AS 1418.1-2002

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Cranes, hoists and winches, Part 1: General requirements

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Specifies general requirements for cranes as defined in AS 2549. Includes the design of cranes by the traditional working stress method and also allows design by the limit states method. No set of generally accepted partial load factors necessary for crane design by the limit states method are available.

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About this publication

PREFACE

FOREWORD

1 SCOPE AND GENERAL

1.1 SCOPE

1.2 NEW DESIGNS, INNOVATIONS AND DESIGN METHODS

1.3 REFERENCED DOCUMENTS

1.4 DEFINITIONS

1.5 NOTATION

1.6 CONTACT SURFACE TEMPERATURE

2 CLASSIFICATION OF CRANES

2.1 SCOPE OF SECTION

2.2 GENERAL

2.3 GROUP CLASSIFICATION

2.3.1 Bases of classification

2.3.2 Class of utilization

2.3.3 Load spectrum

2.3.4 Group classification

3 MATERIALS FOR CRANES

3.1 SCOPE OF SECTION

3.2 MATERIAL SPECIFICATIONS

4 CRANE LOADS

4.1 SCOPE OF SECTION

4.2 REFERENCE TO OTHER PARTS OF THIS STANDARD

4.3 DETERMINATION OF CRANE LOADS

4.4 CATEGORIZATION OF CRANE LOADS

4.5 PRINCIPAL LOADS

4.5.1 General

4.5.2 Dead loads

4.5.2.1 Dead load dynamic factor

4.5.3 Hoisted load

4.5.3.1 Description

4.5.3.2 Hoisting operations to be considered

4.5.3.3 Hoisted load dynamic factor (ϕ2)

4.5.3.4 Rapid load release dynamic factor (ϕ3) (see Figure 4.5.3.4.)

4.5.4 Inertia loads

4.5.4.1 General

4.5.4.2 Methods of determination of inertia loads

4.5.4.3 Simplified method of determination of traction forces

4.5.4.4 Application of traction forces

4.5.4.5 Determination of loads due to slewing and luffing motions

4.5.5 Loads induced by displacements

4.6 ADDITIONAL LOADS

4.6.1 General

4.6.2 Wind forces

4.6.2.1 Principles

4.6.2.2 Wind forces on the hoisted load

4.6.3 Snow and ice loads

4.6.4 Forces due to temperature variation

4.6.5 Lateral forces due to oblique travel

4.6.5.1 General

4.6.5.2 Coefficient of frictional contact (KO)

4.6.5.3 Calculation of steering contact force (POTE)

4.6.5.4 Calculation of steering contact force (POTW)

4.6.5.5 Oblique travel force (POTE) and reduction factor (KF)

4.6.6 Bulk material loads

4.7 SPECIAL LOADS

4.7.1 General

4.7.2 Loads due to off-vertical hoisting

4.7.3 Dynamic effects of test loads

4.7.4 Buffer forces

4.7.5 Tilting forces

4.7.6 Miscellaneous loads

4.7.7 Loads caused by emergency conditions

4.7.7.1 Mechanical failure

4.7.7.2 Emergency cut-out

4.7.7.3 Application of loads

4.7.8 Seismic loads

4.7.9 Loads during erection

4.7.10 Forces during transport

4.8 PRINCIPLES FOR DETERMINATION OF CRANE LOAD COMBINATIONS

4.8.1 Basic considerations

4.8.2 Application of load combinations

4.8.2.1 Use of Table 4.8

4.8.2.2 Working stress design method

4.8.2.3 Limit states design method

4.8.2.4 Proof of fatigue strength

4.8.2.5 High risk applications

5 DESIGN OF CRANE STRUCTURE

5.1 GENERAL

5.2 BASIS OF DESIGN

5.2.1 Design of structure

5.2.2 Classification of crane structures

5.2.2.1 Bases of classification

5.2.2.2 Class of utilization

5.2.2.3 State of loading

5.2.2.4 Structure classification

5.3 DESIGN OBJECTIVE

5.4 METHOD OF DESIGN

5.4.1 General

5.4.2 Working stress design method

5.4.3 Limit states method

5.5 FATIGUE STRENGTH

5.5.1 General

5.5.2 Working stress design

5.5.3 Limit states design

5.6 DESIGN FOR SERVICEABILITY DEFLECTION AND VIBRATION

5.6.1 General

5.6.2 Deflection limits of crane structural members

5.6.3 Driver exposure to vibration

6 STABILITY

6.1 SCOPE OF SECTION

6.2 OVERTURNING

6.3 STABILITY DURING ERECTION AND MAINTENANCE

6.4 SAFETY AGAINST DRIFTING

7 CRANE MECHANISMS

7.1 GENERAL

7.2 MECHANISMS

7.3 BASIS OF DESIGN

7.3.1 Design of mechanism

7.3.2 Design for strength

7.3.3 Design for life

7.3.3.1 Wear

7.3.3.2 Fatigue strength

7.3.4 Classification of crane mechanisms

7.3.4.1 Basis of classification

7.3.4.2 Class of utilization

7.3.4.3 State of loading

7.3.4.4 Group classification

7.4 MECHANISM LOADINGS

7.4.1 Determination of loads

7.4.2 Categorization of mechanism loads

7.4.3 Categorization of mechanism loading

7.5 PRINCIPAL LOADS

7.6 ADDITIONAL LOADS

7.7 SPECIAL LOADS

7.8 CATEGORIZATION OF FREQUENCY OF MECHANISM LOAD COMBINATIONS

7.9 PRINCIPLES FOR DETERMINING MECHANISM LOAD COMBINATIONS

7.9.1 General

7.9.2 Application of load combinations

7.9.2.1 Use of Table 7.9

7.9.2.2 Working stress design method

7.9.2.3 Proof of fatigue strength

7.9.2.4 High-risk applications

7.9.2.5 Calculation of loads

7.9.2.6 Static strength

7.9.2.7 Determination of stresses

7.9.2.8 Permissible stresses for strength

7.10 MECHANICAL COMPONENTS

7.10.1 General

7.10.2 Bearings

7.10.3 Gearing

7.10.3.1 General

7.10.3.2 Strength requirements

7.10.3.3 Gears

7.10.3.4 Gear enclosures

7.10.3.5 Bearings and supports

7.10.4 Couplings

7.10.4.1 General

7.10.4.2 Clutches

7.11 DRIVING MEDIA

7.12 BRAKING

7.12.1 Braking media

7.12.2 Size and characteristics

7.12.3 Environmental protection

7.12.4 Accessibility

7.12.5 Materials

7.12.5.1 General

7.12.5.2 Friction lining

7.12.5.3 Brake cone, disc, drum or equivalent friction-surface component

7.12.5.4 Springs

7.12.6 Design

7.12.7 Operation

7.12.8 Hoisting motion

7.12.8.1 General

7.12.8.2 Emergency load lowering

7.12.8.3 Multiple brake hoists

7.12.8.4 Dangerous goods lifting

7.12.8.5 Special lifting applications

7.12.8.6 Lifting personnel

7.12.8.7 Molten metal handling

7.12.9 Travel and traverse motions

7.12.10 Luffing motion

7.12.11 Slewing motion

7.13 MOTION LIMITS, INDICATORS AND WARNING DEVICES

7.13.1 Provision of limits

7.13.2 Range of limitation of motion

7.13.3 Operation of motion limit

7.13.4 Indicators and warning devices

7.14 ROPES AND REEVED SYSTEMS

7.14.1 Ropes

7.14.2 Components

7.14.3 Tensiometers

7.15 GUYS, OTHER FIXED-ROPE SYSTEMS, AND STATIONARY ROPES

7.16 REEVED SYSTEMS

7.16.1 Wire rope

7.16.2 Wire rope selection procedure

7.16.2.1 General

7.16.2.2 Selection of Zp values

7.16.2.3 Rope coefficient (C)

7.16.2.4 Calculation of minimum rope diameter

7.16.2.5 Minimum wire rope breaking load

7.16.2.6 Dangerous goods applications of wire rope

7.16.2.7 Personnel applications for wire rope

7.16.3 Fleet angle from drum or sheave

7.16.4 Rope anchorages

7.16.5 Rope equalizers

7.16.6 Overhauling weight

7.16.7 Fibre rope

7.17 SHEAVES

7.17.1 Materials

7.17.2 Design

7.17.3 Diameter of sheave

7.17.4 Sheave guard

7.18 DRUM AND SHEAVE DIAMETERS

7.19 DRUMS

7.19.1 Materials

7.19.2 Design

7.19.2.1 Grooved drum

7.19.2.2 Ungrooved drum

7.19.2.3 Rope anchorage

7.19.3 Diameter of drum

7.19.4 Actual thickness of drum shell

7.19.5 Theoretical thickness of drum shell (abbreviated method)

7.20 WHEEL AND RAIL SYSTEMS

7.20.1 Selection of wheels and rails

7.20.2 Wheel loading

7.20.3 Wheels

7.20.3.1 Material

7.20.3.2 Load capacity of wheels (PW)

7.20.3.3 Permissible unfactored bearing stress (FpW)

7.20.3.4 Group classification coefficient (CC)

7.20.3.5 Wheel-speed coefficient (CW)

7.20.3.6 Tread and flange profile

7.20.3.7 Unflanged wheels

7.20.3.8 Matched wheels

7.20.3.9 Overhung wheels

7.20.3.10 Anti-drop and anti-derailment pads

7.20.4 Tyres

7.20.5 Side guide rollers

7.20.6 Rails

7.20.6.1 Material

7.20.6.2 Load capacity of rail (PT)

7.20.6.3 Number of stress cycles applied by wheels to rail (NXW)

7.20.6.4 Permissible unfactored wheel load (PTS)

7.20.6.5 Effective railhead width (BTE)

7.20.7 Rail fastening and joining

7.20.7.1 Methods

7.20.7.2 Welding

7.20.7.2.1 Rail section profiles

7.20.7.2.2 Billet sections

7.20.7.3 Direct bolted

7.20.7.4 Hook bolts

7.20.7.5 Rail clips

7.20.7.6 Rail clamps

7.20.7.7 Laid-on sleepers

7.20.8 Rail joints

7.20.9 Rail alignment

7.20.10 Runway flanges—Lateral support

7.21 GUIDES FOR MOVING PARTS

7.22 DETACHABLE PARTS

7.23 DIRECTLY FITTED HOOKS

7.24 COUNTERWEIGHTS

8 ELECTRICAL EQUIPMENT AND CONTROLS

8.1 SCOPE OF SECTION

8.2 MATERIALS AND EQUIPMENT

8.3 INFORMATION RELEVANT TO DESIGN OF ELECTRICAL SYSTEM

8.4 MOTORS

8.4.1 Enclosure and duty type

8.4.2 Rated output and performance characteristics

8.4.3 Resistors for motor power circuits

8.5 MOTOR CONTROL

8.5.1 Control systems

8.5.2 Electrical braking

8.5.3 Motor control circuit

8.6 CONTACTORS

8.7 CONTROLLERS (see also Section 11)

8.7.1 Means of control

8.7.2 Requirements common to all controllers

8.7.3 Manual control

8.7.3.1 Cabin control stations

8.7.3.2 Pendent control station

8.7.3.2.1 Electrical power supply

8.7.3.2.2 Design and construction

8.7.3.2.3 Pendent support cable

8.7.3.2.4 Pendent support cable (see also Clause 11.3)

8.7.3.3 Whole-current controller

8.7.3.3.1 Method of operation

8.7.3.4 Cordless controllers

8.7.3.4.1 General

8.7.3.4.2 System design requirements

8.7.4 Electronic control

8.7.5 Automatic control

8.7.5.1 System design requirements

8.7.5.2 Safety enclosure

8.7.5.3 System requirements

8.7.5.4 Access for power-on faults diagnosis

8.7.6 Stop functions

8.7.6.1 General

8.7.6.2 Emergency stop

8.8 LIMIT SWITCHES (see also Clause 7.13)

8.8.1 Purpose

8.8.2 Motion limiting devices

8.8.3 Optional limit switches

8.8.4 End of travel limit switch

8.8.5 Working-limit switch

8.8.6 Final-limit switch

8.8.7 Design and construction

8.8.8 Application

8.8.8.1 Hoisting motion

8.8.8.2 Motions other than hoisting

8.8.8.3 Spreader (for container and similar handling)

8.8.8.4 Twistlock details (for container similar handling)

8.9 CONTROL CIRCUITS

8.9.1 Control circuit supply

8.9.2 Control circuit voltages

8.9.3 Protection

8.9.4 Connection of Control Devices

8.10 ELECTRICAL ISOLATION

8.10.1 Purpose

8.10.2 Arrangement of isolation

8.10.3 Main isolator

8.10.3.1 General

8.10.3.2 Alternative power supplies

8.10.3.3 Sectionalized collector system

8.10.3.4 Design and construction

8.10.3.5 Remote operation of main isolator

8.10.4 Crane isolator

8.10.4.1 General

8.10.4.2 Location

8.10.4.3 Type of switch

8.10.5 Access isolators

8.10.6 Service isolator

8.10.7 Accessory, ancillary and auxiliary isolators

8.10.8 Emergency isolation

8.11 ELECTRICAL PROTECTION

8.11.1 Purpose

8.11.2 Overcurrent protection

8.11.2.1 General

8.11.2.2 Motor circuits

8.11.2.3 Control, accessory, ancillary and auxiliary circuits

8.11.3 Motor protection

8.11.3.1 Motor overload protection

8.11.3.2 Motor temperature protection

8.11.3.3 Motor overspeed protection

8.11.4 Earthing

8.11.5 Electromagnetic compatibility (EMC)

8.11.6 Phase sequence protection

8.11.7 Lightning protection

8.12 HIGH-VOLTAGE SUPPLY TO CRANES

8.13 CRANES WITH MAGNET ATTACHMENTS

8.13.1 General

8.13.2 Lifting capacity

8.13.3 Magnet controllers

8.13.4 Application of magnets

8.13.5 Emergency batteries

8.13.6 Magnet circuits

8.13.7 Rectifiers

8.13.8 Magnet leads

8.13.9 Magnet couplings

8.13.10 Magnet attachments

8.13.11 Magnet types

8.13.11.1 Battery-fed lifting magnets

8.13.11.2 Mains-fed lifting magnets

8.13.11.3 Permanent lifting magnets

8.13.11.4 Electro-permanent lifting magnets

8.14 WIRING AND CONDUCTORS

8.14.1 Materials and installation

8.14.2 Multi-outlet electrical supply

8.14.3 Crane collector systems

8.14.3.1 General

8.14.3.2 Material

8.14.3.3 End support

8.14.3.4 Intermediate support

8.14.3.5 Arrangement

8.14.4 Collector rings

8.14.5 Electrical supply cables

8.14.6 Flexible cable

8.15 ACCESSIBILITY

8.15.1 General

8.15.2 Servicing platforms

8.16 ELECTRICAL EQUIPMENT MARKING AND INSTALLATION DIAGRAMS

8.16.1 Marking

8.16.2 Diagrams

9 HYDRAULICE QUIPMENT AND CONTROLS

9.1 SCOPE OF SECTION

9.2 MATERIALS

9.3 BASIS OF DESIGN

9.3.1 General

9.3.2 Braking

9.3.3 Emergency stop

9.3.4 Tubes, hoses, fittings and fluid passages

9.3.5 Safety features

9.4 CIRCUIT DIAGRAM

9.5 COMPONENTS

9.5.1 Accumulators

9.5.2 Cylinders

9.5.3 Filters and strainers

9.5.4 Hydraulic controls

9.5.5 Hydraulic pumps and hydraulic motors

9.5.6 Hydraulic tubing, hoses, fittings and fluid passages

9.5.7 Reservoirs

9.6 INSTALLATION

9.7 TESTING

9.8 MARKING

9.9 INSPECTION AND MAINTENANCE

10 PNEUMATIC EQUIPMENT AND CONTROLS

10.1 SCOPE OF SECTION

10.2 MATERIALS

10.3 BASIS OF DESIGN

10.3.1 General

10.3.2 Braking

10.3.3 Emergency stop

10.3.4 Tubes, hoses, fittings and air passages

10.3.5 Safety features

10.4 CIRCUIT DIAGRAM

10.5 COMPONENTS

10.5.1 Cylinders

10.5.2 Filters

10.5.3 Pneumatic controls

10.5.4 Pneumatic motors

10.5.5 Pneumatic tubing, hoses, fittings and air passages

10.5.6 Receivers

10.6 INSTALLATION

10.7 TESTING

10.8 MARKING

10.9 INSPECTION AND MAINTENANCE

11 OPERATIONAL DESIGN

11.1 SCOPE OF SECTION

11.2 CONTROL CABIN

11.2.1 Location of control cabin

11.2.2 Space for operator

11.2.3 Seating of operator

11.2.4 Controls and indicators

11.2.5 Visibility from the cabin

11.2.6 Ventilation

11.2.7 Lighting

11.2.8 Thermal environment

11.2.9 Noise exposure criteria

11.2.10 Communication

11.2.11 Fire extinguisher

11.2.12 Emergency entry to control cabin

11.2.13 Emergency egress from control cabin

11.3 PENDENT CONTROL STATIONS AND PENDENT CORDS

11.3.1 Pathway for crane operator

11.3.2 Operating level of controls

11.4 OPERATOR CONTROLS AND INDICATORS

11.4.1 Operation of controls

11.4.2 Interlocking of controls

11.4.3 Controls and indicators for ancillaries

11.4.4 Marking of operator controls

11.5 WARNING DEVICES

12 MANUFACTURE AND CONSTRUCTION

12.1 SCOPE OF SECTION

12.2 MATERIALS

12.3 FABRICATION AND ASSEMBLY

12.4 REWORK

12.5 FINISH

12.6 DRAINING

12.7 ACCESS AND CLEARANCES

12.7.1 General

12.7.2 Access to crane operating position

12.7.3 Access and egress facilities

12.7.3.1 General

12.7.3.2 Access for inspection and servicing

12.7.4 Clearances

12.8 REPAIRS

13 INSPECTION AND TESTING

13.1 SCOPE OF SECTION

13.2 INSPECTION

13.3 TESTING

13.4 COMMISSIONING

14 MARKING

14.1 SCOPE OF SECTION

14.2 MARKING

14.2.1 General

14.2.2 Marking on lifting devices

15 OPERATING ENVIRONMENT

15.1 GENERAL

15.2 INDOOR INSTALLATION

15.2.1 Normal indoor service conditions

15.2.2 Special service conditions

15.3 OUTDOOR INSTALLATION

15.3.1 Normal outdoor service conditions

15.3.2 Special service conditions

15.4 HAZARDOUS AREAS

16 MANUALS

16.1 GENERAL

16.2 CRANE OPERATOR’S MANUAL

16.3 MAINTENANCE MANUAL

16.4 SERVICE RECORD (LOGBOOK)

16.5 PARTS BOOK

APPENDIX A

APPENDIX B

B1 REFERENCED DOCUMENTS

APPENDIX C

C1 GENERAL

C2 COMMON FAIL-SAFE SYSTEMS

C2.1 Emergency stop systems

C2.2 Fail-safe brake

C2.3 Structural elements

C2.4 Ratchet locks

APPENDIX D

APPENDIX E

E1 GENERAL

E2 GENERAL METHOD OF CALCULATION APPLICABLE TO ALL BRIDGE AND GANTRY CRANES

APPENDIX F

F1 INTRODUCTION

F1.1 General

F1.2 Approaches

F1.3 Choice of approach

F2 DESIGN CRITERIA

APPENDIX G

APPENDIX H

H1 EXAMPLE 1

H2 EXAMPLES 2

APPENDIX I

APPENDIX J

APPENDIX K

APPENDIX L

L1 APPLICATION

L2 NOTATION

L3 PERMISSIBLE STRESSES

L4 LIMITATIONS ON DRUM-SHELL THICKNESS

L5 STRESSES IN SINGLE-LAYER DRUM∗

L6 STRESSES IN MULTILAYER DRUM∗

L7 DRUM DESIGN FACTORS

APPENDIX M

M1 STANDARDS FOR COMPONENTS USED IN LIFTING SYTEMS

M2 OTHER RELATED DOCUMENTS

Amendment control sheet

AS 1418.1—2002

Amendment No. 1 (2004)

Revised text