Crane rail slab track construction

Stabirail’s innovative bottom-up slab track construction method for terminal environments revolutionizes the installation of rail systems for crane and warehouse applications. Developed specifically for container- and intermodal terminals, harbors, warehouses and ports, this innovative approach delivers unmatched efficiency, precision, and durability, ensuring smooth operation under demanding conditions. Stabirail’s method addresses the unique challenges of terminal environments, such as heavy loads and stringent operational requirements.

The construction process: step-by-step

Stabirail’s bottom-up slab track method utilizes specialized techniques and equipment tailored to your rail installation. This step-by-step approach ensures superior performance, longevity, and minimal maintenance.

Step 1: Constructing the concrete beam

The foundation for the rail system begins with the construction of the concrete beam:

• Site preparation: level and compact the terrain to create a stable base.
• Concrete foundation: lay a lean concrete layer to stabilize the foundation.
• Rebar placement: position reinforcement bars to ensure structural strength and accommodate positioning of future rail anchors.
• Formwork installation: set up formwork to shape the concrete beam.
• Concrete pouring: pour and cure the concrete to create a robust and precise foundation.
• Formwork removal: remove the formwork once curing is complete, leaving the surface ready for milling.

This creates a stable and precise base that is ready for the rail system installation.

The rail systems using the Stabirail Method can be installed on a beam, in a trench or on a floor, inside or outside.

Step 2: Concrete milling

Using Stabirail’s state-of-the-art milling machines, precise rail beds are created on the concrete surface. Key adaptations for terminal solutions include:

• Beam-by-beam milling: machines work independently on beams spaced approximately 30 meters apart.
• WET milling: no dust formation
• Straight and flat tracks: advanced 2D technology ensures precision within 2mm for straight and flat track geometries.

These adjustments optimize milling for terminal-specific conditions, delivering precise rail beds for subsequent drilling and anchoring.

Step 3: Diamond-core or pneumatic drilling

After milling, the next step involves drilling precise holes into the concrete slab for anchoring the rails. There are two options:

• Pre-rail drilling: drill holes before rail installation, ensuring alignment.
• Post-rail drilling: drill holes after the rails are positioned and temporarily secured.

A specialized drilling machine runs along the track to bore precise holes through the soleplates into the concrete base. The use of diamond-core drills ensures:

• Efficient execution: automated processes ensure consistent and accurate drilling.
• Anchoring precision: ensures secure fixing points for the rails.
• Durability: compatibility with heavy-load terminal requirements

If applicable, the use of pneumatic drilling ensures a higher production capacity and is very cost-effective.

The anchor points are vital for securing the rails and maintaining track stability over decades of use.

Step 4: Rail anchoring

Once the anchor points are drilled, the rails are secured to the concrete bed using specialized anchoring systems. This step ensures:

• Track stability: no longitudinal or lateral movement under high-speed and heavy-load conditions.
• Load distribution: the rigid slab evenly disperses the dynamic forces, capable of handling heavy loads without damage.

Stabirail’s method avoids the challenges of traditional rail alignment processes, such as shifting due to temperature changes or due to unwanted movements of personnel or equipment during installation.

Installation process:

• Cleaning: the drilled holes are thoroughly cleaned using a water vacuum to remove debris and ensure proper adhesion. If drilled by a diamond core drill, removal of the drilled core.
• Control: checking the required installation depth and adjustment if needed
• Adhesive injection: a two-component adhesive is injected into each hole to provide maximum strength and stability.
• Anchor installation: rail anchors are inserted into the adhesive-filled holes with precision.
• Tightening: each anchor is tightened to the exact torque specification required for optimal performance.

This anchoring process guarantees accurate and robust support for high-speed and heavy-load rail traffic.

Step 5: Quality assurance and alignment checks

Stabirail employs advanced systems to verify the alignment and positioning of the installed rails. These checks ensure:

• Accurate geometry: guaranteeing smooth operations and minimal wear on rolling stock.
• Long-term reliability: preventing deviations that could lead to costly maintenance.

This rigorous quality control is a significant upgrade over conventional methods, where alignment issues are often corrected post-installation.

Stabirail is fully compliant with regulatory standards. We’re VCA, ISO9001 en ISO45001 certified. Read more about us here.

Magnet grid installation

A unique feature for Automation on Container Terminals is the installation of magnet grids. Magnets are installed as a predefined linear or hexagon grid using their polarity to create a unique pattern on the yard.

These serve as position markers for automated guidance systems for Automated Horizontal Transportation System (AHTS) e.g. Straddle Carriers or other automated equipment when network or GPS systems fail due to the interference of structures like Ship to Shore Cranes, moored vessels, moving ARMG or stacked containers.

These Magnet Grids provide additional operational benefits:

• Efficient container handling: supports precise Straddle Carrier positioning.
• Enhanced safety: reduces risks e.g. collisions during operations by ensuring accurate and real-time paths.
• Durability: engineered for long-term use in high-load environments and no batteries to be replaced
• Automation: the system enables reliable automated container handling operations

The installation requires exact positioning to ensure accurate Straddle Carrier operation. Stabirail improved the installation process by using a marker robot guided by a Total Station instead of a marking board. We developed a small electric-powered cart that carries a water supply, a gen set and a drill standard to ensure fast execution with no water hoses and power cables crossing the yard. One person can drill 800 holes in one day, while another person installs the magnets, ensuring very efficient construction.

Advantages over traditional methods

Stabirail’s bottom-up slab track offers significant advantages compared to traditional methods like ballast tracks on sleepers or using grout to align and stabilize the rail system.

Traditional methods

Ballast tracks on sleepers:

• Cannot ensure the accurate rail system construction for automated systems
• High transfer of vibrations on the equipment.
• High frequency of maintenance while the whole area/stack needs to be emptied and out of use.

Rail systems installed on grout or epoxy (top-down slab track)

• During installation weather-dependent and low production not ensuring consistent quality which leads to cracking of the grout.
• Complicated and time-consuming installation, requires extensive alignment work and a big workforce.
• In case of repair or maintenance, the grout has to be removed which is complicated and the whole rail system needs to be realigned to ensure smooth operation afterwards.

Bottom-Up slab track

• One unified structure: eliminates the need for multiple material layers, reducing risks of deformation and cracking.
• Weather independence: ensures uninterrupted progress regardless of rain or freezing conditions.
• Repairability: easy and straightforward repair methods, enable targeted interventions in case of damage without major disruption.
• Compatibility: independent of fastening systems, offering flexibility in choosing rail system suppliers based on project requirements.

The benefits of Stabirail’s bottom-up slab track construction are numerous, for a detailed breakdown of these advantages, read our Advantages page.

Why choose Stabirail?

Stabirail’s method is more than just a construction process—it’s a paradigm shift in crane railway infrastructure:

• Efficiency: faster construction with reduced project timelines and less workforce
• Durability: systems designed to last over 60 years with minimal maintenance.
• Sustainability: lower material usage and reduced environmental footprint.
• Precision: industry-leading accuracy of up to 2mm.

For superior future-proof infrastructure, Stabirail sets the benchmark for crane rail installations.