Standard
UPDATE AVAILABLE
AS 1418.1-2002
[Superseded]Cranes, hoists and winches, Part 1: General requirements
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.
Published: 20/06/2002
Pages: 165
Table of contents
Cited references
Content history
Table of contents
Header
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
Cited references in this standard
Content history
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