sample and i production welds. i Approved: 5 é Date: