Why does the wide 200 mm base of an A100 rail require 9 Series Welded Clips?
The 200 mm base of the DIN 536 A100 rail creates a significant surface area that handles massive vertical loads, but it also generates substantial horizontal forces. The 9 Series welded clips are specifically engineered to manage these unique physical requirements.
Here is why this specific pairing is the industry standard for A100 installations:
1. Lateral Force Resistance
The A100 rail is typically used for heavy cranes that produce high lateral (sideways) thrust during acceleration, braking, or when the crane is "crabbing" along the track.
- The 9 Series Advantage: These clips are "two-part" systems consisting of a weldable lower base and a bolted upper cap. The 9 Series is designed to withstand extremely high lateral loads-often up to 150 kN to 250 kN per clip-ensuring the 200 mm base does not shift on the girder.
2. Physical Clearance and Geometry
The A100 rail has a low profile (95 mm total height) relative to its 200 mm width.
- Low Profile Design: 9 Series clips have a compact vertical footprint. Because crane wheels and their flanges often run very close to the rail base, these clips provide the necessary clearance to prevent the crane's wheel assembly from striking the fastening system.
- Base Fit: The "nose" of a 9 Series clip is specifically contoured to reach over the thick edge of the A100's 200 mm flange, providing a secure grip without interfering with the rail's structural integrity.
3. "True" Controlled Tightening
The wide base of the A100 requires consistent downward pressure across the entire length of the runway to prevent "rail wave" or "rattling".
- Weldable Base Stability: By welding the lower component of the 9 Series clip directly to the steel girder, you create a permanent reference point that won't vibrate loose.
- Self-Locking Mechanism: Most 9 Series clips feature a self-locking design. As the crane passes over and the rail deflects slightly, the clip is engineered to maintain its torque, which is vital for a rail as heavy as the A100 (74.3 kg/m).
4. Adjustability for Alignment
With a base as wide as 200 mm, even a tiny misalignment in the girder can lead to significant tracking issues for the crane.
- Lateral Adjustment: 9 Series clips typically offer 15 mm to 20 mm of lateral adjustment. This allows installers to perfectly align the A100 rails for a straight track, even if the steelwork underneath isn't perfectly centered.
5. Protection of the Rail Pad
A100 rails are almost always installed with a reinforced rubber pad underneath to distribute stress.
- Pre-stressed Clamping: The 9 Series clip applies a specific "clamping force" that keeps the 200 mm base firmly pressed against the pad. This prevents moisture and debris from getting under the rail, which would otherwise cause "fretting corrosion" or damage to the concrete/steel support.
 |
F(mm) | C(mm) | A(mm) | RAIL WEIGHT (kg/m) | CLIP REFERENCE FOR RAIL WITH PAD |
CLIP REFERENCE FOR RAIL WITHOUT PAD |
| P 50 | 132 | 70 | 152 | 50 | 9120/15/38 (S) | 9120/15/38 (H) |
| QU 70 | 120 | 70 | 120 | 52.8 | 9120/15/38 (S) | 9120/15/38 (H) |
| QU 80 | 130 | 80 | 130 | 63.69 | 9120/15/38 (S) | 9120/15/38 (H) |
| QU 100 | 150 | 100 | 150 | 89 | 9120/15/38 (S) | 9120/15/38 (H) |
| QU 120 | 170 | 120 | 170 | 118.5 | 9120/15/38 (S) | 9120/15/38 (H) |
| A 100 | 200 | 100 | 95 | 74.3 | 9120/15/38 (S) | 9120/15/38 (H) |
| A 120 | 220 | 120 | 105 | 100 | 9120/15/38 (S) | 9120/15/38 (H) |
| A 150 | 220 | 150 | 150 | 150.3 | 9120/15/38 (S) | 9120/15/38 (H) |
| ISCR 100 | 150 | 102 | 150 | 89 | 9120/15/38 (S) | 9120/15/38 (H) |
| ISCR 120 | 170 | 120 | 170 | 118.5 | 9120/15/38 (S) | 9120/15/38 (H) |
| GCR 183 | 280 | 75 | 120 | 183.06 | 9120/15/38 (S) | 9120/15/38 (H) |
| CR 73 | 140 | 100 | 135 | 73.3 | 9120/15/38 (S) | 9120/15/38 (H) |
| CR 100 | 155 | 120 | 150 | 100.2 | 9120/15/38 (S) | 9120/15/38 (H) |
| JIS 50 N | 127 | 64 | 153 | 50.4 | 9120/15/38 (S) | 9120/15/38 (H) |
| JIS 60 | 145 | 64 | 174 | 60.8 | 9120/15/38 (S) | 9120/15/38 (H) |
| S 41 | 125 | 67 | 138 | 41.4 | 9120/15/38 (S) | 9120/15/38 (H) |
| S 49 | 125 | 67 | 149 | 49.43 | 9120/15/38 (S) | 9120/15/38 (H) |
| MRS 67 (135CR) | 132 | 79 | 146 | 67 | 9120/15/38 (S) | 9120/15/38 (H) |
| MRS 86 | 165 | 102 | 102 | 85.5 | 9120/15/38 (S) | 9120/15/38 (H) |
| MRS 87 B | 152 | 102 | 152 | 86.8 | 9120/15/38 (S) | 9120/15/38 (H) |
| 68 kg AS | 152 | 73 | 186 | 67.6 | 9120/15/38 (S) | 9120/15/38 (H) |
FAQ
- Can 9 Series clips be used on concrete beams?
Yes, but they must be welded to a steel soleplate that is anchored into the concrete. This ensures the A100 Crane Rail Dimensions remain stable and the clips provide their full rated lateral resistance.
What is the recommended spacing for 9 Series clips on an A100 track?
For most heavy-duty cranes, the standard spacing is 600mm center-to-center. This ensures the 74.3 kg/m rail is supported frequently enough to prevent vertical deflection between support points.
- Are 9 Series clips compatible with R1100 grade A100 rail?
Yes. While R1100 is a harder material, the 200mm base dimensions remain identical to Grade 900A, making the 9 Series the standard choice for all material variations of the A100 profile.
- Do I need a special welding rod for 9 Series clips?
The base of the 9 Series clip is usually made of weldable cast steel. Standard low-hydrogen electrodes are typically used to weld them to the runway beam, ensuring a high-strength bond that matches the rail's durability.
- How do I check if my 9 Series clips are properly tightened?
Maintenance teams should use a torque wrench to verify the bolts on the clip cap. Proper torque ensures the rubber nose is applying the correct pressure to the 200mm flange without over-compressing the reinforced crane rail pad.
- Can 9 Series clips accommodate the 60mm web thickness of the A100?
The web thickness does not directly affect the clip, but the clip's design ensures that the high vertical loads supported by the 60mm web are not compromised by lateral instability at the base.
GNEE RAIL provides qualified A100 crane rail manufactured per DIN 536-1:1991 standard, with accurate dimensional tolerance and solid load-bearing performance.We also supply fully matched rail clamps, which fit the wide base profile of A100 rail well with stable clamping force and convenient lateral adjustability.
