Thermite Welding ASRS, AGV, Activ, WMS

Retrotech Thermite Welding: Reasonable Solutions to AS/RS Challenges. Quality is the foundation of the products and services provided by Retrotech.

Retrotech’s phased installation approach minimizes disruption of plant operations.

1. Preliminary Evaluation: Our engineer is dispatched to the site to evaluate the existing rail design and current condition. Detailed project designs are prepared and submitted to the customer for approval. All materials are ordered based on the customer-approved Bills of Materials.
2. Project Preparation: The existing aisle floor is surveyed. Elevations at the pad locations are measured with a laser optical system. From the data, our engineers calculate the quantity and thickness of additional shim packs required for each location. This validates the correct positioning of the rail to the rack for proper storage and retrieval of loads.
3. Thermite welding process: The rail joints are thermite welded. As part of the preparation, sections of engineered rails are matched, assembled, and clamped in place with the extrusion profile direction matched to assure joint continuity. Careful preheating and post heating of the joints is done to assure joint continuity. Careful preheating and post heating of the joints is done to assure maximum joint integrity. Upon completion of the weld, the rail is precision ground in the area of fusion to assure correct rail contour.
4. Retrofit installation- All of the old hardware and rail is removed. New rails are installed. New anchor bolt holes are template-drilled and vacuumed to remove all concrete dust prior to installation of new Grade 5 epoxy anchors. New shims are installed as specified by the engineer to provide optimum elevation.
5. Rail Alignment and Adjustment: A final laser alignment and clamping of the rail is made and hold-down nuts are firmly torqued. A visible beam, rotating beacon laser transit is used to provide highly accurate rail alignment based on pre-established reference points. Aisle measurements are taken in two-foot increments to assure that the rail is in near perfect alignment-epoxy grouting if required is infused at this point. Any crane wheel alignment problems are identified.
6. Review, Approval, and Thermite Welding Service: Customers review and approve all installations. Support documentation is provided to assure customer awareness of proper maintenance procedures for an extended rail life.

The Thermite Welding Process:

Uses high temperature chemical reaction to heat rail joints to their fusion point, assuring a complete joint weld.
Precision grinding of finished welds assures correct rail contour.
Creates a continuous rail for the entire length of the aisle.
Eliminates excessive shock load damage to electrical and mechanical assemblies due to poor rail joint welds and severe wheel-to-rail impacts.
Results in a finished installation with the same hardness and material characteristics as the parent rail.

High- impact epoxy grout under the crane rails.

Provides continuous rail support.
Eliminates rail deflection
Prevents anchor pullout and rail creep.

The benefits of Retrotech AS/RS Thermite Welding Crane Rail Replacements:

Less equipment downtime
No open or worn rail joints
Reduced anchor-bolt breakage
Smoother crane operation
Reduced crane component damage and load shifting due to jarring.
Longer rail and wheel life.