SB Rail developed innovative attachments for its Kirow KRC 250UK rail cranes to improve efficiency and capabilities. This included a robotic arm for precise load placement, an automatic sleeper relaying beam for one-person track laying of up to 16 sets per hour, and a tandem tensioning system combining two cranes for heavy load installation. Further attachments enabled the cranes' use in electrification works through an Electrification Piling Train for fast mast and pile installation, setting a record of 44 days from first pile to operational electric trains. These innovations have increased productivity in track replacement and electrification works.

1. Gordon Suthorn, Business Development
Manager, Swietelsky, describes SB Rail’s
development of the Kirow KRC 250UK rail cranes
through a series of innovative attachments.
Background
The First Swietelsky Joint Venture (now SB
Rail) placed an order for three Kirow KRC
250UK cranes in 2005. Taking delivery of the
first of these in the summer of 2006
represented a step-change in capability.
Improvements for the UK introduction included
60mph running in train formation, 15 tonnes
capacity at a 16 metre radius and outriggers
for heavier loads.
Ever since that initial introduction, SB Rail
has pursued the development of a series of
innovative attachments for its Joint Venture
crane fleet. The enhancements include a robotic
arm, automatic sleeper relaying beam, tandem
tensioning system (for twin crane operations)
and configurations for electrification work,
including a high output piling and mast/portal
erection system. The patented attachments are
unique in the industry and offer significant
value-adding benefits for a variety of railway
engineering works.
Robotic arm
This innovative device is attached to the end of
the crane’s boom via a quick hitch couple. It
operates through a series of hydraulic pivots
and servos, providing complete control over tilt,
rotation and inclination. The arm enables rigid
load attachment, preventing sway and allowing
total control during lifting, movement and
precision placement.
The articulation allows long, wide or
complex loads to be carefully maneuvered
around areas of restricted clearance such as
overhead line equipment, station canopies,
footbridges, over-bridges and underbridges. The
robot arm unlocks the potential of the cranes by
enabling a series of further attachments
described below.
Automatic sleeper relaying beam
The 28 sleeper automatic relaying beam has
been designed and purpose-built for operations
in the UK. During the lift and delivery cycle, a
fully automated programme spaces sleepers to
600 or 650mm centres. Once placed, a laser
alignment target positioned on the previously
laid section allows the operator to align the
next set of sleepers within ± 2 millimetres of
final alignment.
In this genuine one-man operation, the
crane operator controls sleeper pick-up,
movement, spacing, alignment and placement
without additional site operatives. Depending
on site conditions, haulage arrangements and
other equipment in support of the works, it is
possible to lay up to 16 sets (of 28) sleepers
per hour.
The 500 S -
with ‘tandem tensioning’
The 500 S incorporates two KRC 250 cranes
with an integrated wagon in a fixed formation.
During lifting operations the tandem
tensioning system balances and controls the
forces exerted by the suspended load through
each crane. The system comes to the fore
installing difficult or heavy loads in confined
spaces, including all conventional and
modular S&C panels up to and including those
for a ‘G’ switch. The robotic arms enable rigid
load attachment, preventing sway in windy
conditions and improve both the speed of
working and precision of installation, even
with the most challenging load configurations.
The robotic arm, automatic sleeper
relaying beam and 500 S with ‘tandem
tensioning’ all serve to improve the speed and
quality of track installation works, allowing
wider efficiencies to be realised more easily,
including line speed hand-backs.
Electrification
Further developments and systems
integration have seen the cranes deployed on
electrification works. The robot arm has been
combined with a side-insertion ‘vibro’ piling
unit forming a powerful yet highly-versatile
system, dubbed the Electrification Piling Train
(EPT). Integrated flat wagons fitted with
custom bases and frames are used to
transport piles from depot to site, forming an
entirely self-contained system deployed in a
production-line methodology.
Where greater embedment depths are
required or more challenging ground
conditions are encountered, the system can
be augmented by a second heavy-duty ‘vibro’
pile hammer. The uplift forces encountered
during piling with a side insertion unit are
countered by the weight and power of the
The Swiss army knife of rail cranes
RAIL INFRASTRUCTURE 45
On-Track Plant
The KRC 250UK’s robot arm and 28 sleeper
automatic relaying beam in action.
The robot arm also has the ability to have a
lifting beam attached for single track panel
or modular S&C installation.

2. KRC 250, together with an impressive 16 metre reach. Safer
operations are achieved due to the self-contained nature of the
system with fewer individual machines, movements and personnel
required on-site. Further unique attachments allow the lifting,
movement, positioning and securing of electrification masts or portals.
Deployed on the Paisley Canal Electrification project, the high-
output production efficiencies of the EPT contributed to a significant
new record: the first electric train running just 44 days after the first
pile was driven! On the back of this success, the EPT was selected for
electrification works on the Edinburgh Glasgow Improvement
Programme where piling commenced at the beginning of November.
Conclusion
SB Rail has developed the KRC 250UK through a series of specialist
attachments designed and built to extend the capabilities of the
cranes, make operations safer and generate significant production
efficiencies to lower the unit cost of delivery. These innovations have
improved core processes in plain line and S&C track replacement
works and are now conveying similar productivity improvements
within electrification programmes.
46 RAIL INFRASTRUCTURE
On-Track Plant
SB Rail’s KRC 500 S double jib crane system with ‘tandem
tensioning’ for S&C track renewal work.
The SB Rail Electrification Piling Train working on the Edinburgh to
Glasgow Improvement Programme.