Efficiently securing goods handling in ports: refurbishing the rail joints of container gantry cranes with MM1018 P

Im EUROGATE Container Terminal Hamburg ermöglichen 24 Containerbrücken den effizienten Warenumschlag von Schiffenauf Kaianlagen. Die bis zu 2.100 Tonnen schweren Stahlkolosse auf Schienen können Lasten von bis zu 66 Tonnenbewegen – bei einer Gesamthubhöhe von 70 Metern. Um den reibungslosen Betrieb der Containerbrücken, und damit denschnellen Warenumschlag im Hamburger Hafen, mit voller Kapazität langfristig sicherstellen zu können, wurde an den Schienenstößen der Brücken ein kraftschlüssiger Spaltausgleich mit dem Flüssigen Futterblech® MM1018 von DIAMANT durchgeführt. Das Sanierungskonzept wurde von EUROGATE und der DIAMANT Polymer GmbH erarbeitet, um gemeinsam ein weltweit bestehendes Problem beheben zu können.

The joints at the 90° folding jib transition, which makes it easier for ships to dock and cast off, are a well-known and notorious wear point on container gantry cranes. Settlements or displacements often occur here under permanently high loads. This results in unevenness in the rail joint, which is problematic for safe crane operation.

Pressure-resistant compensation of gaps, joints and imperfections

In Hamburg, but also in other EUROGATE container terminals, DIAMANT MM1018 P was used as a pressure-resistant leveling material to level out gaps, joints and imperfections at the rail joints. The Liquid Lining Sheet® was used to efficiently create positive and non-positive connections between the top chords of the crane runway and the steel slats of the newly installed crane rails.

The new crane rails were attached to the existing girder in Hamburg using steel slats. The resulting gap between the new steel lamella and the old steel girder was professionally filled with MM1018 by a DIAMANT installation team.

Professional application by a DIAMANT installation team

Before application, the contact surfaces were cleaned and treated with a special release agent spray. The experienced specialists applied the paste-like MM1018 P, which was delivered ready for use, to the center of the slat on both sides of the transition. Once the rail (including the lamella) had been set down in its final position, the escaping material was carefully removed. The curing of MM1018 P depends on temperature and volume. A compressive strength of up to 90 N/mm2 can be achieved in 24 hours. After seven days, the compressive strength is up to 122 N/mm2.

Time and cost-saving refurbishment ensures permanent high operation

Thanks to the professional refurbishment, it was possible to create a force-fit, permanent connection between the steel parts in Hamburg in a time and cost-saving manner, which enables optimum load transfer to the support structure. The renovation method, which was new to EUROGATE, enabled the terminal operator to achieve significant time and cost savings. The first transition from land to water was refurbished on July 13, 2021 and is still in perfect condition today.
Further applications of the liquid lining plate on container gantry cranes in Hamburg and Bremen followed in the course of 2022 and 2023.

DIAMANT Managing Director Carsten Kunde is delighted that “with our Liquid Lining Plate® we are making a contribution to the long-term
to ensure the efficient handling of goods in container ports”.

“We are currently also in talks with other ports in Rotterdam and Turkey about the refurbishment of container gantry cranes.”
Carsten Kunde

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Mr. Carsten Kunde

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