SINGAPORE STANDARD

SS 497 : 2011
(ICS 53.020)

CODE OF PRACTICE FOR

Design, safe use and maintenance of gantry cranes, overhead travelling cranes and monorail hoists

Published by SPRING Singapore 1 Fusionopolis Walk #01-02 South Tower, Solaris Singapore 138628 SPRING Singapore Website: www.spring.gov.sg Standards Website: www.standards.org.sg

SINGAPORE STANDARD

SS 497 : 2011
(ICS 53.020)

CODE OF PRACTICE FOR

Design, safe use and maintenance of gantry cranes, overhead travelling cranes and monorail hoists

All rights reserved. Unless otherwise specified, no part of this Singapore Standard may be reproduced or utilised in any form or by any means, electronic or mechanical, including photocopying and microfilming, without permission in writing from SPRING Singapore at the address below: Head Standards SPRING Singapore 1 Fusionopolis Walk #01-02 South Tower, Solaris Singapore 138628 Telephone: 6278 6666 Telefax: 6659 0639 Email: standards@spring.gov.sg

ISBN 978-981-4353-15-1

SS 497 : 2011

Contents
Page Foreword CLAUSES Section One General 1 2 3 4 5 Scope Normative references Definitions Legislation relevant to this standard Responsibilities 9 9 11 14 14 7

Section Two Design considerations 6 7 8 9 10 11 12 13 14 Group classification of cranes Loads and load combinations Design of crane structures Crane mechanisms Electrical equipment and controls Hydraulic equipment and controls Pneumatic equipment and controls Documentation and marking Manufacture and construction 15 18 32 35 44 50 53 56 58

Section Three Operation and maintenance 15 16 Safe use and operation of cranes Inspection and testing 61 64

ANNEXES A B C D E Application of the allowable stress method of design Application of the limit state method of design Information to be considered when installing an overhead travelling or gantry crane Selection of wire ropes Sample checklist for inspection of crane by owner 67 69 71 73 75

TABLES 1 2 3 4 Group classification of cranes according to utilisation Classes of utilisation of cranes Nominal load spectrum factor and state of loading for cranes Categories of loads and load combination table 5
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Page 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Application table for dynamic multiplier (1) Hoisting classes of cranes Factors 2, 2 min and 2 max Lateral loads due to acceleration from traverse (cross-travel) drives Lateral loads due to acceleration from travel (long-travel) drives In-service wind data 22 22 24 26 27 28

Recommended minimum values for the natural frequency of vertical vibration at different bridge spans 34 Classes of utilisation of mechanisms Nominal load spectrum factor and state of loading for crane mechanisms Group classification of crane mechanisms Permissible stress (Pc) for mechanism components Mechanism duty factor, G Minimum drum-to-rope and sheave-to-rope diameter ratios Duty type factors Values of coefficients f , m and p Zp values Minimum breaking load factor, K 35 36 36 39 40 44 48 69 73 74

FIGURES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Illustration of typical lifting attachments in relation to safe working load Typical load spectra Acceleration loads due to traverse (cross-travel) drives Acceleration loads due to travel (long-travel) drives Distribution of horizontal forces Skew load coefficients Dynamic multiplier (5 ) for buffers Headroom above platforms and walkways on crane Clearances for access landings Shearing and crushing conditions Typical flow chart of the allowable stress method of design Typical flow chart of the limit state method of design Single girder overhead travelling crane Double girder overhead travelling crane Gantry crane 13 17 26 27 27 29 31 59 59 68 70 71 71 72

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SS 497 : 2011

Foreword
This Singapore Standard was prepared by the Technical Committee on Safety and Health involving the Use of Equipment under the purview of the General Engineering and Safety Standards Committee. It is a revision of SS 497 : 2002 which was for overhead travelling cranes only. This revised standard is based on AS 1418.1:2002 Cranes, hoists and winches, Part 1 : General requirements and is reproduced with permission from SAI Global under Licence 1108-c146. Australian Standards can be purchased online at: http://www.saiglobal.com. This standard is expanded to include overhead travelling, gantry, jib cranes and hoists on monorails. It is aligned with current industrial practices and legal requirements on the safe use, design, maintenance and testing of such cranes. The salient points are as follows: (a) The responsibilities of the relevant parties who are involved in the design, use, maintenance, testing and inspection of cranes are delineated. The requirements under each clause are elaborated to provide a common understanding amongst the various interested parties. The in-service wind speeds in Table 10 are based on the updated data obtained from the Singapore Meteorological Service and SS EN 1991-1-4: 2009 Eurocode 1 Actions on structures Part 1-4: General actions Wind actions. Section Two covers the basic design considerations for the crane. Where the design and calculations are based on an overseas / established crane standard, there shall be no mixand-match of the data quoted in this Singapore Standard and the aforesaid crane standard (e.g. the load factors, coefficients, etc). Various safety limiters and indicating devices are introduced as part of the crane mechanism to ensure safe operation. These include anti-collision devices, overload limiters, etc. Work space limiters are also introduced to prevent operation of cranes in prohibited areas where there is danger of collision of crane structure or load with a permanent object or structure. When tested with the SWL, the maximum deflection at the centre of the bridge shall not exceed 1/750 of the span. The deflection at end of cantilevered bridge shall not exceed 1/300 of the span of the cantilevered portion of the bridge. The markings on cranes have been provided to ensure proper identification and SWL limits, particularly for cranes fitted with at least 2 lifting devices. Manufacturer or supplier of cranes is required to provide complete documentation for the crane installed. It includes operations manual, maintenance manual, parts book and log book.

(b)

(c)

(d)

(e)

(f)

(g)

(h)

In preparing this standard, references were made to the following publications: 1. AS 1418 Cranes, hoists and winches Part 3 : 1997 Bridge, gantry and portal cranes (including container cranes) Rules for the design of cranes Part 1 : 1983 Classification, stress calculations and design criteria for structures Part 2 : 1980 Classification, stress calculations and design criteria of mechanisms

2.

BS 2573

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3. 4. 5. 6. DIN 15018 IEC 60204 ISO 2408 : 1985 ISO 4301 Cranes Steel structures Part 1 : 1994 Verification and analyses Safety of machinery Electrical equipment of machines Part 32 : 1998 Requirements for hoisting machines Steel wire ropes for general purposes Characteristics Cranes Classification Part 1 : 1986 General Part 5 : 1991 Overhead travelling and portal bridge cranes Cranes and lifting appliances Selection of wire ropes Part 1 : 1986 General Cranes Test code and procedures Cranes Design principles for loads and load combinations Part 1 : 1989 General Part 5 : 1992 Overhead travelling and portal bridge cranes Cranes Inspections Part 1 : 1994 General Cranes Limiting and indicating devices Part 1 : 1994 General Part 5 : 1995 Overhead travelling and portal bridge cranes Cranes Requirements for mechanisms Part 1 : 1998 General Cranes Access, guards and restraints Part 5 : 2001 Bridge and gantry cranes Code of practice for the safe use of mobile cranes Code of practice for safe use of tower cranes Code of practice for factory layout Safety, health and welfare considerations

7. 8. 9.

ISO 4308 ISO 4310 : 2009 ISO 8686

10. 11.

ISO 9927 ISO 10245

12. 13. 14. 15. 16.

ISO 10972 ISO 11660 SS 536 : 2008 SS 559 : 2010 SS 567 : 2011

Acknowledgement is made for the use of information from the above publications. Attention is drawn to the possibility that some of the elements of this Singapore Standard may be the subject of patent rights. SPRING Singapore shall not be held responsible for identifying any or all of such patent rights.

NOTE 1. Singapore Standards are subject to periodic review to keep abreast of technological changes and new technical developments. The changes in Singapore Standards are documented through the issue of either amendments or revised editions. Compliance with a Singapore Standard does not exempt users from legal obligations.

2.

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SS 497 : 2011

Code of practice for design, safe use and maintenance of gantry cranes, overhead travelling cranes and monorail hoists
Section One General 1 Scope

This standard applies to the following types of powered cranes (hereinafter called cranes): 1.1 1.2 1.3 1.4 Gantry cranes Overhead travelling cranes Jib cranes; and Monorail hoists.

It specifies the basic requirements of cranes and lays down the responsibilities of the various parties involved.

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