Client Background
At Glory Rail, we were assigned to supply a customized conveyor rail system for an apron conveyor tail section in an Indonesian industrial material handling project. The system was based on ASCE 60 (30 kg/m) heavy rail, widely used in high-impact conveyor and industrial transport applications.
The client is an industrial components supplier supporting heavy-duty material handling projects across Indonesia. The conveyor tail section requires reliable rail guidance to redirect chain plates from the return path back to the carrying path under continuous loading conditions.
Project Requirements
During the initial design stage, the client specified single-piece 12-meter ASCE 60 rails for the conveyor tail assembly. Each rail section was designed to maintain precise geometry through both straight and curved transition zones.
However, standard mill production lengths for ASCE 60 rail are 6, 8, and 10 meters. Producing non-standard 12-meter rails would result in unnecessary material waste and increased procurement cost.
In addition to length requirements, the system also demanded vertically bent rail geometry to ensure smooth transition of conveyor movement in the vertical plane. This required high precision control of bending radius and alignment to maintain stable operation under continuous impact loads.
Glory Rail Engineering Solution
After reviewing the technical drawings, our engineering team proposed an optimized modular solution using standard 6-meter ASCE 60 rail segments. The original 12-meter design was re-engineered into a two-piece bolted splice configuration.
The splice joint was positioned in the straight section before the curved transition zone to ensure smooth load transfer and eliminate interference with bending stress areas. Machined bolt holes and connecting plates were used to maintain precise alignment and structural continuity.
Once the revised design was submitted, the client approved the optimization for production.
Fabrication & Processing
The final solution included four complete rail assemblies, manufactured from eight standard 6-meter ASCE 60 rail segments.
Each rail was processed as follows:
Front straight segment: 6,000 mm with 75 mm chamfered lead-in for smooth entry transition
Rear curved segment: CNC cold-bent to the specified vertical radius with high precision control
Bolted splice connection: pre-drilled and machined for accurate on-site assembly
Surface inspection: verified for straightness, curvature, and dimensional tolerance
All bent rails were checked using 3D measurement equipment to ensure compliance with the approved drawings.
Quality Inspection & Packaging
Each rail segment underwent strict dimensional inspection, including radius verification, alignment control, and end preparation quality checks.
For export delivery, all rails were securely fixed on steel transport frames designed to preserve the vertical bending geometry during ocean freight. W116 rail clamps and all connection hardware were packaged together as a complete installation system.
The full package was shipped to Surabaya, Indonesia.
Why Glory Rail
Glory Rail provides more than rail supply—we deliver complete engineering solutions. For this project, we optimized the original design, eliminated material waste, and provided a fully engineered conveyor rail system including bent rails, fastening components, and shop drawings.
With in-house CNC bending, 3D inspection systems, and export-ready packaging solutions, we ensure precise fabrication and reliable global delivery for industrial rail projects.
Inquiry
If your project involves conveyor rail systems, vertical bent rails, or custom heavy rail layouts, our engineering team can review your drawings and provide optimized fabrication solutions to reduce cost and improve installation efficiency.