AS-1418.4-2004.pdf

AS 1418.42004 Australian Standard Cranes, hoists and winches Part 4: Tower cranes AS 1418.4 Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 This Australian Standard was prepared by Committee ME-005, Cranes. It was approved on behalf of the Council of Standards Australia on 13 February 2004 and published on 30 March 2004. 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 Construction and Mining Equipment Association of Australia Crane Industry Council of Australia Department for Administrative and Information Services, S.A. Department of Consumer and Employment Protection, WorkSafe Division, W.A. Department of Infrastructure, Energy and Resources, Tasmania Department of Labour New Zealand Institution of Engineers Australia State Chamber of Commerce Victorian WorkCover Authority WorkCover New South Wales 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 Standards may also be withdrawn.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. Australian StandardsTM and other products and services developed by Standards Australia are published and distributed under contract by SAI Global, which operates the Standards Web Shop. 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 mailstandards.org.au, 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 03237. Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 AS 1418.42004 Australian Standard Cranes, hoists and winches Part 4: Tower cranes Originated as AS 1418.41988. Previous edition AS 1418.42001. Third edition 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 5748 0 Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 AS 1418.42004 2 PREFACE This Standard was prepared by the Standards Australia Committee ME-005, Cranes. The objective of this Standard is to provide nationally uniform requirements for the design of tower cranes for reference by importers, designers, users, and regulators. Cognizance has been taken of the development of Standards for tower cranes as undertaken by the International Standards Technical Committee ISO/TC 96/SC7, Tower Cranes, at the time of developing this Standard. Considerations for loads and load factors are based on ISO 8686-3, Cranes, Design principles and load combinations, Part 3: Tower cranes. The term informative has been used in this Standard to define the appendix to which it applies. An informative appendix is for information and guidance only. This Standard differs from the previous edition as follows: (a) Requirements for limiting and indicating devices have been revised. (b) Crane Standards have traditionally been based on the permissible stress method and problems arose when the various parts of AS 1170, Structural design actions, were revised based on the limit states design method. These problems have been addressed. (c) Requirements for inspection and testing have been updated. Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 3 AS 1418.42004 CONTENTS Page SECTION 1 SCOPE AND GENERAL 1.1 SCOPE 5 1.2 NEW DESIGNS AND INNOVATIONS .5 1.3 APPLICATION.5 1.4 TYPES.5 1.5 REFERENCED DOCUMENTS 6 1.6 DEFINITIONS 6 SECTION 2 GENERAL REQUIREMENTS FOR DESIGN 2.1 CLASSIFICATION AND LOAD RATING 7 2.2 CRANE LOADS .8 2.3 WIND ACTIONS 12 2.4 CRANE STRUCTURE DESIGN. 13 SECTION 3 CRANE MECHANISMS 3.1 MECHANISMS. 17 3.2 CLASSIFICATION OF MECHANISMS 17 3.3 REEVED ROPE, DRUM AND SHEAVE SYSTEMS. 17 3.4 LIMITING DEVICES . 17 SECTION 4 CONTROLS AND INDICATING DEVICES 4.1 CONTROLS 20 4.2 INDICATORS. 21 SECTION 5 OPERATIONAL EQUIPMENT 5.1 ELECTRICAL EQUIPMENT AND CONTROLS. 23 5.2 HYDRAULIC EQUIPMENT AND CONTROLS 23 5.3 PNEUMATIC EQUIPMENT AND CONTROLS . 23 SECTION 6 OPERATIONAL DESIGN AND ACCESS 6.1 OPERATIONAL DESIGN 24 6.2 ACCESS 24 SECTION 7 MARKING AND MANUAL 7.1 MARKING ON CRANE . 29 7.2 MARKING OF ACCESS AND SERVICE ISOLATORS 29 7.3 MANUAL 29 SECTION 8 INSPECTION AND TESTING 8.1 INSPECTION 31 8.2 OPERATION TESTS 31 8.3 TYPE TESTS 31 Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 AS 1418.42004 4 Page APPENDICES A INFORMATION TO BE SUPPLIED WITH AN ENQUIRY OR ORDER 32 B INFORMATION TO BE SUPPLIED BY THE MANUFACTURER 34 C TYPICAL ILLUSTRATIONS OF TOWER CRANES 37 D TYPICAL GROUP CLASSIFICATIONS OF THE TOWER CRANE AS A WHOLE. 42 E TYPICAL GROUP CLASSIFICATIONS OF THE MECHANISMS OF TOWER CRANES. 43 Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 5 AS 1418.42004 www.standards.com.au © Standards Australia STANDARDS AUSTRALIA Australian Standard Cranes, hoists and winches Part 4: Tower cranes 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 sets out requirements for tower cranes (a) that are dismantled when they have served their purpose; and (b) of the permanently erected type, as defined in AS 2549. Horizontal jib and luffing jib and boom cranes which may be of the travelling, fixed, or climbing type, are also included. Power-driven mobile cranes fitted with tower crane configurations are excluded except for the stability and foundation considerations when used in the capacity of a tower crane. The Standard covers requirements from and including the hook to the anchorages of the tower crane as well as requirements for rail-mounted types. NOTES: 1 Guidance on information to be supplied with an enquiry or order is given in Appendix A. 2 Guidance on information to be supplied by the manufacturer is given in Appendix B. 3 Guidance on selection and operation of tower cranes is given in AS 2550.4. 1.2 NEW DESIGNS AND INNOVATIONS 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. 1.3 APPLICATION This Standard covers specific requirements for tower cranes and is intended for use in conjunction with AS 1418.1; however, requirements given herein take precedence over corresponding requirements of that Standard. 1.4 TYPES The types of tower cranes within the scope of this Standard are power-driven cranes that have a vertical tower designed to be freestanding up to a specified height. The general types of tower cranes are designated by specific features as follows: (a) Ram luffing crane. (b) Rope luffing crane. (c) Trolley jib (horizontal jib) crane. Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 AS 1418.42004 6 © Standards Australia www.standards.com.au (d) Articulated trolley jib crane. (e) Self-erecting crane. NOTE: Typical illustrations of these types of tower crane are given in Appendix C. 1.5 REFERENCED DOCUMENTS The following documents are referred to in this Standard: AS 1000 The international system of units (SI) and its application 1359 Rotating electrical machines General requirements 1359.101 Part 101: Rating and performance 1418 Cranes, hoists and winches 1418.1 Part 1: General requirements 1666 Wire-rope slings 1666.2 Part 2: Care and use 2549 Cranes (including hoists and winches)Glossary of terms 2550 Cranes Safe use 2550.4 Part 4: Tower cranes AS/NZS 1170 Structural design actions 1170.2 Part 2: Wind actions 1.6 DEFINITIONS For the purposes of this Standard, the definitions given in AS 2549 and those below apply. 1.6.1 Crane structure All components of the crane excluding the crane support structure. 1.6.2 Crane support structure The portion of the crane from the top of the tower to the foundation, including the transition piece (if used), grillages, ties and attachment to the building, and the foundation of the crane (whether it be rail-mounted or stationary). 1.6.3 Boom The use of the term boom herein may also be applicable to jib. 1.6.4 Design installation life The time that a loading action acts on a particular tower crane structural support system, e.g., foundation, building ties or combinations thereof. 1.6.5 Weathervane A feature of a crane where the wind is able to slew the crane when out of service so that the boom provides the least resistance to the wind. Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 7 AS 1418.42004 www.standards.com.au © Standards Australia S E C T I O N 2 G E N E R A L R E Q U I R E M E N T S F O R D E S I G N 2.1 CLASSIFICATION AND LOAD RATING 2.1.1 Classification of tower crane 2.1.1.1 General The basis of the classification of tower cranes is given in AS 1418.1, which establishes a classification of lifting appliances based on the number of operating cycles to be carried out during the expected life of appliance and a load spectrum factor that represents a nominal state of loading. The classification of tower cranes is defined according to their category. 2.1.1.2 Categories of tower cranes Tower cranes shall be divided into three general categories based on the service the tower crane is intended to endure, as follows: (a)Light Tower cranes in irregular use or having a light state of loading. (b)Moderate Tower cranes for general building construction. (c)Heavy Tower cranes in regular use or having a heavy state of loading. 2.1.1.3 Classification of the tower crane as a whole The classification of the tower crane as a whole shall be as given in Table 2.1.1.3 and shall be interpreted in accordance with AS 1418.1. NOTE: Guidance on typical group classifications of the tower crane as a whole is given in Appendix D. TABLE 2.1.1.3 CLASSIFICATION OF TOWER CRANES Crane classification Crane category Class of utilization State of loading Group classification Light U1 to U4 Q1 and Q2 C1 to C4 Moderate U3 and U4 Q2 C3 and C4 Heavy U4 and U5 Q2 and Q3 C4 to C6 2.1.2 Crane rating The tower crane shall be rated in terms of (a) the rated capacity of each hoisting motion; and (b) the classification of the application of the tower crane or the use for which it is intended. NOTE: The use of a tower crane may vary during its life. Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 AS 1418.42004 8 © Standards Australia www.standards.com.au 2.2 CRANE LOADS 2.2.1 General The proof of competence of components shall be determined by either the limit state method or the permissible stress method, as set out in AS 1418.1. 2.2.2 Loads and applicable factors Table 2.2.2(A) specifies factors n for dynamic effects, which are used for load combinations listed in Tables 2.2.2(B1) and (B2). The line numbers listed in the first column of Table 2.2.2(A) are those shown in column 3 of Tables 2.2.2(B1) and (B2). Reduced partial load factors shall be applied to the masses of parts of the crane that act to reduce load effects and are therefore favourable loads. Where the masses and their centres of gravity are determined by experiment (weighing), the factors in accordance with favourable effects 1.2.1 of Table 2.2.2(B2), line 1, shall be used. Where the masses and their centres of gravity are calculated based on final piece lists, the factors in accordance with favourable effects 1.2.2 of Table 2.2.2(B2), line 1, shall be used. NOTE: Tables 2.2.2(B1) and 2.2.2(B2) categorize load combinations as follows: Afrequently occurring load combinations. Binfrequently occurring load combinations. Crarely occurring load combinations. Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 9 AS 1418.42004 www.standards.com.au © Standards Australia TABLE 2.2.2(A) FACTOR n FOR DYNAMIC EFFECTS (APPLICABLE FOR BOTH PERMISSIBLE STRESS AND LIMIT STATE METHODS) Line No. in Table 2.2.2(B) Factor n Guidance on values of factors n and load factors 1 = 1 ± aa = 0.1 11 1 = 1 for design against tipping 2 2 3 In accordance with AS 1418.1 37 7 = 1.1 is recommended for building site crane. Other values may be used when the rail tracks tolerances (as agreed between user and manufacturer) vary from Standard When using rigid body kinetic models: 4 = 1.2 if the acceleration or braking forces are changed with stepless control systems without backlash 4 = 1.5 in other control systems where drive forces are acting on the crane practically free of backlash 4 = 2 where considerable backlash exists 4 and 5 4 Other values for 4 may be used when substantiated or in accordance with AS 1418.1 6 Partial load factors shall be considered where appropriate 7 In-service wind load as specified in Clause 2.3.1(c)(i) 8 Snow and ice loads need only be considered in special cases and then in accordance with regional conditions 9 Loads due to temperature variations need only be considered where appropriate, according to regional and local conditions 10 Loads caused by skewing are negligible when using common undercarriages, otherwise requirements for AS 1418.1 apply 11 2 In accordance with AS 1418.1 12 Out-of-service wind load in accordance with AS/NZS 1170.2 13 5 In accordance with AS 1418.1 14 6 In accordance with AS 1418.1 Buffer forces need not be considered where the travelling velocity at contact with the buffer or end stop is less than 0.7 m/s 15 Tilting forces shall not be considered 16 4 In accordance with AS 1418.1 17 Loads caused by failure of mechanism or components shall be considered where appropriate 18 Excitation effects shall be considered where appropriate Accessed by UNIVERSITY OF SOUTH AUSTRALIA on 30 Jul 2008 © Standards Australiawww.standards.com.au 10 AS 1418.42004 TABLE 2.2.2(B1) LOADS AND LOAD COMBINATIONS TOWER CRANESPERMISSIBLE STRESS METHOD 1 2 3 4 5 6 Load combinations A Load combinations B Load combinations C Categories of loads List of the loads fi Line No. A1 A2 A3 A4 B1 B2 B3 B4 B5 C1 C2 C3 C4 C5 C6 C7 C8 1.1 Unfavourable ef