Overhead Rail Systems & Components

How Overhead Rail Systems Work

Overhead Rail Systems help operators ergonomically perform work on heavy or oversized items. The overhead rail system supports the weight of the item allowing the operator to quickly access areas to perform work without the need to pick up, turn over, balance, or manipulate the item during the process. Additionally the overhead rail system can also help operators quickly transport the item between work cells.

Overhead Rail System Benefits

• Lightweight and ergonomic - with rolling resistance of less than 1%.
• A precision running surface - rail systems are available in aluminum, steel and stainless steel.
• Modular and flexible - our rail systems are bolted not welded together.
• Clean, maintenance free operation - no lubrication required.
• Safety - our rail systems are designed to meet or exceed all national and international standards.

Overhead Rail System Design & Construction Features

The enclosed rail system design - reduces the accumulation of dirt and grime on internal rolling surface. As a result, the effort expended to move objects on the rail system is less. Enclosed rail systems are offered in three types of materials.

• Aluminum – a lightweight option that is ideal for long rail system spans and feature:
  • Extruded from aluminum alloy 6063-T6.
  • Clear anodized for a smooth, clean, corrosive free surface.
  • Available in lengths up to 30 feet.
  • Strong backing is an available option for increased capacities.
• Steel – is a strong yet economical choice that is ideal for heavy weight applications. Steel enclosed rail systems feature:
  • Roll formed from 9 gauge, A569 hot rolled steel.
  • Spot welded with an automated welder for maximum strength.
  • Powder coat painted for durability and smoothness.
  • Available in lengths of up to 24 feet.
  • Strong backing is an available option for increased capacities.
• Stainless Steel – is ideal for clean room, food and beverage, and pharmaceutical applications. Stainless steel enclosed rail systems feature:
  • Roll formed from 10 gauge, 316L stainless steel.
  • Spot welded with an automated welder for maximum strength.
  • Available in lengths up to 24 feet.

Enclosed rail systems also come with a wide variety of attachable hangers. These hangers are designed to match the material handling application and are available in either, rigid or pivoting styles, and both fixed and adjustable lengths. Likewise, for safety reasons, all hangers with a drop of 24 inches or greater must have sway/thrust bracing for stability.

Enclosed rail systems are designed for safety. The safety features that Bastian's enclosed rail systems offer include:

• Deflection – the rail is designed to not exceed 1/450 of span in accordance to ANSI B30.11 Monorail and Under hung cranes.
• Safety cables – safety cables are required at all moving suspension points including hangers and end trucks.
• Redundant end stops – are available for extra safety.
• Load ratings – that are clearly marked on both sides.
• Safety factor – rating all hardware components on a 5 to 1 safety factor based on meticulous tests performed at independent testing laboratories.

The advanced trolley design – works in conjunction with the enclosed track rail to efficiently reduce the rolling effort necessary to move loads. When using the advanced trolley design only a force of 1% the total rolling weight is needed to move loads. The advanced trolley design offers the following features:

• Lightweight – since trolleys are primarily made from high strength, Aluminum / Magnesium castings. Steel and stainless steel stampings are also available.
• Injection molded wheels – Delrin wheels provide a clean, wear free operation that resists flattening.
• Sealed precision bearings – which are also lubricated providing a long life and reduced maintenance. Like
• Rail safety lugs – work to prevent the body of the trolley from being pulled through the enclosed track rail.
• Versatile – since the trolleys Bastian offers are available for use on every manufacturer's enclosed track system.

Additional power supply and accessory options are available for rail systems.

Industries that Use Overhead Rail Systems