IS 807 (2006): Design, erection and testing (structural ...

1 Disclosure to Promote the Right To InformationWhereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public. ! $ ' + - Satyanarayan Gangaram Pitroda Invent a New India Using Knowledge 0 1 ' 5 Jawaharlal Nehru Step Out From the Old to the New 1 + , 1 + Mazdoor Kisan Shakti Sangathan The Right to Information, The Right to Live ! > 0 B Bhart hari N ti atakam Knowledge is such a treasure which cannot be stolen Invent a New India Using Knowledge IS 807 (2006): Design, erection and testing (structuralportion) of cranes and hoists - Code of practice [MED 14:Cranes, Lifting Chains and Related Equipment].

2 - IndianStandardDESIGN,ERECTIONANDTESTING( STRUCTURALPORTION)OFCRANESANDHOISTS CODEOFPRACTICE(SecondRevision) ,9 BAHADURSHAHZAFARMARGNEWDELHI110002 April2006 PriceGroup-15 Cranes,LiftingChainsandItsRelatedEquipme nt SectionalCommittee,ME14 FOREWORDThisIndianStandard(SecondRevisio n)wasadoptedbytheBureauofIndianStandards ,afterthedraftfinalizedbytheCranes, , :TodealwiththesubjectconventionalIy, :1999 Codeofpracticeforuseofweldinginbridgesan dstructuressubjecttodynamicloading , ,inthecurrentrevision.[nthecurrentrevisi on,thefollowingpointsareadded:a)Theclass ificationsofthecranesarebasedonoperating timeandloadspectrumandclassificationfrom MltoM8,b)Stateofloadingisbasedonthehoist spectrum,c)Thevariousloadshavebeenexplai nedelaboratelyandnotcheffect,d)Thefatigu eandnotcheffecthavebeendealtelaborately, , ,e)Theweldingjointdesign,weldingprocedur esandinspectionofweldingforindustrialcra neshavebeenexplainedindetail, )Thedesignofbolts,qualityofbolts, :1s3177:1999 Codeofpracticeforoverheadtravelingcranes andgantrycranesotherthansteelworkcranes( secondrevision)1S4137:-1985 Codeofpracticeforheavydutyelectricoverhe adtravelingcranesincludingspecialservice mathinesforuseinsteelwork(firstrevision) 1S807 ,3 StateofStress (CombinationofLoads) , , ,14141414142121212126%262727272727 IS807 , ~DiaphragmsandVerticalStifl% (p) ,WeldingProceduresandInspectionofWelding forIndustrialandMillCranesPage2828292929 293636373838384040424242.]

3 ,,,4242424242424244444445454545454548ii IS807:2006B-1 AllowableStressB-2 BaseMetalB-3, IS807:2006 IndianStandardDESIGN,ERECTIONANDTESTING( STRUCTURALPORTION)OFCRANESANDHOISTS CODEOFPRACTICE(SecondRevision)1 SCOPET hisstandardcoversthecodeofpracticefordes ign,manufacture,erectionandtesting(struc ture)ofEOTcranes,goliath, , , :1 SNo,800:1984875(Partl):1987(Part-2):1987 (I?art3):1987(Part4):1987(Part5):1987961 :19751363(Part1):2002(Part2):2002(Part3) :1992 TitleCodeofpracticeforgeneraIconstructio ninsteel(secondrevision)Codeofpracticefo rdesignloads(otherthanearthquake)forbuil dingsandstructures:Deadloads Unitweightsofbuildingmaterialandstoredma terials(secondrevision)Imposedloads(seco ndrevision)Windloads(secondrevision)Snow loads(secondrevision)Specialloadsandload combinations(secondrevision)Structuralst eel(hightensile)(secondrevision)Hexagonh eadbolts,screwsandnutsofproductgrade C :Hexagonhead bolts(sizerangeM5toM64)(fourthrevision)H exagonheadscrews(sizerangeM5toM64)(fourt hrevision)Hexagonnuts(sizerangeM5toM64)( thirdrevision) (Part1):2002(Part2):2002(Part3):2002(Par t4):2002(Part5):20021367(Part1):2002(Par t2):2002(Part3):2002(Part5):2002(Part6): 1994(Part7):1980 TitleHexagonheadbolts,screwsandnutsofpro ductgradesAandB.

4 Hexagonheadbolts( )(thirdrevision)Hexagonheadscrews( )(thirdrevision)Hexagonnuts( )(thirdrevision)Hexagonthinnuts(chamfere d)( )(thirdrevision)Hexagonthinnuts(unchamfe red)( )(thirdrevision)Technicalsupplycondition sforthreadedsteelfasteners:Generalrequir ementsforbolts,screwsandstuds(thirdrevis ion)Tolerancesforfasteners Bolts,screws,studsandnuts ProductgradesA,BandC(thirdrevision) Bolts, (fourthrevision)Mechanicalpropertiesoffa stenersmadeofcarbonsteelandalloysteel Setscrewsandsimilarthreadedfastenersnotu ndertensilestresses(thirdrevision)Mechan icalpropertiesandtestmethodsfornutswiths pecifiedproofloads(thirdrevision)Mechani calpropertiesandtestmethodsfornutswithou tspecifiedproofloads(secondrevision)1 IS807:2006 ISNo.(Part8):2002(Part9/See1):1993(Part9 /See2):1993(Part10):2002(Part11):2002(Pa rt12):1981(Part13):1983(Part14):1984(Par t14/Sec1):2002(Part14/Sec2):2002(Part14/ Sec3):2002(Part(Part(Part(Part6):20027): 19968):9):996997(Part20):1996 TitlePrevailingtorquetypesteelhexagonnut s Mechanicalandperformanceproperties(third revision)Surfacediscontinuities,Section1 Bolts,screwsandstudsforgeneralapplicatio ns(thirdrevision)Surfacediscontinuities, Section2 Bolts,screwsandstudsforspecialapplicatio ns(thirdrevision)Surfacediscominuities Nuts(~hirdrevision)Electroplatedcoatings (thirdrevision)Phosphatecoatingsonthread edfasteners(secondrevision)Hot-dipgalvan izedcoatingsonthreadedfasteners(secondre vision)Stainless-steelthreadedfasteners( secondrevision)Mechanicalpropertiesofcor rosion-resistantstainlesssteelfasteners, Section1 Bolts,screwsandstuds(thirdrevision)Mecha nicalpropertiesofcorrosion-resistantstai nlesssteelfasteners,Section2 Nuts(thirdrevision)Mechanicalpropertieso fcorrosion-resistantstainlesssteelfasten ers,Section3 SetscrewsandsimiIarfastenersnotundertens ilestress(thirdrevision)Designationsyste mforfasteners(thirdrevision)Inspection,s amplingandacceptanceprocedure(thirdrevis ion)Packaging(thirdrevision)

5 Axialloadfatiguetestingofbolts,screwsand studsTorsionaltestandminimumtorquesforbo ltsandscrewswithnominaldiameters1mmto10m mISNo1893:19841929:1982 TitleCriteriaforearthquakeresistantdesig nofstructures(fourthrevision)Specificati onforhotforgedsteelrivetsforhotclosing(1 2to36mmdiameter)(firstrevision)2062:1999 Steelforgeneralstructuralpurposes Specification(Jjihrevision)2155:1982 Specificationforcoldforgedsolidsteelrive tsforhotclosing(6to16mmdiameter)(firstre vision)3138:1966 Specificationforhexagonalboltsandnuts(M4 2toM150)3737:1966 Leathersafetybootsforworkersinheavymetal industries6610:1972 Specificationforheavywashersforsteelstru ctures6623:1985 Specificationforhighstrengthstructuralnu ts(firstrevision)6639:1972 Specificationforhexagonboltsforsteelstru ctures6649:1985 Specificationforhardenetf andtemperedwashersforhighstrengthstructu ralboltsandnuts(firstrevision)8500:1991 Structuralsteel(microalloyed)(mediumandh ighstrengthqualities) Specification(,firsfrevision) Ashortendtruckattachedtotheendofonegirde r(ortoaconnectingmember,ifmorethanonebog ieisusedpergirder).

6 Ashortendtruckwhichisflexiblyconnectedto onegirder(orconnectingmember) Thatpartofacraneconsistingofgirders,truc ks,endties, IS807 (Buffer) -Anenergyabsorbingbumperorenergydissipat ing(buffer) Theoperator Theslight,upward, ,FloorOperated ,Gantry ,HotMoltenMaterialHandling(Ladle) ,ManuallyOperated ,Semi-gantry (DeadLoad) Theverticaldisplacementofabridgegirderdu etoitsown-weightplustheweightofpartsperm anentlyattachedthereto,suchasfootwalk,dr ivemechanism, (LiveLoad) Averticalplate(orchannel)betweenthegirde rwebs, Astructuralmember,otherthantheendtruck, (EndCarriage) Anassemblyconsistingofstructuralmembers, wheels,bearings,axles,etc, Awalkwaywithhandrailandtoeboards, Main (End) Theminimumhorizontaldistance,paralIeltot herunwaybetweenthecentrelineofthehook(s) andthefaceofthewall(-orcolumns) (Side) Theminimumhorizontaldistance,perpendicul artotherunway,betweenthecentrelineofahoo k(mainorauxiliary) , ,theliveloadconsistsoftheratedloadplusth eweightofthetrolley, IS807 Theratedliftedloadfromthemechanismdesign considerationshallmeantheexternalloadlif tedandhandledbythecraneandshallincludein additionthesafeworkingload,liftingtackle ssuchasmagnets,grabs,liftingbeams, Theassemblyofrails,girders, Thecriticalplates, Thedistancefromcentre-to-centreoftheoute rmostwheelsofthebridgeortrolley, Theverticalforce(withoutimpact)producedo nanybridgewheelbythesumoftheratedload,tr olleyweightandbridgeweight, Theverticalforce(withoutimpact) ~rialofstructuresshallbeintheformofplate , , ,pinsandbolts, ( ,5) (1)(2)(3)i)Rivets21551929ii)Pinsandbolts 1364(Parts1to5)3138iii)Highstrengthbolts and6639.

7 ,,,nuts662366493757 Table2 PhysicalPropertiesofSteel( ) (1)(2)(3)i) (E),inN/mm2ii) (G),inN/mmziii)Poisson sratio(I/m) ) (a)v)Specificgravity(y) ,thatis:a)Classofoperatingtime;andb) )Classofoperatingtimeindicatestheaverage periodperday;b)Twohundredfitlyworkingday speryearshallbeconsidered;andc) ,whichthecranewouldaccomplishduringitsli fe(seeTable3). HoistLoadSpectrumThestateofhoistloadingd eterminestheextenttowhichthecraneliftsth emaximumload,L~aoronlyalesserload,L, :2006 Therearefourstatesofloading,designatedby thevahresP=1,P=213,P=1/3andP= StressSpectrumThestateofstressaredefined inthesamemanneronthoseofthehoistedloadsw ithsame-spectraaccordingtoTable5, (cranegirders,endcarriage,plateforms,LTm achineryandelectricalitemspanel,resistan ceboxes). (hookloads)comprisetheusefulloadandthese lfweightsofmembersdesignedtocarrytheusef ulload,forexample,thebottomblockspreader bar,thegrab, ,.,Table3 ClassesofUtilization( ) (.I)(2)(3)(4) )B Regularuseonintermittentduty2x105iii) )DIntensive,heavydutymorethanone2x106shi ftldayTable4 StateofLoading ( ) (1)(2)(3)(4)OVerylightCraneswhichhoistSW LexceptionallyP=oand,normally,veryIightl oadsii)LightCraneswhichonlyhoisttheSWLan dP=1/3normallyloadedaboutone-thirdofSWLi ii)ModerateCraneswhichhoisttheSWLfairlyP =2/3frequentlyandnormallyloadsbetween1/3 to213ofSWLiv)HeavyCraneswhichareregularl yloadedcloseP=ltotheSWL5 IS807 \ (-) ( ) (1)(2)(3)(4)i)VeryIightComponentssubject edexceptionallytoitsP=omaximumstressandn ormallytolightii)LightComponentsrarelysu bjectedtoitsmaximumP=113stressbutnosksll yabout1/3ofmaximumstressiii) )HeavyComponentsregularlysubjectedtoitsP =lmaximumstress6.

8 -.,!_ _____IS807:2006 Table6 GroupClassificationofCranes ( ) , ()( (1)(2)(3)(4)(5)i)Verylight,P=O(6)MlM2,M3 M4ii)M5 Light,P=i/sM2M3,M4M5iii)M6 Moderate,P=2/3M3M4,M5M6,M7iv)M8 Heavy,P=IM4M5M6,M7M8 Table7 ExamplesofClassificationofCranesS1No(1)O ii)iii)iv)v)( )TypeofCranesApplicationsClassofStateofG roupUtilizationLoading(2)(3)(4)Overheadt ravei]ing(5)(6) ,cranesforpowerAo-1MI-M2cranesstation, ,AI-2M2-M3-M4stockingyard, , cranes, , , ,repairA-B1-2MI-M3shop, IS807 :a)b)c)d) (.ordeceleration)ofthetraverse,travel, (ordeceleration)anditsvaluesaregiveninTa ble8;Effectsofcentrifugalforce;Transvers ehorizontalreactionresultingfromrollinga ction; ,travelmotion,levelluffingmotionandslewi ngmotionofthecraneshallgenerallybeconsid eredas~timesoftheweightofthemovingpartsa ndthehoistingload,andbegivenbythefollowi ngformula:Forlevelluffhgmotion,~= ,~= ,~= , ,incaseoftraversemotionandtravelmotionby thewheeldrive, ,fortheslewingmotion, ) ) ) ) ) ) . viii) ix) x) 8 ~Ia%Fi~.

9 5 RATIOOFSPA:,ANDEFFECTIVEWIIEELBASE versusSIDEFORCECONSTANTONWHEELS wheres,=L=//.1=a=SF=X,Rlateralforceonwhe els,inkgforN;sideforceconstantonwheel;wh eelload,inkgforN;span,inm;andwheelbase, , ,whenthehorizontalguiderollersareprovide d,thecentredistancebetween1S807 :a)Thecaseinwhichthesuspendedloadcanswin g;andb) (a) ,noaccountshallbetakenofbuffereffect, , ,forhigherspeed(greaterthan1m/s) . -IIIIIaa6 AFourWheelsonaRail66 EightWheelsonaRailIIIIIIII1I - - IS807 , )b) ; , 16gdensity,inkglm~;pressure,inkgffmz;win dvelocity,inm/s;andgravitationalaccelera tion, , ,inkgfiareapresentedtothewindbygirder9=( ;aerodynamicpressure,inkgf/m2; ,thewindforceontheprotectedpartofthegird erisdeterminedbyapplyingareducingcoeffic ient q totheforcecalculatedinaccordancewiththef ormulaP= q isdependsupon b and h andontheratioofA/Ae( ).whereA=A,=h=b=&visiblearea(areaofsolid portions);envelopedarea(solidportion+voi ds);depthofthegirder; ;andaerodynamicpressure,inkg/m ,theratioQ= , ,2 ValuesoftheReducingCoefficient(q) (inm-2)thatis, ( )I, )20to100iii)Over100 LimitingWorkingWindIMaximumWind(CraneOut ofService)IVelocity,VwAerodynamicVelocit y,VwAerodynamicPressure,qPressure,qmlskm lhkgf/m2ormlskmthkgf/m2orN/m*N/m2(3)(4)( 5)(6)(7)(8)2072253613080doldoldo14211501 110doIdoIdoI46I165I13010.

10 1S807:2006 Table10 ValuesoftheAerodynamicCoefficientClrl ..n~19\.\GLUUJC/. (1)c(2)(3)(4)(5)i)Trussofrolledsectionsi d~>l0, , ,forthehandlingofmiscellaneousloadspress uresfordifferentregionsinIndiashallbetak enlessthan25t,wherethewindfacingareacann otfkom1S875(Part3).11 IS807:2006 Table11 ValuesofCoefficientqinTermsofQ=A/A,andb/ h( )Q= ,0(1)(2)(3)(4)(5)(6)(7)(8)(9)b/h= , !). \\mL\hIb/h=6\ \\\\1\\\1kb/h=3\b/i=2\\I\\blh=lb/h= [ , ,themaximumtemperaturefluctuationshallbe takentobe 20 Cto+45 ,driver scabinsandplatforms,,,,shallbedesignedto carrythefollowingconcentratedloads:a)b)c ) ,whichmaybe, , ,thehorizontalloadofthehoistingloadsuspe ndedbythe12 (Y)TheimpactIoadscausedinthehoistingoper ationaredifferentinvalueaccordingtotheho istingspeed,deflectionofthegirder,ropele ngth,andaregivenbymultiplyingtheimpactfa ctorspecifiedinTable12, ,thestresscausedfromthehoistingloadisdif ferentinsign,fromthatoftheself-weight,al oadmultipliedby(1 V) (M)orDutyFactorsThevalueoftheampli~ (CombinationofLoads)Inthecalculationofst resses, :a)Workingwithoutwind;b)Workingwithlimit ingworkingwind;andc)Forexceptionalloadin gs,IS807 [(staticloadduetodeadweight)+(workingloa d)x(dynamiccoefficient,W)].]