Gantry Alignment

When considering alignment of the crane supporting structure (gantry) the Competent Person should refer
to the manufacturer’s specifications for crane running tolerances.

In the absence of such information, reference can be sought from BS466 and ISO12488, depending on the
standard to which the structure was designed.

For in-service overhead cranes, it is likely that over a period of time the gantry will move; the original
tolerances will then be exceeded. This can be caused by settlement of the structure or general vibrations
and stresses resultant from the crane movements.

The types of gantry alignment issues that are commonly found are:

 Level differences between the gantry rail heights

 Span differences between the gantry rails (parallel running)
 Line deviation of individual gantry rails
 Inclination of tracks in the vertical position

Notes:

189

Gantry Levels Out of Tolerance

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Gantry Rail Line Problem

Possible Span and/or Line Problem

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Notes:

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Gantry Tolerances

BS 466 and ISO 12488-1 specify the dimensional and geometrical tolerances of tracks for top running and
under-slung cranes. BS 466 lists standard tolerances for all cranes, whereas ISO12488-1 has varied
tolerances depending on the crane classification.

In the absence of manufacturers’ specifications, the classification of a crane, as stated in ISO 12488-1 can
be calculated as follows:

The classification of the long travel drive mechanism (from ISO 4301-1) will provide the amount of service
hours (S)

L (Km travelled in crane life) = service hours (S) multiplied by the travel speed x 60

Example:

ISO 12488-1 Tolerances - M5 Duty Crane

Service hours (6,300 hours) x 32 metres/min x 60

= 12096 Km, therefore as per the table below, it would be in tolerance Class 2
and have a span tolerance of +/- 5mm.

ISO 12488-1 Tolerances

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BS 466 Tolerances

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BS 466 and ISO 12488
Tolerances

BS 466 Tolerances
The tolerance on span should be as follows:

 ∆S ≤ 3mm where S < 15m

 ∆S ≤ 3mm + 0.25 (S 15)mm where S > 15m 192
 ∆S Max = 15mm

Misalignment of track running surfaces in the vertical plane

 Δ H ≤ 0.001S
 Δ H Max = 10mm

Tolerances on track width under-slung only

 Δ W = 0.025W

Track Straightness
For the total length of track, the maximum lateral deviation from the straight line mean datum should not
exceed 10mm.

Local lateral deviation at any point of the track should not be greater than L/2000, measured over a length
L of not less than 2m on a line parallel to the straight line mean datum.
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Permissible Deviation in the Vertical Plane
For the total length of the track, the maximum vertical deviation from the theoretical datum line should
not exceed 10mm. The theoretical datum line may be the true horizontal line or a theoretical camber line.

Local vertical deviation at any point of the track should not be greater than L/2000, measured over a length
L of not less than 2m on a line parallel to theoretical datum.

Running Surface Permissible Transverse Inclination from the Horizontal Datum Position

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Notes:

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Measurement of Crane Tracks

When measuring crane tracks, calibrated steel measuring tapes should be used. It is important that the
readings obtained are corrected to allow for sag in the tape and for temperature variation. All track
measurements for a particular crane should be made with the same measuring tape and the same applied
tension force.

Gantry and Crane Surveys

We have previously noted that the major cause of wear on crane wheels and tracks is misalignment.

This could be misalignment of the track or misalignment of the crane.

Check crane against end stops until buffers are touching, run crane back along track and come back to end
stops. Should buffers not both be touching then the crane or buffers are out of line, but in any case this
would suggest movement of the bridge girder connections.
194

Gantry Bridge Survey

A crane bridge can be checked for serious misalignment whilst on the track, it is not easy and requires
accurate measurements. The following checks should be made to establish any serious misalignment:

1. Check end carriages for parallelism

2. Check crane wheels for diameter and flange wear
3. Check crane wheels alignment in end carriages
4. Check crane wheel diagonals, i.e. from centre line of tread plumb down to rail, if not plumb down
from axles
5. Check for issues with long travel drive and/or braking mechanisms

If the crane appears reasonable the gantry should be checked.

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 Notes:

Line and Level Surveys

The Competent Person may be able to look along a crane track and detect serious misalignment. A line and
level survey would then be required to decide what remedial action will be necessary.

Line Check
1. Working from a datum point, e.g. a string line stretched the length of the gantry, the horizontal
variations of the track would be measured and tabulated using numbered stanchions for reference
195
2. Using a steel tape and tension gauge, the span of the tracks could be measured at the numbered
stanchion positions
3. The design office would lay those dimensions out as a drawing using an exaggerated scale for the
track variation

Level Check
Again working from a datum level, using either a dumpy level or some other means, deviations from the
datum level would be noted at the stanchion positions for both tracks.

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Line and Level Drawings

This drawing would show deviation in lines and levels and allow a decision to be made as to how best
remedial action could be taken.

By adjusting the datum lines it may be possible to reduce the amount of remedial work required.

Great care must be taken to ensure end clearances are maintained between crane and steelwork.

Notes:

196

Levelling

Accurate levelling is far more difficult to achieve since we need to measure from an imaginary line. The
traditional method is the dumpy or automatic optical level used in conjunction with a staff.

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Line and Levelling
Positioning a dumpy (optical level) for sighting gantry rails will often need improvisation. Engineers tend to
make up their own attachments for clamping to gantry rails etc.

The level is set up using a built-in bubble, similar to a spirit level except the glass is spherical, with a circular
reticule thus providing a 360° level.

The optical level, once set up, provides our datum from which variations can be calculated as previously
explained.

Laser Levelling
A more recent innovation is the laser leveller. Power operated, the
laser leveller will automatically plumb itself. 197

The laser beam is then rotated and becomes a continuous

horizontal reference until switched off. Having set the laser the
engineer can walk to where he wishes to measure and take a
reading off the staff which is power operated and automatically
seeks out the laser beam.

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