AS 1418.01-2002

AS 1418.12002 (Incorporating Amendment No. 1)

Australian Standard

Cranes, hoists and winches

Part 1: General requirements

AS

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This Australian Standard was prepared by Committee ME-005, Cranes, General. It was approved on behalf of the Council of Standards Australia on 15 February 2002.

This Standard was published on 20 June 2002.

The following are represented on Committee ME-005:

Association of Consulting Engineers Australia

Australian Elevator Association

Australian Industry Group

Australian Institute for Non-destructive Testing

Bureau of Steel Manufacturers of Australia

Crane Industry Council of Australia

Department of Administrative and Information Services (SA)

Department of Industrial Relations (Qld)

Department of Infrastructure, Energy and Resources (Tas)

Department of Labour New Zealand

Institution of Engineers Australia

State Chamber of Commerce

University of New South Wales

Victorian WorkCover Authority

WorkCover New South Wales

WorkSafe Western Australia

Keeping Standards up-to-date

Standards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased.

Detailed information about Standards can be found by visiting the Standards Web Shop at www.standards.com.au and looking up the relevant Standard in the on-line catalogue.

Alternatively, the printed Catalogue provides information current at 1 January each year, and the monthly magazine, The Global Standard, has a full listing of revisions and amendments published each month.

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We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at [email protected], or write to the Chief Executive, Standards Australia International Ltd, GPO Box 5420, Sydney, NSW 2001.

This Standard was issued in draft form for comment as DR 00321.

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AS 1418.12002 (Incorporating Amendment No. 1)

Australian Standard



Originated as part of AS CB21938. Previous edition 1994. Fourth edition 2002. Reissued incorporating Amendment No.1 (November 2004)

COPYRIGHT

Standards Australia International

All rights are reserved. No part of this work may be reproduced or copied in any form or by

any means, electronic or mechanical, including photocopying, without the written

permission of the publisher.

Published by Standards Australia International Ltd GPO Box 5420, Sydney, NSW 2001,

Australia

ISBN 0 7337 4372 2

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AS 1418.12002 2

PREFACE

This Standard was prepared by the Standards Australia Committee ME-005, Cranes, to

supersede AS 1418.11994, SAA Crane Code, Part 1: General requirements.

This Standard incorporates Amendment No. 1 (November 2004). The changes required by the

Amendment are indicated in the text by a marginal bar and amendment number against the

clause, note, table, figure or part thereof affected.

The objective of this Standard is to provide uniform requirements within Australia for the

design and construction of cranes and similar lifting appliances.

Requirements that apply to more than one type of crane are included in Part 1: General

requirements. Any requirements that apply to only one type of crane should only appear in

the specific part for that crane and not in Part 1. Some requirements have been deleted from

this Standard and are being moved to their applicable Part.

The term shall is used to indicate those requirements that have to be met for compliance

with the objectives and intent of this Standard.

The Commonwealth, State and Territory governments may choose to incorporate this

Australian Standard into their laws and regulations. The exact manner of incorporation will

determine whether the whole document is incorporated or whether specific sections or

provisions of the Australian Standard are incorporated. The manner of incorporation will

determine which of the Standards requirements (shall statements) have been made a legal

requirement in a jurisdiction. As a general principle, where an Australian Standard is

incorporated by a regulation, the legal status of the Standards requirements and

recommendations is made clear by the incorporation of provisions of the regulation.

Thus, the requirements (shall statements) in an Australian Standard are not mandatory for

legal purposes unless incorporated specifically by an Act or regulation. Readers will need to

refer to their jurisdictions law to determine which parts of the Australian Standard (if any)

have been incorporated and the manner of incorporation.

This Standard deviates from ISO 11660.1 in regard to access requirements for safety

reasons.

This revision includes the following changes:

(a) The maximum temperature of touchable surfaces is now 55C.

(b) The term safe working load has been changed to rated capacity and other uses of

the word safe have been avoided due to the legal significance placed on the word.

(c) Reference to approval by the relevant authority has been removed to reflect the

current regulatory environment.

(d) Tear-out/tear-off forces for cranes equipped with magnets or grabs have to be taken

into consideration.

(e) There is a new method of calculating the hoisting factor (2), which is taken from

DIN 15018.

(f) Out-of-service wind loads are now considered additional loads instead of special

loads.

(g) Transport loads have to be taken into consideration where the crane is transported

during its life.

(h) The design of monorail beams has been moved to a new Part 18: Runways and

monorails.

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3 AS 1418.12002

(i) The factor of safety against drifting during operation has changed to 1.5.

(j) The design life of mechanisms may be less than 10 years provided this is

documented.

(k) In determining the group classification of mechanisms, an adjustment to an equivalent

number of running hours is allowed after the load spectrum factor has been set.

(l) Requirements for gearing have been expanded.

(m) Requirements for hoisting, travel, and traverse motion brakes have been expanded.

(n) A minimum worn wheel flange thickness has been defined.

(o) Hookbolts used for rail fastening are required to be ductile.

(p) Detachable parts are required to be designed for safe assembly and disassembly.

(q) The attachment of hooks directly attached to structural members is required to be

designed such that no bending moment is experienced by the hook shank.

(r) Some requirements for counterweights have been added.

(s) Requirements for controllers have been revised.

(t) Requirements for limit switches have been revised.

(u) Motor protection requirements have been revised.

(v) Mention is made of electromagnetic compatibility (EMC) and phase sequence

protection.

(w) Extra requirements for cranes with lifting magnets have been added.

(x) Emergency egress requirements have been revised.

(y) Requirements for installation of cranes in hazardous areas have been revised to

interface with recently revised applicable Standards.

(z) Requirements for operators and maintenance manuals have been added.

Questions concerning the meaning, the application, or effect of any part of this Standard,

may be referred to the Standards Australia Committee on Cranes. The authority of the

Committee is limited to matters of interpretations and it will not adjudicate in disputes.

Statements expressed in mandatory terms in notes to tables and figures are deemed to be

requirements of this Standard.

The terms normative and informative have been used in this Standard to define the

application of the appendix to which they apply. A normative appendix is an integral part

of a Standard, whereas an informative appendix is only for information and guidance.

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AS 1418.12002 4

CONTENTS

Page

FOREWORD.............................................................................................................................. 8

SECTION 1 SCOPE AND GENERAL

1.1 NEW DESIGNS, INNOVATIONS AND DESIGN METHODS ................................. 9

1.2 REFERENCED DOCUMENTS .................................................................................. 9

1.3 DEFINITIONS ............................................................................................................ 9

1.4 NOTATION .............................................................................................................. 10

1.5 CONTACT SURFACE TEMPERATURE................................................................. 10

SECTION 2 CLASSIFICATION OF CRANES

2.1 SCOPE OF SECTION ............................................................................................... 11

2.2 GENERAL ................................................................................................................ 11

2.3 GROUP CLASSIFICATION..................................................................................... 12

SECTION 3 MATERIALS FOR CRANES

3.1 SCOPE OF SECTION ............................................................................................... 15

3.2 MATERIAL SPECIFICATIONS............................................................................... 15

SECTION 4 CRANE LOADS

4.1 SCOPE OF SECTION ............................................................................................... 16

4.2 REFERENCE TO OTHER PARTS OF THIS STANDARD...................................... 16

4.3 DETERMINATION OF CRANE LOADS ................................................................ 16

4.4 CATEGORIZATION OF CRANE LOADS............................................................... 16

4.5 PRINCIPAL LOADS................................................................................................. 17

4.6 ADDITIONAL LOADS ............................................................................................ 25

4.7 SPECIAL LOADS..................................................................................................... 28

4.8 PRINCIPLES FOR DETERMINATION OF CRANE LOAD COMBINATIONS..... 30

SECTION 5 DESIGN OF CRANE STRUCTURE

5.1 GENERAL ................................................................................................................ 33

5.2 BASIS OF DESIGN .................................................................................................. 33

5.3 DESIGN OBJECTIVE............................................................................................... 35

5.4 METHOD OF DESIGN............................................................................................. 35

5.5 FATIGUE STRENGTH............................................................................................. 35

5.6 DESIGN FOR SERVICEABILITY DEFLECTION AND VIBRATION .................. 36

SECTION 6 STABILITY

6.1 SCOPE OF SECTION ............................................................................................... 37

6.2 OVERTURNING....................................................................................................... 37

6.3 STABILITY DURING ERECTION AND MAINTENANCE ................................... 37

6.4 SAFETY AGAINST DRIFTING............................................................................... 37

SECTION 7 CRANE MECHANISMS

7.1 GENERAL ................................................................................................................ 39

7.2 MECHANISMS......................................................................................................... 39

7.3 BASIS OF DESIGN .................................................................................................. 39

7.4 MECHANISM LOADINGS ...................................................................................... 42

7.5 PRINCIPAL LOADS................................................................................................. 43

7.6 ADDITIONAL LOADS ............................................................................................ 45 Acc

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7.7 SPECIAL LOADS..................................................................................................... 45

7.8 CATEGORIZATION OF FREQUENCY OF MECHANISM LOAD

COMBINATIONS..................................................................................................... 46

7.9 PRINCIPLES FOR DETERMINING MECHANISM LOAD COMBINATIONS ..... 46

7.10 MECHANICAL COMPONENTS ............................................................................. 51

7.11 DRIVING MEDIA .................................................................................................... 53

7.12 BRAKING................................................................................................................. 53

7.13 MOTION LIMITS, INDICATORS AND WARNING DEVICES ............................. 57

7.14 ROPES AND REEVED SYSTEMS .......................................................................... 58

7.15 GUYS, OTHER FIXED-ROPE SYSTEMS, AND STATIONARY ROPES ............... 58

7.16 REEVED SYSTEMS................................................................................................. 59

7.17 SHEAVES ................................................................................................................. 62

7.18 DRUM AND SHEAVE DIAMETERS ...................................................................... 62

7.19 DRUMS..................................................................................................................... 63

7.20 WHEEL AND RAIL SYSTEMS ............................................................................... 66

7.21 GUIDES FOR MOVING PARTS.............................................................................. 83

7.22 DETACHABLE PARTS............................................................................................ 83

7.23 DIRECTLY FITTED HOOKS................................................................................... 83

7.24 COUNTERWEIGHTS............................................................................................... 83

SECTION 8 ELECTRICAL EQUIPMENT AND CONTROLS

8.1 SCOPE OF SECTION ............................................................................................... 84

8.2 MATERIALS AND EQUIPMENT............................................................................ 84

8.3 INFORMATION RELEVANT TO DESIGN OF ELECTRICAL SYSTEM.............. 84

8.4 MOTORS .................................................................................................................. 85

8.5 MOTOR CONTROL ................................................................................................. 85

8.6 CONTACTORS......................................................................................................... 86

8.7 CONTROLLERS (see also Section 11) ..................................................................... 87

8.8 LIMIT SWITCHES (see also Clause 7.13) ................................................................ 93

8.9 CONTROL CIRCUITS.............................................................................................. 95

8.10 ELECTRICAL ISOLATION ..................................................................................... 96

8.11 ELECTRICAL PROTECTION................................................................................ 101

8.12 HIGH-VOLTAGE SUPPLY TO CRANES ............................................................. 104

8.13 CRANES WITH MAGNET ATTACHMENTS....................................................... 104

8.14 WIRING AND CONDUCTORS ............................................................................. 108

8.15 ACCESSIBILITY.................................................................................................... 111

8.16 ELECTRICAL EQUIPMENT MARKING AND INSTALLATION DIAGRAMS.. 111

SECTION 9 HYDRAULIC EQUIPMENT AND CONTROLS

9.1 SCOPE OF SECTION ............................................................................................. 112

9.2 MATERIALS .......................................................................................................... 112

9.3 BASIS OF DESIGN ................................................................................................ 112

9.4 CIRCUIT DIAGRAM ............................................................................................. 113

9.5 COMPONENTS ...................................................................................................... 113

9.6 INSTALLATION .................................................................................................... 115

9.7 TESTING ................................................................................................................ 115

9.8 MARKING .............................................................................................................. 115

9.9 INSPECTION AND MAINTENANCE ................................................................... 115

SECTION 10 PNEUMATIC EQUIPMENT AND CONTROLS

10.1 SCOPE OF SECTION ............................................................................................. 116

10.2 MATERIALS .......................................................................................................... 116

10.3 BASIS OF DESIGN ................................................................................................ 116

10.4 CIRCUIT DIAGRAM ............................................................................................. 117 Acc

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AS 1418.12002 6

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10.5 COMPONENTS ...................................................................................................... 117

10.6 INSTALLATION .................................................................................................... 118

10.7 TESTING ................................................................................................................ 118

10.8 MARKING .............................................................................................................. 118

10.9 INSPECTION AND MAINTENANCE ................................................................... 118

SECTION 11 OPERATIONAL DESIGN

11.1 SCOPE OF SECTION ............................................................................................. 119

11.2 CONTROL CABIN ................................................................................................. 119

11.3 PENDENT CONTROL STATIONS AND PENDENT CORDS.............................. 121

11.4 OPERATOR CONTROLS AND INDICATORS..................................................... 122

11.5 WARNING DEVICES ............................................................................................ 122

SECTION 12 MANUFACTURE AND CONSTRUCTION

12.1 SCOPE OF SECTION ............................................................................................. 123

12.2 MATERIALS .......................................................................................................... 123

12.3 FABRICATION AND ASSEMBLY ....................................................................... 123

12.4 REWORK................................................................................................................ 123

12.5 FINISH .................................................................................................................... 123

12.6 DRAINING ............................................................................................................. 123

12.7 ACCESS AND CLEARANCES .............................................................................. 123

12.8 REPAIRS................................................................................................................. 124

SECTION 13 INSPECTION AND TESTING

13.1 SCOPE OF SECTION ............................................................................................. 125

13.2 INSPECTION.......................................................................................................... 125

13.3 TESTING ................................................................................................................ 125

13.4 COMMISSIONING................................................................................................. 125

SECTION 14 MARKING

14.1 SCOPE OF SECTION ............................................................................................. 126

14.2 MARKING .............................................................................................................. 126

SECTION 15 OPERATING ENVIRONMENT

15.1 GENERAL .............................................................................................................. 127

15.2 INDOOR INSTALLATION .................................................................................... 127

15.3 OUTDOOR INSTALLATION ................................................................................ 128

15.4 HAZARDOUS AREAS........................................................................................... 128

SECTION 16 MANUALS

16.1 GENERAL .............................................................................................................. 129

16.2 CRANE OPERATORS MANUAL......................................................................... 129

16.3 MAINTENANCE MANUAL .................................................................................. 129

16.4 SERVICE RECORD (LOGBOOK) ......................................................................... 130

16.5 PARTS BOOK ........................................................................................................ 130

APPENDICES

A ORGANIZATION OF AUSTRALIAN STANDARD FOR CRANES .................... 131

B LIST OF REFERENCED STANDARDS AND STANDARDS FOR REFERENCE136

C FAILURE TO SAFETY (FAIL-SAFE SYSTEMS)................................................. 140

D TYPICAL CRANE APPLICATION CLASSIFICATION ....................................... 142

E OBLIQUE TRAVEL FORCESDETAILED ANALYSIS .................................... 144

F FATIGUE DESIGN OF MECHANISMS................................................................ 148

G REEVED SYSTEMSALLOWANCE FOR FRICTIONAL EFFECTS ................. 150

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Page

H EXAMPLES OF WIRE ROPE SELECTION .......................................................... 152

I ROPE ANCHORAGE POINT LOCATION............................................................. 153

J GROOVE PROFILES FOR WIRE ROPE SHEAVES ............................................. 154

K GROOVE PROFILES FOR ROPE DRUMS ........................................................... 157

L THEORETICAL THICKNESS OF HOIST DRUM................................................. 158

M RELATED STANDARDS ....................................................................................... 172

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AS 1418.12002 8

FOREWORD

This Standard is an authoritative source of fundamental principles for application by

responsible and competent persons and organizations. It has no legal authority in its own

right but it may acquire legal standing in one or more of the following ways:

(a) Adoption by a regulatory authority.

(b) Reference to compliance with the Standard as a contractual requirement.

(c) Claim, by a manufacturer or manufacturers agent (or both), of compliance with the

Standard.

This Standard has been prepared bearing in mind that it will be used by a number of

different categories of users, with entirely different objectives.

Essentially, the users of this Standard are

(i) crane and hoist manufacturers, importers and agents;

(ii) crane and hoist owners;

(iii) crane and hoist users and operators; and

(iv) regulatory and legal authorities.

Crane and hoist manufacturers, importers and agents require acceptable data that can be

used in the design, manufacture, testing and acceptance inspection of cranes and hoists for

both general and particular applications.

Crane and hoist owners require data for specification and selection of cranes and hoists. In

this situation, applications can be more specific.

Crane and hoist users and operators require statements of their responsibilities in the safe

use of equipment.

Regulatory and legal authorities look to Standards as a framework on which regulations,

directives and other legislation can be based. Further legal aspects of crane Standards must

be recognized because they may also be utilized as measures of legal responsibility.

This Standard references the alternative limit states design method in addition to the

working stress design method.

A general requirement for safety is that, upon the occurrence of a high risk condition, a

safety device or system (or both) should halt the condition or revert the crane to a

non-dangerous condition. Depending on the risk assessment of the application, it may be

necessary to exceed the minimum safety requirements described herein.

Where personnel are being conveyed, this principle is modified in one of the following

ways:

(A) a fail-safe design, allowing for the simultaneous malfunction of two items, may be

required.

(B) The operator in control is at personal risk.

(C) An increased factor of safety is applied.

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www.standards.com.au Standards Australia

STANDARDS AUSTRALIA

Australian Standard



S E C T I O N 1 S C O P E A N D G E N E R A L

1.1 SCOPE

This Standard specifies the general requirements for cranes, hoists, winches, and their

components, and appliances intended to carry out similar functions, as defined in AS 2549.

It does not include powered industrial trucks as defined in AS 2359.

The term crane used herein applies to a crane, hoist or winch as appropriate.

NOTES:

1 Specific requirements for particular types of cranes and associated equipment are specified in

other parts of AS 1418; these requirements take precedence over corresponding requirements

in this Standard where any difference exists. Appendix A outlines the structure of the

AS 1418 series of Standards.

2 Requirements for the selection, operation and maintenance of cranes are given in the

appropriate part of AS 2550.

1.2 NEW DESIGNS, INNOVATIONS AND DESIGN METHODS

This Standard does not preclude the use of materials, designs, methods of assembly,

procedures, and the like, that do not comply with a specific requirement of this Standard, or

are not mentioned in it, but which can be shown to give equivalent or superior results to

those specified.

Where the limit states design method is used, cranes shall be designed to give a degree of

safety not less than that given in this Standard by the working stress design method for

strength, buckling, deflection, torsion, fatigue and the like.

NOTE: This Standard does not provide specific guidance on the limit state design methods, as the

necessary dynamic factors have not been formulated for the complex forces cranes are subjected

to. This is a worldwide situation and ISO has established a working group specifically to resolve

the issue. Design of structural members by limit state methods, including determination of the

partial load factors for individual loads, should comply with the appropriate Australian Standard,

e.g., AS 1664.1 for aluminium members and AS 4100 for steel members.

1.3 REFERENCED DOCUMENTS

A list of the documents referred to in this Standard is given in Appendix B.

1.4 DEFINITIONS

For the purpose of this Standard, the definitions given in AS 2549 and below apply.

1.4.1 Classification

The system used to provide a means of establishing a rational basis for the design of

structures and machinery. It also serves as a framework of reference between the purchasers

and the manufacturers, by the use of which a particular crane may be matched to the service

for which it is required.

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AS 1418.12002 10

Standards Australia www.standards.com.au

NOTE: Classification considers only the conditions of operation for the intended life of the crane.

These are independent of the type of crane and the way it is operated.

1.4.2 Competent person

A person who has acquired through training, qualification, experience or a combination of

these, the knowledge and skill enabling that person to correctly perform the required task.

1.4.3 Controlled stop

The stopping of a machine motion in a controlled manner, which limits the deceleration to

significantly less than the deceleration experienced in a sudden uncontrolled stop.

NOTE: An example of one method is to reduce the electrical command signal to zero once the

stop signal has been recognized by the control and retain electrical power to the hoisting machine

actuators during the stopping process.

1.4.4 Fail-safe

A state or condition whereby if the fail-safe component fails, a system exists to prevent any

increase of the assessed risk associated with the device.

NOTE: Information regarding fail-safe systems is given in Appendix C.

1.4.5 May

Indicates the existence of an allowable option.

NOTE: Neither inclusion nor exclusion of the option results in non-compliance with the Standard.

1.4.6 Shall

Indicates that compliance with a statement is mandatory for compliance with the objectives

and intent of his Standard (see Preface).

1.4.7 Should

Indicates a recommendation. Neither following nor ignoring the recommendation results in

non-compliance with the Standard.

1.4.8 Rated capacity

The maximum gross load which may be applied to the crane or hoist or lifting attachment

while in a particular working configuration and under a particular condition of use.

1.4.9 Uncontrolled stop

The stopping of a motion by removing power to the machine actuators, all brakes and/or

other mechanical stopping devices being actuated.

1.5 NOTATION

Symbols used in equations in this Standard are defined in relation to the particular equation

in which they occur.

1.6 CONTACT SURFACE TEMPERATURE

Surfaces with temperatures exceeding 55C, which may cause pain by contact with human

skin, shall be protected over all areas that can be touched during normal operation, daily

maintenance and assembly/erection, such that the touchable surfaces are below 55C.

Except where surface temperatures can be increased by solar radiation, surfaces on which

the temperature exceeds 55C shall be located more than 300 mm from hand-related access

points.

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S E C T I O N 2 C L A S S I F I C A T I O N O F C R A N E S

2.1 SCOPE OF SECTION

This Section specifies the classification of a crane (see Clause 1.1) based on the maximum

number of in-service cycles to be carried out during the intended life of the crane and a load

spectrum. Other parts of AS 1418 define which parts of the classification range are

applicable to the various types of cranes.

NOTES:

1 See Clause 1.4.1 for a definition of classification.

2 The C classification relates to the duty (i.e. load spectrum and number of operating cycles) of

the crane as a whole and is intended for contractual and technical reference purposes (see

Clause 2.3).

3 The purpose of the S and M classification is to provide a basis for the load determination

and fatigue analysis of the individual structural and mechanical components (see Sections 5

and 7, respectively). The designer takes the estimated load spectrum and the number of load

applications to determine the group class of the crane.

4 Cranes for specific applications may require minimum classifications as specified elsewhere

in this Standard, or other parts of AS 1418.

2.2 GENERAL

The classification of the crane and its constituent parts shall be as follows:

(a) Group classification Overall classification of the crane based on the number and

magnitude of operating cycles the crane will be expected to see during its design life

(see Clause 2.3.2).

(b) Structural classification Classification of each part of the crane structure based on

the number and magnitude of the load cycles which that part of the structure will see

during the design life of the crane (see Clause 5.2.2).

(c) Mechanical classification Classification of each of the mechanical components of

the crane based on the expected magnitude of the applied load and the number of

operating hours, at the load, for the design life of the crane (see Clause 7.3.4).

Unless otherwise specified in the applicable part of AS 1418, the required design life of any

crane and its constituent parts shall be as follows:

(i) Structures .................................................................................................... 25 years.

(ii) Mechanical components............................................................................... 10 years.

For cranes designed for special applications, the design life may be less than that specified

in Items (i) and (ii) above, provided that

(A) the structural and mechanical components of the crane have been designed for a

specific task of short duration with no intention of redeployment;

(B) the design life and design classification of the components are marked on the

components and crane;

(C) the intended service conditions are well defined in writing by the designer; and

(D) the crane is used in accordance with the designers instructions and actual service

conditions are monitored and recorded in accordance with AS 2550.1.

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AS 1418.12002 12


2.3 GROUP CLASSIFICATION

2.3.1 Bases of classification

The group classification of the crane shall be determined from the class of utilization (see

Clause 2.3.2) and the load spectrum (see Clause 2.3.3) where relevant data is available or

selected from typical crane applications in Appendix D.

2.3.2 Class of utilization

The maximum number of in-service cycles expected from the crane during its intended life

shall be the first basic parameter of classification. The range of classes of utilization are

divided into 10 categories, as shown in Table 2.3.2.

TABLE 2.3.2

CLASSES OF UTILIZATION OF CRANES

Maximum number of

operating cycles

Classes of

utilization Description of use

1.6 104 U0 Infrequent use

3.2 104 U1

6.3 104 U2

1.25 105 U3

2.5 105 U4 Fairly frequent use

5 105 U5 Frequent use

1 106 U6 Very frequent use

2 106 U7 Continuous or near-continuous use

4 106 U8

Greater than

4

106

U9

2.3.3 Load spectrum

The second basic parameter of classification is the load spectrum, which is concerned with

the number of times a load of a particular magnitude, in relation to the capacity of the

crane, is hoisted. The four nominal values of load spectrum factor (Kp) shall be as shown in

Table 2.3.3 and illustrated in Figure 2.3.3, each numerically representative of a

corresponding nominal state of loading.

The load spectrum factor for the crane (Kp) is given by the following equation:

max

i

3

T

ip =

P

P

C

CK . . . 2.3.3

where

Ci = number of load cycles that occur at the individual load levels

= C1, C2, C3, ..., Cn

CT = total of all the individual load cycles at all load levels

= Ci

= C1 + C2 + C3 + ... + Cn

Pi = individual load magnitudes (load levels) characteristic of the duty of the

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= P1, P2, P3, ... Pn

Pmax = rated capacity

NOTE: A load cycle accounts for all motions of the crane when operated between an unloaded

state through to loaded state and returns to its unloaded state.

The nominal load spectrum factor for the crane shall be established by matching the

calculated load spectrum factor to the closest (higher) nominal value of Kp in Table 2.3.3.

NOTE: t1, t2, t3 and t are time increments expressed as a percentage of design life.

FIGURE 2.3.3 TYPICAL LOAD SPECTRA

TABLE 2.3.3

NOMINAL LOAD SPECTRUM FACTOR AND

STATE OF LOADING FOR CRANES

Nominal load

spectrum factor

(Kp)

State of loading Description of use

0.125 Q1Light Cranes that hoist the rated capacity very rarely and,

normally, very light loads

0.25 Q2Moderate Cranes that hoist the rated capacity fairly frequently

and, normally, light loads

0.50 Q3Heavy Cranes that hoist the rated capacity frequently and,

normally, medium loads

1.00 Q4Very heavy Cranes that are frequently loaded close to the rated

capacity

2.3.4 Group classification

The group classification for the various combinations of classes of utilization and state of

loading shall be as given in Table 2.3.4.

NOTE: The application of group classification to specific types of cranes is covered in the appropriate parts

of AS 1418.

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TABLE 2.3.4

GROUP CLASSIFICATION OF CRANES

Group classification of crane

Classes of utilization State of loading

Nominal

load

spectrum

factor

(Kp) U0 U1 U2 U3 U4 U5 U6 U7 U8 U9

Q1Light 0.125 C1 C1 C1 C2 C3 C4 C5 C6 C7 C8

Q2Moderate 0.25 C1 C1 C2 C3 C4 C5 C6 C7 C8 C8

Q3Heavy 0.50 C1 C2 C3 C4 C5 C6 C7 C8 C8 C9

Q4Very heavy 1.00 C2 C3 C4 C5 C6 C7 C8 C8 C9 C9

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S E C T I O N 3 M A T E R I A L S F O R C R A N E S


This Section specifies requirements for materials used in the manufacture of cranes (see

Clause 1.1).

3.2 MATERIAL SPECIFICATIONS

Where applicable, materials shall comply with the relevant Australian Standard

specifications.

Where the properties of any material are in doubt, the material shall be subjected to

sufficient testing in order to determine the properties concerned.

NOTE: Refer to specific parts of AS 1418 for material Standards applicable to a particular crane

type.

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AS 1418.12002 16


S E C T I O N 4 C R A N E L O A D S


This Section specifies the requirements for the determination of loads and load

combinations to be used in the design of crane structures (see Clause 1.1).

4.2 REFERENCE TO OTHER PARTS OF THIS STANDARD

The determination of loads in this Section shall be supplemented by the requirements of the

other relevant parts of this Standard.

4.3 DETERMINATION OF CRANE LOADS

Determination of crane loads shall include all loads resulting from the intended crane

operation, and loads caused by the environment, erection, testing and fault conditions.

Steady-state loads, such as gravity-induced loads, shall be determined from the masses of

all component parts permanently attached to the crane.

Live loads induced on in-service cabin floor walkways and platforms shall be determined in

accordance with the provisions of this Standard and the referenced Standards including

AS 1170.1.

Dynamic loads due to acceleration or deceleration of masses shall be determined by

either

(a) dynamic analysis capable of modelling the characteristics of the crane operations; or

(b) methods of determination of loads specified in this Section.

4.4 CATEGORIZATION OF CRANE LOADS

For convenience of referencing, the crane loads are divided into three load groups as

follows:

(a) Principal loads (see Clause 4.5).

(b) Additional loads (see Clause 4.6).

(c) Special loads (see Clause 4.7).

Each load group is divided into load types as shown in Table 4.4.

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TABLE 4.4

CATEGORIZATION OF CRANE LOADS

Load group Load Reference

Clause

Principal loads

(see Clause 4.5)

Dead loads

Hoisted loads

Inertia loads

Displacement-induced loads

4.5.2

4.5.3

4.5.4

4.5.5

Additional loads

(see Clause 4.6)

In-service and out-of-service wind loads

Snow and ice loads

Temperature-induced forces

Oblique travelling forces

Bulk material loads

4.6.2

4.6.3

4.6.4

4.6.5

4.6.6

Special loads

(See Clause 4.7)

Off-vertical hoisting loads

Test loads

Buffer impact forces

Tilting forces

Live loads on walkways and in chutes, etc

Loads due to emergency condition

Seismic loads

Loads during erection

Loads during transport

4.7.2

4.7.3

4.7.4

4.7.5

4.7.6

4.7.7

4.7.8

4.7.9

4.7.10

4.5 PRINCIPAL LOADS

4.5.1 General

Principal loads comprise the mass of the crane and highly repetitive loads arising from the

intended service of the crane.

4.5.2 Dead loads

4.5.2.1 Dead load dynamic factor

The loads due to the mass of the crane in operation shall be given by the following

equation:

1w

WP = . . . 4.5.2.1

where

Pw = factored deadweight load

W = gravitational force induced by the mass of the crane.

1 = dynamic factor for the mass of the crane subject to inertial forces and

vibrations

The upper bound value of 1 shall be as given in Table 4.5.2.1 unless a more accurate

determination is made by using an appropriate dynamic analysis.

The lower bound value of 1 shall be taken as 1.0, except where the vibration of the

stabilizing part of the crane structure reduces the resistance to overturning. In such case, the

lower bound value of 1 shall be taken as 0.9.

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TABLE 4.5.2.1

APPLICATION OF DYNAMIC Factor (1)

1 2 3 4 5 6 7

Dynamic factor (1)

Travel velocity, m/s Type of

runway

Condition

of runway

Wheel

type

Suspension

type

1.0 >1.0

1.5 >1.5

Unsprung 1.1 1.1 1.2 Smooth

welded

continuously

Steel Sprung 1.1 1.1 1.1

Unsprung 1.1 1.2 1.2

Steel

rails

or

beams Joints

4 mm wide Steel

Sprung 1.1 1.1 1.1

Smooth

no joints Rubber Sprung 1.1 1.1 1.1

Concrete

Jointed Rubber Sprung 1.2 1.2 1.25

Rubber Sprung 1.1 1.1 1.15 Roadway

or flexible

pavement

Crawler

tracks Sprung 1.1 1.2 1.25

NOTES:

1 Do not interpolate, use nearest higher value for 1.

2 It is assumed that the rail joints are in good condition. The detrimental effect on

hoisting appliances of rail tracks in poor condition is so great, both for the

structure and the machinery, that it is necessary to stipulate that the rail joints

must be maintained in good condition: no shock loading coefficient can allow for

the damage caused by faulty joints. In so far as high speed appliances are

concerned, the best solution is to butt-weld the rails, in order to eliminate entirely

the shock loadings that occur when an appliance runs over joints.

4.5.3 Hoisted load

4.5.3.1 Description

The hoisted load shall include the rated capacity together with the weight of the hook and

hook block, full length of hoist cable, and any devices attached to the hook block for the

purpose of grappling the hoisted load.

Where hoists are equipped with magnets or grabs, allowances shall be made in selecting the

hoists capacity to account for tear-off or tear-out forces respectively. A tear-out force is

equal to the weight of the load plus additional forces applied as a result of removing the

load from the heap.

4.5.3.2 Hoisting operations to be considered

The basic hoisting operations covered in this Section are the following:

(a) Hoisting a load from rest The effects of the hoisted load shall be determined by the

following equation:

2hhdPP = . . . 4.5.3.2(1)

where

Phd = factored hoisted load

Ph = hoisted load as specified in Clause 4.5.3.1

2 = hoisted load dynamic factor for hoisting as given in Clause 4.5.3.3. Acce

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(b) Rapid releasing of a part of the hoisted load Where the intended operation requires

rapid releasing of the hoisted load, the effect of rapid release shall be determined by

the following equation:

( )3rhrd

PPP = . . . 4.5.3.2(2)

where

Prd = the peak intensity of the loads acting on the hoist as a result of the rapid

releasing

Ph = hoisted load as specified in Clause 4.5.3.1

Pr = the upper estimate of the part of the load being released

3 = rapid load release dynamic factor for rapid load release as given in

Clause 4.5.3.4.

4.5.3.3 Hoisted load dynamic factor (2)

The value of the dynamic factor for hoisting (2) depends on the hoisting velocity (h), and

the hoisting application group as determined by Table 4.5.3.3(A). The dynamic factor (2)

shall be taken from Table 4.5.3.3(B), except where a more appropriate or more accurate

determination has been carried out using a dynamic analysis or by certified tests.

Where the hoist drive control system automatically selects the steady creep speed at the

start of hoisting, such speed shall be used for the determination of the dynamic factor (2).

Where the hoist drive is equipped with a stepless variable speed control, the value of the

dynamic factor (2) shall be determined for a hoisting velocity of not less than 0.5 times the

nominal speed for the unloaded hoist drive.

TABLE 4.5.3.3(A)

HOISTING APPLICATION GROUP FOR CRANES

1 2 3 4 5

Hoisting application group

Hoisting acceleration

m/s2

Fundamental

natural

frequency of

structure

(vertical plane)

Hz 0.2 >0.2 to 0.4 >0.4 to 0.6 >0.6

3.2 H1 H1 H2 H3

>3.2 5.0 H1 H2 H2 H3 to H4

>5.0 H2 H2 H3 H4

NOTE: For hoisting accelerations/decelerations greater than 0.6 m/s2 analysis of inertial effects in accordance

with Clause 4.5.4 should be considered.

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TABLE 4.5.3.3(B)

HOISTING FACTORS 2

Hoisting application

group h 1.5 h >1.5

H1

H2

H3

H4

1.1 + 0.13h

1.2 + 0.27h

1.3 + 0.40h

1.4 + 0.53h

1.3

1.6

1.9

2.2

LEGEND:

h = the nominal speed related to the lifting attachment, derived

from the steady rotational speed of the unloaded drive, in

metres per second

Where two or more hoists are installed, the dynamic factor (2) shall be applied as follows:

(a) Where the two hoists are designed not to operate simultaneously, the appropriate

factor shall be applied to one drive at a time taking into account that drives hoisting

speed. The other hoist drive shall be considered to be stationary.

(b) Where the hoists are designed to operate simultaneously, the appropriate factor shall

be applied to each hoist in accordance with its hoisting speed.

4.5.3.4 Rapid load release dynamic factor (3) (see Figure 4.5.3.4.)

The value of 3 is given by the following equation:

W

W 5.1 1 =

3 for hoisting appliances in the form of grabs; or

W

W 0.2 1 =

3 for hoisting appliances using magnetic holding devices

where

W = released mass

W = mass of the hoisted load including the load to be released

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FIGURE 4.5.3.4 DYNAMIC FACTOR (3)

4.5.4 Inertia loads

4.5.4.1 General

The designer shall determine the inertia forces induced by acceleration, braking and the

travel, slewing and luffing drives.

4.5.4.2 Methods of determination of inertia loads

The loads due to acceleration of drives shall be determined by one of the following

methods:

(a) Simple method of determination based on upper bounds of parameters for drives

relying on frictional transfer of the reactive forces. The procedure shall be as given in

Clause 4.5.4.3.

(b) An appropriate method of dynamic analysis for any type of load transfer.

4.5.4.3 Simplified method of determination of traction forces

Where the maximum traction forces are limited by friction, the traction forces shall be

determined from the friction between the driven wheels and the runway. To eliminate wheel

slip, drives shall be selected so that the maximum traction force does not exceed the

minimum frictional force between the driven wheel and the rail.

For travel and traverse motions, the maximum traction forces may be determined by the

following equations:

(a) For independent drives:

wij4SR PNT = . . . 4.5.4.3(1)

NOTE: This equation assumes matched power and rating of motors on each driven wheel.

(b) For synchronized drive:

jiN

i

N

j

PT

t

w

1 = 1 =

4R

s

= . . . 4.5.4.3(2)

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AS 1418.12002 22


where

TR = resultant of the traction forces

Ns = number of drivesfor independent drives

= number of driven pairs of wheelsfor synchronized drive(s)

4 = dynamic factor

= coefficient of friction

Pwij = minimum driven wheel load (see below)

i = runway number, e.g., 1 = left runway, 2 = right runway (see below)

j = number of the wheel pair

) + ( 2 w 1 w

s

PP jj

N

1 =j

= minimum sum of the driven wheel loads

The value of 4 shall be determined as follows:

(i) 4 = 1 for centrifugal forces;

(ii) 1 4 1.5 for drives with no backlash or in cases where existing backlash does

not affect the dynamic forces and with smooth change of forces;

(iii) 1.5 4 2 for drives with no backlash or in cases where existing backlash does

not affect the dynamic forces and with sudden change of forces;

(iv) 4 = 3 for drives with considerable backlash, if not estimated accurately by

using a spring-mass model.

Where a force that can be transmitted is limited by friction or by the nature of the drives

mechanism, the limited force and a factor 4 appropriate to that system shall be used.

For steel wheels on steel rails, the nominal coefficient of friction () shall be taken as 0.20,

unless a more accurate determination has been made.

The minimum driven wheel loads of the unladen crane shall be used to calculate the

maximum traction forces.

4.5.4.4 Application of traction forces

The traction forces shall be applied to the loaded crane and shall be in accordance with the

drive type and the driving system of the crane as illustrated in Figures 4.5.4.4(A) and

4.5.4.4(B). The effect of eccentricity of the resultant traction forces to the centre of mass of

the driven system shall be considered.

(a) Acceleration due to cross-travel drives The reactive loads (PHC) from

Table 4.5.4.4(A) due to the traction force of the crab (Pc) shall be transmitted to the

runway through all travel wheels equally (see Figure 4.5.4.4(A)).

Horizontal forces due to inertial forces for cranes with more than two wheels per

runway side shall be equally shared by all wheels.

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FIGURE 4.5.4.4(A) ACCELERATION LOADS DUE TO CROSS-TRAVEL DRIVES

TABLE 4.5.4.4(A)

LATERAL LOADS DUE TO ACCELERATION FROM CROSS-TRAVEL DRIVES

Lateral loads Lateral fixity

of crane wheels PHC11 PHC12 PHC21 PHC22

All wheels laterally

fixed 4

cP 4

cP 4

cP 4

cP

Wheels on only

one side laterally fixed 2

cP 2

cP 0 0

NOTES:

1 This Table is for four-wheel cranes only; however, similar principles apply for other travel systems.

2 A laterally fixed wheel is a flanged wheel with laterally fixed bearings or side-guide rollers.

(b) Acceleration due to long-travel drives For the travel drive system illustrated in

Figure 4.5.4.4(B), the drive forces (PHT) are assumed to be distributed equally to the

driven wheels. The resulting lateral force (PHB) due to the eccentricity (ls) of the

centre of the drive force with respect to the centre of mass is assumed to be

distributed equally to the applicable travel wheels. The moment shall be calculated

from the following equation and the forces from Table 4.5.4.4(B):

RsE TlM = . . . 4.5.4.4

where

ME = moment due to eccentricity of drive forces

ls = maximum eccentricity of the point of application of the drive force with

respect to the centre of mass of the crane including the rated capacity

TR = resultant of the traction forces PHT1 and PHT2 in Figure 4.5.4.4(B)

The effect of acceleration of long travel drives shall be taken into account in designing the

crane.

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AS 1418.12002 24


FIGURE 4.5.4.4(B) ACCELERATION LOADS DUE TO LONG-TRAVEL DRIVES

TABLE 4.5.4.4(B)

LATERAL LOADS DUE TO ACCELERATION

FROM LONG-TRAVEL DRIVES

Lateral loads Long travel drive

system PHB11 PHB21 PHB12 PHB22

All wheels laterally fixed

G

E

2S

M

G

E

2S

M

G

E

2S

M

G

E

2S

M

Wheels on only one side

laterally fixed S

M

G

E 0 S

M

G

E 0

NOTES:

1 For a four-wheel crane, SG equals the distance between the means of lateral guidance.

2 For cranes with more than four wheels, SG equals the bogie pivot centre distance

(see Figure 4.5.4.4(C)).

3 A laterally fixed wheel is a flanged wheel with laterally fixed bearings or side-guide rollers.

FIGURE 4.5.4.4(C) DISTRIBUTION OF HORIZONTAL FORCES

4.5.4.5 Determination of loads due to slewing and luffing motions

The determination of loads due to slewing and luffing motions shall be as follows:

(a) Loads due to the acceleration of slewing drives shall be determined by an appropriate

method of dynamic analysis.

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25 AS 1418.12002


The centrifugal forces acting on slewing cranes shall be from the dead load of the

boom components, the counterweight, where used, and the hoisted load without

applying the dynamic factor and assuming the hoisted load to be positioned at the tip

of the jib or boom.

(b) Loads due to the acceleration of luffing drives shall be calculated by an appropriate

dynamic analysis.

4.5.5 Loads induced by displacements

Account shall be taken of loads arising from displacements caused by movement of the

supporting structure, for example, from prestressing or differential movement due to

settlement or temperature.

4.6 ADDITIONAL LOADS

4.6.1 General

Additional loads and effects include loads induced by wind, snow, ice, temperature and

oblique travel.

4.6.2 Wind forces

4.6.2.1 Principles

The determination of wind forces on a crane exposed to wind (e.g., outdoors operation or

partially enclosed building) shall be as specified in AS 1170.2.

NOTES:

1 This applies to in-service and out-of-service wind forces.

2 Cranes are considered to be high-risk installations. Allowances given in AS 1170.2 to reduce

loads on temporary structures should only be applied after the appropriate risk analysis has

been carried out by the designer.

4.6.2.2 Wind forces on the hoisted load

Wind forces (PD) acting on the hoisted load shall be calculated for the largest dimensions

and the least favourable configuration of the load using the drag coefficients (CD) taken

from AS 1170.2.

4.6.3 Snow and ice loads

Snow and ice loads, where applicable, shall be taken into consideration including

(a) increased dead load

(b) increased wind exposure surfaces due to encrustation.

4.6.4 Forces due to temperature variation

Forces caused by the restraint of expansion or contraction of a component due to local

temperature variation shall be taken into account.

4.6.5 Lateral forces due to oblique travel

4.6.5.1 General

The following Clauses outline a simplified method of analysis of lateral forces due to

oblique travel. A detailed analysis is provided in Appendix E.

Where a crane or crab is subjected to oblique travel in the moment of contact between rail

and front guiding element (wheel flange or guide roller), a steering force (POT) develops

and straightens the crane in its tracks.

The magnitude of the steering force (POT) depends on the type of crane drives, the crane

geometry, and on the coefficient of frictional contact (KO) which is determined by the

maximum oblique travel gradient ().

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AS 1418.12002 26


4.6.5.2 Coefficient of frictional contact (KO)

The coefficient of frictional contact (KO) shall be obtained from Table 4.6.5.2.

NOTE: Interpolation of KO values is permissible under this Standard.

TABLE 4.6.5.2

COEFFICIENT OF FRICTIONAL CONTACT

2.0 3.0 4.0 5.0 7.0 9.0 12.5 15 >15

KO 0.118 0.158 0.196 0.214 0.248 0.268 0.287 0.293 0.3

LEGEND:

= oblique travel gradient, in millimetres per metre

=

S

C

G

L

where

CL = maximum clearance between wheel flange or guide roller and side of rail, in millimetres

SG = centre distance of track wheels, track wheel groups or guide rollers, in metres

4.6.5.3 Calculation of steering contact force (POTE)

The calculation of the steering contact force (POTE) and Y11 and Y21 reactions for a crane

supported by four wheels with two independent drives is determined in accordance with

Figure 4.6.5.3.

Equilibrium condition gives:

0OTEj == PYi

where

Yij are the frictional forces between the wheels and the rail

Y21 = POTE Y11

= KO PW21 KF

NOTE: Y21 is the force that is to be used for design of crane structure and runway beams; POTE is only important for

design of guiding elements and the like. The most adverse condition for analysis is with the crab on the opposite side of

the crane girder to the contact force.

FIGURE 4.6.5.3 WHEELS WITH TWO INDEPENDENT DRIVES (EFF) Acc

esse

d by

SW

INBU

RNE

UNIV

ERSI

TY O

F TE

CHNO

LOG

Y on

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Aug

2007

27 AS 1418.12002


4.6.5.4 Calculation of steering contact force (POTW)

The calculation of the steering contact force (POTW) and Y11, Y12, Y21 and Y22 reactions for a

crane supported by four wheels with two or more mechanically or electrically coupled drive

wheels is determined in accordance with Figure 4.6.5.4.

NOTE: This method is simplified and the results are slightly conservative, being not more than

15% greater than the exact calculation in Appendix E. Forces parallel with runway beams are

very small and can be disregarded.

NOTES:

1 POTW, Y11 and Y21 are calculated in accordance with Clause 4.6.5.3.

2 Y21 and Y22 are forces to be used for design of crane structure and the runway beams; POTW is only

important for the design of guiding elements and the like.

3 Equilibrium condition gives approximately:

0OTWij =+ PY

where

Yi j are frictional forces between the wheels and the rail.

FIGURE 4.6.5.4 MECHANICALLY OR ELECTRICALLY COUPLED DRIVE WHEELS (WFF)

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

Because of flexibility of the crane and runway, reactions Y in Clauses 4.6.5.3 and 4.6.5.4

shall be reduced by multiplying with factor (KF) from Table 4.6.5.5. The natural frequency

of the crane beams shall be determined for vibrations in the vertical plane.

TABLE 4.6.5.5

REDUCTION FACTORS

Type of crane

Natural frequency of

crane beams, Hz

(vertical plane)

Reduction factor

(KF)

Double girder

Cranes only

> 5.0 1.0

Single girder and

Double girder cranes

> 3.2 5.0 0.83

Single girder and

Double girder cranes

3.2 0.66

4.6.6 Bulk material loads

Where applicable, effects due to the dropping of bulk material shall be taken into

consideration. Effects include impact and recoil.

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AS 1418.12002 28


4.7 SPECIAL LOADS

4.7.1 General

Special loads include loads caused by testing, buffer forces and tilting, as well as from

emergency cut-out, failure of drive components, and external excitation of the crane

foundation.

4.7.2 Loads due to off-vertical hoisting

A lateral load of not less than 4% of the rated capacity shall be applied to account for

inadvertent off-vertical lifting.

Where off-vertical hoisting is required by the crane operation, lateral loads induced by this

effect shall be determined by a competent person.

4.7.3 Dynamic effects of test loads

The values of test loads and their locations shall be determined as appropriate for the type

of crane or hoist tested.

The dynamic test load shall be multiplied by a factor (5) from the following equation:

( )25

15.0 += . . . 4.7.3

where

2 is calculated in accordance with Clause 4.5.3.3.

4.7.4 Buffer forces

The impact force (PB) due to cranes or parts of a crane running against other cranes or stops

shall be absorbed by appropriately designed buffers or similar energy-absorbing means.

The total buffer capacities required and the maximum buffer force (PB) shall be determined

for longitudinal travel at 85% of full travel velocity and for traverse at 100%. Where

automatic retarding means are provided, the maximum buffer force (PB) shall be determined

for cranes and crabs at not less than 70% of full travel velocity.

For two-speed cranes fitted with fail-safe duplicated automatic retard switching to slow

speed and sufficient distance from end stop to slow before impacting buffer, the maximum

buffer force (PB) may be determined for 100% of the slow speed.

Where two cranes of masses m1 and m2 and having velocities VF1 and VF2 collide, the kinetic

energy released on the collision shall be calculated by the following equation:

) + 2(

) + ( =

21

2

2121

mm

VVmmE

FF . . . 4.7.4(1)

The total energy (E) shall be absorbed by all buffers engaged in the collision, with each

taking its share of energy in proportion to its rigidity.

Where a crane of mass m and having a velocity V collides with an end stop, the kinetic

energy released on collision shall be calculated by the following equation:

mVE2

2

1 = . . . 4.7.4(2)

NOTE: In some circumstances, the effects of the kinetic energy of the rotating long travel

components, e.g., motors, brake drums, gearboxes, should be considered.

For calculation of the buffer capacities and the strength of the structure, the forces resulting

from the masses in motion (dead loads plus any rigidly guided hoisted loads in the worst

position) shall be used, but not the factors mentioned in Clause 4.5.3. Loads suspended

from hoisting equipment and freely swinging loads need not be taken into consideration. Acce

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For cranes and crabs with or without attached hoisted loads, no negative wheel loads shall

result from 1.1 times the buffer force and the abovementioned dead loads and hoisted loads.

For tower cranes and portal slewing cranes, an analysis of the buffer capacity and of the

effect that the buffer forces have on the structure need not be made, provided that the rated

travelling velocity is lower than 0.67 m/s and reliable limit switches are provided in

addition to the buffer stops.

The resulting forces as well as the horizontal inertia forces in balance with the buffer forces

shall be multiplied by a factor (6) to account for elastic effects that cannot be evaluated

using a rigid body analysis. Factor 6 shall be taken as 1.25 in the case of buffers with

linear characteristics (e.g., springs) and as 1.60 in the case of buffers with rectangular

characteristics (e.g., hydraulic constant force buffers). For buffers with other

characteristics, other values justified by calculation or by test shall be used (see

Figure 4.7.4).

Intermediate values of 6 shall be calculated as follows:

(a) 6 = 1.25 for 0.0 0.5

(b) 6 = 1.25 + 0.7 ( 0.5) for 0.5 < 1.0

where is defined in Figure 4.7.4.

FIGURE 4.7.4 DYNAMIC Factor (6) FOR BUFFERS

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AS 1418.12002 30


4.7.5 Tilting forces

If an appliance with a horizontally restrained load (rigidly guided load) can tilt when its

load or lifting attachment is in collision with an obstacle, the resulting static forces shall be

determined. For the determination of this force, the crab shall be assumed to be in the worst

position. The possibility of lifting the crab wheels off one of the crane bridge girders shall

be considered.

If a tilted appliance can fall back into its normal position uncontrolled, the resulting impact

on the supporting structure shall be evaluated and taken into account.

4.7.6 Miscellaneous loads

The effects of other loads that may be applied to the crane, for example lights, advertising

boards, chutes, maintenance activities and the like shall be considered.

Live loads on walkways during maintenance shall be determined in accordance with

AS 1657 unless higher loads can be generated, for example, placement of equipment on

walkways during maintenance.

4.7.7 Loads caused by emergency conditions

4.7.7.1 Mechanical failure

Where protection is provided by emergency brakes in addition to service brakes, failure and

emergency brake activation shall be assumed to occur under the least favourable condition.

Where mechanisms are duplicated for safety reasons, failure shall be assumed to occur in

any part of either system.

The value of the dynamic factor (4) shall be taken between 1.5 and 2.0.

4.7.7.2 Emergency cut-out

Loads caused by emergency cut-out shall be evaluated in accordance with Clause 4.5.4

taking into account the most unfavourable combination of acceleration and loading at the

time of cut-out. The coefficient of friction shall be taken at its upper bound value. The

value of the dynamic factor (4) shall be taken between 1.5 and 2.0.

4.7.7.3 Application of loads

The resulting loads shall be distributed in accordance with the principles set out in

Clause 4.5.4 for traction forces.

In both these cases, resulting loads shall be evaluated in accordance with Clause 4.5.4,

taking into account any impacts resulting from the transfer of forces.

4.7.8 Seismic loads

Loads induced by seismic or other vibratory excitations of crane foundations shall be

considered.

4.7.9 Loads during erection

The loads acting at each stage of the erection and dismantling process shall be taken into

account.

4.7.10 Forces during transport

The effects of loads occurring during transport shall be considered, where appropriate.

4.8 PRINCIPLES FOR DETERMINATION OF CRANE LOAD COMBINATIONS

4.8.1 Basic considerations

Loads shall be combined to determine the maximum stresses an appliance will experience

during operation. To achieve this, the appliance shall be taken in its most unfavourable

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attitude and configuration while the loads are assumed to act in magnitude, position and

direction causing the maximum stresses at the critical points selected for evaluation on the

basis of engineering considerations.

The load combinations appropriate to individual types of appliances shall be in accordance

with Table 4.8, as applicable. The designer shall also consider other load combinations not

shown in Table 4.8, as appropriate to the type of appliance and its operation.

4.8.2 Application of load combinations

4.8.2.1 Use of Table 4.8

For each type of load and each load combination, the Table gives

(a) a dynamic factor () for the particular load;

(b) numeral 1, which signifies that no dynamic factor is required for that load type unless

special conditions of intended operation require that a dynamic factor (different from

1.0) be included; or

(c) a dash (), which signifies that the load of that type need not be included in the load

combination unless special conditions of operation require its inclusion.

4.8.2.2 Working stress design method

Where the working stress design method is used for the verification of the strength and

serviceability of the crane structure, the load effects (moments, shear and normal forces)

derived from each load combination shall be multiplied by the load combination factor (c).

NOTE: As an example for load combination 5, the total load (Ptot) in a girder will be derived

from:

c = 0.9

Ptot = 0.9 [The effect of (1 P1 + 2 P2 + 4 P3 + 1.0 P4 + 1.0 P5 + 1.0 P6 + 1.0 P7)]

4.8.2.3 Limit states design method

The limit states design method uses partial load factors P, which differ for each type of

load and range generally between 1.2 and 1.5 depending on the statistical variability of the

load type in that particular type of crane.

Where the limit states design method is used, cranes shall be designed to give a degree of

safety not less than that given in this Standard for the working stress design method for

strength, buckling, deflection, torsion, fatigue, and the like.

NOTE: At this stage, Standards Australia is unable to give specific guidance on the range of

values of the partial load factors.

4.8.2.4 Proof of fatigue strength

The effects of fatigue shall be considered. Where proof of fatigue strength is found to be

necessary, it shall be carried out in accordance with the principles set down in Clause 4.8.1.

In some applications it may be necessary to also consider occasional loads such as

in-service wind, skewing and exceptional loads such as test loads and excitation of the

lifting appliance foundation (for example, wave effects).

4.8.2.5 High risk applications

In special cases where the human or economic consequences of failure are exceptionally

severe (e.g., ladle cranes or cranes for nuclear applications) increased reliability shall be

obtained by the use of a risk coefficient n > 1, the value of which shall be selected

according to the requirements of the particular application.

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TABLE 4.8

CRANE LOAD COMBINATIONS

Load combination number*

Frequently occurring

load combinations

Infrequently

occurring load

combinations

Rarely occurring load combinations Load

group

Line

No. Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Principal

loads

1 Dead loads 1 1 0.9 1 1 0.9 1 1 1 1 1 1 1 1 1.2

2 Hoisted loads 2 1 3 2 1 3 2 1 1 1 1 1 1

3 Inertia loads 4 4 1 4 1 1 1 1 4 1 1 1

4 Displacement-

induced loads

1 1 1 1 1 1 1

Additional

loads

5 In-service wind

forces

1 1 1 1 1 1 1 1

6 Snow or ice loads 1 1 1

7 Temperature-

induced forces

1 1 1

8 Oblique travelling

forces

1

Special

loads

9 Off-vertical

hoisting loads

1

10 Out-of-service

wind forces

1

11 Test loads 5

12 Buffer impact

forces

6

13 Tilting forces 1

14 Live loads on

walkways and in

chutes

1

15 Loads due to

emergency

conditions

4

16 Seismic loads 1

17 Loads during

erection

1.2

18 Loads during

transit*

1

Load combination

factor, c 1.0 0.9 0.8

* Applicable only to cranes that are frequently moved e.g., mobile cranes, elevating work platforms.

is the mass of that part of the hoist load remaining suspended from the appliance.

NOTE: 1 to 6 are dynamic factors as described earlier in this Section.

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S E C T I O N 5 D E S I G N O F C R A N E S T R U C T U R E

5.1 GENERAL

This Section specifies requirements for both the crane structure and its supporting structure

(see Clause 1.1). The design life shall be 25 years unless the requirements of

Clause 2.2(A) to (D) are followed.

5.2 BASIS OF DESIGN

5.2.1 Design of structure

The crane and its supporting structure shall be designed in accordance with this Section and

Clause 2.2, except where other parts of AS 1418 take precedence, and with the following:

(a) AS 1163.

(b) AS 1594.

(c) AS 1664.1 or AS 1664.2.

(d) AS 1720.1.

(e) AS 1726.

(f) AS 3600.

(g) AS 3990; or AS 4100.

5.2.2 Classification of crane structures

5.2.2.1 Bases of classification

The classification of the structure of a crane or crane components, e.g., the boom, shall be

determined from the class of utilization (see Clause 5.2.2.2) and the state of loading (see

Clause 5.2.2.3).

5.2.2.2 Class of utilization

The number of in-service cycles expected from the structure of a crane or crane component

during its useful life shall be one basic parameter of classification and shall comply with

Table 5.2.2.2.

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TABLE 5.2.2.2

CLASS OF UTILIZATION OF STRUCTURES

Maximum number

of operating

cycles

Class of

utilization Description of use)

1.6 104 U0 Infrequent use

3.2 104 U1

6.3 104 U2

1.25 105 U3

2.5 105 U4 Fairly frequent use

5 105 U5 Frequent use

1 106 U6 Very frequent use

2 106 U7 Continuous or near

continuous use

4 106 U8

Greater than

4

106 U9

NOTE: The number of loading cycles is often significantly higher than

the number of in-service cycles in Table 2.3.2.

5.2.2.3 State of loading

The second basic parameter of classification is the state of loading, which is concerned with

the number of times a load of a particular magnitude, in relation to the capacity of the

structure of the crane or crane component, is hoisted. The nominal values of the load

spectrum factor (Kp) shall comply with Clause 2.3.3.

5.2.2.4 Structure classification

The structure classification for the various combinations of class utilization and state of

loading shall be as given in Table 5.2.2.4.

TABLE 5.2.2.4

CLASSIFICATION OF CRANE STRUCTURES

1 2 3 4 5 6 7 8 9 10 11 12

Classification of crane structure

Class of utilization State of loading

Nominal

load

spectrum

factor

(Kp) U0 U1 U2 U3 U4 U5 U6 U7 U8 U9

Q1Light 0.125 S1 S1 S1 S2 S3 S4 S5 S6 S7 S8

Q2Moderate 0.25 S1 S1 S2 S3 S4 S5 S6 S7 S8 S8

Q3Heavy 0.50 S1 S2 S3 S4 S5 S6 S7 S8 S8 S9

Q4Very heavy 1.00 S2 S3 S4 S5 S6 S7 S8 S8 S9 S9

Load condition 0* 1 2 3 4

* Fatigue analysis not required.

Corresponds to same loading condition in AS 3990.

NOTE: The solid lines in the Table group together the state of loading (Q) and the class of utilization (U),

which belong to the same loading condition (see Clause 5.5).

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5.3 DESIGN OBJECTIVE

Design objectives are to achieve adequate strength and serviceability during the design life

of the crane. Design calculation shall be carried out to determine that the crane structure

will have adequate strength in service when operated in compliance with the manufacturers

written instructions.

The proof of adequacy shall include proof of safety against yielding, elastic instability or

fatigue.

Proof of adequacy shall also include stability against overturning.

The elastic displacements shall be checked to prove that the appliance shall not become

unfit to perform its intended duties, affect stability, or interfere with the proper functioning

of mechanisms.

5.4 METHOD OF DESIGN

5.4.1 General

The design of the lifting appliance shall be carried out by one of the following methods:

(a) The working stress design method.

(b) The limit states method.

5.4.2 Working stress design method

Design by working stress design method shall be determined in accordance with the

provisions of AS 3990, except where otherwise specified in this Standard.

5.4.3 Limit states method

Individual specified or characteristic loads (Fj) are d

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AS 1418.01-2002