Gantry rail welding is a meticulous and skilled-operated process, essential to the final construction of bridges and large infrastructure projects. Gantry welding must create sturdy welds to protect traffic flow while remaining structurally sound for use by other forms of traffic. Therefore, different procedures are used during gantry welding processes in order to achieve durable yet strong welds that provide safety to traffic on bridges and infrastructure projects.
For years, industry had relied on flame cutting machines to weld bridge girders and large components of bridges. While such machines can be effective, their substandard welds often result in failure of critical structural components, which could cause their collapse and lead to massive financial damages, lost lives, and productivity issues. In contrast, the Gantry Rail Dual Welding Station offers a modern solution, overcoming the limitations of traditional flame cutting machines by delivering precise, high-quality welds. Furthermore, using bulky and mechanically operated machines was often both risky and time-consuming, making the Gantry Rail Dual Welding Station a safer and more efficient alternative for large-scale infrastructure projects.
Some companies have turned to robotic systems utilizing dual welding heads in order to enhance the quality of gantry welds. This system dramatically decreases time needed to complete jobs while increasing production without sacrificing quality or precision – for instance a welding team using such an arrangement can weld two pieces of rail together in five minutes while traditional techniques may take up to 15 hours!
This technology not only reduces costs for project managers but also significantly boosts productivity by eliminating additional equipment needs and increasing productivity; in turn, lowering distortion of welds, directly impacting their long-term stability of bridge girders. Furthermore, using robotic systems allows more efficient welding which significantly lowers labor costs while speeding completion times.
Joining rails together requires multiple welding methods, such as flash butt and enclosed arc welding. Which you use depends on factors like site layout, project timeline and budget as well as whether or not it allows joining different sections of a bridge to prevent damage to wheels and mechanical parts.
Enclosed arc welding and aluminothermic welds are popular ways of joining crane rails together. Both methods require significant skill and training, yet both provide high-quality welds with good consistency, reduced welding times, and excellent aesthetic results. Aluminothermic welds use refractory moulds around two square cut rail ends that is preheated before filling any gap of about 20mm using chemically heated charges of molten steel which fills the mould while any excess is discharged into slag bowl.
EVS’s welding team can save up to 15 hours when using the aluminothermic welding process on large projects like overhead crane builds by using this efficient welding method; this efficiency directly translates to increased profitability without compromising accuracy or quality. Furthermore, this form of weld also minimizes waste disposal while producing consistent welds with excellent weld quality.