行车轨道安装Crane track installation.doc

天车轨道安装
Crane track installation
1.轨道安装流程：Track installation flow:
材料进场验收、检验
吊车梁交接验收
测量放线
压板底座焊接
焊接连接
伸缩缝施工
轨道接头连接
对应侧调整固定
轨道摆放就位
一侧轨道调整固定
材料进场验收

Measuring & setting out
Hand-over acceptance of lifting crane beam
Acceptance & inspection of arrived materials

Track in-place
Welding of pressure plate base
Adjustment and fixing of one-side track

Expansion joint construction
Track joint connection
Adjustment and fixing of opposite side

Welding connection

2.轨道梁验收： Track beam acceptance
根据上道工序（结构安装）的工序交接资料，对轨道梁进行复测验收。
Carry out re-measurement and acceptance of track beam according to hand-over documents of last working procedure.
3．天车轨道放线：Setting out of crane track
根据工序交接给定轨道梁中心点，用经纬仪在轨道梁上打点。然后放出一条安装基准线，用钢盘尺测出轨道的跨度，在另一个轨道梁上放出轨道安装的另一条基准线。
Mark center point on track beam by using theodolite according to hand-over of working procedure; then, set out an installation base line and use steel tape to measure out track span; and set another base line for track installation on another track beam.
4. 压板选用及焊接selection and welding of pressure plate
根据图纸要求，选用焊接型轨道固定件，底座、压板及调整板为Q235或Q345钢铸件，螺栓为8.8级；固定件底座与吊车梁焊接，焊条型号选用与连接件材质相适应。如选用Q235或Q345钢时分别采用E4315、E7015型焊条。
According to drawing requirements, select welding type track fixed pieces; foundation, pressure plate and adjustment plate are Q235 or Q345 steel casting pieces; screw bolt is 8.8 grade; foundation of fixed part is welded with crane beam and welding rod type selects those corresponded to materials of connecting piece. If Q235 or Q345 steel is selected, E4315 and E7015 welding rods shall be used respectively.
安装轨道前，根据安装基准线在轨道的两侧布置压板，压板间距按照《吊车轨道联结及车挡》 05GJ25要求间距600mm进行底板定位，然后焊接；要求为中级工作制吊车采用两侧焊缝，重级工作制吊车采用三面围焊缝，焊缝质量应符合三级焊缝外观质量标准。
Before track installation, arrange pressure plate, at both sides of the track according to installation base line; pressure plate distance is 600mm in accordance with requirements in Crane Track Linkage and Car Stop 05GJ25 to carry out base plate location and welding. It is required that intermediate duty crane adopt two-side welding while heavy duty crane adopt three-side welding; welding quality should follow three-level welding appearance quality and standard.
5．轨道吊装：Track lifting and installation
轨道吊装可根据吊装环境、地点、重量选用汽吊进行到场吊装，卸车时垫以枕木，使轨道立放，避免存放变形。
Track installation can select truck crane according to lifting environment, place and weight; use sleeper when unloading and put track in upright direction to avoid deformation during storage.
a、 起吊重量=每根轨道重+钩重+钢丝绳重量
Lifting weight = each piece of track weight + hook weight + steel wire rope weight
b、 起吊高度=轨道标高+1.5米
Lifting height = track elevation + 1.5m
所有的轨道都必须从厂房内侧吊装。
All tracks should be lifted from inner side of workshop
6、轨道调整track adjustment
用千斤顶或撬棍先两端后中间调整到要求数值后固定，再用盘尺按照轨距数值调整另一侧轨道，方法相同。轨道找正后应把紧所有连接螺栓并无松动现象。
Use lifting jack or crowbar to adjust from both ends to the middle to required value before fixing; then use tape to adjust the other side of the track according to track gauge value; the method is the same. After the alignment of the track, screw tight all connecting bolt without loosening.
7、轨道焊接接头施工工艺
Construction technique of track welding joint
按照业主要求，轨道接头焊接接头，要求轨道布置时同一车间内对应轨道接缝位置应错开，其错开的距离不应等于天车前后车轮的基距。
According to client’s requirements, track joints should be welding joints; it is required that when arranging track, corresponding track joints should be alternated within one shop; alternating distance should not be equal to basic distance of front and rear wheels of the crane.
7.1钢轨焊接变形的控制control of steel track welding deformation
在施焊过程中钢轨接头将向下弯曲变形，预先采用赤铜板和钢垫板将钢轨端头垫起40–60㎜，利用已制作好的螺栓和压板等连接件拧紧螺母使钢轨固定在吊车梁上，每一条钢轨接头附近应至少设置4处固定点。当焊完轨底部分以后，松开压板，将钢轨端头的垫起高度降低到10㎜，再拧紧压板螺母。当轨腰部分焊完后，拆除全部垫板并松开压板，此时钢轨接头应该有很小的上挠值，在施焊轨头过程中，根据钢轨恢复平直的情况，决定是否再拧紧压板螺母。在全部施焊过程中，须随时用直钢板尺检查钢轨接头的变形情况，随时调整接头的垫起高度和松紧压板来控制钢轨接头的焊接变形。在施焊前固定钢轨端头时，两根钢轨端头之间是上宽下窄，以轨底间隙为标准，不得小于12㎜也不易过宽，一般控制在12～14㎜范围内。
During welding, steel track joint shall be bended and deformed downward; red copper plate and steel plate shall be adopted in advance to underlay up steel track ends to 40–60㎜. Use manufactured connecting pieces like screw bolt and pressure plate to screw tight bolt to make steel track fix on crane beam; at least 4 fix point should be set near each steel track joint. After welding of track bottom, loosen pressure plate and lower steel track end to 10mm and then screw tight bolt of pressure plate. After finishing welding of track waist, all base plates should be removed and pressure plates should be loosened; by this time, steel track joint should have very small upwarp value. During welding of track head, decide whether pressure plate bolt should be screwed tight again according to recover conditions of steel track. When welding front fixed steel track end, the condition between two steel track ends is upper wide and lower narrow taking track bottom gap as standard to be no less than 12mm and not too wide. Generally, the width should be controlled within 12～14㎜.

7.2预热与回火处理pre-heating and tempering treatment
预热与回火均采用普通的气焊喷嘴围尧轨头，轨腰和底部反复进行加热。两根钢轨端头的预热范围各为20～30㎜，预热温度为250℃左右。钢轨焊接接头的回火温度为600～700℃，从焊缝中心算起两边各为40㎜左右作为回火处理的范围。回火温度达到要求后，立即用装有石棉灰的保温箱包起，使其缓冷到常温，便于拆装的轻型保温箱可用一块石棉底板和两块木制的侧壁板组合而成。
Preheating and tempering adopt ordinary gas welding nozzle around track head; heating is carried out repeatedly on track waist and bottom. Preheating range of two steel track ends is 20～30㎜ respectively and preheating temperature is around 250℃. Tempering temperature of two steel track welding joints is 600～700℃; Calculated from welding joint center, two sides are 40mm or so as tempering treatment range after tempering temperature reaching requirements, use heat preservation box with asbestos to cover it up and make it slow cooling to normal temperature. Light heat preservation box which is easy to dismantle can be assembled with one piece of asbestos and two pieces of wooden side sheets.
7.3焊接工作welding work
每焊接一个钢轨接头，需要电焊工和清洁工共两个人配合进行，气焊工只在预热与回火时才进入现场工作。施焊的好坏和清渣是否干净是影响钢轨接头焊接质量的决定因素。焊接钢轨接头的顺序是由下而上，先轨底后轨腰、轨头，最后修补周围。焊接轨底时用的赤铜垫板和焊接轨腰、轨头时用的赤铜板与赤铜托板。赤铜夹板和赤铜托板的宽度为80㎜，厚度为10㎜左右，其弯曲形状应与钢轨外形相吻合。
Each welding of steel track joint needs cooperation between an electric welder and a cleaner.gas welder only enters the site to work for preheating and tempering. Welding skills and cleaning of slag are decisive factors for steel track joint quality. The order of welding steel track joint is from bottom to top, track bottom first before track waist, track head and finally maintenance around. Red copper base plate used for welding track bottom as well as red copper plate and red copper supporting plate used for welding track waist and track head.
Both red copper plywood and red copper supporting plate are 80mm wide and around 10mm thick; their bending shape coincides with steel track appearance.

焊接材料采用直径4㎜碱性焊条(符合GB/T5117、5118-1995规定的E7015、E7016)焊接钢轨接头，焊条须在直流电焊机上反极使用。施焊轨底的第一层焊波时，使用电流稍大（180-200安培）以便容易焊透和排渣；以后几层焊波可以使用160-180安培电流，每焊完一层焊波必须把焊渣清除干净后才能继续施焊。轨底焊完后将赤铜夹板紧密贴与轨腰两侧，夹板上的槽与钢轨间隙对正。使用150-170安培电流，从轨腰的下部向上施焊。每焊完一根焊条便于取下赤铜夹板清除焊渣；赤铜夹板用水冷却并清除粘滞的焊渣后，再重新贴在钢轨两侧继续施焊。这样重复进行到把轨腰焊满为止。将赤铜托板安装好以后开始焊接头。每焊完一层焊便取下托板清渣一次，直至焊完为止，使用电流150-170安培。最后对焊缝周围未焊饱满之处进行补焊。在施焊每层焊波时，尤其在施焊轨底的每层焊波时，应使用一根焊条焊完，中间应避免因焊条而断狐，前后两层焊波的施焊方向应相反。
Welding materials adopt basic electrode with diameter 4mm (E7015&E7016 following GB/T5117 & 5118-1995 specifications) to weld steel track joint; electrode should be used in reversed polarity on DC electric welding machine. When welding the first layer of weld ripples, relatively large electric current (180-200ampere) should be applied to make it easy for thorough welding and deslagging; and later several layers can apply 160-180 ampere electric current. Each completion of welding one layer of weld ripple, welding slag should be cleaned before going on. After welding of track bottom, put red copper plywood closely to both sides of track waist and groove on plywood should be in alignment with steel track gap. Apply 150-170 ampere electric current to welding track waist from bottom to top. With completion of each electrode, red copper plywood can be taken out to clean slag; after red copper plywood is cooled by water and slag cleaned, re-put it closely to both sides of steel track for welding repeatedly till welding is full on track waist. Start welding joint after installation of red copper supporting plate. Each completion of welding one layer of weld ripple, welding slag on supporting plate should be cleaned before going on till completion; 150-170 ampere electric current is used. Finally, repair welding is carried out on places where welding around welding joint is not full. During welding of each layer of weld ripple, especially during welding each layer of weld ripple at track bottom, one electrode should be used for completion.
每个钢轨接头的焊接工作应连续进行，以使钢轨端头保持有较高的温度。如因故中途长时间停焊时，在再次焊接前须重新进行预热。钢轨接头不宜在低温环境内进行焊接工作，如在冬季施工时，应采取措施使钢轨接头在施焊与热处理过程中，避免急剧冷却现象。在焊接过程中，采用合适的扁钎和小榔头打掉焊渣，渣沫可用压缩空气吹净。已烧热的赤铜夹板和赤铜托板是用长柄钳取下并在水桶里沾水冷却。
Welding work of each steel track joint should be carried out continuously to make steel track end keep relatively high temperature. If for some reason welding is stopped in the midway for quite a long time, preheating should be carried out again before re-welding. Welding work of steel track joint should not be carried out under low temperature. If construction has to be carried out in winter, measures should be taken to avoid drastic cooling during the process of welding and heat treatment of steel track joint. During the process of welding, adopt appropriate flat drill and small hammer to remove welding slag and skim can be blown clean by compressed air. Burnt red copper plywood and red copper supporting plate are taken off by using lazy tongs and put into water bucket for cooling.
7.4钢轨焊接接头的磨平处理
Grinding treatment of steel track welding joint
钢轨焊接接头已回火并冷却到大气温度以后，对轨头的顶面及两侧面的焊缝应进行磨平处理。当焊缝凸起过大时，可先用扁铲将焊波铲除一部分，然后用电动手持砂轮将焊缝磨到与钢轨头平齐，最后用锉刀或细沙纸将表面磨光滑一些，消除大的刻痕。
After steel track welding joint has tempered and cooled to free air temperature, welding joint at top and two sides of track head should be treated by grinding. When welding joint is projected out too much, flat spade can be used first to remove some weld ripple; and then use motor-driven hand-held grinding wheel to grind welding joint to parallel level with steel track head. Finally, use file or fine sand paper to grind smoothly the surface to eliminate large scratch.
8、伸缩缝处理方式handling measures for expansion joint
按照《吊车轨道联结及车挡》05GJ25要求伸缩缝位置将轨道切割成45度斜口，打磨平整，压板固定。详见后附图。
Cut the track into 45 degree diagonal cutting in accordance with requirements in Crane Track Linkage and Car stop 05GJ25; grinding flat, fix pressure plate. Details refer to the attached drawing behind.
同一车间同一列线对应轨道伸缩缝应布置在车间伸缩缝两侧。
The same row line in alignment with track expansion joint in the same workshop should be arranged at both sides of workshop expansion joints.
9、调整轨道的主要要求如下：Major requirements for track adjustment are as follows:
（1） 轨道中心线位移偏差≤±5mm
Track center line displacement deviation ≤±5mm
（2） 轨道中心线跨度允许偏差△S应按下式计算，
Track center line span allowable deviation △S should be calculated according to following formula.
∆S=±【3+0.25（S－10）】 ，但最大不应超过10 mm。
∆S=±[3+0.25（S－10）], but the maximum should not be larger than 10mm.
式中：△S—起重机跨度允许偏差（mm） S—起重机轨道跨度（mm）
In the formula: △S— crane span allowable deviation (mm); S—crane track span (mm)
（3） 厂房横向同一跨间同一位置上两条轨道顶面的标高差，在轨道梁支座处≤10mm,在轨道梁其他处≤15mm；
Elevation deviation of two track top at the same place in the same span in transverse direction of the workshop is ≤10mm at track beam support and ≤15mm at other places of track beam.
（4） 两相邻的吊车轨道端面相互间的偏移应≤1mm。
Mutual deviation of two adjacent crane track end should be ≤1mm.
10．安装检查标准inspection standard for installation
保证项目
Guaranteed items
项次
项目 item
简要措施measures
1
轨道及其附件的材质、规程、型号必须符合设计要求，并有合格证
Materials, regulations, and types of the track and its accessories should follow design requirements and be with quality certificate
1、 安装所用一切材料必须严格验收和入库、出库制度，没有出厂合格证书不得发料施工。
2、严格执行工序间交接制度，对吊车梁进行全面细致的检查和验收，经复测和验收合格方可施工。
1. Materials used for installation should be carried out with strict acceptance and have storage and delivery system; construction should not be carried out with materials without quality certificate.
2. strictly carry out hand-over system among working procedures; carry out comprehensive and careful inspection and acceptance on crane beams; construction can only be carried out after re-measurement and qualified acceptance.

基本项目
Basic items
项目item
简要措施measured
1
轨道与钢梁间接触应符合规范要求。
The contact between the track and steel beam should follow regulations
1、 垫板与基础及轨道与垫板之间接触面积应大于60％局部间隙不应大于1mm，达不到必须进行研磨。
1. The contact area between base plate and foundation as well as the track and the base plate should be larger than 60%; local gap should not be larger than 1mm; if it cannot be satisfied, grinding should be carried out.
2、 材料进厂时要严格检查，按规范严格施工。
2. Strict inspection should be carried out on materials arrived and strict construction should be carried out as per regulation.
3同一端的两车挡与行车撞头必须同时接触。
3. Two car stops at the same end should be in contact at the same time with crane ram.

2
轨道及紧固件应符合规范规定。
Track and fastener should follow regulations
3
车挡安装应符合规范规定。
Car stop installation should follow regulations
极限偏差和公差项目
Limit deviation and allowance items
项目item
极限偏差（mm)
Limit deviation (mm)
检验方法
inspection method
1
轨道的实际中心线对安装基准线的水平位置的偏差。
Deviation of actual center line of the track to installation base line
≯5
拉钢丝线、吊线锤用钢板尺检查。
Pull steel wire and plumbing bob and use steel ruler to check
2
轨距 track gauge
±3－5
用弹簧秤拉钢盘尺检查
Use spring scales and steel ruler to check
3
轨道纵向倾斜度
Track longitudinal inclination
1/1500全程5－10
Whole course
用水准仪和塔尺每6米检查1点。
Use surveyor’s level and leveling rod to check one point every 6m
4
两根轨道相对标高
Relative elevation of two tracks
5－10
用水准仪和塔尺检查。
Use surveyor’s level and leveling rod for inspection
5
轨道接头处上、左、右三面的偏移
Track joint deviation at three sides
1
用钢板尺和塞尺检查。
Use steel ruler and feeler gauge for inspection
6
伸缩缝间隙expansion joint gap
±1
用钢板尺检查use steel ruler for inspection

一：轨道接头可以做成直的或45度斜的，斜接头可使大车轮在接头处平稳过渡。正常街头的缝隙为1-2毫米，在寒冷地区冬季施工或安装前的气温低于常年使用气温20度以上时，应考虑温度缝隙，在单根钢轨长10米左右时可取4-6毫米（包括正常缝隙）
1. Track joint can be made into straight or 45°inclined which can make big wheels experience smooth transition. The joint of normal joint is 1-2mm; for winter construction in cold region or when temperature before installation is more than 20°lower than temperature year-round, temperature joint should be taken into consideration. The joint can be 4-6mm (including normal joint) when single steel track is around 10m long.
二：接头处两轨道的横向错位和高低差均应小于等于1毫米
2. Transverse displacement and height difference of two tracks at the joints should be smaller than or equal to 1mm.
三：在同一截面上的轨面高低差：对桥式起重机。在柱子出不超过10毫米在其他处不得超过15毫米，门式起重机不得超过1