Enclosed Track Aluminum Rail Series

Knight’s RAD4110, RAD6110 and RAD7510 Aluminum Rail Series has an enclosed track design that is extruded from a lightweight, high-strength aluminum alloy. The lightweight aluminum rail eases installation and reduces overhead requirements. The enclosed Series Rail is the ideal solution, whether your load is located directly under the system or cantilevered off to the side. This series, combined with nylon trolley wheels, provides the lowest rolling resistance in the industry.

For capacities greater than 3000 lbs., a Backer rail can be integrated into Knight’s RAD7510 Rail. This allows for greater capacities to be achieved. Either 6″ (RAA4438) or 8″ (RAA4439) Backers are available. See chart below for specific capacities.

Knight also has implemented the RAD8110 Aluminum Rail Series to compete with European-style rails while offering a more robust profile. This rail style uses most accessories for the RAD4110 series. See charts below for specific capacities.

The TR2000 Series Aluminum Rail is a streamlined design ideal for applications under 550 lbs/ft. [249.5 kg/m] capacity. This innovative system allows for festooning trolleys and plant utilities to be attached to the main line rail system, allowing for more travel. Application types can include: light duty weld guns, work benches and stations, filter/regulator/lubrication (FRL), festooning, light fixtures, weld curtains, etc.

General Information

Features

Mechanical Properties: ASTM B221 6005-T5 Series Aluminum.
Multiple Overhead and Floor Mounted Configurations.
Supports Trolleys, End Trucks and Hangers.
TR2000/RAD4110/RAD6110 Rail Lengths:
Up to 25 ft. [7.6m] without Splices.
RAD7510 Rail Lengths: Up to 30 ft. [9.1m] without Splices.

Benefits

Transfer Loads in the “X” and “Y” Directions.
Multiple Pre-Assembled Accessories.
Accessories can be positioned along the rail, no welding required.
Load Trolleys and End Trucks are designed for cantilevered and direct load applications.
All Hangers and End Trucks are designed to prevent binding of bridges and runways.

Rail Series Specifications

Enclosed Aluminum Rail Series

Series	Max. Capacity	Product Weight
TR2000	550 lbs. [250kg]	2.3 lbs/ ft. [3.33kg/m]
RAD4110	1,100 lbs. [499kg]	4.3 lbs/ ft. [6.23kg/m]
RAD6110	1,600 lbs. [725kg]	5.2 lbs/ ft. [7.7kg/m]
RAD7510	3000 lbs. [1,360kg]	8.3 lbs/ ft. [12.02kg/m]
RAD8110	4000 lbs. [1814kg]	6.4 lbs/ ft. [2.90kg/m]

TR2000 Capacity Chart

Rail Capacities

Hanger Span		Deflection Criteria
Hanger Span		1:350 Capacity*		1:450 Capacity*
ft	m	lbs	kg	lbs	kg
5	1.52	550	250	470	213
6	1.83	400	181	340	154
7	2.13	350	159	295	134
8	2.45	250	113	210	95
9	2.74	200	90	170	77
10	3.05	175	80	150	68
11	3.35	160	72	135	61
12	3.66	135	61	115	52
13	3.96	125	57	105	47
14	4.27	115	52	95	43
15	4.57	90	40	75	34
16	4.88	75	34	65	30
17	5.18	65	30	55	25

*Due to Ergonomic considerations, each rail span distance is tested to determine the maximum single point load required to achieve a predetermined deflection based on a ratio of 1:350 (1” of deflection for each 350” of length) or 1:450 (1” of deflection in 450” of length).

For purposes of estimating approximate ergonomic force requirements, the following
formula may be used:

Fs = frictional force = 0.009 x total mass. This indicates the maximum effort (in lbf) required to overcome inertia. Effort required to sustain movement, Fk (dynamic friction force) is generally 0.35 times the frictional force.

E.g.;
Fs = 0.009 x 250 lbs. (113.4 kg) mass = 2.25 lbf (0.9 kg) required to overcome inertia.
Fk = 0.009 x 250 lbs. (113.4 kg) mass x .35 = .79 lbf (0.36 kg) required to sustain movement.

Cantilevered Capacities (based on 8ft. hanger span)

Cantilevered		Deflection Criteria
Cantilevered		1:350 Capacity*		1:450 Capacity*
ft	m	lbs	kg	lbs	kg
1	.30	100	45	75	34
2	.61	50	23	35	16

Elastic deformation: This type of deformation is reversible. Once the forces are removed, the object returns to its original shape. The elastic range ends when the material reaches its yield strength. At this point deformation begins.

Plastic deformation: This type of deformation is not reversible. Once an object reaches this point, it will not return to its original shape. Plastic deformation ends with the fracture of the material.

Knight Global follows material handling industry standards in determining the capacity ratings for enclosed track overhead workstation crane systems. Each component (e.g. rail, hangers, trolleys, etc.) is individually tested to establish its ultimate failure point. From this number, a safe working load is then assigned to the component. Each rail span length is then tested to determine the maximum single point load required to achieve a predetermined deflection based on a 1:350 ratio (1″ of deflection for each 350″ of length). The recommended rated capacity chart is based upon single point loading for the listed spans.

RAD4110 Capacity Chart

Rail Capacities

Hanger Span		Deflection Criteria
Hanger Span		1:350 Capacity*		1:450 Capacity*
ft	m	lbs	kg	lbs	kg
5	1.52	1100	499	950	431
6	1.83	1100	499	950	431
7	2.13	1050	476	875	397
8	2.45	1050	476	775	351
9	2.74	950	431	675	306
10	3.05	850	385	650	295
11	3.35	700	317	550	250
12	3.66	550	250	450	204
13	3.96	500	226	385	175
14	4.27	435	197	300	136
15	4.57	350	159	250	113
16	4.88	335	152	250	113
17	5.18	280	127	175	79
18	5.48	265	120	175	79
19	5.79	230	104	150	68
20	6.10	210	95	150	68
21	6.40	195	88	125	57
22	6.70	175	79	125	57
23	7.01	160	73	125	57
24	7.31	145	66	100	57

For purposes of estimating approximate ergonomic force requirements, the following
formula may be used:

E.g.;
Fs = 0.009 x 250 lbs. (113.4 kg) mass = 2.25 lbf (0.9 kg) required to overcome inertia.
Fk = 0.009 x 250 lbs. (113.4 kg) mass x .35 = .79 lbf (0.36 kg) required to sustain movement.

Cantilevered Capacities (based on an optimum 8ft. hanger span)

Cantilevered		Deflection Criteria
Cantilevered		1:350 Capacity*		1:450 Capacity*
ft	m	lbs	kg	lbs	kg
1	.30	900	408	750	340
2	.61	325	147	300	136
3	.91	125	57	100	45
4	1.20	35	16	30	14

Knight Global follows material handling industry standards in determining the capacity ratings for enclosed track overhead workstation crane systems. Each component (e.g. rail, hangers, trolleys,etc.) is individually tested to establish its ultimate failure point. From this number, a safe working load is then assigned to the component. Each rail span length is then tested to determine the maximum single point load required to achieve a predetermined deflection based on a 1:350 ratio (1″ of deflection for each 350″ of length). The recommended rated capacity chart is based upon single point loading for the listed spans.

RAD6110 Capacity Chart

Rail Capacities

Hanger Span		Deflection Criteria
Hanger Span		1:350 Capacity*		1:450 Capacity*
ft	m	lbs	kg	lbs	kg
5	1.52	1600	725	1300	590
6	1.83	1600	725	1300	590
7	2.13	1500	680	1175	533
8	2.45	1475	699	1075	488
9	2.74	1400	635	1025	465
10	3.05	1325	601	925	453
11	3.35	1100	499	875	397
12	3.66	950	431	750	340
13	3.96	825	374	650	295
14	4.27	750	340	575	261
15	4.57	675	306	515	233
16	4.88	600	272	470	213
17	5.18	525	238	405	184
18	5.48	450	204	350	159
19	5.79	425	193	325	147
20	6.10	400	181	300	136
21	6.40	360	163	275	125
22	6.70	320	145	250	113
23	7.01	285	129	210	95
24	7.31	245	111	185	84

For purposes of estimating approximate ergonomic force requirements, the following
formula may be used:

E.g.;
Fs = 0.009 x 250 lbs. (113.4 kg) mass = 2.25 lbf (0.9 kg) required to overcome inertia.
Fk = 0.009 x 250 lbs. (113.4 kg) mass x .35 = .79 lbf (0.36 kg) required to sustain movement.

Cantilevered Capacities (based on an optimum 8ft. hanger span)

Cantilevered		Deflection Criteria
Cantilevered		1:350 Capacity*		1:450 Capacity*
ft	m	lbs	kg	lbs	kg
1	.30	2200	998	1700	771
2	.61	1000	454	775	351
3	.91	600	272	475	215
4	1.20	250	113	125	57

Knight Global follows material handling industry standards in determining the capacity ratings for enclosed track overhead workstation crane systems. Each component (e.g. rail, hangers, trolleys,etc.) is individually tested to establish its ultimate failure point. From this number, a safe working load is then assigned to the component. Each rail span length is then tested to determine the maximum single point load required to achieve a predetermined deflection based on a 1:350 ratio (1″ of deflection for each 350″ of length). The recommended rated capacity chart is based upon single point loading for the listed spans.

RAD7510 Capacity Chart

Rail Capacities

Hanger Span		Deflection Criteria
		RAD7510 Series				RAD7510 + 6″ Backer				RAD7510 + 8″ Backer
		1:350 Capacity*		1:450 Capacity*		1:350 Capacity*		1:450 Capacity*		1:350 Capacity*		1:450 Capacity*
ft	m	lbs	kg	lbs	kg	lbs	kg	lbs	kg	lbs	kg	lbs	kg
5	1.52	3000	1360	2700	1225	12170	5520	12170	5520	16355	7418	16355	7418
6	1.83	3000	1360	2700	1225	10130	4595	10130	4595	13620	6178	13620	6178
7	2.13	3000	1360	2700	1225	8670	3933	8670	3933	11660	5289	11660	5289
8	2.45	3000	1360	2700	1225	7575	3436	7575	3436	10190	4622	10190	4622
9	2.74	2700	1225	2400	1088	6720	3048	6720	3048	9045	4103	9045	4103
10	3.05	2500	1134	2000	907	6035	2737	6035	2737	8130	3688	8130	3688
11	3.35	2500	1134	1900	862	5475	2483	5475	2483	7375	3345	7375	3345
12	3.66	2500	1134	1800	816	5010	2272	5010	2272	6750	3062	6750	3062
13	3.96	2000	907	1800	816	4610	2091	4610	2091	6215	2819	6215	2819
14	4.27	2000	907	1500	680	4270	1937	4270	1937	5760	2613	5760	2613
15	4.57	1900	861	1500	680	3975	1803	3975	1803	5365	2434	5365	2434
16	4.88	1800	816	1200	544	3710	1683	3710	1683	5015	2275	5015	2275
17	5.18	1700	771	1200	544	3480	1578	3480	1578	4750	2134	4750	2134
18	5.48	1600	726	1000	453	3275	1486	3275	1486	4430	2009	4430	2009
19	5.79	1450	658	1000	453	3090	1402	3090	1402	4185	1898	4185	1898
20	6.10	1300	590	900	408	2925	1327	2925	1327	3965	1798	3965	1798
21	6.40	1100	499	900	408	2775	1259	2535	1550	3760	1705	3760	1705
22	6.70	900	408	800	363	2635	1195	2285	1036	3575	1622	3560	1615
23	7.01	900	408	700	317	2510	1139	2070	939	3410	1547	3230	1465
24	7.31	885	402	700	317	2390	1084	1880	853	3255	1476	2945	1336
25	7.62	850	386	700	317	2250	1021	1710	776	3110	1411	2690	1220
26	7.92	725	329	700	317	2060	934	1555	705	2980	1352	2465	1118
27	8.23	725	329	675	306	1890	857	1420	644	2855	1295	2260	1025
28	8.53	600	272	550	250	1735	787	1300	590	2735	1241	2075	941
29	8.83	600	272	550	250	1595	723	1190	540	2525	1145	1910	866

For purposes of estimating approximate ergonomic force requirements, the following
formula may be used:

E.g.;
Fs = 0.009 x 250 lbs. (113.4 kg) mass = 2.25 lbf (0.9 kg) required to overcome inertia.
Fk = 0.009 x 250 lbs. (113.4 kg) mass x .35 = .79 lbf (0.36 kg) required to sustain movement.

Cantilevered Capacities (based on an optimum 8ft. hanger span)

Cantilevered		Deflection Criteria
Cantilevered		1:350 Capacity*		1:450 Capacity*
ft	m	lbs	kg	lbs	kg
1	.30	3000	1361	2700	1225
2	.61	2200	998	2000	907
3	.91	900	408	775	352
4	1.20	375	170	325	147

Knight Global follows material handling industry standards in determining the capacity ratings for enclosed track overhead workstation crane systems. Each component (e.g. rail, hangers, trolleys,etc.) is individually tested to establish its ultimate failure point. From this number, a safe working load is then assigned to the component. Each rail span length is then tested to determine the maximum single point load required to achieve a predetermined deflection based on a 1:350 ratio (1″ of deflection for each 350″ of length). The recommended rated capacity chart is based upon single point loading for the listed spans.

RAD8110 Capacity Chart

Rail Capacities

Hanger Span		Deflection Criteria
Hanger Span		1:350 Capacity*		1:450 Capacity*
ft	m	lbs	kg	lbs	kg
5	1.52	4000	1814	4000	1814
6	1.83	3575	1622	3575	1622
7	2.13	3060	1388	3060	1388
8	2.45	2670	1211	2670	1211
9	2.74	2370	1075	2370	1075
10	3.05	2130	966	2130	966
11	3.35	1925	873	1925	873
12	3.66	1760	798	1760	798
13	3.96	1620	735	1400	635
14	4.27	1500	680	1200	544
15	4.57	1340	608	1030	467
16	4.88	1165	528	895	406
17	5.18	1020	463	780	354
18	5.48	900	408	685	311
19	5.79	800	363	605	274
20	6.10	710	322	535	243
21	6.40	630	286	470	213
22	6.70	560	254	420	191
23	7.01	500	227	370	168
24	7.31	450	204	330	150

For purposes of estimating approximate ergonomic force requirements, the following
formula may be used:

E.g.;
Fs = 0.009 x 250 lbs. (113.4 kg) mass = 2.25 lbf (0.9 kg) required to overcome inertia.
Fk = 0.009 x 250 lbs. (113.4 kg) mass x .35 = .79 lbf (0.36 kg) required to sustain movement.

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End Trucks – Single / Dual / Rigid

Medium Duty Aluminum Rail

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Accessories

Safety Cables

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RAD4110 RAD6110 RAD7510 TR2000

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Compare Item Eye Bolt Safety Cable Kit

FDA4133

Features

(4) Crosby® Saddle Clamps
(2) Cable Thimbles
(2) Eye Bolts
(1) Safety Cable made of a carbon steel 7 (strand) x 19 (wires) Galvanized Wire Rope (GWR).

Rail Type

RAD4110

RAD6110

RAD7510

TR2000

weight

n/a

cable thickness

0.25 in. [6mm]

lengths

10 ft. [3.048m]

Installation Guides

Eye Bolt Safety Cable Installation Instructions

Compare Item Safety Cable Kit with Oval Sleeves

NICORWA4133

Features

(2) Copper Oval Sleeves
(2) Cable Thimbles
(1) Safety Cable made of a carbon steel 7 (strand) x 19 (wires) Galvanized Wire Rope (GWR).

Rail Type

RAD4110

RAD6110

RAD7510

TR2000

weight

2 lbs. [.91kg]

cable thickness

0.25 in. [6mm]

lengths

10 ft. [3m.]

Compare Item Safety Cable Kit

RWA4133

Features

Used as Knight’s standard safety cable kit.
(4) Crosby® Saddle Clamps
(2) Cable Thimbles
(1) Safety Cable made of a carbon steel 7 (strand) x 19 (wires) Galvanized Wire Rope (GWR).

Rail Type

RAD4110

RAD6110

RAD7510

TR2000

weight

n/a

cable thickness

0.25 in. [6mm]

lengths

6 ft. [1.8m]

Splice Kits

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RAD4110 RAD6110 RAD7510 TR2000

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Compare Item Splice Kit

MRHA7503

Features

Splices (2) two sections of the RAD7510 Series Rail.
Bolt-On Splice Kit.
Bolt-on kit eliminates need to weld bosses.
Provides easier access to bolt heads.

Rail Type

RAD7510

weight

4.4 lbs. [2kg].

CAD Drawings

MRHA7503

Spec Sheet

MRHA7503 Splice Kit

Compare Item Splice Kit

MRHA7585

Features

Splices a section of the RAD7500 Curved Series Rail to the RAD7510 Series Rail.
Bolt-On Splice Kit.
Bolt-on kit eliminates need to weld bosses.
Provides easier access to bolt heads.

Rail Type

RAD7510

weight

n/a

CAD Drawings

MRHA7585

Spec Sheet

MRHA7585 Splice Kit

Compare Item Splice Kit

MRHA4445

Features

Splices (2) sections of the RAD4110 Series and RAD6110 Series Rail.
Bolt-On Splice Kit.
Bolt-on kit eliminates need to weld bosses.
Provides easier access to bolt heads.

Rail Type

RAD4110

RAD6110

weight

3.6 lbs. [1.63kg].

CAD Drawings

MRHA4445

Spec Sheet

MRHA4445 Splice Kit

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MRHA4485

Features

Splices a section of the RAD4100 Curved Series Rail to a section of the RAD4110 Series Rail.
Bolt-On Splice Kit.
Bolt-on kit eliminates need to weld bosses.
Provides easier access to bolt heads.

Rail Type

RAD4110

weight

3.8 lbs. [1.72kg].

CAD Drawings

MRHA4485

Spec Sheet

MRHA4485 Splice Kit

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TRS2067