Customized A65 Rail Project for Sri Lanka Port Authority

1. Project Background

This project is a supporting infrastructure initiative for Sri Lanka’s port development, focusing on customizing dedicated A65 rails for cranes operated by the Sri Lanka Port Authority (SLPA). The rails are designed to support port cargo handling equipment. Delivered in August 2024, the goods were shipped from Tianjin Port (China) to Colombo Port (Sri Lanka). Given the harsh high-humidity and high-salt-spray environment at the port, the project required strict standards for corrosion resistance, dimensional accuracy, and painting workmanship.

2. Client Profile

  • Direct Client: Local Sri Lankan partner
  • End User: Sri Lanka Port Authority (SLPA)
  • Project Nature: Critical port infrastructure project. The end user enforced stringent requirements for rail quality, anti-corrosion processes, and delivery standards, prioritizing the long-term stability and service life of the product.

port crane rail

3. Core Order Details

3.1 Product Specifications & Quantities

  • A65 Long Rails: 28 pieces, 12 meters per piece
  • A65 Short Rails: 8 pieces, 1.5 meters per piece (2 sets total)
  • Application: Running rails for port cranes

3.2 Delivery Information

  • Shipment Date: August 2024
  • Port of Shipment: Tianjin Port, China
  • Destination Port: Colombo Port, Sri Lanka

4. Key Technical & Painting Requirements

To meet the high anti-corrosion demand of the port environment, surface treatment and painting followed strict international standards:

4.1 Surface Preparation

Rails to be sand/grit blasted to a minimum SA2.5 cleanliness level.

4.2 Coating System

  1. Primer: 2 coats of 2-pack epoxy zinc primer (100 microns per coat, total 200 microns)
  2. Topcoat: 1 coat of polyurethane epoxy finish paint (Yellow, RAL-1007, 60 microns)
  3. Minimum Total Dry Film Thickness (DFT): 260 microns (Note: “260mm” in original brief is a typo; rail coatings are measured in microns)

4.3 Non-Painted Areas

  • Rail top (Area above Line A) and weldable areas: No paint applied, ensuring running surface precision and welding reliability.
  • Factory Protection: Special protective film applied to rail heads and cross-sections before 360° full painting, preventing paint contamination on non-painted zones.

4.4 Special Clarification for Short Rails

The client initially requested no paint on both end cross-sections of short rails. Through schematic communication, we clarified that L-shaped notched cross-sections are non-weldable areas and can be painted for better corrosion protection. The client approved this optimized solution.

customized A65 rail for port

epoxy zinc primer rail

5. Key Project Challenges & Solutions

5.1 Challenge 1: Executing High-Standard Anti-Corrosion Coating

High salt spray at the port demanded strong coating adhesion and corrosion resistance with precise thickness control.

Solution: Strict SA2.5 blasting; phased quality control for primer/topcoat application; 100% thickness inspection with professional gauges to ensure ≥260 microns total DFT.

5.2 Challenge 2: Precise Control of Non-Painted Zones

Paint contamination on rail heads/weldable areas would impair subsequent use.

Solution: Custom protective film accurately covered rail heads (above Line A) and weldable areas pre-painting; film removed post-coating to ensure clean non-painted surfaces.

5.3 Challenge 3: Resolving Client Misunderstanding on Short Rail Painting

The client held incorrect assumptions about short rail cross-section painting.

Solution: Technical schematic drawings clearly demarcated welded vs. non-welded zones, explaining that painting non-welded L-shaped notches enhanced durability, resolving the discrepancy efficiently.

customized A65 short rails

6. Project Execution & Delivery

  1. Production: Manufactured per drawings and standards with full in-process sampling inspections to guarantee dimensional accuracy and mechanical performance.
  2. Coating: Blasting, priming, and topcoating executed in controlled phases; non-painted area protection strictly enforced with final full quality checks.
  3. Delivery: Completed production and loading on schedule in August 2024; shipped directly from Tianjin to Colombo Port with full traceable logistics, delivered successfully to the client.

7. Project Value Summary

  1. Product Value: Custom A65 rails met the severe corrosion conditions of Sri Lankan ports; high-standard anti-corrosion coating ensured long-term stable crane operation and reduced maintenance costs.
  2. Cooperation Value: Professional technical communication and meticulous delivery resolved client concerns, earning recognition from SLPA and the local partner, laying a solid foundation for future China-Sri Lanka port infrastructure collaboration.
  3. Industry Value: The project exemplified international high-standard production for port equipment components, providing a practical reference for similar overseas customized rail projects in process and client communication.