T C V N 4244: 2005

TCVN N A T IO N A L S T A N D A R D

T C V N 4244 : 2005
2 n d E d ition

L IF T IN G A P P L IA N C E S
D E S IG N , C O N S T R U C T IO N A N D T E C H N IC A L
SU R V E Y

H A N O I –2009

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TABLE O F CO NTENT

P age
1.1 General regulations 7
1.2 References 7
1.3 Definitions 8
1.4 Technical documents 9
1.5 General requirement on technical safety 9
2.1 Classification and load exerting on structures and components of lifting 23
appliances
2.2 Calculation of stress in the structure 58
2.3 Testing of strength and selection of components of lifting appliances 71
2.4 Electrical equipments 84
2.5 Anti-oscillating stabilization and prevention of movement by wind 108
3.1 Materials 110
4.1 General instructions 122
4.2 Testing and test-running of loose pieces 122
4.3 Testing and test-running of lifting appliances 122

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ACK NO W LEDG EM ENT

TCVN 4244: 2005 replaces for:

 TCVN 4224:1986 – Safe technical procedures of lifting appliances
 TCVN 5863:1995 – Lifting appliances, safety requirements in installation
and operation;
 TCVN 5862:1995 – Lifting appliances, classification based on operational
modes
 TCVN 5864:1995 – Lifting appliances, steel cable, pulley, chain and
chain sprocket.

TCVN 4224:2005 is compiled by Technical Department of TCVN/TC 8 “Shi p

bui
ldi ng and mari neconst ructions”, Directorate for Standards, Metrology and
Quality under approval of Ministry of Science and Technology.

This standard has been changed since 2008 from Vietnam Standard of equal code
into National Standard according to regulation under Clause 1, Article 69 of Law
on Standard and Technical Procedures and section a, Clause 1, Article 6 under
Decision No.127/2007/ND-CP dated 01 August 2007 by the Government
stipulating implementation of some articles in Law on Standard and Technical
Procedures

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L IF T IN G A P P L IA N C E S –D E S IG N , C O N S T R U C T IO N A N D S U R V E Y

C H A P T E R 1: G E N E R A L P R O V IS IO N

1.1 G en eral p rovision

1.1.1 Applied range
This standard is applied for the following lifting appliances:
1. Jib cranes: Car crane, wheel-mounted crane, crawler crane, tower crane,
railway crane, seat crane, etc.;
2. All types of cranes and gantry cranes
3. Lifting appliances:
- Trolley running along high rail track;
- Electric tackle, electric winch;
- Hand tackle, hand winch;
- Construction elevators.
4. Carrier parts
1.1.2 This Standard is not applied for lifting appliances installed in ships, local
marine vehicles and on marine works.
1.1.3 The implementation of requirements on this Standard is the condition for
issuing and remaining the validity of issued certificates.
1.2 R eferen ces
TCVN 5179:90 – Lifting, lowering appliances – Requirements on testing the
safety of hydraulic equipments;
ISO 4309:2004 – Cranes – Wire rope: care, maintenance, installation,
examination and discard;
ISO 2408:2004 – Steel wire ropes for general purposes – Minimum
requirements;
ISO 148:1983 – Charpy impact test (V-notch);
IEC 144 – A liquid bath under ambient air pressure is used to determine the
effectiveness of the seal component parts;
IEC 34-5 – Rotating electrical machines parts degree of protection (IP code)
classification;
IEC 341 – Electrical Specifications – AC motors;
IEC TC 81 – Lightning protection

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1.3 D efin ition s

1. V erification
The examination, testing and analysis of verification agencies to assess safety
status of machines, equipments, materials, substances with strict requirements
on labor safety and labor sanitation according to regulations in State standards
on labor safety and labor sanitation.
2. L iftin g ap p lian ces
Appliances used for lifting, moving and lowering goods.
3. S afety w ork in g load (S W L )
Maximum goods quantity allowable for lifting, including parts used for lifting
goods such as: clamshell, hook, cable, beam, frame, etc. in lifted goods core.
4. S tatic load
Quantity of components causing impacts on considered parts, except for
working load.
5. A llow ab le load for rem ovab le p arts, cab le an d ch ain
Allowable force is calculated on the basis of testing load for removable parts
and breaking load for chain and cable. This load is equivalent to the value fo
maximum force defined when calculating lifting appliances.
6. M etal stru ctu res
Structures in crane stem, piles, base bearer, crane, gantry crane and other
structures bearing load on lifting appliances.
7. M ech an ism
Good lifting mechanism, crane lifting mechanism, rotating mechanism and
moving mechanism of the crane includes their winches.
8. C om p on en ts
Components of lifting appliances used for force transmission and dynamic
link with other components are combined to form a whole structure.
9. Irrem ovab le com p on en ts
Flanges of good lifting cable, brace cable and crane lifting cable; crane tail
fork; pile strap and crane and other abnormal components in fixed link with
other structures of lifting appliances.
10.M ovab le com p on en ts
Pulley, lifting hooks, fastener, rotating shoe, turnbuckle, cable, chain and
other components in removable link with other structures of lifting appliances.
11.W arn in g an d safety p rotectin g d evices
1. Warning devices automatically generate signal to indicate limited working
conditions possible to raise troubles.

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2. Protecting devices automatically stop machine’s operation to avoid
dangerous situations.
12.B rak e safety coefficien t
The rate between static moments caused by brake with static moment on
brake shaft under the effect of calculated load.
13.N orm ally op en b rak e
The type of brakes only closes when being charged with power.
14.N orm ally closed b rak e
The type of brakes only opens when being charged with power.
15.C on trol b rak e
The type of brakes closed and opened by crane operator forcing on control
structure of the brake, not depending on driven parts of the machines.
16.A u tom atic b rak e
Type of brakes automatically closes when power is cut off for the engine of
that brake structure.
17.D an gerou s good s
Those goods when being load and unload can cause fire, explosion which are
dangerous for human lives and health, environment, national safety and
public security.
1.4 T ech n ical d ocu m en ts
1.4.1 Technical documents for lifting appliances manufactured or equipped
under the technical supervision of competent authorities, including:
1. General description; table of electric, hydraulic or compressed air
equipment selection; Table of strength and stability of lifting appliances or
their history.
2. General drawing of lifting appliances stating main dimensions and
parameters.
3. Drawing of operating principle and main technical features of electric ,
hydraulic or compressed air transmission system, control devices and
arranging safety devices.
4. Drawing of metal structure.
5. Drawing of structural groups of lifting appliances, cable diagram.
6. Manufacture process of special parts;
7. Examining and load testing process.
8. Assembly and safe operation instructions.
1.4.2 When using metal structures, components and devices manufactured
according to standardization as well as applying thermal technology
procedure and calculations according to standards or other technical

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conditions approved by competent authorities, it is not required to approve
separately.
1.4.3 When changing lifting appliances in case of reforming or repairing,
technical documents submitted for approval shall be compliant with these
changes according to requirements of this Standard.
1.4.4 When the first examination on lifting appliances manufactured according
to the design fails to be approved by competent authorities and in other
particular cases, amount of necessary technical documents stated in 1.4.1
can be reduced if being approved by competent authorities.
1.5 G en eral req u irem en ts on tech n ical safety
1.5.1 Sealing and labeling the goods of manufacturer.
Lifting appliances shall be sealed and labeled as follows
1.5.1.1Sealing
Allowable lifting force (and outreach) will be sealed fixed in a position
easy to see and possible to see clearly from the ground.
In case crane has lifting force changing according to outreach, it is
necessary to install a suitable scaling table to indicate lifting force and
outreach of the crane.
In case the crane has more than 2 hooks, lifting force of each hook shall be
stated clearly right on related hook pulley block. In addition, it is
necessary to clearly indicate allowable lifting force on each hook in case
all hooks can be used synchronously,
1.5.1.2Labeling
Each lifting appliances shall be labeled of manufacturer at position
suitable with contents as follows:
- Name of manufacturer;
- Year of manufacture;
- Serial number of manufacturer;
- Lifting force in kilogram (kg) and/or ton (t);
- Type of lifting appliances.
1.5.1.3Warning sign
Warning sign “Not allowed to stand under the load” shall be placed in
suitable position easy to see. Openings of lifting appliances shall warned:
“Not getting on lifting appliance except on business”. Specially dangerous
area shall be warned: “Danger – Lifting appliance”.
1.5.2 Safety requirements on structures
1.5.2.1 Clearance
1.5.2.1.1 All moving parts of lifting appliance, except for operating equipments,
clamshell and shovel in most disadvantageous position or loading
conditions shall be at least 0.05m away from fixed objects, at least

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0.1m away from protecting handrail and baluster and at least 0.5m
away from entrances.
1.5.2.1.2 Minimum distance vertical from lifting appliances to common lower
working entrance (to floor as well as fixed or moving devices of the
workshop, except for working floor or maintenance floor or similar)
shall not be lower than 1.8m, to parts of fixed or moving devices with
limited entrances (such as furnace arch, parts of machine, lifting
appliances moving below, etc.) as well as protecting handrail shall not
be lower than 0.5m.
1.5.2.1.3 Minimum distance vertical from lifting appliances to parts of fixed or
moving upper devices (i.e. between components of the winch or
handrail and beam of the workshop, pipelines, lifting appliances
running on other upper running line, etc.) shall not be lower than 0.5,
in maintenance floor and adjacent areas. This distance can be reduced
to 0.1m in case parts of special structures, with the condition of not
causing danger on human beings or having suitable warnings, are used
to eliminate possible risks.
1.5.2.2 Metal structures
1.5.2.2.1 Minimum thickness of loading metal structures with entrance to
examine and maintain all sides and of structures arranged in close
chamber shall not be lower than 4mm. The thickness of box-type
structures with no entrance to examine and maintain the inner side
shall not be lower than 6mm.
1.5.2.2.2 Bolts and screws in joints of loading structures shall have radius not
lower than 14mm. Limited thickness of assembled structures shall not
be larger than 5 times of bolt or screw diameter.
1.5.2.3 Control cabinet
1.5.2.3.1 Cabinet shall be designed so that the controller have clear view on the
whole working site or keep tract of all activities with appropriate
assistance.
1.5.2.3.2 Cabinet shall have enough space for the controller to easily control. It
is possible to control from sitting position or standing position, if
necessary.
A protecting baffle shall be installed on the top of cabinet to for fear of
dropping things on the cabinet.
The arrangement of cabinets and control devices shall be designed so
as to be most convenient.
1.5.2.3.3 Materials of cabinet structures shall be fireless. Side plate and roof
plate can be made by fireless materials. Cabinet floor will be covered
with insulated and non-metal materials.
1.5.2.3.4 In cabinets with windows <1m away from floor and glass part on
cabinet floor, the glass parts shall be structured or protected so that
people inside can not drop outside. It is possible to clean cabinet

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window with no danger. Glass windows on cabinet floor having many
risks to break in case of troubles or suffering from thermal radiation
when lifting appliances operate shall be made by suitable safe glass.
Cabinet doors shall be protected to avoid sudden opening.
1.5.2.3.5 Cabinets shall be equipped with anti-dazzle lights and, if necessary,
shall be ventilated.
1.5.2.3.6 Radiated cabinets shall be protected from thermal radiation and
insulating design, and cabinets shall be air conditioned to ensure
acceptable working conditions.
1.5.2.3.7 Cabinets operating in toxic environment harmful to controller’s health,
such as toxic dust, steam or gas shall be protected from their invasion
and equipped with fresh air supply system for the cabinets.
1.5.2.3.8 Cabinets shall ensure labor safety and sanitation parameters for the
controller such as: vibration (frequency, amplitude). Noise level shall
be within allowable range.
High cabinets shall have telecommunications means with the ground to
receive or inform the controller on information from manager of goods
lifting from the ground.
1.5.2.4 Supplementary requirements for cabinets with hanging-lifting control
1.5.2.4.1 Number of people allowed being present in the cabinets and maximum
load of cabinets shall not be changed and clearly indicated. In addition,
operation and maintenance instruction for cabinets with hanging-lifting
control shall be stuck in the cabinets.
1.5.2.4.2 Cabinets shall be located firmly so as not to rotate or shake, causing
danger.
1.5.2.4.3 Cabinets shall be arranged with a anti-drop device or it is possible to
install 2 structures of hanging cabinets with the condition that the
cabinet is still be kept if one of the two structures is broken, or driven
or brake structures are broken. Each of hanging separate structures
shall be designed with safety coefficient not lower than 5 times of
maximum working load.
If there is a anti-drop device and only one hanging structure, minimum
safety coefficient when calculating for design shall be taken 8 times of
maximum working load.
Driven cable shall be designed with minimum strength according to
M8 structure group. Cable’s diameter shall not be lower than 6mm.
Driven cables working outdoor shall be galvanized steel cables.
1.5.2.4.4 When the lowering speed reaches 1.4 times of normalized speed, the
cabinets will automatically stop.
Cabinets shall move independently from load.
1.5.2.4.5 All controls will automatically stop right after the controller goes out
of the cabinets.

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1.5.2.4.6 All normal and emergent limit switches shall be installed at highest
and lowest positions of the cabinets, with separate closing, opening
and operating system. Emergent limit switches will directly cut main
electric circuit and generate warning signs.
In case the cabinets strike the obstacles or hanged structures are loose,
movements of lifting appliances will automatically stop. Devices to
operate lifting appliances are not automatic-start type.
1.5.2.4.7 If moving speed of cabinets is higher than 40m/min, it is necessary to
install immediate decelerating devices so that dashpots do not strike
with the speed of >40m/min. If striking speed is higher than 40m/min,
it is necessary to install dashpots of power absorbing type.
1.5.2.4.8 The cabinets shall be installed independent warning system for source
power of lifting appliances. Cabinets shall be also equipped so that the
controller can escape to the ground, e.g. rope ladder or escape devices,
and these equipments shall be always available in controlling
compartment.
1.5.2.4.9 The users shall ensure the safe distance of 0.5m away from cabinet
bottom in highest working position with highest good piling height.
1.5.2.4.10 It is only possible to remotely control the lifting appliances from the
ground with cabinet at highest working position.
1.5.2.5 Handrail, corridor and floor
1.5.2.5.1 The entrance to control cabinet shall be easy and safe for any position
of lifting appliance in normal working conditions. If the floor of
control cabinet is <5m away from the ground and entrance to cabinet
can be restricted for certain positions of lifting appliances, the cabinet
shall be equipped with suitable escape devices (such as rope ladder).
Usually used entrance to cabinets is from peer-to-peer floor with
control cabinet floor and the floor shall have protecting handrail. The
entrance through cabinet floor or roof is only used when the real space
is restricted.
When entrance into cabinets passes directly through staircase, floor or
corridor, the horizontal clearance to entrance to cabinets shall not
exceed 0.15m and the difference between floor height and cabinet
floor shall not exceed 0.25m.
1.5.2.5.2 When it is impossible to get into cabinets directly from the ground at
random position of lifting position, and cabinet floor is >5m away
from the ground, lifting appliances shall be arranged with appropriate
accesses. For some certain lifting appliances such as crane, entrance to
cabinets may be restricted for some certain positions. Therefore, it is
necessary to equip suitable devices so that the controller can easily get
out of cabinets.
1.5.2.5.3 Corridors, staircases and floors shall have safe entrance at any
positions of lifting appliances. Regularly used staircases and ladders

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shall lead to floors or corridors. For such entrances, staircases will be
used more than ladders.
1.5.2.5.4 All operating positions and equipments required for regular
examination and maintenance need to be equipped with safe entrance
or get access to these positions by mobile working floors.
1.5.2.5.5 The above mentioned positions 2m higher than the floor and crane
girders shall be accessed through staircases and floors. The staircases
shall be installed with protecting handrail in both sides.
1.5.2.5.6 When assembling, separating, testing, repairing and maintaining lifting
appliances in the positions 2m higher than the floor, appropriate
devices are required to place on lifting appliances and girders to ensure
human safety (such as protecting handrail, baluster, safe devices, etc.)
and allow to get access to these positions. Pulleys and moving parts at
the end of girder shall be designed so as not necessary to lubricating
during the time from assembling to separating lifting appliances. It this
condition fails to be met, the crane girders shall be equipped with
access openings.
1.5.2.5.7 Access openings on crane girders mentioned above can be ignored
when crane girders can lower down for comprehensive examination by
eyes or other structural parts allowing eye examination.
1.5.2.5.8 Staircases, entrances and floors shall have upper clearance not lower
than 1.8m. Entrances with width >0.5m shall be installed near driven
parts with relative movement for entrances and floors. Dimension of
these entrances can be reduced to 0.4m with the condition that the
handrail is available with the height of 0.6m. Width of entrance
between fixed parts shall not be lower than 0.4m.
The clearance on little used entrances arranged within structure of
lifting appliance can reduce to minimum 1.3m, concurrently the width
shall increase to 0.7mm changing in linearity with height decrease. The
clearance on floors only used for maintaining devices may reduce to
1.3m.
1.5.2.5.9 Accesses to the parts of lifting appliances shall install continuous
handrail at the positions in danger of dropping from >1m height. The
height of vacuum shield shall not be lower than 0.1m. It is allowable to
arrange entrances in handrail if installing suitable protecting devices to
avoid human dropping and falling. According to regulations, handrail
height shall not be lower than 1m and arranged with vacuum shield
and medium railing. The height of handrail can be reduced to 0.8m
with entrances having upper clearance of 1.3m. Along entrances shall
be arranged at least one baluster.
For entrances along the workshop wall or having dead partition, it is
allowable to use balusters for handrail. The gap between rails shall not
be higher than 1m.

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1.5.2.5.10 Floor surface shall be of suitable anti-sliding type. Recesses, gaps on
floor shall be restricted in size so that a ball with 0.02m diameter can
not pass through.
1.5.2.5.11 When entrances are placed near electric line, these lines shall be
protected to avoid unintentional touch.
1.5.2.6 Staircases and ladders
1.5.2.6.1 Staircases and ladders shall be installed at the positions with height
difference >0.5m. Foot rests with balusters can be installed on vertical
surface not higher than 2m.
Staircases longer than 8m shall have rest floors at medium positions.
For higher staircases, e.g. for tower crane used in construction, it is
possible to arrange more medium rest floors with the condition that the
vertical distance between rest floors shall not be higher than 8,. In case
of spatial restriction, it is possible to install continuous single
staircases in rest floors along the staircase
1.5.2.6.2 Staircase
The slope of staircases shall not exceed 650, the height of each step
shall not exceed 0.25m (0.2m for tower crane) and the width of step
shall not be lower than 0.15m.
If possible, apply the following rate:
2 x step length + 1 ste width = 0.63m
The distance between steps is the same. In case of main staircases, the
distance between vertical railings of handrail is required at 0.5m
Staircase step surface shall be anti-sliding.
Staircases shall be installed handrails at both sides: when one side has
wall, the other side needs only rail.
1.5.2.6.3 Ladder
The length of horizontal bars between 2 ladders shall not be lower than
0.3m, the distance between horizontal bars shall be the same and not
higher than 0.3m. The horizontal bars shall be at least 0.15m away
from fixed parts. Horizontal bars shall bear a force of 1,200N in the
middle without any permanent deformation.
The holes the ladder passing through shall not be smaller than 0.63m x
0.63m or smaller than 0.8m diameter of the hole.
Over-5m ladders shall be installed safe jacket from the height of 2.5m.
The distance between safe jackets shall not be larger than 0.9m. The
safe jackets shall connect with each other with the minimum of three
equidistant jamb bar.
In any cases, one jamb bar connecting safe jackets shall be placed in
the middle opposite to the vertical central line of the ladders.

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The durability of the safe jackets enhanced by jamb bars shall be
enough to bear a force of 1000N distributed in 0.1m section in any spot
of the safe round without any deformation.
Lift shoulder shall be stretched at least 1m towards the upper of the top
cross bar, except for arranging some suitable handgrips. In case of
restricted space, ladder shoulder stretched 0.8m will be accepted.
Safe jackets are not necessary to be arranged in the ladders inside
structures, they can also protect the safety and the distance from the
middle and the opposite side is 0.7 to 0.8m. Parts of structure are
considered as the safe jackets with the condition that the perpendicular
distance between bars in the dangerous area is always smaller than
0.75m and the inscribed circle between the ladder and vertical jambs is
smaller than 0.75m.
The rest floors arranged for the ladders in the first section shall not be
higher than 10m. That of next ladder is 8m away from each other.
1.5.3 Mechanical devices
1.5.3.1 Driven cables and chain
1.5.3.1.1 Cable drum must have the cable trough. According to the regulation,
drum is only wound with one layer of cable. If the drum is wound with
more than one layer of cable, it is necessary to arrange cablecast
equipment in case of cable wind two layers and automatic in winding.
If the cable get loose in running or winding incorrectly, it is necessary
to set up suitable equipment to prevent from this.
Cable drum need to have wall in two side exception from having
preventing cable rush into.
Cable wall is higher than the top cable over 1.5 times cable diameters
when cable is wind in the drum (2 times for the building crane)
1.5.3.1.2 At the lowest acceptable hook it’s still having at least two cables round
in drum in front of cable head key. If the cable head is being clamped
in drum by clamping bolt, it’s necessary to have at least two individual
clamping with the stable key equipments.
1.5.3.1.3 It is necessary to preserve to prevent from directly affect of radian
heart source, air, melting metal and other risk materials. It is essential
to use the especially cable in the harsh conditions, rusty materials.
1.5.3.1.4 Chain automatic structure have to set an equipment which ensure the
chain is easily running in chain sprocket and prevent the chain from
out of the sprocket, it also need to set up a suitable protect chain.
1.5.3.2 Lifting hook, rope block and other supporting equipments
1.5.3.2.1 It is necessary to install a suitable equipment to prevent cable or chain
out of pulley.
1.5.3.2.2 It is necessary to install a protect equipment to avoid the ability of
finger stuck in cable and lifting hook pulley.

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1.5.3.2.3 Cable driving pulleys shall be designed so as to get access for
maintenance.
1.5.3.2.4 Safety hooks shall be installed and these hooks are designed especially
in such positions where operating methods are in danger hook slipping
or sticking.
1.5.3.2.5 Load devices which can be replaced to each other between lifting
appliances, e.g. clamshell, electric magnet, tank, bucket grab and
lifting beam, shall be fixedly sealed safe working load and their own
gravity. In case the clamshell and tank are used to transport bulk cargo,
it is necessary to seal capacity and name of manufacturer.
1.5.3.3 Brake
Regulations of this Item will not be applied for structures operating by
cylinder, such as hydraulic glass.
1.5.3.3.1 Drives shall be installed mechanical brake. In exceptional cases, if
driving through automatic lock mechanism, it is not necessary to
install brake with the condition that automatic lock mechanism is
ensure not to have excessive stress or any possible movement.
Brake structure shall be easy for examination. Brake spring shall be
compact. Brakes shall be possible to adjust and brake jaw shall be
possible to replace.
1.5.3.3.2 Crane lifting mechanism shall be installed automatic brake and can
keep testing load safety in case of power-off or broken lifting driven
mechanism.
Brake system shall be designed so as to keep the load equal to 1.6
times of lifting load and possible to keep dynamic testing load without
loosing brake efficiency and causing overheat.
Brake of lifting mechanism shall be installed so as to have strong
mechanical link between parts of the winches so that one side arises
brake moment and the other side keeps inner load fixed.
Mechanical and electric structures can keep load reducing speed in
allowable range.
Mechanism of lifting fused materials shall be equipped with two
mechanical brakes operating independently. Each brake shall meet the
defined requirements; the second brake shall have delay time effect
with the first brake.
In emergency cases with damages of driven devices, the second brake
will impact on cable drums, this brake shall be controlled for automatic
impact, not slower than instant speed equal to 1.5 times of norm
reducing speed. In this case, control mechanism of lifting appliances
will stop urgently and automatically activate the brake.
1.5.3.3.3 Driven devices moving lifting appliances and electric crane trolleys
shall be equipped with automatic brake or brake possible to operate
from control location. Except these lifting appliances are not affected

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by wind, speed of operations on horizontal rails shall not exceed
40m/min, or speed of operations on wheels with anti-frictional bearing
shall not exceed 20m/min. For lifting appliances used for transporting
fusing materials, brake is required not depending on speed.
Brake shall be designed so that lifting appliances and crane trolleys
can stop in suitable time and remain fixed in all operational status,
under the impact of wind load as well as in case of power loss.
Movable structures of lifting appliances and crane trolleys (small) in
wind condition equipped with automatic brake shall be equipped rail
clips.
Automatic brake or anti-storm devices of movable structures shall be
designed with safety coefficient not lower than 1.1 times of maximum
force in the condition that the lifting appliances do not operate.
1.5.3.3.4 Brake of electric rotating structures of lifting appliances shall be
designed so as to stop in a certain item and keep rotating parts fixed in
all operating status under the impact of wind load as well as in case of
power loss.
1.5.3.3.5 Brake of structures changing crane’s outreach shall be designed so that
in case of power loss or damage of driven structures, the brake shall
have automatic effect and keep the crane and testing load safe in most
disadvantageous positions.
Brake mechanism shall be designed with minimum brake moment
equivalent to 1.6 times of moment due to load under the hook and
gravity of crane system adding 1.0 times of moment due to wind load
under the most disadvantageous working status (maximum wind load
in operating condition).
In case the lifting appliances do not operate, minimum designed brake
moment shall be equal to 1.1 times of moment due to gravity of crane
system and wind (maximum wind load in case the lifting appliances do
not operate) in the most disadvantageous positions of crane or at the
position where the crane does not operate.
1.5.4 Hydraulic devices
1.5.4.1 Solid steel pipes are used to make pressure pipe with external diameter
up to 30mm; It is not allowable to have weld joints on these pressure
pipes except for weld joints at pipe flange by bolt joint.
1.5.4.2 When load lifting and crane lifting/lowering mechanism is driven by
hydraulic cylinder, automatic devices (load keeping valves) shall be
installed right near pressure pipe joints of cylinder to avoid load’s
sleeper ring, especially in case the pipes are broken. When load is
slippered due to oil leakage in parts, mechanical devices shall be
installed to avoid.
With other hydraulic drives, the above movement shall be stopped by
automatic brake and operated by automatic restart controls.

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1.5.4.3 The extension of maximum working pressure due to the impact from
external load on isolated hydraulic circuits when stopping control will
be prevented by safety valve. Other regulations or methods of suitable
structures shall be applied to prevent working pressure from exceeding
1.6 times, even in case of pressure impulse.
1.5.4.4 Before operation, hydraulic system shall be cleaned. The system shall
be designed so that dust can be cleaned when repairing.
1.5.4.5 Each hydraulic circuit shall have at leas one joint to install pressure
meter to measure pressure without removing the pipes.
1.5.4.6 Hydraulic system shall install air-relief valve at appropriate positions.
1.5.4.7 The movement exceeding limits shall be prevented by suitable devices.
1.5.4.8 Hard and soft pressure pipes shall be designed with safety coefficient
equal to 4 to avoid break-down due to pressure; this safety coefficient
is also applied for joints and flanges. For fixed lifting appliances not
bearing hydraulic shock or vibration, safety coefficient for pipes and
joints is only 2.5.
1.5.4.9 Hydraulic liquids used in hydraulic system of lifting appliances shall
be suitable with requirements on working conditions, technology and
safety. Hydraulic liquids shall be clearly indicated for the users.
Maximum and minimum liquid level in the tank shall be examined.
1.5.4.10 Unintentional restarting drivers after the power is turned on or source
breaker is closed of the cranes shall be prevented.
1.5.4.11 Safety requirements on hydraulic device testing shall comply with
TCVN 5179-90.
1.5.5 Safety devices
1.5.5.1 Working movement restricting devices
1.5.5.1.1. Lifting mechanism

Electric lifting gear must operate within the admissible scale with automatic shut-
off switch (error limit switch) which relates to deceleration required distance.
Reverse operation from limited positions are only done by control device. In the
normal operation, if the limited position is touched, an auxiliary limited switch
will be added and operated independently. In this case, when auxiliary limited
switch is cut off, the operation may be recovered by using the control device. But
if auxiliary limited switch is failed, the operation will not be recovered.

Lifting gear driven from the internal combustion engine and mechanical socket
without through electric drive, hydraulic power or intermediate compressed air
will be equipped with acoustic signal alarm or signal lights instead of limited
switch.

1.5.5.1.2. Displacement mechanism

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Electric lifting device and dan must be provided with some accessories such as
rubber heelpiece, dashpot or soaring or others which can absorb a half of kinetic
energy of moving devices at the normal movement speed and maximum
deceleration in control carbine does not exceed 5m/s2.

If moving speed must be limited regularly in normal operation, maximum

deceleration in control carbine will not exceed 2.5m/s2.

Lifting device and dan with remote control must be equipped with limit cut off
switch if the moving speed is over 40m/minute.

Lifting devices equipped with control carbine and affected by wind must be
equipped with storm prevention system when Lifting device does not operate.

When lifting devices are required to operate in wind condition, wind meter and
alarm must be equipped on.

Moving structure of lifting device must be provided with stickle device in case of
obstacles appear on the rail.

In case two or more than two lifting devices moving on the same rail, a special
device must be equipped to prevent collision.

Within operation of lifting device or dan, it is necessary to have safe methods to

protect people such as signals, flash light, alarm or automatic stopper.

1.5.5.1.3. Reach and rotation change structure

With electric reach and rotation change structure, operation of crane must be
limited at the limited position by automatic cut off switch relating to deceleration
required distance.

Reverse operation from limited position is only done by control device.

Reach change structure of crane is driven from internal combustion engine and
mechanical socket without through electric drive, hydraulic power or
intermediate compressed air will be equipped with acoustic signal alarm or signal
lights instead of limited switch.
Similarly, rotation of crane driven with limited rotating angle must be limited by
automatic emergency breaking.

1.5.5.2. Overload and overturn prevention

1.5.5.2.1. Lifting device and dan must be designed or added with safe devices so
as to minimize the drop to 3cm and prevent the overturn in case wheel runs off
rail or fails or wheel bearing is failed.

Moreover, abnormal forces such as force on dashpot will not overturn lifting
device and dan.

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Lifting devices with cranes and dan with beam may be overturned due to
overload. Lifting devices with carrying capacity which does not depend on reach
of crane must be equipped with cut off switch to avoid overload. However, lifting
capacity changes after reach, this switch will also operate as load moment limit
switch. Limit switches must have reverse effect by reversing direction or in case
of overload; control device will be used to lower the load.

Lifting devices with lifting structure and reach changing structure is driven from
internal combustion engine and mechanical socket without through electric drive,
hydraulic power or intermediate compressed air will be equipped with acoustic
signal alarm or signal lights instead of limited switch.

1.5.5.2.2. Lifting devices depending on reach of crane must be equipped with

diagram of loading capacity; reach must be fixed so as to be observed clearly
from control position in the form of division line with buckles corresponding
with reach.

1.5.5.3. Alarm
Lifting devices must be equipped with alarming producing light and sound in
case operation endangers people around, such as when crane starts lifting goods,
or moving, etc.,

1.5.6. Degradation of lifting devices

As other devices, lifting device is also designed to be used for a certain time.

Regulations in design are developed from scientific knowledge and experience of

users and manufacturers to apply to different types of devices.

However, degradation of this device is only applied to structure, not other lost
accessories such as cable, brake pads, electric -collecting brush, thermal engine,
etc.,

Factors causing degradation of lifting devices:

- Fatigue
- Corrosion
- Problems happening in operation, installation and disassembly;
- Overload
- Insufficient maintenance
Lifting device operator must always care the importance of degradation.

1.5.7. Requirements of safety in installation and usage

1.5.7.1. Requirements of safety in installing the lifting device.
1.5.7.1.1. Installation or disassembly of lifting device must be done in
accordance with installation and disassembly technology process provided by
manufacturers or installation units.

Installation units must diffuse the installation process and safety methods to
installation technicians.

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1.5.7.1.2. In assembling the lifting device running on rail, it is obligatory to

examine the condition of rail. If any error exceeding admissible standard,
assemble will be stopped until the repair is completed.

1.5.7.1.3. In assembling the lifting device, it is necessary to determine the risk

area and put prohibition notice to warn people.

1.5.7.1.4. In case of heavy rain, storm, 5 grade wind and over, above and outdoor
collapsing must be stopped.

1.5.7.1.5. Collapsing workers at the height of over 2m must have certificate of

health for working on the top. They are required to wear the harness during
working on the top.

1.5.7.1.6. In assembling, following activities is banned:

- Using elevator to lift people
- Standing under the load when elevator is operating
- Hang goods at the hanger when elevator stops working
- Temperately reinforcing structures which lack necessary bolts.
- Loosing holding rope before fixing completely the structure.
- Lifting load when cable is stuck or plucked out of channel of block
- Throw any thing from the top
- Using balcony or any prevention device as bearing for lifting or hanging
hoist.

1.5.7.1.7. In putting the lifting device, calculation on bearing of set point and
terrain and surrounding activities needed to be done to arrange the equipment for
safety.

1.5.7.1.8. If the plan for construction is so narrow and lifting devices such crane,
balance must move on, it is necessary to make plan for safe construction and
approved by authority.

1.5.7.1.9. Installation of lifting device in the protected area of the aerial

conduction lines must be approved by conduction line management unit; The
license must be attached in the assembly profile.

If lifting device works near conduction line, it is obligatory to ensure following

specifications:
1.5m for conduction line of 1kV;
2m for conduction line of 1-20kV;
4m for conduction line of 35-110kV;
5m for conduction line of 150-220kV;
6m for conduction line of 330kV;
9m for conduction line of 500kV;

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1.5.7.1.10. In putting the lifting device at the margin of channel or ditch, the
maximum distance from the latest bearing to the margin of channel or ditch must
meet following specifications:

Depth of Minimum distance for categories of land, m

channel
Sand,
and ditch Clay sand Clay loam Clay Loess
gravel
M
1 1.5 1.25 1 1 1
2 3 2.4 2 1.5 2
3 4 3.6 3.25 1.75 2.5
4 5 4.4 4 3 3
5 6 5.3 4.75 3.5 3.5

If the plan can not satisfy distance as the table, it is obligatory to have methods to
prevent avalanche of channel and ditch before putting lifting device in the right
position.

1.5.7.1.11. Automatic cranes are not allowed to be put on the plan with slope
over allowable slope of crane or on land which has just been filled.

1.5.7.2. Safety requirement in using lifting device

1.5.7.2.1. All lifting devices such as machine, equipments, etc., with safety
requirement in accordance with state provision must examined and tested in
accordance with regulation of this Standard.

1.5.7.2.2. Users will use only lifting devices with goods technical condition,
which were tested and certificated under useful working. Untested and non-
certificated lifting devices and loading equipments will not be used .

1.5.7.2.3. Only workers who are trained and issued certificate are allowed to
operate the lifting device. Workers who bind buckle or make a sign must be
professional.

1.5.7.2.4. Lifting device operator must understand specification, functions of

structure of device, at the same time understand safety requirements during usage.

1.5.7.2.5. Only lifting devices with right function and specifications provided by
manufacturers are allowed to be used. The load over safe working load (SWL) of
lifting device is not allowed.

1.5.7.2.6. Lifting devices with lifting structure using friction clutch or cam clutch
is not allowed to lift, lowering and transport people, liquid metal, explosives,
poison, gas or compressed liquid cylinder.

1.5.7.2.7. Only when safety method is provided to limit failure and occupation
accident, lifting device is allowed to transport through factory, house.

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1.5.7.2.8. Lifting a load by two or more than two lifting devices is allowed in
special cases and in case of safety. Weight of loaded things will not exceed
capacity lifting device. In the safety method, it is obligatory to provide diagram
of load binding and catching, diagram of load moving and specify order of
operation, size, materials and technology used to create accessories to catch load.
Lifting and controlling must be undertaken by experienced workers.

1.5.7.2.9. During operation, following activities are not allowed:

- Climb up and down the working lifting device
- Standing within rotating turning radius of the axis
- Standing within operation radius of magnet loading lifting device, air
vacuum or clamshell bucket.
- Lifting or lowering the load while someone is standing on the loading;
- Lifting the load in unstable condition or buckle is caught one side.
- Load is compressed by other things, adherent with other things by bolts
or cement.
- Using lifting to take cable or binding chain which is compressed by other
things.
- Carrying load through windows or balcony while there is no bearing.
- Changing the operation direction of structures while it has not stopped
operation.
- Lifting load which is heavier than allowable weight corresponding the
reach and position of auxiliary strut of crane.
- Attempting to reach the load or dragging the load.
- People push the load and operate the lifting device at the same time.

1.5.7.2.10. Walkway for lifting device operator must be ensured while using the
button from ground or floor

1.5.7.2.11. When portable lifting device is working, barriers must be provided in

any access to the rail.

1.5.7.2.12. No one is allowed to be on lifting device when it is working. Cleaning,

washing, sanitation, lubricating, repairing the lifting device is allowed only when
safety methods are ensured

1.5.7.2.13 Users must organize the signal exchange system between binding
worker and lifting device operator. Signals must be stipulated in detail to prevent
to be mistaken with others.

1.5.7.2.14. When lifting device user fails to observe the load during lifting and
lowering, signal maker must be provided to support.

1.5.7.2.15. When lifting or moving the load near other buildings or things, it is
necessary to ensure safety for such buildings and things.

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1.5.7.2.16. Lifting devices operating outdoor must be stopped operation when
wind speed is higher than admissible one base on the design.

1.5.7.2.17. When lifting device is working outdoor, it is unacceptable for hanging

poster, hoarding, slogan which can increase wind resisting force of lifting device

1.5.7.2.18. Rail chucking device, automatic movement device must be tighten of

crane and kicker crane when they stop operation or when wind speed is over
admissible one. In case of storm, it is essential to add reinforce methods for
above devices.

1.5.7.2.19. Lowering load to certain position only allowed when drop or collapse
is eliminated. Suspension cable, installation parts are allowed to be disassembled
out of the buckle when structure is fixed carefully.

1.5.7.2.20. Before lowering load to the channel, it is required to lower buckle to

the lowest position to examine the remaining cable circles. If number of
remaining cable circles are two and more than two, lifting and lowering the
lifting load is allowed.

1.5.7.2.21. The lifting device must be stopped if:

- Cracks in important position of metal structure are found
- Structure is found deformed.
- Brake of any structure are found failed
- Buckle, cable, block, kettle are found detracted and overdue
- Rail of lifting device is found failed or fails to meet specifications

1.5.7.2.22. In loading goods on the vehicles, such vehicles must be ensured stable

1.5.7.2.23. Buckle binding worker are only allowed to move near the load when
it is lowered to the distance of below 1m from the standing position of buckle
binding worker.

1.5.7.2.24. Lifting device must be regularly maintained. Failed parts must be

repaired

1.5.7.2.25. In repairing and displacing the lifting device, it is necessary to have

safety method. After that, important details must be examined and lifting device
must be tested before usage.

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C H A PTE R 2
D E S IG N

2.1 C lassification an d load exertin g on com p on en ts an d stru ctu res of liftin g

ap p lian ces

2.2.1 Classification and constituents of lifting appliances

2.1.1 Overall classification
When designing lifting appliances and its constituents, operational mode of the
lifting appliances and its constituents shall be considered. For this purpose, lifting
appliances can be classified as follows:
 Overall classification of lifting appliances;
 Classification of specific components of the lifting appliances;
 Classification of components of structure and lifting appliances.
The classification is based on:
 Total time of using the considered item;
 Loading on the lifting hook, loading spectrum and stress spectrum for the
considered item.

2.2.1.2 Overall classification of lifting appliances

2.1.1.2.1 System of classification
In overall, lifting appliances is classified into 8 groups with respective code from
A1, A2 to A8 (refer to 2.1.1.2.4), based on 10 using grades and 4 loading
spectrum grades.

2.1.1.2.2 Utilization grade

U tilization tim e of liftin g applian ces is the umber of lifting circles which are
performed by the lifting appliances. One lifting circle is the total time of
performing all consecutive actions starting when the load is lifted and completing
when the lifting appliances is ready for the next load.

T otal u tilization tim e of liftin g applian ces is the expect duration of using the
lifting appliances, starting when the lifting appliances is put into service and
completing when it is removed.

Based on the utilization time, lifting appliances is classified into 10 grades coded
from U0, U1, U2 to U9 as indicated in T ab le 2.1.1.2.2

T ab le 2.1.1.2.2
G rad es of u tilization tim e

Code Total utilization time of lifting appliances

(No of lifting circles nmax)
U0 nmax ≤ 16 000
U1 16 000 < nmax ≤ 32 000
U2 32 000 < nmax ≤ 63 000
U3 63 000 < nmax ≤ 125 000

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U4 125 000 < nmax ≤ 250 000
U5 250 000 < nmax ≤ 500 000
U6 500 000 < nmax ≤ 1 000 000
U7 1 000 000 < nmax ≤ 2 000 000
U8 2 000 000 < nmax ≤ 4 000 000
U9 4 000 000 < nmax

2.1.1.2.3 Loading spectrum

Loading spectrum indicates the total number of lifting load in total utilization
time (refer to section 2.1.1.2.2) of a lifting appliances. Loading spectrum is a
partition function y = f(x) of which x (0≤ x ≤ 1), indicating the total utilization
time of which the ratio between lifting load and minimum safe working load
shall obtain a given value y (0≤ y ≤ 1).

F igu re 2.1.1.2.3.1 –a an d b - is an example of loading spectrum

F igu re: 2.1.1.2.3.1-a F igu re: 2.1.1.2.3.1-b

mt : Loads
mtmax : safe working load;
n : Number of lifting circles, of which lifting load ≥ mt;
nmax : Number of lifting circles determining the total utilization time of the
lifting appliances.
Each loading spectrum is characterized by a coefficient Kp which is determined
as:

For classification, conventional superscript is 3

In several application, function f(x) can be calculated as approximation to a
function of r steps (refer to F igu re 2.1.1.2.3.2) respectively to n1, n2, …nr lifting

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circle, in fact, lifting load can be considered constant and mei in circle ni of i step:
If nmax indicates the total utilization time and mtmax is the maximum load in all
lifting loads mei, with following connection:

or approximation:

F igu re 2.1.1.2.3.2

According to the loading spectrum, lifting appliances shall be grouped into one
of the four grades Q1, Q2, Q3, Q4 determined in T ab le 2.1.1.2.3.

T ab le 2.1.1.2.3
G rad e of load in g sp ectru m of liftin g ap p lian ces

Code Loading spectrum coefficient KP

Q1 Kp ≤ 0.125
Q2 01.25 < Kp ≤ 0.250
Q3 0.250 < Kp ≤ 0.500
Q4 0.500 < Kp ≤ 0.1000

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2.1.1.2.4 Classification of lifting appliances
Classification of overall lifting appliances is presented in T ab le 2.1.1.2.4

T ab le 2.1.1.2.4
C lassification of liftin g ap p lian ces

Grade of Utilization grade

loading U0 U1 U2 U3 U4 U5 U6 U7 U8 U9
spectrum
Q1 A1 A1 A1 A2 A3 A4 A5 A6 A7 A8
Q2 A1 A1 A2 A3 A4 A5 A6 A7 A8 A8
Q3 A1 A2 A3 A4 A5 A6 A7 A8 A8 A8
Q4 A2 A3 A4 A5 A6 A7 A8 A8 A8 A8

2.1.1.2.5 Instruction to classification of lifting appliances

The method of classification of lifting appliances is presented in T ab le 2.1.1.2.5
As hoists of the same type are used for different purposes, the classification
presented in this table can be only considered as one method of classification.
Especially, it indicates that one kind of lifting appliances can be categorized into
several groups. Thus, in order to determine into which group the lifting
appliances is classified, it is necessary to clarify its utilization grade and loading
spectrum based on the total utilization time and loading spectrum of that lifting
appliances.

T ab le 2.1.1.2.5 –In stru ction to classification m eth od of liftin g ap p lian ces

No Type and functions of lifting Operational conditions Group of lifting

appliances appliances
(refer to
2.1.2.4)
1 Manual driving lifting appliances A1-A2
2 Traveling cranes used in erection A1-A2
3 Traveling cranes used for A2-A4
installation, repair and removal in
power plant, workshops, etc
4 Lifting appliances for transporting Lifting hook A5
materials in warehouse
5 Lifting appliances for transporting Clamshell or electric A6-A8
materials in warehouse magnet
6 Cranes in workshop A3-A5
7 Movable cranes, cranes used in Clamshell or electric A6-A8
disposal or demolition plants magnet
8 Cranes used in ladles in A6-A8
metallurgical workshops
9 Cranes used in mines A8
10 Cranes used to remove pig, open A8
furnace bottom and feed for
metallurgical furnace.

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11 Cranes used in iron forging A6-A8
workshop
12.a Cranes for loading cargo and Use trailer or lifting A5-A6
containers in port frame for containers
12.b Other cranes in port Use clamshell of electric A4
magnet
13 Cranes in the port Clamshell or electric A6-A8
magnet
14 Cranes in ship building workshop. Use hook A3-A5
Cranes use for the disassembling of
machines
15 Tower crane used in construction A3-A4
16 Railway cranes A4

(1)Some typical examples are presented in the above table for instruction.

2.1.1.3 Classification of specific components of overall lifting appliances.

2.2.2.3.1 Classification system

Specific components of overall lifting appliances are classified into 8 groups,
coded from M1, M2….M8 (refer to section 2.1.1.3.4) based on 10 utilization
grades and 4 loading spectrum grades.

2.1.1.3.2 Utilization grades

Ut il
ization t
imeofa l
ift
ing appl
iance’scomponentis the real operational time
of the component.

Total utilizat
ion t ime of a lifti
ng appl iance’s component is the expected
working life of that component until it is replaced, indicated by the number of
hours

Based on the total utilization time, components of lifting appliances can be

categorized into ten utilization grades ranging from T0, T1, T2….T9 as presented
in T ab le 2.1.1.3.2

T ab le 2.1.1.3.2
U tilization grad es of com p on en ts.

Code Total utilization time T (h)

T0 T ≤ 200
T1 200 T ≤ 400
T2 400 < T ≤ 800
T3 800 < T ≤ 1600
T4 1600 < T ≤ 3200
T5 3200 < T ≤ 6300
T6 6300 < T ≤ 12500
T7 12500 < T ≤ 25000

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T8 25000 < T ≤ 50000
T9 50000 < T

2.1.1.3.3 Loading spectrum

Loading spectrum indicates the magnitude of loads exerting on components in

their total utilization time. Loading spectrum is a partition function y = f(x) of
which x (0≤ x ≤ 1), indicating the total utilization time of which components are
exerted by a load y (0≤ y ≤ 1), the maximum load.(Refer to F igu re 2.1.1.2.3.1)
Each loading spectrum is characterized by a coefficient Km, which shall be
determined as:

For classification, conventional superscript is 3.

In several application, function f(x) can be calculated as approximation to a

function of r steps (refer to F igu re 2.1.1.2.3.2) respectively to t1, t2, …tr, in fact,
lifting load S can be considered constant and Sei in duration ti: If T indicates the
total utilization time of components and Smax is the maximum load in all lifting
loads S1, S2….., Sn with following connection:

According to loading spectrum, components of lifting appliances are categorized

into four grades ranging from L1, L2, L3, L4 determined in T ab le 2.1.1.3.3

T ab le 2.1.1.3.3
L oad in g sp ectru m grad e of com p on en ts

Code Loading spectrum coefficient km

L1 Km ≤ 0.125
L2 01.25 < Km ≤ 0.250
L3 0.250 < Km ≤ 0.500
L4 0.500 < Km ≤ 0.1000

2.1.1.3.4 Classification of specific components according to the overall lifting

appliances

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Based on the utilization and loading spectrum grades of specific components,
lifting appliances can be categorized into one of the eight groups ranging from
M1, M2,….M8 as in T ab le 2.1.1.3.4

T ab le 2.1.1.3.4
C lassification of com p on en ts

Grade of Utilization grade

loading T0 T1 T2 T3 T4 T5 T6 T7 T8 T9
spectrum
L1 M1 M1 M1 M2 M3 M4 M5 M6 M7 M8
L2 M1 M1 M2 M3 M4 M5 M6 M7 M8 M8
L3 M1 M2 M3 M4 M5 M6 M7 M8 M8 M8
L4 M2 M3 M4 M5 M6 M7 M8 M8 M8 M8

2.1.1.3.5 Instruction for the classification of specific components

Instruction for the classification of specific components is presented in T ab le

2.1.1.3.5
As hoists of the same type are used for different purposes, the classification
presented in this table can be only considered as one method of classification.
Especially, it indicates that one kind of lifting appliances can be categorized into
several groups. Thus, in order to determine into which group the lifting
appliances is classified (refer to T ab le 2.1.1.3.4), it is necessary to clarify its
utilization grade (refer to 2.1.1.3.2) and loading spectrum (section 2.1.1.3.3)
based on the total utilization time and loading spectrum of that lifting appliances.

T ab le 2.1.1.3.5 – Inst
ruct
ion t
o cl
assi
ficat
ion met
hod ofl
ift
ing appl
iance’
s
com p on en ts

No Type and function Operational Classification of components

of lifting conditions
appliances of lifting
appliances
(1)
Lifting Rotation Boom Carriage Lifting
outreach movement appliances
change movement
1 Manual driving M1 - - M1 M1
lifting appliances
2 Traveling cranes M2-M3 M2-M3 M1-M2 M1-M2 M2-M3
used in erection
3 Traveling cranes M2 - - M2 M2

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used for
installation, repair
and removal in
power plant,
workshops, etc
4 Lifting appliances Lifting M5-M6 M4 - M4-M5 M5-M6
for transporting hook
materials in
warehouse
5 Lifting appliances Clamshell M7-M8 M6 - M6-M7 M7-M8
for transporting or electric
materials in magnet
warehouse
6 Cranes in M6 M4 - M4 M5
workshop
7 Movable cranes, Clamshell M8 M6 - M6-M7 M7-M8
cranes used in or electric
disposal or magnet
demolition plants
8 Cranes used in M7-M8 - - M4-M5 M6-M7
ladles in
metallurgical
workshops
9 Cranes used in M8 M6 - M7 M8
mines
10 Cranes used to M8 - - M5 M6
remove pig, open
furnace bottom
and feed for
metallurgical
furnace.
11 Cranes used in M8 - - M5 M6
iron forging
workshop
12a Cranes forUse trailer M6-M7 M5-M6 M3-M4 M6-M7 M4-M5
loading cargo and or lifting
containers in port frame for
Other cranes in containers
12b port Use
clamshell of M4-M5
electric M4-M5 - M4-M5 M4-M5
magnet
13 Cranes in the port Clamshell M8 M5-M6 M4-M5 M4-M5 M5-M6
or electric
magnet
14 Cranes in ship Use hook M5-M6 M4-M5 M4-M5 M4-M5 M5-M6
building
workshop. Cranes
use for the
disassembling of
machines
15 Tower crane used M4 M5 M4 M3 M3
in construction
16 Railway cranes M3-M4 M2-M3 M2-M3 - -

(1)Some typical examples are presented in the above table for instruction.

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2.1.1.4 Classification of components

2.1.1.4.1 Classification system

Components of the structure and lifting appliance are categorized into 8 groups,
coded with E1, E1, …., E8, respectively, based on eleven utilization grades and
four stress spectrum grades.

2.1.1.4.2 Utilization grades

U tilization tim e of a com pon en t is stress cycles that that component is affected.
A stress cycle is the collection of the collection of continuous stress from when
survey stress exceeds stress σm defined in 2.1.1.4.3 figure to when this stress is
about to the stress σm in the same direction. Therefore, figure 2.1.1.4.3 shows the
direction of the stress σ in a period of direction (5 stress cycles).

The total time of use of a component is the combination of the estimated time of
use and the time of replacing that component.

For parts of a structure, stress cycles are proportional to lifting cycles of lifting
appliances by a inconstant coefficient. Some parts must be subjected to may
stress cycles in a lifting cycle based on the position of those parts in a structure.
Therefore, the proportional coefficient of this component is different from that of
the other. When a proportional efficiency is known, the total time of use of a
component is the total time of use which was used to determine the use level of
lifting appliances.

For a component of a lifting appliance, the total time of use is the total time of
use of a lifting appliance including rotation speed of that component and/or
affects on the operation of that component.

On the basis of the total time of use, parts have use levels: B0, B1, B10 and are
indicated in T ab le 2.1.1.4.2.

T ab le 2.1.1.4.2.
U tilization grad es of com p on en ts
Code Total utilization time of lifting appliances’
components
(No of lifting circles n)
B0 n ≤ 16 000
B1 16 000 < n ≤ 32 000
B2 32 000 < n ≤ 63 000
B3 63 000 < n ≤ 125 000
B4 125 000 < n ≤ 250 000
B5 250 000 < n ≤ 500 000
B6 500 000 < n ≤ 1 000 000
B7 1 000 000 < n ≤ 2 000 000
B8 2 000 000 < N ≤ 4 000 000

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B9 4 000 000 < N 8 000 000
B10 8 000 000 < n

2.1.1.4.3 Stress spectrum

Stress spectrum shows the effect of weight load on a component during the total
time of use of that component. Stress spectrum is the distribution function y= f(x)
in which x ( 0≤ x ≤ 1) shows the total time of use ( refer to figure 2.1.1.4.2).
During this time of use x, that component shall be subjected to the stress, at least
y of the maximum stress. ( 0 ≤ y ≤ 1).

In which, c depends on factors including: property of material, shape,

dimensions, and roughness and wear of such component.
In several applications, the function f(x) is approximately estimated as the
function which is composed of r definite steps with n1, n2,…, n stress cycles; the
stress σ is σi (constant) in the stress cycle ni. If n shows the total time of use and
σmax is the maximum stress of stresses σ1, σ2,…, σr , there is a following relation:

Or in approximation:

According to stress spectrum, a component is put in one of four levels of stress

spectrum indicated in Table 2.1.1.4.3.
Note: Components of the whole frame and lifting appliance structure such as
elastic supporting parts are completely independent of working loading. It is very
careful to classify such parts. For most case KSP = 1, in P4 level.

T ab le 2.1.1.4.3
S tress sp ectru m grad es

Code Stress spectrum coefficient ksp

P1 Ksp ≤ 0.125
P2 01.25 < Ksp ≤ 0.250
P3 0.250 < Ksp ≤ 0.500
P4 0.500 < Ksp ≤ 0.1000

For structural parts, stress which is considered to determine stress spectrum

factor is the difference σSUP – σm and the average stress σm. Definitions are
indicated in Table 2.1.1.4.3, showing stress change for five stress cycles.

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F igu re 2.1.1.4.3- S tress ch an ge as a tim e fu n ction for 5 stress cycles

σSUP: up- stress;

σSUPmax: the maximum up -srtress
σSUP Min: the minimum low-stress
σinf: the low stress
σm: average of all up and low stresses of total using time.

In case the components equipped with the lifting component, state σm= 0,
determine the spectrum stress coefficients is the total stress in the related cross
sections.

2.1.1.4.4 Sectional delivery

In base of their using and spectrum stress, the delivered lifting structure parts
into one of eight groups E1, E2…..,E8 illustrate in Table 2.1.1.4.4

T ab le 2.1.1.4.4
C om p osition or stru ctu re com p on en t grou p s

Spectrum Utilization time

level
B0 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10
P1 E1 E1 E1 E1 E2 E3 E4 E5 E6 E7 E8
P2 E1 E1 E1 E2 E3 E4 E5 E6 E7 E8 E8
P3 E1 E1 E2 E3 E4 E5 E6 E7 E8 E8 E8
P4 E1 E2 E2 E4 E5 E6 E7 E8 E8 E8 E8

2.1.1.5 Consonant usage levels between lifting and composition

This component illustrates a method that helps to determine the usage levels of
lifting devices at the total lifting devices as well as featured data for lifting
devices in all cases.
The start is the average time tmc (s) in each lifting cycle as the definition in
section 2.1.1.2.2. Therefore, that is the required time to complete all works in
single cycle.
Total usage time T (h) of the lifting devices comfort the equivalent:

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Where: N- lifting cycle times determined by lifting usage level

T ab le 2.1.1.5.1 Order the T values in 30-480s cycle periods comforting the

lifting usage levels. The times lifting is maximum in this usage level; however
these values is adjusted to 15,625; 31,250 and 62,500 correspond to U0, U1 and
U2, to reduce the other indicators in T.

Next, determine the indicators for each lifting device, αi ratio between the usage
time in each lifting cycle and average time tmc of one lifting cycle.

T ab le 2.1.1.5.2 Give the total usage time Ti based on the total usage time of the
lifting device and the different conventional values of ratio αi. . This table also
states the composition usage level. Different levels illustrate in the scale.

Therefore, in order to determine the lifting levels see in Table 2.1.1.5.2, average
time of each lifting cycle and the αi value, to identify the usage level for the
lifting devices.

From the curve of C h art 2.1.1.5.3, find directly the usage levels of lifting
devices through 3 data.
T ab le 2.1.1.5.1

T otal tim e of u tilization liftin g ap p lian ces T (h ou rs)

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T ab le 2.1.1.5.2

T otal tim e of u tilization stru ctu res of liftin g ap p lian ces T i (h ou rs)
correspondi ngt oT andα1

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M on ograp h ic 2.1.1.5.3

U tilization level of liftin g ap p lian ce an d stru ctu res

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2.1.2 Loads considered in the structure design of lifting appliance

Implement structural calculations by identifying stresses arising in

structures of lifting appliance during operation. These stresses are
calculated based these following loads
a) Main loads exerting on the structure of lifting appliance, which is
considered static in the most disadvantageous load-withstanding state.
b) Loads caused by vertical movements;
c) Loads caused by horizontal movements;
d) Loads influenced by the weather;
When these loads change, the calculating method shall be tested as
follows.

2.1.2.1 Main loads

Main loads include:
- Loads caused by the weight of the parts themselves: SG
- Loads caused by the service loads: SL
It is supposed that moving parts are in the most disadvantageous state.
Each structural part shall be designed in position symmetry with lifting
appliance and service load (between 0 and safe service load) in order to
produce the maximum stress in the in-consideration structure.
N ote: In som e certa in ca ses, th e m a xim um stress ca n be p rod u ced w h en
th e liftin g ap p lia n ce is n o t a t w o rk.

2.1.2.2 Loads caused by vertical movements

These loads are generated due to sudden increase of service load,
accelerating or decelerating of lifting movement, these loads may joggle
up in vertical direction due to movement along the rail.

2.1.2.2.1 Loads caused by increasing service load

Oscillation generated due to load acceleration should be included by
multiplying the service load with a factor called “dynamic factor ψ”.
1. Value of dynamic factor ψ
The value of dynamic factor ψ is applied to loads arising due to the
service load identified in the following form:

ψ = 1 + § VL
In which:
VL: Lifting speed m/s
§ : factor identified through experiments
N ote: T h e va lu e of§ i s det
ermi
ned t
hrough experi
ment
s conduct
ed i
n
va rio u s liftin g ap p liances.
These following values can be accepted:

ζ = 0.6 with crane and gantry

ζ = 0.3 with hand wheel crane

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The maximum value is taken for loading speed is 1 m/s when applying this
formula. For higher lifting speed, ζ dynamic factor is not taken higher

Applied value for ζ dynamic factor in calculation will not less than 1.15 and more
than 1.6 in all cases

Values of ζ dynamic factor are presented by curves of F igu re 2.1.2.2.1 by lifting

speed VL

F igu re 2.1.2.2.1
Val
uesofζdynami cf act
or
Crane and gantry

N otes:
Thement ionedζf actori sdi fferentwi thCraneandgant ryandhandwheel
cra n e
Di fference ari sesdue t ot he f actt hatζ dynami cfact orwi llbe smal ler
w h en liftin g is p erfo rm ed b y so fter stru ctu re, su ch a s h and w h eel cra n e
th a t han d w h eel is so ft co m p on en t
In t hesameway,ζdynami cf act orusement ioned f orhand wheelcrane
ca n a lso app ly fo r o th er eq u ip m ents, su ch a s co n veyo rs fo r d esign ca ses in
resp o n se to con veyo r o n ha nd w h eel; T h e ment ioned ζ dynami cf act or
va lu e fo r cra n e w ill b e a pp lied fo r d esig n ca ses th a t load is p la ced
bet weencrane’sl egs,becauseharnessofpoi nt’sst ruct urei st hesameas
crane’smai nbeam.

2.1.2.2.2 Loads resulted from acceleration or deceleration if lifting movement

and vertical vibratory load when moving along rail
Because ζ factor regarding to shock level on working load is maximum; therefore
acceleration or deceleration load of lifting load and vertical reaction caused by
rail longitudinal movement is assumed not to be happened in the same time and
ejected.

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N otes: Thi si sassumed t hatrai l’sconnect orsarei n good operat i

on.Negat i
ve
impact sofrai l
’si nval idoperat i
ononst ructureandl iftingappl i
ances’structure
is h u g e, th erefo re it is n ecessa ry to regulaterai l
’sconnect ori ngoodoperat i
on:
Stri ctl yavoi ding damagescaused byi nval i
d rail’sconnect ors.Wi t
h high speed
lift
ing appl i
ances,weneed t o wel d rail
’sendst o elimi natecompl etel
yshocki ng
loadwhenl ift
ingappl i
ancesmovest hroughrai l’sco nn ecto rs

2.1.2.2.3 Special cases

For some lifting appliances, loads caused by their weights are opposite to
operation loads; we must compare “loading appliances” values and ζ dynamic
factor applied for operation load to impact load in “unloading appliances” values
with regard to fluctuation when unloading as following:
Take:
Is algebraic value of load caused by their weight load
Is algebraic value of load caused by their operation load
Total amplified load when unloading is determined by following formula:

The above loads are compared to impact load in “loading lifting appliances” is
determined by formula:

Finally, components will be deigned basing on more inconvenient value between

two values
N otes: T h is fo rm u la b a sed on p ra ctica l d a ta , d yn am ic fa cto r d eterm in es
m a xim um m a rg in o f flu ctu a tio n s im pa cting on stru ctu res w h en liftin g load s.
F lu ctua tion a m p litu d e is ta ken b y:

It is a ssu m ed tha t va lu e o f flu ctua tion on stru ctu res w hen un load in g stru ctu res is
eq ua l to a h a lf o f lifting flu ctua tion am p litude lo a d s
Therefore the final load status will be:

The above load needs comparing to following load.

Load lifting and lowering curve when S1 and S2 loads are opposite to sign

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Lifting Lowering

2.1.2.3 Loads caused by SH horizontal movements

Loads caused by following horizontal movements
1. The inertia impacts resulted from acceleration or deceleration of
horizontal, longitudinal, rotational or reach change movements. The
inertial forces can be calculated by values of acceleration or deceleration.
2. The impacts of centrifugal force
3. Horizontal reaction caused by rolling motions.
4. Impacts of buffer action
2.1.2.3.1 Horizontal impacts caused by acceleration or deceleration
Loads resulted from acceleration or deceleration is transmitted to moving objects
when start for brake is calculated with different structures and components.
1. Horizontal and longitudinal motions
The motions’ measurement is done by observing horizontal forces on wheels
(active wheels) driven in parallel to rail
Loads will be measured by acceleration or deceleration duration according to
working conditions or operation speed
Therefore we can conclude acceleration value (m/s2) used for calculating
horizontal force by weights participating in motions
N otes: If we can not define values of speed and acceleration, acceleration
duration in respect to achieved speed can be selected by 3 following operation
conditions:
a) The lifting appliances operate in low and middle speed in long travel:
b) The lifting appliances operate in middle and high speed in normal use
c) The lifting appliances operate in high speed with high acceleration

T ab le 2.1.2.3.1.1 Giving values of times and acceleration with 3 operation

conditions
T ab le 2.1.2.3.1.1
T im e an d valu e of acceleration

Reached (a) (b) (c)

speed low and middle speed in middle and high speed high speed with high
long travel (in normal use) acceleration
Acceleratio value of Accelerati value of Accelerati value of
n time s accelerati on time s accelerati on time s acceleration

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2 2
on m/s on m/s m/s2

The horizontal calculated forces will not smaller than 1/30 and more than ¼
loads impacting to driven wheels or wheels equipped brakes

2. Rotation motions and outreach change

With rotation motions and reach change, calculations will base on acceleration or
deceleration moment at engine shaft of lifting appliances
Acceleration level will depend on equipments: Normal crane, speed and reach
with acceleration values is in 0.1% m/s2 and 0.6 m/s2, we can use to calculate
crane head’s acceleration in which acceleration time is from 5 s to 10 s

2.1.2.3.2 Impacts of centrifugal force

In case of hand wheel crane, we need considering centrifugal force caused by

rotational motion; in fact we can determine horizontal force impacting on crane
head by gradient of loading cable and eliminating impacts centrifugal forces on
other crane’s structures.

2.1.2.3.3 Horizontal motion caused by rolling motion

When two wheels or wheel group roll on rail, we shall take notice to force couple
is formed by horizontal force in perpendicular to rail. The component forces of
this force couple is determined by multiplying vertical loads on wheels (or wheel
groups) to λ coefficient, this coefficient depends on ratio of p aperture to a wheel
base.

N ote:“wheelbasi s” ist hedi stancebet weent hecent ersoft heo u ter p a irs o f
w h eel, o r th e d istan ce b etw een the cen ters o f ro ta ry ra tch ets on th e stru ctu re
o f tw o w h eel clu sters o r th e system o f w h eel clu sters o f cra n e, in ca se o f
wheelcl uster.Ifhori zont allydi rectionalwheel sarearranged,“wheelbasi s”
is th e d ista n ce b etw een con ta ctin g po in ts w ith ra il o f tw o ho rizo n ta lly
d irectio n w h eels.

As stated in the chart, this coefficient is between 0.05 and 0.2 for p/a ratio of
between 2 and 8.

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2.1.2.3.4. Impacts of vibration elimination ST

It is necessary to consider the cases that the collision with buffer affects the
structure or suspension load.
1. Impacts of the vibration eliminator on the structure:
Distinguish between:
1) Shakable suspension load.
2) Hard directional structure interrupting the shake of suspension load.
In the first case, the following rules must be applied:
If the horizontal speed is less than 0.7m/s, not account for the impacts of
vibration elimination.
If the speed is more than 0.7m/s, account for the counter force working on the
structure due to the collision with the buffer.
Suppose that buffer can absorb the motion energy of lifting appliance (not
carrying working load) at the speed of 0.7 Vt (Vt – rated speed).
The loads affecting on the structure will be calculated on cushioning impulse
transmitted to lifting appliance, using buffer.
However, in case of high speed (more than 1m/s), deceleration equipment
will be used immediately after touching the end of the rail, provided that this
equipment works automatically and enables the lifting appliance to
considerably decelerate and reach the previously – specified low speed value,
before the lifting appliance collides with the vibration eliminator.
In this case, the speed obtained after the deceleration is considered as Vt
value when the impact of vibration elimination is calculated.
N ote: It is em ph a sized th a t relia b le a n d efficien t eq u ipm en t m u st b e in sta lled .
O n ly a m ovem en t restrictin g sw itch fo r en g in e d isco nnectio n is n o t su fficien t
to a ssum e th e d ecrea sed sp eed for vib ra tio n elim in a tion im pa cts.
In the second case in which the load is unshakable, the speed of vibration
elimination will be calculated in the similar way except for considering the
impact of working load.
2. Impacts of vibration elimination on suspension load.
The shock due to collision between lifting load and fixed objects must be
considered, only for the lifting appliances of which the lifting load is firmly
directional. In such cases, incurred loads due to shock must be considered.
The loads can be calculated by taking into account one horizontal force
corresponding to the loading level which can lifts two of wheels.

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2.1.2.4. Loads because of weather

The loads are caused by the weather such as impacts of wind and temperature
change.

2.1.2.4.1. Impact of wind

These regulations are related to the impacts of wind on the structure of lifting
equipment.
In this section, a simple calculation method is given and an assumption is
made that is wind can horizontally blow in every direction, at any speeds and
have static counter force to the loads affecting the structure of lifting
equipment.
1. Wind pressure
Dynamic pressure of wind is calculated by the formula:
q = 0.613 V2
Where: q: dynamic pressure of wind (N/m2)
V: design wind speed (m/s)
2. State of design wind
Two states of design wind are considered in calculation of wind load on
lifting appliance.
1) State of wind that allows the lifting appliance to work
This is the maximum wind state in which the lifting appliance is allowed to
work. The wind loads are assumed to affect in disadvantageous direction,
combined with other loads in working condition. The design wind pressure
allows the lifting appliance to work. The corresponding wind speeds are listed
in Table 2.1.2.4.1.2.1. They are assumed to be unchanged at the same height
with the lifting appliance.
N ote: N o rm a lly, th e in sta lla tion p la ce fo r w in d sp eed in d ica to r on th e liftin g
a pp lian ce m u st b e in th e h ig h est p la ce. In ca se th at th e w in d sp eed a t
d ifferen t h eig h ts co n sid erab ly in flu en ces on th e sa fety o f th e liftin g a pp lian ce,
th e M a nu fa ctu rer m ust sp ecify th e h eigh t fo r in sta lla tio n o f w ind sp eed
in d ica to r.
Suppose that the working speeds and rated accelerations are not necessary
reached in case of strong wind.

T ab le 2.1.2.4.1.2.1
D esign w in d p ressu re allow in g th e liftin g ap p lian ce to w ork

Design wind pressure Design wind speed allows

Type of lifting appliance
allows the lifting the lifting appliance to

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appliance to work N/m work m/s

The lifting appliance is

easily lifted to protect
against the wind impact or
specifically designed for
125 14
light wind.
Lifting appliance is used in
installation and
construction
All normal types of outside
250 20
lifting appliance
The lifting appliance must
always operate in strong
wind. 500 28
(for example: Type 12a,
see Table 2.1.1.2.5)

Impact of wind on the load:

The impact of wind on the load suspended by hook of the lifting appliance
will be identified by the following formula:
F = 2.5 A x q
Where:
F: wind force on the load under hook, N;
q = wind pressure allowing the lifting appliance to work, see Table 2.1.2.4.2.1,
N/m2;
A: the maximum wind-resistant area of tight sections of the load under hook,
m2. If the wind load-resistant area of the lifting load cannot be calculated,
take the minimum value of 0.5m2.1ton of safe working load.
If the lifting appliance is designed only to lift the goods with special sizes and
forms, wind load will be calculated for corresponding sizes and forms.
2) Wind state that does not allow the lifting appliance to work
This is the strongest level of wind (storm) in which the lifting appliance still
remains its stability in non-working condition, as stated by the Designer. The
wind speed changes according to the height of the lifting appliance compared
to the ground, geographical point and windproof level.
For the lifting appliances that are used outsides, the specified theory wind
pressure and wind speed corresponding to the state that does not allow the
lifting appliance to work are stated in Table 2.1.2.4.1.2.2.

T ab le 2.1.2.4.1.2.2
D esign w in d p ressu re n ot allow in g th e liftin g ap p lian ce to w ork

The height from the Design wind pressure Corresponding design

ground surface that does not allow the wind speed that does not
m lifting appliance to allow the lifting appliance
work to work

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2
N/m m/s
0 – 20 800 36
20 – 100 1100 42
> 100 1300 46

When wind load is calculated in the condition that the lifting appliance is not
allowed to work, wind pressure can be taken an unchanged value in each gap
of vertical height as stated in Table 2.1.2.4.1.2.2. In other words, design wind
pressure at the highest point of the lifting appliance can be assumed to be
unchanged at its overall height.
If the lifting appliance is fixedly installed or used for a long time in the region
of which wind speed is extremely high, the values above can be changed in
accordance with the agreement of the authorized unit and the Designer
through the meteoric data of this region.
For some types of lifting appliance of which arms can be quickly lowered (for
example, bride crane can be easily lowered by a lifting mechanism attached
on it), the wind state of the lifting appliance that is not allowed to work is not
necessary to take into account, provided that the lifting appliance must be
designed to lower the arms after a working day.
3. Calculation of wind load
For most of the structural cluster, structural parts and individual components
used in the structure of the lifting appliance, the wind load is calculated by the
following formula:
F = A. q. C1
Where:
F: wind load, N;
A: windproof area of the structural part that under consideration, m2;
q: wind load corresponding to the design condition, N/m2;
C1: the form factor of the structural part under consideration according to the
wind direction.
The total wind load on the structure is the sum of wind loads on its structural
parts.
The total wind load must be considered in calculating the stability and
durability of the lifting appliance.
The permissible wind load magnitude in design of lifting mechanism for the
demand of engine and brake must ensure the safety for the lifting appliance
operation.
4. Form factors
1) Separating components, frame, etc
Form factors for separating components, single rafter frame and machine
room are stated in Table 2.1.2.4.1.4.1. C1 values for separating components
change according to aerodynamic slenderness, the magnitude of box cross
section and section rate. The aerodynamic slenderness and section rate is
presented in Figure 2.1.2.4.1.4.1.
The wind load on single rafter frame can be calculated on the form factors of
separating components presented in Table 2.1.2.4.1.4.1. In this case, the
aerodynamic slenderness of each component must be taken into consideration.
It is possible to apply the form factor of the whole rafter frame which is

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combined from plane and round section as presented in the middle of the
Table.
If the rafter frame is made of the structures with plane and round sections, or
round sections for both modes of blowing wind, appropriate form factors are
applied for corresponding windproof surfaces.
If welded joint gusset plates with standard size are used in the rafter frame, it
is unnecessary to consider this area, provided that the length of separating
components is calculated from the center points of joints.

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T ab le 2.1.2.4.1.4.1
F orm factors C 1

A erod yn am ic slen d ern ess l/b or l/D (l)

T yp e F eatu res
≤ 5 10 20 30 40 50 > 50
L, U shaped roll sections 1.15 1.15 1.3 1.4 1.45 1.5 1.6
Quadratic hollow section, 1.4 1.45 1.5 1.55 1.55 1.55 1.6
356mm
Rectangular sections, 254 x 1.05 1.05 1.2 1.3 1.4 1.5 1.6
457mm
Other sections 1.30 1.35 1.60 1.65 1.70 1.80 1.80
Round sections, where:
D.Vs < 6m2/s 0.60 0.70 0.80 0.85 0.90 0.90 0.90
2
D.Vs ≥ 6m /s 0.60 0.70 0.70 0.70 0.75 0.80 0.80
b/d
Separating Quadratic hollow 2 1.55 1.75 1.95 2.10 2.20
structural sections more than 1 1.40 1.55 1.75 1.85 1.90
parts 356m and rectangular 0.5 1.0 1.20 1.30 1.35 1.40
hollow sections more 0.25 0.80 0.90 0.90 1.0 1.0
than 254 x 457mm

Plane sections 1.70

Single rafter Round sections, where:
frame D.Vs < 6m2/s 1.10
D.Vs ≥ 6m2/s 0.80
Machine Rectangular structure on rigid 1.10
rooms base or ground base

Note:
(l) See Figure 2.1.2.4.1.4.1
D: outer diameter of the section
Vs: design wind speed

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F igu re 2.1.2.4.1.4.1 –D efin ition of aerod yn am ic slen d ern ess, tigh tn ess
ratio, sp acin g ratio an d section ratio

In the rafter frame structure, the length of separating components is the distance
between the center points of contiguous joints. See the figure below.

For “a”, take the minimum geometric value of windproof surface

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2) Complex rafter frame, windproof coefficient

The frames or components will be protected if they are arranged in parallel.
Wind loads on the frames or the components in the fair wind direction and on
the wind-unbounded components behind will be calculated by using suitable
form factors. The wind load on protected components will be calculated by
multiplying by the windproof coefficient η as presented in Table 2.1.2.4.1.4.2.
η value changes according to the tightness coefficient and spacing coefficient
as stated in Figure 2.1.2.4.1.4.1.

T ab le 2.1.2.4.1.4.2
W in d p roof factors

Spacing Tightness coefficient A/Ae

coefficient
a/b 0.1 0.2 0.3 0.4 0.5 ≥ 0.6
0.5 0.75 0.40 0.32 0.21 0.15 0.10
1.0 0.92 0.75 0.59 0.43 0.25 0.10
2.0 0.95 0.80 0.63 0.50 0.33 0.20
4.0 1.0 0.88 0.76 0.66 0.55 0.45
5.0 1.0 0.95 0.88 0.81 0.75 0.68
6.0 1.0 1.0 1.0 1.0 1.0 1.0

For some of similar frames or structures which are equally placed, the
windproof coefficient is assumed to gradually increase until the ninth frame
and remain unchanged in the later frames. Wind loads are calculated as
follows:
The first frame: F1 = A. q. Cr (N)
The second frame: F2 = η. A. q. Cr (N)
(n -1)
Frame n: Fn = η . A. q. Cr (N)
(n: 3 – 8)
The ninth frame and the following frames: F9 = η8. A. q. Cr (N)
The total wind load:
9 frames:

More than 9 frames:

N ote:Thet erm ηx u sed in th e fo rm u la a bo ve ha s th e lo w er lim it o f 0 .10. It w ill

be0. 10wheneverηx < 0 .10 .
3) Frame tower

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In calculating the wind load on the quadratic frame tower, when thorough
calculation cannot be obtained, the tight area of tower’s windproof face is
multiplied by the total force coefficient that is accounted as follows:
For plane - sectioned frame tower: 1.7.(1 + η)
For round – sectioned frame tower:
D.Vs < 6m2/s 1.1.(1 + η)
2
D.Vs ≥ 6m /s 1.4
η value is taken from the Table 2.1.2.4.1.4.2 with ab = 1 in accordance with
the tightness coefficient of the windproof face. The maximum load on the
quadratic frame tower can be 1.2 times more than the load on one tower face.
4) Structural parts oblique with the wind direction
Separating components, frames, etc
When the wind direction is oblique with the vertical shaft of component or
frame surface, the wind load according to the wind direction is calculated as
follow:
F = A. q. Cr. sin2 θ (N)
Where: F, A, q and C1 – as stated in section 2.1.2.4.1.3; θ – the angle between
wind direction and vertical shaft or frame surface (θ < 900).
Frame and frame tower
When the wind direction is oblique with the vertical shaft of frame or frame
tower, the wind load according to the wind direction is calculated as follow:
F = A. q. Cr. K2 (N)
Where: F, A, q, C1 – as stated in section 2.2.4.1.3

K2 will be no less than 0.35 and more than 1.0.

θ – the angle between wind direction and vertical shaft of frame or frame
tower, degree (θ < 900).
Sp – the area of brace rods in the frame or tower reflected on the windproof
plane, m2.
S – the area of all brace rods (brace rods and main rods) of the frame or tower
reflected on the windproof plane, m2.
Value K2 is assumed to have the upper limit and lower limit of 0.35 and 1.0
respectively. K2 is 0.35 when the calculation value < 0.35 and it is 1.0 when
the calculation value > 1.0.

2.1.2.4.2. Temperature change

The stresses caused by temperature change will be considered in special
circumstances; for instance, in case that the structural parts do not freely
expand.

2.1.2.5. Other loads

The passages, control cabinets and floors must be designed to bear the
collective loads as follows:
3000 N for the passages and floors for equipment maintenance. The materials
can be put on the floors.
1500 N for the passages and floors planned for people.

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300 N is considered the horizontal force affecting the handrails and covering
plate
These loads are not be used in calculating main beam.

2.1.3. Cases of load in calculating the structure of the lifting appliance

In design calculation of lifting appliance, three cases of load must be taken
into account:
- The lifting appliance working without wind;
- The lifting appliance working with wind in permissible limit;
- Abnormal load.
The loads affecting the lifting appliance are stated in section 2.1.2. To
consider the exceeding of calculation stress due to inaccuracy in calculation
method and catastrophic failure in use, during the design calculation of lifting
appliance, an amplification coefficient γc will be applied. This coefficient will
change in accordance with the group of lifting appliance.
γc values are stated in section 2.1.3.4.

2.1.3.1. Case I: the lifting appliance working without wind

The following loads will be taken into consideration: static loads caused by
self weight SG; the loads caused by the working load SL multiplied by
dynamic coefficient ψ, and two most disadvantageous horizontal loads among
the impacts SH, not accounting vibration elimination.
All these loads are multiplied by the amplification coefficient γc as stated in
section 2.1.3.4 and presented in collective form as follow:

γc (SG + ψ.SL + SH)

In the cases in which the lifting appliance moves to reach a particular position
and is not used for moving the lifting load, the impact of this movement will
not be combined with other horizontal movements. For instance, in case of
lifting appliance in port, when reaching the specified position, the lifting
appliance only works at this position.

2.1.3.2. Case II: the lifting working with wind in permissible limit
These loads include the loads in case I, added with the loads due to wind in
working permissible limit SW which is identified in section 2.1.2.4.1.2.1
(Table 2.1.2.4.1.2.1). The load due to temperature change can also be applied
if possible and presented in collective form as follow:
γc (SG + ψ.SL + SH) + SW

N ote: th e dyn am ic effects o f a ccelera tio n and d ecelera tio n w ill ha ve d ifferen t
va lu es in ca se I a nd II. In ca se of b lo w ing w ind , th e tim e o f a ccelera tio n o r
b ra king w ill n o t b e th e sa m e a s that in ca se o f n o w ind .

2.1.3.3. Case III: the lifting appliance bearing abnormal loads

Abnormal loads occur in the following cases:
- The lifting appliance is out of work and bearing the strongest wind
loads;

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- The lifting appliance is working and bearing the vibration
elimination force;
- The lifting appliance is under the trial load corresponding to
Chapter 4.
The maximum collective load must be considered:
a) Loads SG due to self weight, combined with the impacts of load SWmax due
to the strongest wind load as stated in Section 2.1.2.4.1.2.2 (including
counter force of storm-resistant equipment).
b) SG due to self weight and SL due to working load combined with the
impact of the maximum vibration elimination force ST as stated in Section
2.1.2.3.4.
c) The load SG caused by self weight, combined with the higher load in ψ
ρ1SL and ρ2SL: ρ1 and ρ2 are the coefficients multiplied by the permissible
safe working load corresponding dynamic trial load condition (ρ1) and
static trial load condition (ρ2) as presented in Chapter 4.
Three cases above are presented in collective forms as follows:
a) SG + SWmax
b) SG + SL + ST (1)
c) SG + ψρ1SL or SG + ρ2SL
N ote: w h en th e d ecelera tio n equ ipm en t is p la ced in fro n t o f b u ffer, th e
p ercu ssive fo rce is id en tified in th e cond ition a s sta ted in sectio n 2 .1 .2 .3 .4 .1 ,
S T w ill b e th e h ig h er va lu e in tw o lo ad va lu es o r d u e to d ecelera tio n b y th e
d ecelera tio n equ ipm ent o r th e co llisio n w ith th e bu ffer.

2.1.3.4. Selection of amplification coefficient γc

The value of amplification coefficient γc is identified based on the
classification of lifting appliance.

T ab le 2.1.3.4
Val
uesofamplif icationcoef
fici
entγc

Group of lifting A1 A2 A3 A4 A5 A6 A7 A8
appliance
γc 1.00 1.02 1.05 1.08 1.11 1.14 1.17 1.20

2.1.4. Earthquake effects

Normally, in Vietnam, the structures of lifting appliance will not be inspected
for earthquake effects.
However, the regulations of administrative government or the special
demands require the inspection, the specific rules or recommendations will be
applied for the earthquake regions.
N o te: th e lo ad s du e to w o rking lo a d s m ust b e co n sid ered in ca lcu la tio n .
H ow ever, th e effect o f sh a ken lo ad s d u e to sh o ck w ill b e ig n o red beca u se th is
effect o n ly ha s in flu en ces on the stru ctu res w h en o ther effects a re n ea rly
a b so rb ed . T h is recom m end a tio n is n o t ap p lied fo r firm ly d irectio na l load s in
w h ich th e lo ad s a re unsh a ka b le.

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2.1.5. The loads taken into consideration in structure design of lifting appliance
The structures of lifting appliances bear two types of load as follows:
a) The loads designated SM are the loads that directly depends on the rotary
moment or the engine or brake affecting the structure.
b) The loads designated SR are the loads that do not depend on the effects of
the engine or brake. However, they are identified by the counter forces
affecting the components of the structure and not balanced to the rotary
moment on driven shafts (1).
N o te: (1 ) fo r exa m p le, in d isp lacem en t m otio n , th e lo ad s du e to vertica l
co un ter fo rce o n th e w h eels ru nn ing on the ra il a n d h o rizon ta l lo ad s w ill
ca u se a stress o n th e w h eel sha ft b u t no t a ffect th e co m pon en ts o f d riving
m echa n ism .

2.1.5.1. SM loads
The loads of this type are considered as follows:
a) SMG loads, corresponding to the vertical motion of the median points of
traveling components of the lifting appliance, not taking the working load
into account.
b) SML loads, corresponding to the vertical motion of the working load as
identified in Section 2.1.2 for the structure
c) SMF loads, corresponding to friction forces that are not considered in the
calculation of structure efficiency.
d) SMA loads, induced by acceleration (or braking) of motion.
e) SMW loads, corresponding to the impact of wind load that allows the lifting
appliance to work.

2.1.5.2. SR loads
The structures of the lifting appliance will bear two types of load as follows:
a) SRG, due to self weight of components affecting the component that is
being considered.
b) SRL loads, due to the working load as stated in Section 2.1.2. for the
structure.
c) SRA loads, due to the acceleration or deceleration of different motions of
the lifting appliance or its components, as calculated in section 2.1.2.3.1
for the structure.
d) SRW loads, due to the wind load in the working condition SW or the
maximum wind load SWmax (see section 2.1.2.4.1)

2.1.1.6. Cases of load in the calculation of lifting appliance mechanism

Three cases of load must be considered in the calculation of mechanisms:
Case I: normal operation without wind
Case II: normal operation in wind
Case III: abnormal loads
It is necessary to identify the maximum load in each case of load and use this
load in calculation.
The considered loads are defined in section 2.1.5. To consider the exceeding
of calculation stress due to inaccuracy in calculation method and catastrophic
failure in use, during the calculation and design of lifting appliance, an

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amplification coefficient γm will be applied. This coefficient will change in
accordance with the group of mechanism.
γm values are stated in Table 2.1.6.

T ab le 2.1.6
Val
uesofamplificat i
oncoef
fici
entγm

Group of mechanism M1 M2 M3 M4 M5 M6 M7 M8
γm 1.00 1.04 1.08 1.12 1.16 1.20 1.25 1.30

2.1.6.1. Case I: normal operation without wind

2.1.6.1.1. SM loads
The maximum load SMmaxI of SM type (see section 2.1.5) is defined by
combining the loads SMG, SML, SMF and SMA as identified in section 2.1.5.1
and presented in the formula:

N ote: In th is fo rm u la , it m u st b e u n d erstoo d th a t th is is n o t th e co m bin a tion o f

th e m a xim u m va lu e o f ea ch lo ad , but th e va lu e du e to th e m ost
d isad van tag eou s co m b ina tion possib le in rea lity.
2.1.6.1.2 SR loads
The maximum load SRmaxI of SR type (see section 2.1.5) is defined by
combining the loads SRG, SRL and SRA as identified in section 2.1.5.2 and
presented in the formula:

The note in section 2.1.6.1.1 above is also applied for this formula.

2.1.6.2. Case II: normal operation in wind

2.1.6.2.1. SM loads
The maximum load SMmaxII of SM type (see section 2.1.5) is defined by
combining the loads SMG, SML and SMF as identified in section 2.1.5.1with one
of two following combination:
a) Loads SMA and SMW8 when the wind pressure is 80N/m2.
b) Loads SMW25 when the wind pressure is 250N/m2.
The higher value in two values presented in the following formulas:

Or

The note in section 2.1.6.1.1 above is also applied for this formula.
2.1.6.2.2. SR loads
The maximum load SRmaxII of SM type (see section 2.1.5) is defined by
combining the loads SRG, SRL and SRA as identified in section 2.1.5.2 with

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SRW25 and presented in the following formula (when the wind pressure is
250N/m2):

The note in section 2.1.6.1.1 above is also applied for this formula.

2.1.6.3. Case III: abnormal loads

2.1.6.3.1. SM loads
The maximum load SMmaxIII of SM type (see section 2.1.5) is defined by
considering the maximum load that the engine can transmit to the mechanism
in fact, allowing the limits due to practical operating conditions.
The values of SMmaxIII are defined in section 2.1.6.4.

2.1.6.3.2. SR loads
Because the effect of overload due to collision with the buffer or obstacles for
mechanism is less than for the structure, the abnormal load is used for the
calculation in part a) of section 2.1.3.3:

In the cases in which the storm-resistant equipments are used to ensure no

displacement of lifting appliance; or for the stability in storm condition, the
effect of this equipment on the mechanism must be considered in calculation.

2.1.6.4. Application of the calculations above in calculation of SM

The mechanisms of the lifting appliance carry out one of the following
functions:
- The pure vertical motion of the centers of the motional volume
(lifting movement)
- The pure horizontal motion in which the centers of motional
volume is considered to be a horizontally motional block
(horizontal motion, vertical motion, rotary motion or change in
reach with counterweight balance).
- The combined motion between the lifting movement of centers of
motional volume and the horizontal motion (change in reach
without counterweight balance).

2.1.6.4.1. Lifting movement

For SM loads, the formula is reduced in the following form:
Case I and II:

In these cases, the load due to lifting acceleration is ignored because it is so

little compared to SML.
Case III:

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Look again the general regulation in section 2.1.6.3.1, it is assumed that the
maximum load affecting the lifting mechanism is limited up to 1.6 times of
SMmaxI.

N ote:
F o r th e liftin g m o vem en t in n o rm al o p era tion co nd ition , th ere is n o lo ad m o re
th an th e w orkin g loa d b ecau se o f little effect o f a ccelera tio n .
T h e la rg er lo ad can o ccu r d u e to th e m iseva lu a tio n o f liftin g load .
O n th e exp erien ce o b ta in ed th ro ugh m an y yea rs o f p ra ctice w ith va rio u s
liftin g app lia n ces, th e co efficien t 1 .6 tim es is en ou gh fo r th e safety. It is
em ph a sized to a vo id u sin g th e en g in e w ith excessive ca p acity.

2.1.6.4.2. Horizontal movement

Case I: the formula is reduced in the following form:

Case II: take the higher value in two following values:

Or

Case III: for SMmax III, take the load in correspondence with the maximum
moment of the engine (or brake) except that the operational conditions limits
the practical transmitting moment through the wheel slide on the rail or
through appropriate limiting equipments (such as hydraulic joints, moment
limiting mechanism, etc). In this case, take the practical transmitting moment
value.

N ote: in ca se o f n o rm a l lifting m o vem en ts, th e w eigh ts tra n sm itted to th e

m echa n ism a re lim ited b y th e liftin g lo ad . In h o rizon ta l m o vem en ts, th e
m a xim um m om en t o f th e eng in e ca n b e a lw a ys tra n sm itted to th e m echa n ism
if th ere is no m ech an ica l lim itin g equ ipm en t. T h is exp la in s w hy th ere is
d ifferen ce o f th e va lu e S M m ax III tha t is id en tified in a ccord an ce w ith the lifting
m o vem en t o r o th er m ovem en t to be co n sid ered .

2.1.6.4.3. Combines movement

Case I and II:
For loads in case I and II, SM max II (1) is identified by applying the general
formula as specified in section 2.1.6.1.1 and 2.1.6.2.1.
N ote: (1 ) o r S M m ax I in ca se th a t liftin g a pp lia n ces do no t b ea r th e effects o f
w ind loa d .

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Case III:
The load caused by the maximum moment of engine SMC max can be taken for
the maximum value of SM max III. This is normally inappropriate; the higher is
always accepted for safety assurance.
SMC max must be used when the required engine capacity to lift the center of
motional volumes is so little in comparison with the necessary capacity to win
the forces due to acceleration or wind.
In contrast, when the effect of acceleration or wind is so little in comparison
with the effect of the central movement of vertically motional volumes, this
value is so high and SMC max III can be calculated by the following formula:
SMC max III = 1.6 SM max II
In each particular case, two limit values must be inspected in accordance with
the selected engine, the starting method, relevant magnitude of the loads due
to the effect of inertia and wind, or the lifting of center masses.
There is no exception when the operation limits the moment transmitted to the
mechanism (see section 2.1.6.4.2), this moment will be taken as value of SMC
max if it is less than the value identified previously.

2.2.C alcu lation of stresses in stru ctu re

The stresses induced in the different structural parts are identified for three
cases of load as stated in section 2.1.3 and inspected to ensure the durability
and safety coefficient v for critical stress. In addition, three possible cases of
damage are taken into account as follows:
- Exceeding the elastic limit
- Exceeding the critical buckling load or collapsing load
- Exceeding the fatigue limit
The quality of used steel must be regulated. Its physical characteristics,
chemical components and welding quality must be ensured by the material
manufacturing establishment.
The permissible stresses for the used materials must be identified in
accordance with section 2.2.1, 2.2.2, 2.2.3 and 2.2.4 below, with the
consideration of critical stresses on the used materials.
These critical stresses have corresponding elastic limits (the practical elastic
limits are set up in correspondence with the critical expanding limits), the
critical buckling limits, or collapsing limits. In case of fatigue, corresponding
to the stresses that the structures are still able to exist and not damaged is 90%,
in accordance with the testing result.
The stresses in the structural parts will be calculated on different load cases as
stated in section 2.1.3, by applying normal method of material durability
calculation.
The sections to be considered must be overall sections (not deducting the area
of holes in the sections) for all parts bearing compressive load; and will be
real sections (deducting the area of holes in the sections) for all parts bearing
pulling load.

N ote: T h e a rea o f ho les in th e sectio n w ill be ca lcu la ted in to th e h o rizon ta l

sectio n a rea on ly w h en th e ho les a re sea led b y screw s o r clin ch b o lts.

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In case of flexural parts, the area of real section at stretched points and overall
section at compressive points will be taken.

2.2.1. Inspection of elastic limit

For this type of inspection, it is necessary to distinguish between real
structural parts and joints in form of clinch bolts, screws or welding.

2.2.1.1. Structural parts except for joints

2.2.1.1.1. Purely stretched and compressive parts
1. For the steels of which the ratio between the elastic limit σE and tensile
limit σR is less than 0.7.

The calculating stress σ must not exceed the permissible stress σa. The
permissible stress σa is calculated by dividing the elastic limit σE by a
coefficient νE. The coefficient νE depends on the cases of load as stated in
section 2.1.3.

The values of coefficient νE and permissible stresses are identified in

accordance with the following table:

Case I Case II Case III

νE values
1.5 1.33 1.1

Permissible stress σa

For normal carbon steels (A.37, A.42, A.52), the critical stress σE is indicated
to be corresponding to the elongation 0.2%.
2. For the steels with high elastic limit σE (σE/ σR > 0.7).
For the steels with high elastic limit σE, the use of the coefficient νE will not
ensure the sufficient and safety provision. In such case, it is necessary to
inspect the calculating stress. It must not exceed the permissible stress σa
which is calculated by the following formula:

Where:
σE and σR: elastic limit and tensile limit of the used steel.
σE 52 and σR 52: the stresses in correspondence with steel A52 which means that
the elastic limit is 360N/mm2 and the tensile limit is 510N/mm2.
σa 52: the permissible stress for steel A52 in case of load consideration.

2.2.1.1.2. Shearing structural parts

The permissible stress τa is identified by the following formula:

Where:

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σa: permissible tensile stress

2.2.1.1.3. Structural parts under combined load – equivalent stress

σX, σY, τXY: two normal stresses and corresponding contact stress at the point
to be inspected:
1 – The calculating normal stresses σX and σY must be less than the
permissible stress σa and calculating shearing stress τXY must be less than the
permissible shearing stress τa.
2 – Equivalent stress σCP must be less than the permissible σa.

When this formula is used, the simple method is taking the highest values of
σX, σY and τXY. However, in fact, such calculation brings excessive equivalent
stress because there are not any cases in which all of three stresses reach the
highest values. This calculation method is still accepted because of the safety.
To obtain more accurate calculation, it is necessary to identify the most
disadvantageous stress status (if possible to occur). Three tests will be carried
out by calculating the equivalent stresses from three combined stress states as
follows:
σX MAX and equivalent σY and τXY
σY MAX and equivalent σX and τXY
τXY MAX and equivalent σX and σY
N ote: W h en tw o in three stress va lu es a re nea rly eq ua l a nd m o re th an h a lf o f
p erm issib le stress va lu e, th e com b in a tio n o f th ree m o st d isad va n ta g eou s
stresses ca n o ccu r in ca se o f differen t lo a d s b ecau se th ese stresses a re
co rresp o ndin g to th e hig h est va lue o f ea ch stress.
Special case: tension (compression) combined with cutting
The inspection must be carried out in accordance with the following formula:

2.2.1.2. Joints
2.2.1.2.1. Clinch bolt joints
1. Clinch bolts under shearing load
Considering the impact of tight clamping force, the calculating shearing stress
τ must not exceed:
τ = 0.6 σa in case of Single-level shearing (single shearing)

And τ = 0.8σa in case of Double-level or multi-level shearing

Where σa is the permissible tensile stress of the material for clinch bolts.

Single-level shearing Double-level or multi-level shearing

2. Clinch bolts under tensile load

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The calculating tensile stress σ must not be less than the following value:
σ = 0.2σa
3. Clinch bolts under tensile and shearing load
The following conditions must be tested:
σ ≤ 0.2 σa
And τ ≤ 0.6 σa in case of single-level shearing
Or τ ≤ 0.8 σa in case of multi-level shearing
4. Limit of compressive pressure on riveting hole surface
The compressive pressure σn on the riveting hole surface must not exceed:
σn ≤ 1.5 σa in case of single-level shearing
σn ≤ 2 σa in case of multi-level shearing
5. Much attention must be paid to the joints by clinch bolts
a) Avoid letting the clinch bolts under tension, especially in main structural
parts
b) Among all connected joints, there must be at least two alignment clinch
bolts in force direction.
2.2.1.2.2. Screw joints
2.2.1.2.2.1. General view
The screw joints can bear the stresses due to the acting forces in quadrature
with the joints, the forces in parallel with the joint surface and the forces both
in quadrature and parallel with the joint surface.

2.2.1.2.2.2. Joints by screw under controlled tensile force

1. Overview
The joints by screw under controlled tensile force are the joints of which the
main tensile force is in the direction of bolt axis, screw or the part of thread
bolt. The bolts must be under tensile force, even without outside loads. These
joints should be applied for the joints under fatigue impact.
The bolts must be ensured the accurate tension and unchanged extensibility
(tolerance +/-10%). The coefficient Ω = 1.1, accounting for tolerance of
extensibility.
When applying the initial tension on the bolts, under the combined impact of
tensile load and torsion load, the induced stress must not exceed 80% of the
elastic limit of the material for bolts, accounting for the force dispersion when
the initial tension is applied.
2. Calculation of permissible load on screw joints
A. Calculation of initial tension
a) Tension with torsion

Where:
σ p: theoretical tensile stress under fastening force

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τ b: torsional stress under the fastening force
d2: the diameter of the screw thread root
d1: the nominal diameter of the screw
Pa: thread pitch of the screw
μ: the friction coefficient on the thread
σE: elastic limit of the screw metal
b) Tension without torsion
σb ≤ 0.8 σE

B. Permissible load F1 affecting the screw joint

Two following tests must be carried out:
a) Under the maximum load with the account of safety coefficient k and k’,
the permissible load F1 must not exceed the bolt elastic limit.
Identification:

Inspection:

Where:
Sb: cross section area of thread root < section area of body

Δl1: the retraction of the compressed structural part under the tensile force
Δl2: the expansion of screw under the tensile force
For assembly steel parts, the area must consider Δl1:

Where:
Seq: equivalent section area of fastening screw
s1: compressed diameter under the screw head top
lk: the length of the compressed part
Dt: diameter of screw hole
For the screws of which body diameter is in much difference with diameter of
thread root and the thread part is within the stressed zone, Δl2 must be
sufficiently calculated.
Under the maximum load with the consideration of coefficients Ω, K’ and K’’, it
is the safety coefficient for disjunction resistance of structural parts.

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K’: safety coefficient related to the elastic limit in Table 2.2.1.2.2

K’’: safety coefficient for disjunction resistance of structural parts

T ab le 2.2.1.2.2

Coefficient Loading case I Loading case II Loading case III

K’ 1.50 1.33 1.10
K” 1.30 1 1

Note: Coefficients K’ and K” are applied to the most unfavorable case caused by
pressure distribution when original tension is applied
c) Endurance test
Endurance test of bolts is done in loading case I.
Under working load F, tensile stress varies in the flowing range:

σp and
The test is done based on:

σA: is limit fatigue stress specified in the graph below

For any type of bolt, its σA must ensure safety concerning endurance.

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L im it fatigu e stress
Note: E1 ÷ E8 is the group of components
The graph is applied to bolts under ISO standards
- Standard thread
- Grades 8.8, 10.9, 12.9
- Cool thread chasing and heat insulation after threading chasing.

2.2.1.2.2.3 Bolt joint under strain of forces running parallel with the surface of
the joint.
1. Bolts in pure shear
Tests are done with the assumption that bolts are in proper conditions, i.e. they
are assembled within tolerance limits under ISO standards, and their shank is put
through nut slot along the components to be fixed.
Nut slots have sizes varying within tolerance limits of ISO standards.
Design stress value τ specified of shank of bolt must not exceed that of rivet
specified in 2.2.1.2.1.1.
The value of compressive pressure must not exceed that specified in 2.2.1.2.1.4.

2. Bolts in single shear and in tension

Such bolts are tested by the following formula:
σ ≤ 0.65 σa
and τ ≤ 0.6 σa for those in single shear
or τ ≤ 0.8 σa for those in multiple shear

Satisfying the condition that

Allowable stress of a bolt is up to:
σa = 0.7 σE(0.2) for bolts with normal structure
σa = 0.8 σE(0.2) for bolts with anti-thread wear structure
Where: σE(0.2) is the stress for test of bolt materials with elongation of 0.2%

3. Bolt joint of durability and controlled tension

This type of joint should be used in structures bearing fatigue stress and load
pressure square with the surface of the structure bolted. The structures jointed
with bolts of high durability are under the following loads:
A. Loads on the surface of joint (T)
In this case, loads make structures bolted slide and forces are transferred due
to friction. In order to determine allowable loads (Ta) on each bolt, transferred
by friction, tensile force F of the bolt after fastened must be taken into
account. This tensile force is multiplied with coefficient of friction µ of
contact area inside the joint and safety coefficient vT with values as those
specified in 2.2.1.1.1 is applied to this ultimate force.
vT = 1.5 for loading case I
vT = 1.33 for loading case II
vT = 1.1 for loading case III
Ta can be determined with the formula below:

Where: m is the number of contact surfaces.

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F in the bolt depends on its tightening moment; values of friction coefficient µ
depend on materials of components, conditions of contact surfaces and
preparation of the joint (See Appendix 1).

B. Forces perpendicular to the surface of joint (N)

Testing by calculation of forces perpendicular to the surface of joint is done
as in 2.2.1.2.2.2.
If the bolt joint is affected by the moment of external force M, tensile load
will be determined at the bolt under the maximum load and the existing
tensile load N.
C. Combination of T, N, M
The two following tests must be carried out:
a) For bolts under maximum stresses, total tensile force caused by loads N
and M must be less than the allowable tensile force stated in 2.2.1.2.2.3.3.
b) Medium load transferred by friction must be less than the following
values:

D. Determination of internal stresses of joint.

For compressed elements, the stress is calculated on the total area of the
cross-section (cross section area of the bolt is not excluded)
For elements bearing tension:
In the first case, when bolts are placed in a line perpendicular to force vector,
the following factors will be checked:
a) Total loads on the total cross section area
b) 60% of loads on the actual area of the surface (cross section area of bolt
holes are excluded)

In another case, if bolts are arranged in lines perpendicular to force vector:

The part bearing the heaviest load (relative to line 1 as in the detail A) shall
be analyzed in accordance with the two following factors:
a) Total load on the total cross section area
b) Total load on actual cross section area is load on line 2 to line 3 (i.e. the
above illustration, it is 2/3 the total load on total cross section area) plus
60% of load on line 1.
In this test, it is assumed that the load is distributed evenly on each bolt and
the number of bolts is minor, if too many lines of bolts are arranged, the final
line of bolts will only bear minimal load, therefore, it is advisable that 2 or 3
lines of bolts are arranged.

E. Bolt joint of durability

Note that the above calculations are only effective in testing durability of
bolts when bolt joints in practical use meet requirements for tensile property

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and surface treatment is done in a manner that ensures appropriate friction
coefficient (See A p p en d ix 1).
2.2.1.2.3 Weld joints
All weld joints are assumed to have enough properties of the metal they are made
of.
Stress arising in case of tension and compression is check whether it exceeds σa
in 2.2.1.1.1.
For weld joints cut off, allowable stress τa is determined by the following
formula:

However, for some types of loads, especially those putting transverse stress
inside a weld joints, allowable stress of such joint must be reduced.
T ab le 2.2.1.2.3 is the summary of limit allowable stress of joints, depending on
types of loads.
A p p en d ix 2 gives further information about weld joints.

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T ab le 2.2.1.2.3
L im it allow ab le stress of w eld join ts (N /m m 2 )
T yp es of steel: A .37 –A .42 –A .52
Types of loads A .37 A .42 A .52
I II III I II III I II III
Longitudinal stress of all types 160 180 215 175 19 240 240 27 325
of weld joints 5 0
Tensile transverse stress
1) Of butt weld and K-shaped 160 180 215 175 19 240 240 27 325
weld joints of special quality 5 0
2) Of K-shaped weld joints of 140 158 185 153 210 210 285
normal quality 17 23
3) Of corner weld joints 113 127 152 124 0 170 170 6 230

13 19
8 1
Transverse
compressive stress
1) Of K-shaped weld joints of 160 180 215 175 19 240 240 27 325
special quality 5 0
2) Of corner weld joints 130 146 175 142 195 195 265
15 22
8 0

Shear stress distributed evenly 113 127 152 124 13 170 170 19 230
8 1

N ote: I, II, III are loadin g cases

2.2.2 Testing elements bearing Vertical bending stress

Principles for such test are that the elements have safety coefficient of elastic
limit must be that approved before. In other words, design Vertical stress must be
smaller than the limit allowable stress as in 2.2.1.1.1.

Designer must specify the origin of the calculation methods used.

If the calculation method related to the multiplication of design stress to the

coefficient of Vertical bending ω depends on slenderness coefficient of the
element and if the stress test shows that the exaggerated stress is smaller than the
given allowable stress, values of such stress will be ass specified in 2.2.1.1.1.
N ote: A ppen dix 3 show s a pp lica tio n o f ca lcula tio n a ltern a tives to m eet th e
a bo ve req uirem en ts.

2.2.3 Testing elements bearing horizontal bending stress

When determining safety coefficient of horizontal bending stress as below, note
that flat slab under compressive stress distributed evenly on the surface of the

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slab is a more dangerous case when compared to flat slab under tensile stress
converted from compressive stress on the surface if the slab.

Safety coefficient of horizontal bending depends on the ratio of two stresses at

two edges of the plats (See A p p en d ix 4).

Besides, it is necessary to determine critical horizontal bending stress of

cylindrical objects, spacing, inertia moment and cross section of reinforcing ribs
to avoid significant differences in actual safety gained by using data in technical
manuals.

Check design stresses whether they exceed the value gained by dividing critical
horizontal bending stress by each of these coefficients vv in turn:

Types of load and Loading case Safety coefficient of horizontal

elements bending
Horizontal bending I 1.70 + 0.175 (ψ – 1)
stress on flat slabs II 1.50 + 0.125 (ψ – 1)
III 1.35 + 0.075 (ψ – 1)
Horizontal bending I 1.70
stress on bent slabs, II 1.50
cylindrical objects like III 1.35
pipes
Ratio of stresses at two edges of the slab ψ varies within the range from +1 to – 1.
N ote: A ppen dix 4 g ives in stru ctio n s on d eterm in ing critica l h o rizonta l b end ing
stresses.
2.2.4 Testing elements bearing deformation
In this case, stresses inside the element may not be corresponding to forces
caused deformation.

For example, for stresses arising inside crane column (see illustration), bending
moment is not corresponding to the forces as the deformation raises their
moment arm.

The calculation shall be as follows:

1. First, carry out tests under requirements in 2.2.1, 2.2.2, 2.2.3. The
calculation of stresses arising in different loading cases and check
safety coefficient of critical stresses (elastic limit, horizontal
bending allowance, and vertical bending allowance). In the

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calculation of stresses, deformation caused by loads in the element
should be put into account.
2. Next tests are conducted by multiplication of stresses caused by
loads to factor v of the relevant loading case considering
deformation caused by added loads and check if the design stresses
are smaller than elastic limit, horizontal bending allowance, and
vertical bending allowance.
However, in practical conditions, varying stresses Sv (varying stresses is
calculated by multiplying the load to ψ, caused by wind pressure and horizontal
motions) are more dangerous than constant stresses caused by gravity load.
Therefore, consider the two following cases:
1. When SG and Sv create reserve deformations:
Determine stress σG due to gravity load, and stress σV due to varying loads
multiplied by v corresponding to the relevant case (2.2.1 - elastic limit, 2.2.2
– Vertical bending and 2.2.3 – Horizontal bending) and check whether they
are smaller than critical stresses, or:
σby (SG + v.Sv) ≤ σCT
2. When gravity load and varying load are in the same direction, determine
stresses caused by varying load multiplied at factor v and stresses caused
by gravity load multiplied at factor v’:
v' = 1 + (v – 1)r

Where: is calculated at the first stage of deformation.

Under condition that: σdue to (v’SG + vSV) ≤ σCT

2.2.5 Testing endurance of structures

Hazards caused by fatigue occur when the structure bears varying loads
repeatedly.

Fatigue durability is calculated by considering factors as follows:

1- The number of circle of change in specified load and stress spectra that the
structure bears

2- Materials of the structure and concentration of stresses at specific point.

3- Maximum stress σmax probably arising inside the structure

4- Ratio K among values of maximum stress

2.2.5.1. Circle of change in specific load and stress spectra

Circle of change in specific load and stress spectra shall be considered as

specified in 2.1.1.4.2 and 2.1.1.4.3.

These two parameters are taken into account when the category that the structure
falls into is fit for 2.1.1.4.

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2.2.5.2. Material of the structure and concentration of stress

Fatigue durability of a structure depends on quality of its materials, shape and

connection. Shape of structures connected together and methods of connecting
them as well as fabricating methods have effects on the presence of concentration
of stress, making fatigue durability of that structure weaker considerably.

2.2.5.3 Determination of maximum stress σmax

Maximum stress σmax is absolute value (i.e. this stress can be compressive or
tensile stress) in case I (see 2.1.3.1) without applying magnification factor γC.

In the test of fatigue durability of the structure bearing compressive stress,

coefficient of vertical bending stress ω given in 2.2.2 does not aply.

2.2.5.4 Ratio K among values of maximum stress

This ratio is determined by calculating maximum values of the stress that the
structure bears in case I.

This ratio may vary depending on cycle of operation; however, K can be

determined by using two maximum values of the stress in case I.

If σmax and σmin are algebraic values of the maximum stress and σmax has larger
absolute value, K can be determined as follows:

or in shearing

This ratio varies from + 1 to – 1. It is positive if the two extremum stresses are in
the same direction (the stresses fluctuate with the same sign) and negative of the
two extremum stresses are in reverse directions (the stresses fluctuates with
opposite signs).

2.2.5.5 Testing structures resistant to fatigue:

Use parameters determined from 2.2.5.1 to 2.2.5.4. Satisfaction of the structure

and joints resistant to fatigue ensures that σmax is smaller than allowable fatigue
stress of the relevant structure.

The allowable fatigue stress is determined based on the corresponding critical

stress with 90% of fatigue failure resistance (tests done on samples), therefore:

2.3 D u rab ility test an d selection of com p on en ts of th e liftin g ap p lian ce

2.3.1 Calculation procedure

Components of the lifting appliance are designed after tested for degree of safety
and resistance to damage caused by fracture, unstableness, or abrasion.

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Take into account other factors to avoid overheating or errors affecting
operations of such components.

2.3.1.1 Durability test

Components of the lifting appliance is tested for tensile strength by calculating
stresses to determine if they are exceed the allowable stress depending on
resistance to tension of the materials of the components.
2.3.1.1.1 Allowable stresses:
Values of allowable stresses are determined as follows:

Where:
σR: Resistance to tension of materials
vR : Safety factor corresponding to each loading case (See 3.1.3)
2.3.1.1.2 Values of vR
These values of vR are specified in 2.3.1.1.2
T ab le 2.3.1.1.2
V alu es of v R

Loading case I and II III

Values of vR 2.2 1.8

If the material is grey iron, each values of vR is increased 25%.

2.3.1.1.3 Relationship between design stress and allowable stress
Depending on types of load considered, the following relationships shall be
tested:
σt : Design tensile stress
σc : Design compressive stress
σf : Design bending stress
τ : Design shearing stress
1) Simple tension: 1.25σt ≤ σa
2) Simple compression: σc ≤ σa
3) Simple bending: σf ≤ σa
4) Bending in combination with tension: 1.25σt + σf ≤ σa
5) Bending in combination with compression: σc + σf ≤ σa
6) Simple shearing: 3 ≤ σa
1.25 t   f   3 2
2
7) Tension and bending in combination with shearing:
≤ σa
3.1.2 Testing for resistance to vertical bending
Components of a structure bearing vertical bending are designed in such a
manner that can meet requirements in 2.2.2. Test whether design stress exceeds
allowable stress or not. If it exceeds allowable stress, unstableness may occur due
to vertical bending.
In this test, consider coefficient γm values of which depend on categories of
lifting appliances. (See T ab le 2.1.6).

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Test components bearing vertical bending stress as in A p p en d ix 3.

2.3.1.3 Test for fatigue durability

Fatigue durability of a component in a lifting appliance is determined based on:
- Material
- Shape, surface, erosion conditions, sizes and concentration of stress
- Ratio k of minimum stress to maximum stress in varying stress circles
- Stress spectra
- The number of stress circles
Fatigue durability of a component in a lifting appliance is determined in
exceptions only. In general, fatigue durability depends on properties of material
of that component and its functions in the appliance.

We take a sample of smooth surface with endurance limit (k = -1). Decrease in

fatigue durability depends on surface, erosion condition, size and shape of the
component parameters of which are considered

Basing on fatigue durability under varying stress, determine limits of k, the ration
of extremum stresses with SMITH graph in which assumptions are used to form
curves representing durability.
Therefore, fatigue durability limit of the component in practical use of the
appliance and the ration k are bases to draw WOHLER curves (representing
fatigue durability under stress circles). PALMGREN-MINER assumption about
fatigue failure can also be used to determine fatigue durability of the component
of the appliance corresponding to its category.

Test for fatigue durability is done in only loading case 1.

For components bearing fewer than 8000 stress circles, there’s no need to test for
fatigue durability.

2.3.1.4 Abrasion test

For components resistant to abrasion, determine physical factors of abrasion like
surface pressure, or rotation speed.
Base on parameters in practical use to test whether the component is resistant to
over abrasion.

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2.3.2. Design calculation for important components
2.3.2.1. Choosing anti-friction bearings
In order to choose anti-friction bearings, check whether the bearings can bear:
- Worst static load in cases I, II, or III, and
- Greatest dynamic load in cases I or II.
2.3.2.1.1 Theoretical service life
Anti-friction bearings not only bear static and dynamic loads but also have the
theoretical service life by the hour (see Table 2.1.1.3.2) as the function of
working level of the structure under the constant average load defined in article
2.3.2.1.2 and 2.3.2.1.3 below.
2.3.2.1.2 Average load of SM bearings.
Regarding to the inconstant factors of SM bearings in cycles of operation, the
equivalent average load SM mean is defined with the theory that the force is
constant in the whole service life, defined in article 2.3.2.1.1.
SM mean is defined by multiply SM max II (1) stated in articles 2.1.6.4.1 and 2.1.6.4.2
with cubic root of Km defined in article 2.1.1.3.3.

N ote: (1 ) o r S M m ax II fo r no n - w in d lo ad ing co m p on en ts.

2.3.1.2.1 To determine SM mean average load on anti-friction bearings in mixed
motions
In cases, mixed motions lift centers of moving weights with horizontal
displacement (for example to change with balance space), SM mean average load is
defined by combining:
- The average load caused by acceleration motions and wind impacts as
determined by Items 2.3.2.1.2, with
- Average load caused by vertical displacement of center if moving weights,
is determined by formula:

In which, SM max and SM min is maximum and minimum values of respective

loads

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3.2.1.3 Average load of bearings under impacts of SR loads

The SR max and SR min in case that I load with lifting appliances are not impacted by
wind or II load is impacted by wind (see item 2.1.6) will be considered and
bearings shall be designed with average load determined by following formula:

And this is effective during the theoretical life expectancy according to 2.3.2.1.1.
2.3.2.1.4 The average life expectancy of bearing at the same time exerted by SM
and SR.
Basing on these, the equivalent average loads identified with each supposed type
of SM and SR are independent and the bearing is chosen for the equivalent
average loads combined from the average value of SM and SR.
2.3.2.2 Choosing cable
Applying these principles to determine necessary requirements for choosing
cable used in lifting appliances.
These principles are applied to types of cables appropriate with recommendation
No.2408 under ISO: “Steel cable: common use – properties”.
These hereinafter methods can be applied providing that the cable is greased and
the diameter of the pulley and cable drum are complied with 2.3.2.3 and the cable
is regularly maintained, checked during the operation in accordance with
recommendation No4309 under ISO:”Cable checking”.
The diameter of cable (and cable drum in 2.3.2.2) is chosen based on the lifting
structure group. However, the cable in lifting appliances regularly disassembled
(like tower crane in construction) is usually replaced, it is therefore possible to
choose lifting cable in the group right after the lifting structure group but not
lower than group No.3.
The cable used in appliances lifting dangerous goods (like melt steel, radiant
goods or highly- rusty goods) should be chosen from the group above of normal
lifting appliances.

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Group M5 is the lowest group for cable and pulley used to lift the dangerous
goods.
For passenger lifting mechanism, Group M8 is the lowest group for cable and
pulley.
2.3.2.2.1 Diameter of cable
There are two ways to select the cable’s diameter:
- Use actual minimum safe factor Zp (refers to section 2.3.2.2.1.2)
applicable to moving and static cable (as cable bracing).
- Use C factor (refers to section 2.3.2.2.1.3) applicable to moving cable.
2.3.2.2.1.1 Principle of cable’s diameter selection
2.3.2.2.1.1.1 To determine the maximum pulling force S in the lifting cable
(excluding cable of the bucket)
The maximum pulling force is determined according to the following factors:
- The maximum safe working load of the lifting equipment;
- The weight of the pulleys and the load-carriers, the weights of themselves
is added in the lifting load to strengthen the pulling force;
- Cable passing efficiency;
- Load caused by the acceleration if such load is larger than 10% of vertical
load;
- The slope of the cable at the highest position if the inclining angle of the
lifting cable is 22.50 greater than the lift shaft.
2.3.2.2.1.1.2 To determine the maximum pulling force which is not the load
cable
To determine the maximum pulling force in different cables which are not used
to lift the vertical load based on the load defined in the Load type I and II, taking
account the worst conditions which may be repeated in normal situation.
Cable making cross motion in loading shall consider rolling motion and friction
as well as the maximum lean of bearing in which load moves, can regard as local
under normal loading.
2.3.2.2.1.13 Determine the maximum strength S of grapping cable (lifting,
closing, opening).

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In case of the grapping devices in which the lifting load is not always equal
delivery between the closing and lifting grapping devices in one cycle, the S
value is determine as:
1) If the auto- operated system can ensure the equal loading delivery between the
closing and lifting grape, or any variation load between the closing and lifting
cable in short-time in last stage of closing bailer or at opening bailer start, S is
calculated in:
a) Closing bailer cable: S= 66 % bailer load per grapping cable.
b) Lifting bailer cable: the same percentage.
2) If the system does not ensure the equal load auto delivery between closing
and lifting cable, in fact almost load affect to closing cable, S calculate as:
a) Bailer closing cable: S= Total load of the bailer per the number of cable wires.
b) Lifting bailer cable: S= 66 % total load of loaded bailer per the number of
cable.
2.3.2.2.1.2 Using method of Zp minimum safety factor
Zp minimum safety factor is ratio between:
- F0 minimum breaking load of cable (The minimum breaking load shall be
determined when implement cable breaking test),
- And the S maximum pulling cable in cable.

2.3.2.2.1.2.1 To select cable

Selected cable have minimum real safety factor to be equal to Zp minimum value
with structure group (see table 2.3.2.2.1.2.1)

T ab le 2.3.2.2.1.2.1
S afety F actor Z P
Structure ZP minimum value
Group Running cable Static cable
M1 3.15 2.5
M2 3.35 2.5

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M3 3.55 3
M4 4 3.5
M5 4.5 4
M6 5.6 4.5
M7 7.1 5
M8 9 5
2.3.2.2.1.3 Method of factor C
Definitions:
C = factor of selecting cable;
S =highest tension force on cable when using;
d = nominated diameter of cable;
f = fill factor of cable
k = loss factor caused by contortion of cable structure
R0 = minimum tension strength of cable fibre
k' = experience factor for minimum tensile load for given cable structure

2.3.2.2.1.3.1 Cable Selection

When the structure, minimum tensile load of cable and structure group are given,
factor C can be defined according to following formula:

Where: Zp is the minimum value for running cable determined in Table

2.3.2.2.1.2.1., respective to structure group selected for cable.
Nominal diameter of cable must be:
d≥C√S
2.3.2.2.2.3.2 Calculation of guarantee factor C
Value of C is calculated on the basis of:
- Factor Zp respective to lifting structure group;
- Breaking strength of steel to make cable fiber;

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’
- Factor k (or factor k and f) ensured by cable manufacturer if cable has
special structure. In this case, the certificate issued by cable manufacturer
must state guarantee cable value k’.

2.3.3 Choosing puly, cable drum and cable fittings

2.3.2.3.1 Minimum winding diameter
Minimum winding diameter is determined as the following formula:
D≥H.d
Where:
D: the winding diameter on puly, drum or balanced puly measured to cable axis.
H: factor depending on structure group
d: nominal diameter of cable.

N ote: R efer to item 2 .3.2 .2 fo r liftin g stru ctu re g ro up .

2.3.2.3.1.1 Value of H
Minimum values of factor H depending on lifting structure group, shown in tab le
2.3.2.3.1.1 as for drum, puly and balanced puly.
Factors in table suitable with normal steel cable currently and based on
experience related to their working condition.

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T ab le 2.3.2.3.1.1
V alu es of H

Component Barrel Rope block Balance

group Rope block
M1 11.2 12.5 11.2
M2 12.5 14 12.5
M3 14 16 12.5
M4 16 18 14
M5 18 20 14
M6 20 22.4 16
M7 22.4 25 16
M8 25 28 18

2.3.2.3.1.2 Notice:

When applying the formula in section 2.3.2.2.1 to determine the minimum

diameter of cable, leading to the determination of diameter of barrel and Rope
block, cable with diameter larger than the of minimum calculated cable can be
used if usable cable diameter shall not exceed the minimum cable diameter of
25% and cable tension shall not exceed S which is used to calculate the minimum
diameter of this cable.

2.3.2.3.2 Radius of cable reel track

The working life of cable depends not only on the diameter of rope block and
barrel but also active pressure between cable and cable supporting track.
Radius of cable supporting track r can be determined according to this following
formula:
r = 0.53 d
Of which: d is the rated diameter of track
2.2.2.3.3 Cable steady-brace

Steady braces shall be designed to bear a tension of 2.5 times of maximum cable
tension S without causing permanent deformation.
Steady braces on barrels shall be designed to bear a tension of 2.5 times of
maximum cable tension S, considering friction of remaining rings winds on the
barrel, total friction and cable retaining force.
Friction coefficient between the cable and barrel shall be calculated as:
μ = 0.1
When the cable is completely released from barrel, at least 2 winds shall remain
on the barrel at the fixed ends.

2.3.2.4 Selection of wheels on the rail

In order to select wheel on the rail, its diameter shall be determined by
considering:
 Load exerting on wheels;
 Quality of materials making wheels;

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 Type of rail on which wheels run;
 Rotary speed of wheel;
 Classification of components;

2.3.2.4.1 Size of wheels

To determine size of wheels, following tests shall be conducted:
 Wheel is able to bear maximum load as calculated;
 Wheel allows equipments to work in normal conditions without causing
abnormal abrasion;
Two requirements shall be verified according to the two following formula:

Of which:
D: diameter of wheel (mm);
b : width of rail (mm);
P L : limited pressure depending on materials of wheel (N.mm2)
C 1: coefficient depending on rotary speed of wheel;
C2: coefficient depending on group of component
Pmean III: is the average load of wheel in case load III is calculated according to
formulae in section 2.3.2.4.1.1 (N);
Pmin I, II is the average load in case of I and II load.

2.2.2.4.1.1 Determination of average load.

In order to determine average load, consider maximum load and minimum
load on wheels if the load is considered, that is, lifting appliances are in
normal operational conditions but neglecting Ψ when determiningPmin I, II and
with lifting appliances for Pmean III. Value of Pmean in three cases of I, II and III
load shall be determined as:

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2.3.2.4.1.2 Determination of useful width of rail (b)

For plate rail with the total width and fillet angle (r) at each side, the useful width
(b) is determined as follows:

For convex and curved rail, b is calculated as follows:

Note: (1) With the same width of rail terminal, the useful width of convex and
curved rail is larger than that of plate rail. It means that it is suitable to use small-
sized convex and curved rail for rolling motion of the wheel.

2.3.2.4.1.3 Determination of limited pressure PL

T ab le 2.3.2.4.1.3 shows values of PL as a function for strength limit of materials
which are used for wheel.
T ab le 2.3.2.4.1.3
V alu es of P L
Limit of strength PL
N/mm2
>500 N/mm2 5.0
2
>600 N/mm 5.6
2
>700 N/mm 6.5
2
>800 N/mm 7.2

The material quality has significant impacts on casting steel, forging steel or
laminated steel and nodular cast iron.
In case of covered rail wheel, it is necessary to pay attention to the quality of case
with suitable thickness.
In case the rail wheel is made of high-strength steel which is processed to ensure
the high hardness, the maximum value of PL is equal to value of wheel steel
before surface treatment as stated in Table 2.3.2.4.1.3 because the higher value
will speed up the rail abrasion. However, with the pre-set load, such rail will
have longer service life in comparison with wheel of lower hardness and such rail
is used in lifting machine with high intension.

It is suitable to use wheel which is made of common cast-iron, especially cast-

iron with high hardness. However, it is necessary to pay attention to cast-iron

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with high fragility and to avoid high speed as well as bumping load. The
dimension of cast-iron wheel is determined by PL = 5N/mm2.

2.3.2.4.1.4 Factor C1
C1 depends on wheel speed and is shown in T ab le 2.3.2.4.1.4.a

Such similar values are also shown in T ab le 2.3.2.1.4.b which is considered as

function of wheel dimension and speed m/min

T ab le 2.3.2.4.1.4.a
V alu es of C 1
Wheel C1 Wheel C1 Wheel C1
speed speed speed
r/min r/min r/min
200 0.66 50 0.94 16 1.09
160 0.72 45 0.96 14 1.1
125 0.77 40 0.97 12.5 1.11
112 0.79 35.5 0.99 11.2 1.12
100 0.72 31.5 1 10 1.13
90 0.84 28 1.02 8 1.14
80 0.87 25 1.03 6.3 1.15
71 0.89 22.4 1.04 5.6 1.16
63 0.91 20 1.06 5 1.17
56 0.92 18 1.07 - -

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T ab le 2.3.2.4.1.4.b
V alu e of c1 as fu n ction of w h eel d iam eter an d tran slation al sp eed
Wheel Value of factor c1 as for translational speed (m/minute)
Diameter 10 12.5 16 20 25 31.5 40 50 63 80 100 125 160 200 250
[mm]
200 1.09 1.06 1.03 1 0.97 0.94 0.91 0.87 0.82 0.77 0.72 0.66 - - -
250 1.11 1.09 1.06 1.03 1 0.97 0.94 0.91 0.87 0.82 0.77 0.72 0.66 - -
315 1.13 1.11 1.09 1.06 1.03 1 0.97 0.94 0.91 0.87 0.82 0.77 0.72 0.66 -
400 1.14 1.13 1.11 1.09 1.06 1.03 1 0.97 0.94 0.91 0.87 0.82 0.77 0.72 0.66
500 1.15 1.14 1.13 1.11 1.09 1.06 1.03 1 0.97 0.94 0.91 0.87 0.82 0.77 0.72
630 1.17 1.15 1.14 1.13 1.11 1.09 1.06 1.03 1 0.97 0.94 0.91 0.87 0.82 0.77
710 - 1.16 1.14 1.13 1.12 1.1 1.07 1.04 1.02 0.99 0.96 0.92 0.89 0.84 0.79
800 - 1.17 1.15 1.14 1.13 1.11 1.09 1.06 1.03 1 0.97 0.94 0.91 0.87 0.82
900 - - 1.16 1.14 1.13 1.12 1.1 1.07 1.04 1.02 0.99 0.96 0.92 0.89 0.84
1000 - - 1.17 1.15 1.14 1.13 1.11 1.09 1.06 1.03 1 0.97 0.94 0.91 0.87
1120 - - - 1.16 1.14 1.13 1.12 1.1 1.07 1.04 1.02 0.99 0.96 0.92 0.89
1250 - - - 1.17 1.15 1.14 1.13 1.11 1.09 1.06 1.03 1 0.97 0.94 0.91

2.3.2.4.1 Determination of factor c2

Factor c2 depends on the sub-group of structure and shall be
presented in the T ab le 1.3.2.4.1.5
T ab le 1.3.2.4.1.5
V alu e of c2
Sub-group of structure C2
M1 to M4 1.12
M5 1
M6 0.9
M7 to M8 0.8

2.3.2.4.2 Notes
Note 1:
Above formula shall be applied for wheels with the diameter not
more than 1.25 m. As for greater diameter, according to experience,
we can point out that allowable pressure between rail and wheel

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shall be decreased. It is recommended not to use the wheel with
greater diameter.
Note 2:
We have to pay attention to limited pressure PL as relative pressure
defined by assumption that the contact between wheel and rail on
the surface in which its width is useful width of rail defined above
(Article 2.3.2.4.1.2) and its length is diameter of the wheel. Above
established calculation method origins from the application of
HERTZ formula which is established as follows:

Where:
σ cg : Compression stress within the wheel and rail (N/mm2);
E: Elastic modulus of manufacturing material (N/mm2);
P: Applied load on wheel (N);
b: Useful width of rail (mm);
D: Diameter of wheel (mm)

Set KL expressed for value with dimensionality is pressure

N/mm2 has relationship as follows:

And KL shall be characterized for pressure of wheel on rail.

Formula in article 2.3.2.4.1 shall be defined by setting:
KL = PL .c1. c2
2.3.2.5 Design of Gear
Selection of calculation and design method for gear shall be under
the responsibilities of manufacturer. They also are responsible for

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pointing out the dimensionality of selected methods, considered
load defined in accordance with instruction in article 2.1.6
In the calculation in consideration of operation time, we have to use
the number of hours as convention defined in article 2.1.1.3.2.
2.4 E lectric E q u ip m en t
2.4.1 Power Supply
2.4.1.1 Features of Power Supply System
2.4.1.1.1 Voltage
These regulations shall be applied for standardized alternative low
voltage power supply system (less than 1000 V)
2.4.1.1.2 Voltage Drop
Voltage change at the connection point of power grid with power
supply system of lifting equipment shall not exceed ± 5% of rated
voltage of the system in normal operation.
2.4.1.2 Power source switchgear devices and safety devices between power
supply system and power grid
- Power supply system shall be broken by switch connected to
power grid; switches shall be suitable for power grid.
- Local switch shall be arranged at points which are easy to access
within the operation range of lifting devices or they shall be
remotely controlled. In necessary case, we have to arrange quick
access to them.
- As for gantry crane with close conduction system or scattered
electric cable (using cable drum and electric cable range), it is not
necessary to arrange main switch on the gantry crane. In this case,
quick access to position of switches shall be eliminated if we can
break the power from the ground.
- As for power supply system with many branches connected to the
same power grid, each power supply branch shall have one switch
and all branches shall be connected to master switch to break all
branches at the same time.

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- Cut-in the circuit of the power supply system of many branches
shall be done at sole position. Switch of each branch together with
control equipment shall be marked. For example, switch of power
supply for lifting device No. 3
- Switches and controlling devices for cutting-in circuit shall be
designed to ensure the safety in all incidental cases.
2.4.1.3 Power Supply System
2.4.1.3.1 Electric Bus - Cable Drum
2.4.1.3.1.1 Electric Bus and Safe Slip Ring (Cool Contact)
When supplying electricity by contact bar or slip ring, electric bus
and slip ring shall be clearly recognized to ensure safety; it is not
allowed to use safety trolley bus as an electronic trolley bus.
Lifting devices shall be connected to safety trolley bus via slipper
It is not allowed to use trolley and roller as connector in stead of
safety trolley bus
Current sensor as for safety trolley bus shall be designed according
to the manner that they cannot replace for each other for current
sensor of electric bus.
2.4.1.3.1.2 Arrangement
Electric bus shall be arranged or protected by guarding to prevent
any contact. For example, contact to access, corridor, handrail or
floor of lifting devices.
Electric bus shall be arranged in the manner that these purchase
tackles cannot contact to each other even in shaking load.
2.4.1.3.1.3 Minimum Clearance
Minimum clearance among components with current passing by
and between component with current passing by and cooling
contact component shall be 10 mm. As for equipments
manufactured and inspected at the workshop and equipments with
working voltage of less than 500 V, minimum clearance shall be 6
mm.
2.4.1.3.2 Soft Electric Cable

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Soft electric cable shall be arranged and moved in the manner to
avoid erosion and hitch. Soft cable drum shall be designed in the
manner that the minimum internal diameter of cable drums shall be
ten times of external diameter of cable with external diameter of
less than 21.5 mm and shall be 12.5 times of external diameter of
cable with external diameter of more than 21.5 mm.
As for soft electric cable of crane trolley which can be connected
according to skid wire along the beam, as for the cable with
external diameter of not more than 8 mm, diameter of bendable
internal wire shall be 6.3 times of external diameter of cable. As for
cable with external diameter of more than 8 mm, minimally
diameter of bendable internal wire shall be 8 times of external
diameter of cable. As for cable with external diameter of more than
12.5 mm, diameter of bendable internal wire shall be 10 times of
external diameter of cable.
In case of ribbon cable, thickness of cable shall be equivalent to
diameter of round cable
Constant stretching force on cable shall be small as possible. As for
non-consolidated and symmetric cable, maximum stretching force
on total cross section of copper cores of total cable shall be 20
N/mm2.
In case cable has to move fast or has considerate weight, it is
necessary to have specific methods to prevent over stretching.
Cable shall be rolled into the dram automatically
2.4.1.3.3 Calculation of Electric Bus
Cross section of electric bus shall be defined:
- As function of the maximum allowable thermal intensity;
- As function of the maximum allowable voltage drop.
One of two conditions shall create minimum cross section of trolley
bus; greater cross section shall be selected.
2.4.1.3.3.1 Calculation of minimum cross section related to current density and
heat capacitance of trolley bus

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Minimum cross section related to current density shall be stipulated
in specification of manufacturer
When calculating cross section related to allowable rated thermal
intensity IN as for power supply trolley bus for many lifting devices,
simultaneous operation of electric drive equipments shall be
considered. In case of not having accurate data, refer T ab le
2.4.1.3.3.1
T ab le 2.4.1.3.3.1
As for all lifting devices (IX)
First engine Second Third engine Forth
engine engine
Number of lifting devices Engine with Engines in the order of decreasing
powered on the same trolley the largest capacity (1)
bus and power grid capacity
(1)
1 x x
2 x x x
3 x x x
4 x x x
5 x x x x
Two lifting devices are x x x x
working
N o te: (1 ) A s fo r d rive m echa n ism b y n eng ines in p a ra llel: IN = n x IN
IN = ra ted cu rren t fo r I en g in e
2.4.1.3.3.2 Calculation of Cross Section related to Allowable Voltage Drop
When calculating the voltage drop, the most disadvantage point of
lifting device related to power supply shall be considered.
When calculating the allowable voltage drop on the power grid for
many lifting devices, it need to take account of run-up current
intensity and rated current of engines working at the same time. In
case of not having accurate data, refer T ab le 2.4.1.3.3.2

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T ab le 2.4.1.3.3.2
Number of lifting As for all lifting devices
devices powered First Second engine Third Forth
on the same trolley engine ID engine engine
bus and power grid ID IN ID ID
IN IN IN
1 x x
2 x x x
3 x x
4 x x x
5 x x x x
Two lifting x x x x
devices are
working

As for squirrel cage rotor ID (intensity of run-up current), refer

specification of manufacturer
As for slip ring rotor, consider ID as 2 x IN
As for driven mechanism by n engines in parallel, consider n x ID or
n x IN
Engine shall be arranged as in table in line with intensity of run- up
current (ID)
Calculation of three phrased electronic bus:

S Cross section (mm2)

L Useful length of trolley bus (m);
Iωt Total current intensity ID and IN (A);
Δu Allowable voltage drop (V);

K Conductivity
Cosφ Capacity factor

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N ote: (1 ) A s fo r lo n g tro lley b u s in th e con sid era tion o f in du ctan ce
2.4.2 Installation of Electric Cable and Wire
2.4.2.1 Selection of Electric Cable and Wire
Electric cable and wire shall be selected in line with actual using
features
Bare electric cable and wire shall be used in indoor cubicle and in
specially insulated environment.
2.4.2.2 Calculation of Wire’s Cross Section
Cross section of wire shall be defined to meet the requirements of
mechanical durability and power transmission.
As for often- used wire, voltage drop shall be taken into account
Cross section of wire shall be defined in the consideration of:
- Heat capacitance of wire shall be in line with T ab le 2.4.2.2
T ab le 2.4.2.2
Cross Section Allowable current for insulated wire at environmental
(mm2) temperature of 400C for used factor equal to:
100% 60% 40%
A A A
1.5 18 18 20
2.5 26 26 30
4 34 34 40
6 44 44 50
10 61 61 75
16 82 87 105
25 108 120 145
35 135 145 175
50 168 180 210
70 207 240 270
95 250 270 330
120 292 310 380
150 335 350 430
- Calculation of voltage drop:

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Δu : Voltage drop
l: Length
I: Run-up current of the engine;
r: Resistance on an unit of length;
x: inductance on an unit of length;
Allowable minimum cross section copper wire:
- 1.5 mm2 for wire of many strand;
- 0.75 mm2 for soft wire with protection coat;
- 0.25 mm2 for soft wire between electronic components
It is not acceptable wire of solid core
2.4.2.3 Installation Conditions
Protection type for connector and electric distributor shall be
suitable for adjacent environmental conditions; minimum
protection level is IP 43 according to IEC 144 Standard.
Connection panel shall be placed in electric box or cabinet
Connection panel which can cause danger in emergency shall be
placed in isolated area with other connection panels unless the
design of connection has taken these risks into account.
To protect from the mechanic collision, electric cable and wire
shall be passed through the protection tube with ends are closed or
similar equipments.
Electric cable or wire installed in the circuit with different rated
voltage shall be arranged in separate close box or detached when
these electric cable and wire have been insulated to protect from
the maximum rated voltage.
Independently insulated wire shall only be installed in sluice box or
conducting tube with their terminals is suitably protected.
Un-coated cable and wire installed in structure component shall be
protected from any damage due to mechanic corrosion and stretch.
2.4.3 Protection Devices and Electric Safety
2.4.3.1 Protection of Electric Equipments

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2.4.3.1.1 Electric equipments shall be used according to continuous
operation mode or short time mode (S1- S2 according to IEC 341)
In this case, protection shall be by:
- Heat sensor in the engine;
- Magnetic relay with inverse conversion time or by thermal relay
which set the time on each source phrase.
2.4.3.1.2 Electric equipments shall be used according to interrupt operation
mode (S3-S8 according to IEC 341)
When we understand the operation cycle, operation time, load and
engine with corresponding norm, the protection from the overload
is unnecessary.
2.4.3.2 Wire Protection
Cross section of wire shall be defined according to current intensity
which the wire withstands in the normal operation and start-up of
engine or in braking process.
Whether the load is protected or not, all wire shall be protected
from over current due to the short circuit or corrupt insulation
cover of wire.
Protection equipment shall be defined to be in line with estimated
short-circuit level.
2.4.3.3 Protection from Phrase Lost and Reversal
When starting up, the right order of phrase shall be ensured. In case
phrase lost can cause danger, we need to apply suitable safety
methods.
2.4.3.4 Performance of Protection Equipments
In case of driven engine of the same movement, performance of
protection equipment shall have capacity of stopping all engines for
this movement.
After the safety equipments have operated, we only restart by hand
to make the electric engine to operate.
2.4.3.5 Protection from Lighting
It is necessary to consider the impact of lighting so:

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- Structure on the top of the lifting devices installed outdoor shall
be affected by lighting (crane supporting cable);
-Anti-frictional bracket or running component to make the
connection between larger component of the lifting devices (for
example: rotational table ring and wheels)
When necessary, we have to carry out the protection from lighting
impact in accordance with regulations of IEC TC 81.
To ensure the safety for people, rails of lifting devices shall be
connected to earth
2.4.4 Route Limit Switch (terminal break)
2.4.4.1 Limit Switch
Movement driven by electric engine of the lifting devices stated in
Article 2.4.4.1.1 to Article 2.4.4.1.4 shall be equipped with at least
one route limit switch which can break automatically to prevent the
movement of exceeding the safety limit. Limit switch functions as
safety limit but not the actuator. When the limit switch operates
according to the circuit principle, each structure shall meet
following requirements:
2.4.4.1.1 Load Lifting Mechanism
- Load lifting motion shall exceed the lifting position;
- Load lowering motion shall exceed the load lowering position of
cable, when lifting hook, the crane is on the ground without two
rings of safety cable on the drum.
2.4.4.1.2 Arm Lowering and Lifting Mechanism (main arm, sub-arm,
cantilever of gantry crane)
- Arm lifting motion needs to reach the highest position as possible;
- Arm lowering motion needs to reach the lowest position as
possible; in certain case, this function can be done by moment limit
mechanism.
2.4.4.1.3 Horizontal, Direct Motion and Distribution

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In case horizontal or direct motion is driven from the fixed
controlling point by remote control or by radio waves, motions
shall be limited automatically.
In case the crane is equipped with motor car on the crane, motion
of motor car shall be limited before it runs to terminal of the crane.
These limit switches are not necessary to frictional driven in case
the speed of motor car is less than 0.4 m/s and working load is
smaller than 100 kg.
2.4.4.1.4 Rotational Mechanism
In case we use lifting devices outside the safety area, devices shall
be equipped with rotational limit switches.
2.4.4.2 Mechanism of Load Limit and Moment
In case lifting devices have detached with load limit and moment
mechanism or have designed in accordance with electric operating
principle, they shall meet all requirements stated in Article 2.4.4.3
2.4.4.3 Technical Operating Conditions of Limit Mechanism
Position limit switch or operating limit switch do not stop volumes
in motion and create the stress on one component or total lifting
devices.
Limit switch shall break the motion by breaking the circuit and
remain at the position of breaking circuit until all safety conditions
are recoverable.
Limit switch shall be equipped with safety devices
Safety devices must be:
- Active operation mechanism or driven by minimum
medium structure component
- Or by quick breaker switch. In this case, the circuit shall be
installed quick breaker and protected from short circuit to
ensure that breakers not contact to each other.
- Or by static (electronic) system: e.g. early breaker when
approaching to the terminal

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To avoid parallel connection of one safety device, this action
shall be operated with the support of other equipment and
when these equipments do not operate, safety devices shall
be reset.
The automatic performance of limit mechanism enables to
move in the inverse direction.
Limit mechanism box shall be placed in dry place and
minimally it has the protection level of IP 43. Limit
mechanism box placed in wet place or outdoor shall have
the protection level of IP 55.
Environmental temperature does not affect on performance
of limit mechanism
Range of changing temperature: 00C to + 400C
2.4.5 Control
2.4.5.2 Components
2.4.5.1.1 Relay and Switch
Relay and switch shall be suitable to actual conditions especially
using level
In case crane is used at the height of more than 1000 m, this height
shall be taken into account when selecting relay and switch
Circuit switch shall be interlock type driven by electric or mechanic
mechanism.
Lifting device shall be activated when all controlling devices are on
the breaking point. This breaking point shall be defined by
checking the control circuit or by return spring.
2.4.5.1.2 Resistor
Resistor installed outside the cabinet of lifting devices shall be
place in the suitable protection box at least reach to IP 10 level for
indoor and IP 13 for outdoor as stated in IEC Standard 144.
It is not allowed to use the resistor by liquid.

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Temperature limit of resistor shall be defined by resistor material.
When designing resistor, we need to take the corresponding
moment, cycle factor and circuit breaking speed in to consideration.
2.4.5.2 Electric Box and Cabinet
Equipments, switchgear mechanism and panel board can be
protected as follows:
- In electric cabinet or box;
- In special space;
- In structure (longitudinal beam of gantry crane) of lifting devices
In case we use separate electric box and cabinet, they shall be solid
and stable with the minimum protection level of IP 43 for indoor
and IP 55 for outdoor.
Electric box and cabinet shall be arranged in cabinet door or box
cover
In case on the electric cabinet door, we install the electric
equipments; electric cabinet doors shall be cool contacted by
separate wire.
Electric cabinet door or box cover shall be locked on the blocked
state.
It needs a space in front of electric cabinet or box of minimum of
400 mm; floor of electric cabinet and box does not have the
hindrance with enough solid degree.
2.4.5.3 Controlling Type
2.4.5.3.1 Electric Breaking
Lifting device shall be equipped with electric breaking equipments
which can be locked at the open position. When many lifting
devices are powered from the same power source, each lifting
device shall be installed one lockable electric breaking device
2.4.5.3.2 Feature of Controlling System
Controlling system shall be designed in the manner that the load
limit can reach 120% of rated load, lifting device can move safely

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Lifting 100% of working load at 95% of rated voltage but it does
not cause the load drift at any controlling point
Lowering 100% of working load not exceeds 120% of rated speed
at any controlling point unless otherwise the control circuit allows.
As for route controlling system and arm rotational control. Start-up
and breaking controlling shall gradually increase in both directions
2.4.5.3.3 Controlling Circuit
In case controlling circuit is powered by transformer (voltage
transformer with rectifier), voltage of the primary coil shall not
exceed 250V; it is necessary to protect from wrong motion control
due to short circuit or within the common pole connection with
equipotential connection of the block or by corresponding method
e.g. insulation checkers.
Common pole shall not be broken by switchgear mechanism,
switch or fuse. We have to apply suitable methods to protect other
poles to prevent overload or short circuit.
In case control circuit is powered from the transformer, we have to
apply corresponding safety methods.
2.4.5.4 Controlling Type
2.4.5.4.1 Activation
Lifting devices are only activated when all controlling devices are
on the breaking position. This breaking point shall be defined by
checking the control circuit or by return spring.
2.4.5.4.2 Controlling from the cabinet
- Controlling unit shall be arranged in the manner that the operator
can observe the whole working area of lifting devices.
- Controlling unit in lifting devices shall be arranged on the right
side of the seat of operator
- A switch of red press button for breaking all motion shall be
arranged on the easy-to- access position on the control panel. This
button shall not be mechanic locked type.
2.4.5.4.3 Controlling from the floor

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Press button or other circuit breakers shall be returned to the
breaking position automatically as soon as they are released; they
shall be equipped to control all movement by overhead wire control
mechanism. In addition to movement control mechanism, we need
to arrange an equipment to open and close the main switch (as
described in Regulation 2.4.5.4.2)
Except for direct control of equipments, voltage at the overhead
wire control mechanism shall not exceed 250 V
Coating overhead wire controller shall be done by absolutely
insulation material or coated insulation material. Metal part outside
the insulation material shall be cool contacted.
Surface of coating shall be colorful. As for indoor and outdoor
control mechanism, we need the respective protection level IP43
and IP55 in accordance with IEC 144 regulation.
Control unit shall be hang by mechanism which decrease the
tension
2.4.5.4.4 Remote Control by Radio Waves
As for controlling of crane by radio waves, the safety shall be
ensured:
- Controlling system shall be “safe-reliable” type; wave receiver is
only compatible to one code of corresponding transmitter of each
lifting device.
- In addition to controlling part for motion, we need to arrange
equipment to switch the main switch in the ON (Close) state and
OFF (Cut-off) state
- Motions shall be control by press button or lever which installed
return spring to the “cut-off position (OFF)”. Controlling lever
shall be arranged or by mechanical equipment to lock on the “cut-
off position (OFF)” or by control circuit (it is not allowed to use
manual performance).
Waves transmitter needs to have the minimum protection level IP
43 for indoor and IP 55 for outdoor.

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2.4.5.4.5 Dual Control
When the dual control is arranged for lifting device, there is only
controlling system always in operating state (e.g. controlling from
the cabin or from the floor of crane)
2.4.5.5 Braking Control
2.4.5.5.1 Braking is directly connected to engine
Control circuit for braking system shall be protected by engine
breaker and brake in emergency.
In case the distance from the operator to the brake ≤ 5 m, it is not
necessary to use the brake protection equipments.
2.4.5.5.2 Braking is isolated connected to engine
We have to apply preventive method to avoid uncontrolled motion
before the brake operate in the start-up and stop.
When using electric brake, mechanical brake shall operate after the
electric brake operates.
Except for transient condition, brake structure shall not take effect
when the engine is activated
2.4.5.5.3 Sub- brake Structure
As for lifting devices with special requirements as lifting dangerous
load or lifting these fused objects, we need to arrange one sub-
brake.
In normal operation, sub-brake shall take effect after the motion
has decreased a half by main brake. Sub- brake structure enables to
adjust this delay
In case of sudden stop, sub – brake shall take effect immediately.
2.4.6 Environment
2.4.6.1 Oil Leakage
Any component of lubricating oil system and hydraulic oil system
or other equipment which contain oil are not allowed to operate or
install in the easy-to- cause- oil leakage positions to the electric
equipment unless electric equipments are protected from damage
from this reason.

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2.4.6.2 Environmental Temperature
All electric equipment shall be suitable for continuous operation in
the environment with designed temperature. When electric
equipments are installed in closed space (or in box beam of lifting
devices), we have to apply method to ensure that the temperature
shall be in line with allowable temperature as for operation function
of the equipments

However, in case of estimated high or low temperature, user shall

point out the required temperature for lifting devices and in this
case, electric equipment shall be designed in accordance with
pointed-out temperature or by other ways that means we shall
arranger heater or cooler.
2.4.6.3 Humidity
All electric equipments shall be suitable in atmosphere with
average humidity of 80%. In case estimated humidity exceed this
value, we need to apply special preventive methods even arrange
heater or varnish coating to prevent from wetness for electric
components which are sensitive to wetness.
2.4.6.4 Protection Level
Minimum protection level has just pointed out in different parts for
specific installation items. In case installation environment requires
higher protection level or additional protection to prevent dust,
protection level shall be agreed between authorities and designers.
2.4.7 Engine Selection
2.4.7.1 Overview
Standards for selecting engine (definition in accordance with IEC
341 Standard)
- Required capacity,
- Largest rotational moment
- Time factor of cycle operation (Factor of using engine)
- Start-up level

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- Controlling type
- Speed regulation
- Power supply type
- Protection level
- Environmental temperature
- Installed height (height in term of geography)
2.4.7.2 Define the required capacity, the largest rotational moment and
corresponding rotational moment on average of engines
2.4.7.2.1 Load Lifting Engine
2.4.7.2.1.1 Parameters
As for load lifting engine, required largest capacity PNmax (kW)
shall be defined according to following formula:

Where:
L: allowable largest lifting force (N);
VL: lifting speed (m/s)
η : output factor as for structure
From this formula, the largest rated rotational moment for lifting
load can be defined as follows:

Where:
MNmax = the largest rotational moment (Nm);
PNmax = the largest required capacity (kW);
n= rotational speed of engine (round per minute)
In order to increase rotational moment in case of acceleration,
within load test or to compensate for the voltage and main
frequency change, rotational moment of the engine shall meet
minimum requirements as follows:
As for cage rotor:

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Where: Mmin = smallest rotational moment of the engine in the

start-up
As for slip ring rotor:

Where: Mmax = largest rotational moment of the engine

As for DC electric equipment and equipments controlled by
Thyristor:

Safety shall be ensured in case braking moment of engine MP:

2.4.7.2.1.2 Calculation of thermal emission of engine

A verage corresp on d in g m om en t
To calculate the thermal emission, we need to calculate the
corresponding rotational moment on average as the function of load
spectrum of lifting device by following formula:

Where:
l1, l2, l3: arising cycle of different rotational moment without
considering the non-operation cycle of the engine.
We use the average corresponding rotational moment and capacity
defined according to following formula:

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Therefore, defined engine shall be selected for following operation
types:
- Operation mode S3 when average corresponding rotational
capacity shall take inertia moment of volume for being driven into
account.
- Operation mode S4 or S5 in the consideration of actual start-up or
start-up or brake (electric brake)
Average capacity shall be adjusted as the function of elevation in
terms of geography (Figure 2.4.7.2.1.2.a) and environmental
temperature to cool the engine (Figure 2.4.7.2.1.2.b). As for certain
cases (steel workshop, cast workshop), protection level shall be
selected properly.

Figure 2.4.7.2.1.2.a Figure 2.4.7.2.1.2.b

KH: adjustment factor for geographic KT: adjustment factor for cooling
elevation environmental temperature.

In case we use electric brake, we have to take additional arising

heat (depend on brake type) into account
In case of electric typed capacity control, we need to take speed
range control type and cooling system of the engine into account.
F actor of u sin g en gin e:
As for case of using S4 and S5, factor of using engine shall be
calculated according to following formula:

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This formula is only applied when the cycle time does not exceed
10 minutes
S tart-u p L evel of en gin e:
Start-up level shall be defined by following formula:

Where:
de = number of start-up time within 1 hour;
di = number of impulse or failed start-up;
f= number of operation of electric brake;
q and r = factor established by manufacturer depending on engine
type and electronic brake type
These values shall be applied for start-up levels of: 150, 300 and
600
Engine output as for operation mode S4 and S5 shall be larger or
equal to average capacity defined as for use factor and start-up
level.
Normally, use factor and start-up level can be taken from following
table:
T ab le 2.4.7.2.1.2a
Structure Group Lifting Motion
Start-up level Use factor
M1 90 15%
M2 120 20%
M3 150 25%
M4 180 30%
M5 240 40%
M6 300 50%
M7 360 60%

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M8 ≥ 360 60%

As for drive motor of many speeds, value in the table shall be

applied for sum of use factors and start-up level as for different
speed.
For example, following ratio shall be applied for the system 2 –
speed:
T ab le 2.4.7.2.1.2.b
Low Speed High Speed
Start-Up Level 2/3 1/3
Use Factor 1/3 2/3

2.4.7.2.2 Drive Motor of Horizontal Motion

2.4.7.2.2.1 Drive Motor of Horizontal Motion without vertical displacement of
mass center.
To select drive motor in motion, value of all necessary rotational
moment (or output) shall be taken into account in the consideration
of start-up time, number of start-up cycle within one hour and
engine use factor. Rotational moment of drive motor in motion
shall be limited by adhesive force of wheel on the rail.
Mechanical Parameters:
Define the necessary largest rotational moment
Necessary largest rotational moment shall be defined from loads:
- Case I:- as for lifting devices which are not under the impact of
wind;
- Case II- as for lifting devices which are under the impact of wind;
Sum of force (W) to remain movement speed shall be taken into
consideration:
- Anti-movement resistance caused by static load (own weight) and
operation conditions as:
+ Deformation of movement surface;
+ Friction factor between wheel and flat and curve surface of rail;

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+ Actual wind force;
+ Slope of rail
+ Tension of cable
- Accelerating moment MA
In addition to necessary rotational moment to remain the speed,
drive motor in motion need to transmit the accelerating moment
(MA) to reach the required speed.
As for accelerating value, refer Table 2.1.2.3.1.1
Average accelerating rotational moment of engine shall be defined
by following formula:

Where:
a: acceleration (m/s2)
m1: volume of useful lifting load (kg)
W: Sum of resistance force
V: Speed (m/s)
n: speed of engine (round per minute)
η : output of the total structure
∑mH: total volume (kg), except for working load

Inertia of engine related to linear movement shall be assessed

according to following formula:

Where:
JM: inertia moment of engine and brake (kgm2);
n: speed of engine (round/minute)
V: route speed (m/s)
η: output of the total structure

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C alcu lation of H eat E m ission

Define the average corresponding moment:
In order to calculate heat of engine, average corresponding moment
need to be defined as the function of load spectrum of lifting
device:
In case we have known the working cycle of driven system or user
and manufacturer of lifting devices come into agreement to use
given working cycle which is approximately to the most
disadvantages Mn med defined by following formula:

Where:
t1, t2, t3: operation time as for different rotational moment value
including start-up and average braking moment (electric brake).
The engine shall be selected in the manner that rated rotational
moment of engine in the operation mode S3 as for operation factor
which can be considered as greater or equal to average
corresponding rotational moment.
Normally, use factor and start-up level shall be selected in
accordance with Table 2.4.7.2.2.1 as follows:

T ab le 2.4.7.2.2.1

Group Horizontal motion

Starting degree Utilization factor
M1 60 10%
M2 90 25%
M3 120 20%
M4 150 35%

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M5 180 30%
M6 240 40%
M7 360 50%
M8 ≥ 360 60%

2.4.7.2.2.2 Motor driving horizontal motion with vertical displacement of

gravity center
Above studies relating to horizontal motion without vertical
displacement of gravity center shall apply by entering values in
accordance with vertical displacement of gravity center of motional
volumes into formula of maximum rotational moment and average
equivalent capacity
2.4.7.2.2.3 Rotational motion
Calculate as the same procedure in Section 2.4.7.2.2.1; replace linear
speed with rotational speed
2.4.7.2.2.4 Other methods of calculating engine to any motion
If operating cycle of driven machine is known, or user and manufacturer
of lifting devise agree to use known cycle approximately to the most
unfavorable conditions, corresponding rotational moment of Mn med shall
be calculated in accordance with Section 2.4.7.2.2.1 and 2.4.7.2.2.2
In most cases, user cannot provide exact details of operating cycles. In
this case, use the following calculation method:
Assume that values of instantaneous rotational moment of engine in time
as the following graph:

G rap h 2.4.7.2.3
C on sid er rotation al m om en t of en gin e as fu n ction of tim e
T = len gth of cycle
fi = u tilization factor

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fi . T = op eratin g tim e of en gin e.
1
τ =
fi .T
When actual curve drawn by using fi .T as a time unit, the following
formula shall be determined:
1
M = Mmax (1 – τ).

Where:
M
 = m ed

M max

Mmed = M = average rotational moment in time fi .T

Mmax = maximum rotational moment value
Mn med = Km . Mmax

Km =
2 
Mmax shall be calculated as follow:
This is maximum value of instantaneous rotational moment, usually as
follow:
- To driving mechanism of lifting movement when the heaviest lifting-
load accelerated up so fast that that can be combined with all other
losses
- To driving mechanism of traveling movement when the heaviest load is
operated and affected by air, or maximum resistance of movement and
maximum moment of inertia appear at the same time with other losses
Then, Mmed shall be calculated
This is arithmetic mean of absolute value of rotational moment in
operational cycles
In principle, Mmed is:
- To lifting mechanism:
1 2
M m ed = K m .M f
.
(1 –fs) + fs . M x
2
Where:
Mf : Required rotational moment to lift rated load
Km : Average lifting-loaf factor, depends on driving degree of lifting
devise
fs : Time factor of relative acceleration and deceleration
T ab le 2.4.7.2.3

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Utilization type fs
Lifting mechanism Displacement Slewing
mechanism mechanism
Mechanism Engine Mechanism Engine Mechanism Engine
brake brake brake brake brake brake
Normal M 1 – M5 0.03 0.1 0.2 0.3 0.2 0.3
goods M6 0.05 0.2 0.3 0.5 0.3 0.5
M7. M8 0.1 0.3 0.4 0.6 0.4 0.6
Bulk M6 0.1 0.3 0.4 0.6 0.5 0.6
goods M7. M8 0.2 0.4 0.5 0.7 0.6 0.7

Mx = arithmetic mean of engine rotational moment value during

acceleration and deceleration process.
- To displacement mechanism:
Mmed = Mf med (1-fs) + fs.Mx
Where: Mf med is resistance of displacement motion caused by the load
Km . Mf
When calculating Mmed , do not need to mention air’s effect, grade of
guided road, stretching of cable on kettle, because when driving forward
and backward, they do not affect the formation of average moment
S elect m otor:
The following procedure calculated to losses when starting and losses
caused by driving procedure and those losses depend on engine
rotational moment, not depend much on rotational speed.
To slip-ring rotor motor and direct current motor:
Require:
Pn ≥ Pn med
Where:
Pn = rated capacity of motor under required utilization factor ED
M n
Pn med = n m ed
(M n m en d , see 2.4.7.2.3)
9550
To short-circuited rotor motor when starting, or some drives that are
controlled electronically, losses of motor depend on load moment and
rotational speed
To short-circuited rotor motor, calculate as follow:
W
Pa = 1  PN
W max

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Condition: Pa ≥ Pn med
W : required starting moment
Wmax : the biggest value of starting moment from stilling position
To electronic-controlled drives, discuss with manufacturer of motor.
2.4.7.3. Types of motor
2.4.7.3.1 Direct current motor
Negotiate with manufacturer of motor to select motor, and selection
shall calculate to rotational moment and capacity calculated in previous
sections and actual operating conditions of motor
2.4.7.3.2 Alternative current motor
2.4.7.3.2.1 Slip-ring rotor motor
Factors q and r are determined in calculating formula of starting degree
in Section 2.4.7.2.1.2 by 0.1 and 0.8
To displacement motion, values of starting resistant-force shall be
determined so that motor has rotational moment more than 1.2 times of
correspondent rotational moment with total required forces to preserve
traveling speed.
2.4.7.3.2.2 Short-circuited rotor motor
Factors q and r are determined in calculating formula of starting degree
in Section 2.4.7.2.1.2 by 0.5 and 3
2.4.7.4 Degree of motor protection (under Standard IEC 34-5)
2.4.7.4.1 Degree of motor protection when operating indoor
Motor shall meet requirements of protection degree IP 23
In dusty environment, motor shall meet requirements of protection
degree IP 44
2.4.7.4.2 Degree of motor protection when operating outdoor
Motor shall meet requirements of protection degree IP 55
2.4.7.4.3 Degree of motor protection when operating separately
Motor can meet the requirement of lower degree of protection if it can
protect its own specific applications properly.
2.4.7.4.4 Explosion-hazard environment
In working environment with explosion hazard, motors shall be
antiknock motor (such as EN 50014 – En 50020)
2.4.8 Traffic-carrying device
2.4.8.1 Power-supply current
Because power-supply system must bear harsh work mode, electric
devices must be selected and installed with special consideration

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- Electric cable can be winded on ripe drum, mechanical strength can
resist heat and external effects in accordance with operating
conditions.
- Electric-cable locating methods shall be selected so as to avoid
damages and stretching at the cable connections
- Electric cable shall be installed and instructed carefully to avoid
damages of cable in normal operating conditions
2.4.8.2 Traffic-carrying electromagnet
2.4.8.2.1 Reel
Insulation level of reel shall be selected according to power loss,
environmental temperature, and if desired, temperature of lifted load
2.4.8.2.2 Operating condition
Electromagnets used for load lifting are normally designed with
utilization factor 50%, other factors shall be negotiated by user and
manufacturer
2.4.8.2.3 Characteristics
To exact lifting-load at rated voltage and working temperature of
magnetic reel, lifting capacity of traffic-carrying electromagnet shall be
presented
2.4.8.2.4 Safety factor
Attraction of electromagnet shall be at least double lifting capacity
2.4.8.2.5 Permanent power-supply
If there is permanent power supply from accumulator, time for keeping
load is 20 minutes at least. In this case, install charging equipment for
battery and read-out meter of charging level. The use of permanent
power-supply from battery shall be indicated by acoustic signal and
signal light. If voltage of battery is not enough, there should have an
equipment to prevent permanent power resources from using.
2.4.8.3 Clamshell bucket
2.4.8.3.1 Drive
Driving motors (electrical drive, hydraulic drive or electro-mechanic
drive) shall be designed with operating mode S3, S4 or S6 depending on
applying type.
2.4.8.3.2 Degree of protection
In normal operating conditions, motor and electric equipments shall
meet requirement of protection degree 55. To underwater clamshell
bucket, protective degree shall be IP 57 at least. Because special
operating conditions of this equipment, specially pay attention to
impulses and vibrations.
2.4.8.4 Load-rotating device

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2.4.8.4.1 Design
Load-rotating device shall be designed so that loads is accelerated and
decelerated but cable is not twisted. Arranging lifting cable, load;
calculating load-lifting height, gravity center, inertia moment of lifting-
load in design process of rotary device
2.4.8.4.2 Power resources of rotary device
To supply power for rotary devices, current-supplying system shall be
designed in accordance with this Specification
2.4.8.4.3 Protection degree
If load-rotating motor is installed on frame of lifting devices, it shall
meet requirements of protection degree as other motors on frame
If load-rotating motor is installed on frame of load-lifting devices, it
shall meet requirements of protection degree IP 44 when operating
indoor and protection degree IP 55 when operating outdoor
2.4.9 Supplemental electrical installations
2.4.9.1 Lighting
2.4.9.1.1 Control cabin
- Installing a fixed undazzled-illuminator to light control devices
- If lighting is not enough brightness to go in and out of control cabin
safely, arrange a supplementary handle illuminator. This device must
work even if main circuit of lifting device was de-energized.
2.4.9.1.2 Working area
- When lighting working area with illuminator of lifting devices,
headlights shall be arranged on lifting devices appropriately to ensure
that brightness on the ground is 30 lux at least.
- Illuminator’s circuit shall be independent from main circuit of lifting
device.
- Applying all methods to avoid voltage drop caused by starting
motors make discharging illuminators go off.
2.4.9.1.3 Lighting lifting-device machine room and entrance of machine room
If common lighting is not enough brightness, arrange a supplementary
illuminator. This illuminator must be independent from main circuit of
lifting device. The minimum brightness shall be 30 lux
2.4.9.1.4 Lighting when accident happens
If common lighting is not enough brightness to escape from lifting-
devices safely, arrange a handle torch and charger of the torch in cabin.
2.4.9.2 Heating and air conditioning
2.4.9.2.1 Machine room

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- Natural ventilation or forced-draft ventilation shall be arranged to
disperse the heat energy from machine and its devices.
- Arrange air conditioner in places where using electronic devices; and
working conditions do not ensure environmental temperature for the
operation of electric devices
2.4.9.2.2 Control cabin
If desired, arrange a heating appliance in cabin
This heating appliance generate heat from electrical resistance which is
not red hot/ radiationless and shall be installed permanently. Device
shall accompany with thermometer and have capacity so that the
minimum temperature is 15o C, calculated to environmental temperature
where installing device.
If environmental temperature requires, install an air conditioner in
working cabin to maintain the highest acceptable temperature. Power
resource of air conditioner shall be independent from main circuit of
lifting device.
2.4.9.2.3 Branch circuit
If it cannot supply power from main circuit, arrange branch circuits to
implement maintenance works as follow:
- If natural light is not enough for implementation of maintenance
works, arrange circuits for handle illuminator with minimum
capacity of 200W
- A circuit for handle tools with minimum capacity of 2 kW, voltage of
100v or 200v. This circuit shall be protected by high-sensitive circuit
breaker.
These circuits shall be independent from main circuits of lifting device,
and voltage shall be indicated near the outlet; apply all method to
prevent the mistakes between low-voltage outlet and very low-voltage
outlet.
2.5 A n ti-flip stab ility, an d an ti-m ovin g cau sed b y w in d
2.5.1 Anti-flip stability
Calculate to check anti-flip stability, assume that upsetting point has
been reached by increasing workload and dynamic and weather actions
as factors specified in Table 2.5.1, guided road or bearer of lifting
devices is placed horizontally.

T ab le 2.5.1

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S tab le req u irem en ts
Test contents Considered loads Amplification factor
Static test - Safe working stress 1.6
- Horizontal actions 0
- Wind load 0
Dynamic Traffic- - Safe working stress 1.35
test carrying - Two horizontal actions (2) 1
lifting-
device - Wind-load in work limit 1
(1)

Lifting - Safe working stress - 0.1

device - Two horizontal actions (2) 1
without
load - Wind-load in working 1
limit (1)
Test when wind is - Safe working stress 0
strongest (storm) - Horizontal actions 0
- Highest wind load 1.1
Test when lifting wire is - Safe working stress - 0.3 (3)
broken - Two horizontal actions 1
without load (2) 1
- Wind-load in work limit
(1)

(1) Wind in working limit have the most unfavorable directions

(2) Displacement motions is to determine positions, shall be considered
independently. Stability of those motions shall be calculated
separately. In case of collision, stability shall be calculated to
dynamic component.
(3) Except when calculate and prove lower value.
Special method: Supplementary devices such as tie-back and anchoring
wire may be equipped to ensure the stability of lifting device
2.5.2 Anti-moving caused by wind
Do not depend on anti-flip stability, check and ensure that lifting-device
does not move under effect of wind in the strongest speed increased 105.
This test shall be implemented with supposition that friction factor is
0.14 to wheel with brake, and resistance force is 10N/kN to wheel
without brake installed on antifriction bearing or 15N/kN to wheel
without brake installed on bearing.

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Moving can cause danger, equip with anchoring devices such as chain,
rail clip, manual or automatic latch-lock
To rail clip design, friction factor between clip and rail must be 0.25
2.5.3 Note
When calculating anti-flip stability, acting-load cannot be reduced
because factors ,  and YC as specified in S ection 2.1.2.2.1.1, 2.1.2.3.3
an d 2.1.3.4
If lifting-devices are equipped with guy-wire, anchoring wire, lock
devices and other special arrangements, its effect in calculation shall be
moment of stability

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C H A P T E R 3: M A T E R IA L A N D W E L D

3.1 Material
3.1.1 Select quality of manufacturing materials.
Test calculation required in this Specification about safety of structure
against break caused by the loss of flexibility, stability doest not ensure
structural safety against break caused by brittle fracture
To reach the full safety against the break caused by brittle fracture,
quality of selected steel depends on brittle-fracture actions.
The most important actions to brittleness in steel structure are:
A. Combination actions of residual vertical tensile-stress with stresses
caused by static load (own weight)
B. Thickness of structural part
C. Actions of cold temperature (considered if lifting-devices locate in
places where temperature is lower than 0o C, such as cold-storage
house)
Actions A, B, C shall be evaluated with score; quality of required steel is
selected in accordance with those scores.
3.1.1.1 Evaluation of brittle fracture actions
Actions A, B and C shall be determined as follow:
3.1.1.1.1 Action A: Combination actions of residual vertical tensile-stress with
stresses caused by static load
ZA is evaluating factor of action A, determined as follow:
Line graph I, II, III as specified in F igu re 3.1.1.1.1
Line I: not welded, or have horizontal weld
G
ZA = - 1 (applied if  G ≥ 0.5  a )
0.5   a
Line II: vertical weld
G
ZA =
0.5   a
Line III: concentration point of welds
G
ZA = +1
0.5   a

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Where:
 a : Allowable tensile stress for elastic limit, in case of load I
 G : Tensile stress caused by static load

F igu re 3.1.1.1.1: Z A accord in g con d ition s of stress an d w eld

The danger of brittle fracture increases caused by concentration of stress,
it will very dangerous in case of 3 triaxial tensioning stress, as in case of
welds concentration.
If components combine with low stress because stress was removed after
welding (approximately 600oC to 650oC), line I can be used for all types
of weld
3.1.1.1.2 Action B: Thickness of structural part t

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t : Thickness of structural part t
ZB : Evaluating factor of action B
Consider thickness: t = 5mm to 20mm, ZB shall be determined as follow:
9 2
ZB = t
2500 t ZB t ZB t ZB
mm mm mm
Consider thickness: t = 20mm to 16 0.9 60 4.3
100mm, ZB shall be determined as 5 0.1 20 1.45 65 4.55
follow: 6 0.15 25 2.0 70 4.8
7 0.2 30 2.5 75 5.0
8 0.25 35 2.9 80 5.2
ZB = 0.65 t  14.81 - 0.05 9 0.3 40 3.2 85 5.4
10 0.4 45 3.5 90 5.6
12 0.5 50 3.8 95 5.8
15 0.8 55 4.0 100 6.0

Thickness of structural part

F igu re 3.1.1.1.2
E valu atin g factor Z B = f(t)
To cross section which is rolled shapely, perfect thickness t* shall be
used as follow:
d
To round section: t* =
1 .8
t
To square section: t* =
1 .8
b
To rectangular section: t* =
1 .8

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b b
Where: b is larger side of rectangular section and ratio ≤ 1.8; if >
t t
1.8, take t* = t
3.1.1.1.3 Action C: action of cold temperature
If lifting-devices locate in places where temperature is lower than 0o C,
action of cold temperature shall be considered when selecting quantity
of manufacturing steel
T: Temperature at locations where installing
lifting-device (oC)
ZC : Evaluating factor of Action C
From T=0oC to T = -30oC, have:
6
ZC = T 2

1600
From T=-30oC to T = -55oC, have:
 2.25 xT  33.75
ZC =
10

T ZC T ZC
o o
C C
0 0 - 30 3.4
-5 0.1 - 35 4.5
- 10 0.4 - 40 5.6
- 15 0.8 - 45 6.7
Temperature T (oC) - 20 1.5 - 50 7.9
F igu re 3.1.1.1.3 - 25 2.3 - 55 9.0
E valu atin g factor Z C = f(T )

3.1.1.2 Determine quality of required steel

It is the sum of evaluating factors in S ection 3.1.1.1. This sum shall
determine minimum quality of steel for steel structure.
T ab le 3.1.1.2 indicates categorization of steel quality related to the total
score of evaluating factors.
If sum of evaluating factors is more than 16 or doest not meet the
requirement of steel quality, apply special techniques to prevent brittle
fracture
T ab le 3.1.1.2
S teel q u ality categorization related to th e total score of evalu atin g
factors.
Total points of evaluating factors in Steel quality categorization corresponds

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3.1.1.1 to Table 3.1.1.3
 Z = ZA + ZB + ZC
≤2 1
≤4 2
≤8 3
≤ 16 4
3.1.1.3 Quality of steels
Quality of steels in this Specification is plastic characteristic at specific
temperature
Steels are divided into 4 categorizations of quality. Determine quality
categorization of steel by impact resistance obtained in tests and at
specific temperature
Table 3.1.1.3 consists of values of impact resistance and test
temperatures for 4 categories of steel quality
Impact resistances indicated in Table is minimum values and is average
value of 3 test, no value is less than 20Nm/cm2
Determine impact resistance by impact test on V letter – sample in
accordance with Standard ISO 148
Steels in different quality groups can be welded together.
TC is test temperature for V letter-sample
T is environmental temperature at location where installing lifting-
device.
TC and T cannot directly compare to each other, because V letter-sample
must bear more unfavorable conditions in comparing to the load affect
lifting device during operation process or even out of work.

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T ab le 3.1.1.3
S teel q u ality category
Impact Steels
Quality resistance Test correspond to
category measured on temperature quality Standard
V letter- TC oC category
sample, ISO
148
Fe 360 – A Euronorm 25
Fe 430 - A
1 - - St 37 – 2 DIN 171CO
St 44 – 2
E 24 – 1 NF A 35 –
501
43 A 50 B BS 4360 1972
Fe 360 – B
Fe 430 – B Euronorm 25
Fe 510 – B
R St 37 – 2 DIN 171CO
2 35 + 20 St 44 – 2
E 24 (A37) –
2 NF A 35 –
E 26 (A42) – 501
2
E 36 (A52) –
2
40 B 43 B BS 4360 1972
Fe 360 – C
Fe 430 – C Euronorm 25
Fe 510 – C
St 37 – 3U
St 44 – 3U DIN 171CO
3 35 ±0 St 52 – 3U
E 24 (A37) –
3 NF A 35 –
E 26 (A42) – 501
3
E 36 (A52) –
3

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40 C 43 C BS 4360 1972
50 C 55C
Fe 360 – D
Fe 430 – D Euronorm 25
Fe 510 – D
St 37 – 3N
St 44 – 3N DIN 171CO
4 35 - 20 St 52 – 3N
E 24 (A37) –
4 NF A 35 –
E 26 (A42) – 501
4
E 36 (A52) –
4
40 D 43 D BS 4360 1972
40 D 55 D

3.1.1.4 Special regulations

In addition to above regulations for selection of steel characteristic,
comply with following regulations:
1. Open steels of category I used for carriage only in case profile steel
and tube have thickness of not more than 6mm.
2. Structural parts have thickness of more than 50mm shall not be
used for carrying welded-structure, except manufacturer is
experience in welding thick steel plates.
3. If structural parts cold bended with bend radius ratio/ thickness of
plate < 10, steel quality shall be suitable type for bending, folding
at cold state.
3.1.2 Test materials in manufacturing
3.1.2.1 Materials for manufacturing
- Bearing structural parts of lifting appliances
- Do not need to test codes and removable parts
- Rim of turn-plate of swing crane
- Bearing hydraulic cylinders
- Pressure tube Type I
- Rip drum
- Parts with important functions of equivalent to mentioned parts
above.
All materials shall have certificates in accordance with regulations of
authority
3.1.2.2 In all case, manufacturer shall indicate degree of steel quality to
manufacturing removable parts.

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3.1.2.3 If there is any doubt related to material’s quality, authority has rights to
require checking and issuing certificate if results meet requirements.
3.2 H eat treatm en t
3.2.1 All casting steels, forging steels for components of lifting appliances,
weld-fabricated component, casting – welding components, forging –
welding components which has stressed welds intermingled together,
distance between welds is less than five times the thickness of welded
material, or welds crossed each other (body of bearing, decelerating
housing, and removable parts…) after manufactured, shall be heat
treated to remove residual stress.
3.2.2 Heat treatment of components shall be implemented in close furnace and
components were implemented temperature checking. Heat treatment
mode shall be set basing on grade of steel, use, and dimension of
components approved by authority. Welded components may not need
to heat treated if approved by authority.
3.3 Weld
3.3.1 General regulation
3.3.1.1 Bearing components, codes and removable components of lifting
appliance shall have welding characteristic in accordance with welding
regulation.
3.3.1.2 Weld shall be implemented in accordance with approved procedure,
welding material and welder shall have certificates in accordance with
regulation of authority
3.3.1.3 If not approved by authority, shall not implement to repair cracked,
broken welds. In all case, those repairs shall be implemented under
supervision of authority
3.3.1.4 Type of weld, dimension and edge treating of weld shall be indicated in
welding structure drawing and submit to authority for approval.
3.3.2 Butt weld
3.3.2.1 Butt welds should calculate according to thickness of thinner plates, do
not accept unripe welds.
3.3.2.2 Butt welds can be X, K or V type.
When welding as V type (weld on 1 surface only), it is allowed to poke
and weld the back side
3.3.2.3 To butt welds between two plates with different thickness, beveling and
welding procedure shall be implemented so that the height of weld is
smallest in comparing to plane of steel plate.
Thicker plate shall be beveled as in F igu re 3.1 (a) an d 3.1 (b ) in
following cases:
- Symmetric connection (F igu re 3.1 (a))
When t1 ≤ 10mm if t2 > t1 + 6

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When 10mm < t1 < 40 mm if t2 > t1 + 8
When t1 > 40 mm if t2 > 1.20t1

F igu re 3.1 (a) D raft of tw o p lates w ith d ifferen t th ick n ess in b u tt

w eld
(Symmetric connection)
- Asymmetric connection
When t1 ≤ 10mm if t2 ≥ t1 + 3
When 10mm ≤ t1 < 40 mm if t2 ≥ t1 + 4
When t1 ≥ 40 mm if t2 > 1.1t1

F igu re 3.1 (b ) D raft of tw o p lates w ith d ifferen t th ick n ess in b u tt

w eld
(Asymmetric connection)
It is advised to use symmetric connection
3.3.3 Corner weld

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3.3.3.1 Corner welds of bearing structure, codes, and removable parts of lifting
appliance shall be straight time. Corner weld can be the unripe double-
webbed joint or ripe joints.
3.3.3.2 Design height (a) of corner weld is determined as in F igu re 3.2 (a) and
3.2 (b ) for unbevelled corner weld and beveled ripe weld.

Figure 3.2 Design height of the weld

3.3.3.3 Require completely ripe corner weld of V or K type for structural
components bearing the maximum stress, especially thickness of plate
shall be more than 15mm [see F igu re 3.3 (a)] or when it is difficult to
access one side of plate or even cannot access [see F igu re 3.3 (a) and
3.3 (c)]
3.3.3.4 Incompletely ripe corner-weld can be accepted in stead of completely
ripe corner-weld in some cases. In those cases, design height of weld
shall be determine as in Figure 3.2 (b) and not less than 0.5 times the
thickness of plate
3.3.3.5 Normally, the calculating height of fillet weld between two surfaces
must be not less than 3.5mm and not 0.7 time more than the width of the
thinner plate in the joint. It is not necessary to specify that the
calculating height of the welding joint is 0.5 time more than the width of
the web plate, except for special cases or when the calculating height is
increased to avoid erosion, or when two welding lines are not symmetric.
When the slot weld or overlap weld joint are allowed, the calculating
height must be normally 0.7 time more than the width of welded-edged
plate.

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K - Fillet weld
(a)

V-Fillet weld (b) V-Fillet weld with web plate (c)

Figure 3.3 Completely - gobbled fillet welds

3.3.3.6 See the regulations as stated in section 3.3.3.5, the calculating height a
of the symmetric fillet weld between two planes is equal to the following
value, and changes according to the width t of the thinner plate in the
joint:
- a = 0.45t for the welds of significantly – stressed structures without
the demand of completely - gobbled weld (for example, the
structures under tensile force of which the durability continuousness
must be ensured; or the structures under great shearing force such as
the web plate of the beam with little width or in code joints).

- a = 0.4t for the welds of bearers or flange plates of single beam (I -

beam)
- a = 0.35t for the welds in web plates of box beam or in reinforcing
ribs
- The competent authority will lessen the requirements of this part depending on
the property or level of the stress in the relevant structure.
3.3.3.7. When the two welds are not symmetric with each other, the calculated
heights of the welds a1 and a2 must meet the requirement: a1 + a2 = 2a (“a” is
stated in article 3.3.3.6) with the condition that a1 and a2 comply with the
regulations in article 3.3.3.5.
3.3.4. Weld checking
3.3.4.1 General rule:

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(1) Lifting appliance manufacturer must check the quality of weld and welding
process itself. The checking result must be written and submitted to the
competent authority.
(2) On checking during manufacturing, checkers must inspect welding process in
the factory with appointed workers, proper welding materials and by approved
welding instruction.
(3) The final check must be done after finishing welding on joints, assemblies or
their parts and heat treatment and before painting.
(4) The final check includes:
- Dimension and outside check.
- Non-destructive check of internal structure and consolidation of weld by X-ray
and/or supersonic method.
- Non-destructive check of surface defects, especially detecting outside leakages
by liquid osmosis test and/or magnetic particle examination which can detect
invisible leakages on the surface (very close to the outer surface of the weld)
3.3.4.2 Checking dimensions and outside factors
(1) The calculated height of weld should be checked by measure tape.
- The inspector checks the height of weld compared with dimension specified in
the approved drawing in a random way.
(2) Checking outside dimensions of all welds within the structure of lifting
appliance or supporting base and its parts.
Ensuring the continuity and plain of welds. Corner welds should not protrude and
edge weld should not be empty and concave or show any defect.
3.3.4.3 Non-destructive check
(1) The scope of applying this method should be agreed between the
manufacturer and the authority. All checking points and methods should be
presented on the drawing or document submitted to the authority for approval.
Then in approved drawings, the authority can request non-destructive checked
carried out to special parts apart from the ones in the drawing of the manufacturer.
(2) Approved methods and standards using X ray or supersonic or any other one
should comply with applicable standards.
(3) For butt weld of cross sections in iso-static structures (non-super-static link)
or highly tensile, bending and twisting stressing components, the following
minimum percentages along the length of the weld must use non-destructive
check:
- 10% X-ray check;
- 40% Supersonic check;
- 20% Check by magnetic particle or liquid osmosis.
For the column with SWL ≤ 25t, the scope of this check can be reduced after
reaching an agreement with the competent authority. For cranes and columns
with SWL ≤ 25t, X-ray check can be replaced by supersonic check after reaching
an agreement with the competent authority. In this case, however, supersonic
check should be done 100% along the length of each weld.
(4) Check all the cross points among vertical and horizontal welds and heat-
affected areas by suitable non-destructive method. Besides, detection of the
system’s leakages must be done with the check by magnetic particle or liquid
osmosis.

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(5) Welds with large cross section, especially cast steel, wrought iron welds,
highly stressing welds, code-linking welds and welds of difficult conditions (for
example: overhead weld) must be checked after reaching an agreement with the
competent authority.
(6) In some special cases, the competent authority can require a check after the
load test.
3.3.4.4. Defect repair and final conclusion
(1) Checker must inform all defects found in the check.
Unacceptable defects must be removed. If the number of unacceptable defects
is too big, the whole weld must be redone. After repairing, the check must be
done following the regulation.
(2) Important repairs must be done with the agreement of the competent authority.
Repairs decided by the manufacturer must be informed to the competent
authority. Result of the initial check or after-repair check must be submitted to
the competent authority.
(3) In case the number of defects is big or repeated defects are found, the check
must be done until meeting the requirements of the competent authority to give
reliable conclusions for the welds.
(4) The final decision such as increasing checking rate, removed and repaired
defects and final acceptance of the weld must have the agreement of the
competent authority.
4.1. G en eral in stru ction
4.1.1. The purpose of the check and test is to determine whether lifting
appliances and their parts are
suitable with the Standards and ensure safety or not.
4.1.2. Lifting appliances managing and using units must check and test
complying with the regulation and do all necessary preparations for the test.
Checkers have the right to refuse to monitor, inspect and test if finding that the
lifting appliance has been well prepared before the test or finding defects
affecting the safety on testing.
4.1.3. Before checking lifting appliances, the owner must report to checkers
about all defects, changes, repairs or replacements of any part and cable in the
previous check.
4.1.4. When there is any accident with a lifting appliance, the owner must report
to the competent authority to check that appliance timely.
4.1.5. Check and test the lifting appliance, its devises and parts after
manufacturing or repairing done by the competent authority after receiving
acceptance documents of the implementing unit.
4.1.6. On checking and testing, if detecting that steel components, parts and
structure of the lifting appliance are not suitable with the Standards or in a
condition that does not ensure safety, the competent authority will not issue the
certificate and issued certificates will be invalid until the lifting appliance is
repaired.
4.1.7. The certificate issued by the competent authority for lifting appliances will
be invalid in the following cases:
- Lifting appliances are not suitable with the Standards;
- Lack of one requirement in the Standards on checking and testing;
- Regular check is overdue;

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- Lifting appliances are not suitable with the issued certificate;
- After having any accident.
4.2. C h eck an d test rem ovab le p arts
The check of newly manufactured parts and cables or those without factory
certificate will be done in accordance with the A n n ex of each checked item
stated in this Standard.
Time of static load bearing test must be more than 10 minutes. After the test, the
parts will be checked.
The pull-to-break test of chains and cables without factory certificate must be
done in accordance with the current State’s or corresponding branch’s standards.
For removable parts with extremely load bearing design (SWL ≥ 160t generally)
that can not practically be tested separately, the competent authority can accept to
cancel this test but can require for extra check or non-destructive test.
4.3. C h eck an d test liftin g ap p lian ces
4.3.1. Lifting appliances under the control of the competent authority must be
checked:
1. Initial check
2. Annual check
3. Regular check
4. Irregular check
Checking volume and order comply with Table 4.3.1
T ab le 4.3.1
C h eck an d test liftin g ap p lian ces

T yp e of ch eck E xecu tion tim e C h eck in g volu m e

- Initial - Before putting into use - Check during assembling
- Static and dynamic test
- Annual - Once per 12 months - Check, inspect.
- Static and dynamic test with the
load equal to lifting capacity (SWL).
- Regular - One per 3 years - Check, inspect.
- Static and dynamic test.
- Irregular - After repairing, re- - Check, inspect (assembling
equipping or replacing accuracy)
parts. - Static and dynamic test

- After moving cranes to - Check, inspect.

new working place. - Static and dynamic test.

- After post-accident - Check, inspect.

repairing - Static and dynamic test.

4.3.2. When checking lifting appliances, static and dynamic test, check and
inspection must be done.
–C h eck , in sp ect:
On checking lifting appliances, check the working condition of all electric parts
and equipment, safety devices, brakes, and control, lighting, signal, sound
devices.

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Besides, check:
1. Steel structure and weld (leakage, distortion, critical corrosion), cabin,
banister and protection parts.
2. Lifting hook and hook elements do not exceed 10% of the initial height of the
cross section.
3. Cable and its connections.
4. Pulley, axes, studs and other connecting elements.
5. Conformity of weight, earth connecting of appliances with electric drive.
6. Conformity of crane track (see A n n ex 5)
–S tatic test:
+ Static test is done by overload trial load 125% SWL in order to check the
general durability of the crane and the durability of separate parts. For crane with
boom, check the stability on lifting load at the place the crane has the least
durability. The trial load is lifted to the height of 100 – 200 mm.
+ In static test, crane is put on the track bearing while carriage is put at the place
with the greatest sag (between bearings and console ends). The trial load is lifted
to the height of 200 – 300 mm.
+ The tested crane is considered to meet the requirements when the trial load
does not fall for 10 minutes and the steel structure has no leakage or permanent
distortion.
–D yn am ic test:
+ Dynamic test is done after static test meets the requirements with the trial load
not more than 110% SWL, in order to check all the structure of the crane and its
brakes.
+ In dynamic test, the trial load is lifted up and down at least 3 times and the
structure on carrying load must be checked.
+ For hydraulic driving crane, when it can not lift the overload trial load 125%
SWL, it is allowed to lift its greatest load but not smaller than 110% SWL.
4.3.3. For crane with more than 1 lifting structures, each structure must be tested.
The numeric value of trial static and dynamic loads must be determined with
their working conditions. For crane with some lifting properties, initial check
must be confirmed to be suitable with these properties at the biggest and smallest
extensions of the crane. On regular and irregular checks, the test must be done at
the place of the greatest lifting capacity.
4.3.4. After replacing steel cables, check carefully the cable reserve and the
reliable connection of cable ends as well as cable pressing and stretching under
loading. If the cables are proved to meet the requirements, the load test after
assembling and replacing is not necessary. However, this must be written in the
technical and safety check book of the lifting appliance.

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ANNEX 1
D E S IG N JO IN T S W IT H H IG H L Y D U R A B L E B O L T
W IT H C O N T R O L L E D T E N S IO N

Define general requirements to comply with on designing joints with highly

durable bolt as stated the article 2.2.1.2.2.3.3.3.
This annex points out some methods to prepare joint surfaces, gained friction
factors and tension methods.
1.1 Friction factor µ:
Friction factor is used to calculate friction force depending on the joint’s material
and the surface preparation.
The surface preparation before jointing at least consists of dust, rust, grease and
paint cleaning with iron brusher. Grease should be cleaned with a flame or
suitable paint stripping chemicals.
Good surface preparation will increase the friction factor. Cleaning can be
sandblasting or using oxyacetylene torch flame in no more than 5 hours before
jointing; just before jointing, use brusher to clean the joint surface.
The friction factors are given in the table below:
T ab le 1.1
Val uesofµ

Jointed material Normally prepared Well prepared surfaces

surfaces (using torch flame,
(degreasing, cleaning) sandblasting)
E-24 (A.37) Fc 360 0.30 0.50
E-26 (A.42) 0.30 0.50
E-36 (A.52) Fc 510 0.30 0.55

Fit two rings, one under the bolt head and the other one under the screw nut.
These rings must be ones that bend at least 45º with the spiral towards the bolt
head or screw nut. The rings must be heat-treated to gain the hardness at least
equal to that of the bolt’s metal.
4.2. Tie bolt
The tension value from the bolt should reach the value defined by calculation.
This tension can be defined by calculating rotating moment on the bolt with the
following formula:
Ma = 1.10 C.d.F
In which:
Ma : rotating moment (Nm);
d : nominal diameter of the bolt (mm);
F : tension generated in the bolt (kN);
C : factor that depends on the screw type, friction factor of the threads and
between screw nuts and rings.
For bolts with metric screw thread and for rings with thin grease layer without
rust or dust:
C = 0.18
The tension stress in bolt does not exceed the allowable stress stated in article
2.2.1.2.2.3.3.

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4.3. The value of tension stressed area of bolts:
On defining the stress of bolts, the stressed area will be calculated by taking the
arithmetic average of thread root’s diameter and thread’s effective diameter. The
values are given in the following table:

Nominal 8 10 12 14 16 18 20 22 24 26 28
diameter
(mm)
Tension 36.6 58 84.3 115 157 192 245 303 353 459 561
stressed area
(mm2)

4.4. Quality of bolts

The bolts used in this joint have high elastic limit.
Ultimate tensile strength σR must be greater than the values given below:

The diameter of bolt hole is not 2 mm larger than that of the bolt.
Table 1.4 below gives the values of a bolt and a friction surface of forces that can
be transferred in the parallel plane with connecting plane with 1000 – 1200
N/mm2 bolts with the friction limit σE = 900 N/mm2, for different friction factors
of steels A.37, A.42, A.52.
Define the number of effective friction surfaces in these pictures:

E ffective friction su rfaces

1 friction surface: m = 1

2 friction surface: m = 2

3 friction surface: m = 3

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T ab le 1.1
F orces th at can b e tran sferred in th e p lan e of join ts on a b olt an d in a
friction su rface

1000 – 1200 N/mm2 bolts: σE = 900 N/mm2

and preventions from thread breaking: σa = 0.8 σE

N ote: I, II an d III are loadin g cases I, II an d III respectively.

For bolts with the elastic limit σE, the values of force and moment in the above
table must be multiplied with the factor σE/900.
If there is no prevention from thread breaking (σa = 0.7 σE), the above values
must be divided by 1.14.

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ANNEX 2
IN T E R N A L S T R E S S O F W E L D S

It is really complex to determine the internal stress of welds and impossible to

deal with all welding-related issue within the general scale of this Standard. The
Standard therefore only provides some guidelines as follows:
1- All calculating methods supposed as welds should be conducted properly,
ensuring the connection and esthetics of welds between assembled structural
parts, as well as the continuity of welds. The welding cross section should not be
changed suddenly and rough due to weld burning.
The weld design should be able to withstand the load and be consulted from
more specialized reference.
Notice that the weld duration can be considerably improved thanks to a carefully-
grinding weld.
2- It is not necessary to pay attention to the stress concentration due to the weld
design or redundant stress.
3- Allowable stress of welds are identified according to 2.2.1.2.3 and the
corresponding σCP in the event of combined stress (tension or compression) σ and
cutting stress τ are calculated according to the form”

If withstanding such stresses as σX and σX and cutting stress τXY, then apply the
following form:

4- To angle welds, the width of the weld is considered its height and the effective
length is considered the length, excluding defected sections.
There is no need to deduct the weld length if these welds are close or special
method is applied to minimize the influence of defected sections.
In fact, rarely can weld fatigue cause damage to the welding line, but normally to
its edge which is made of basis metal.
Such stress as σmin and σmax of the fatigue resistance of basis metals on weld edge
can be calculated in traditional methods of calculating material strength.
In order to test the fatigue resistance of welds, it is recommended to test whether
the weld can transmit the load as well as its basis metal-made edge or not.
This regulation, however, is not compulsory to welds with dimension appropriate
with the factual transmitted load.
More importantly, the weld dimension shall not change corresponding to the
thickness of parts in need of welding.
S p ecial cases: If welding is chosen to assemble parts, especially the ones
withstanding horizontal load (means that the load is vertical with the welding
line), the allowable stress should be reduced (see 2.2.1.2.3).

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ANNEX 3
C H E C K B U C K L IN G S T R U C T U R A L P A R T S

There are a number of ways to calculate and check buckling structural parts. This
Annex uses a more practical and simpler way which is amplifying calculated
stresses with different loads defined in articles 2.1.3.1, 2.1.3.2 an d 2.1.3.3 by
buckling factor ω depending on the slenderness ratio of the structural part, and
check that these increasing stresses are smaller than allowable ones in each case.
The values ω in the following table is considered to be the function of the
slenderness ratio λ:
Table 3.1 : Profile steel St 37 (Fe 360)
Table 3.2 : Profile steel St 52 (Fe 510)
Table 3.3 : Pipe steel St 37 (Fe 360)
Table 3.4 : Pipe steel St 52 (Fe 510)

3.1. Define the effective length to calculate the slenderness ratio λ

1 – In normal case, hinged joint bars at two ends and axial bearing, the effective
length is equal to the length between two hinge pins.
2 – For axial bearing bars with one fixed end and one free end, the effective
length is twice as many as the bar’s length.
3.2. For compressed and bent bars:
For eccentric or centric loading bars with bending moment, the bars will be
checked with two formulas below:

In which:
F: compressed load on the bar
S: area of the bar’s cross section
Mf: bending moment at the cross section
V: distance between the outermost metal fiber of the cross section and the neutral
axis
I: moment of inertia of the cross section

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T ab le 3.1
St
ressreduct
ionf
act
orω correspondi ngt oslendernessf
act
orλofprof
ilest
eelSt
37 (F e 360)

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T ab le 3.2
St
ressreduct
ionf
act
orω correspondi ngt osl endernessf
act
orλofprof
ilest
eel
S t 52 (F e 510)

T ab le 3.2
St
ressreduct
ionf
act
orω correspondi ngt oslendernessf
act
orλof
tu b e steel S t 37 (F e 360)

To λ >115, see Table 3.1

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T ab le 3.4

St
ressreduct
ionf
act
orω correspondi ngt oslendernessf
act
orλof
steel tu b e S t 52 (F e 510)

To λ>115, see Table 3.1

N o te: T h e va lu es ofω i nTabl e3. 3and3. 4areappl iedtocal cul ateift hebari sa
sin g le tu b e su fferin g vertica l lo a d w ith the m in im um d ia m eter 6 tim es g rea ter
th an th e th ickn ess o f th e tu b e w a ll.

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A P P E N D IX 4
T E S T IN G S T R U C T U R A L P A R T S W IT H S T A N D IN G H O R IZ O N T A L
B E N D IN G

Theoretically, ultimate horizontal bending stress is considered the multiple of

Ole stress according to the following form:

This represents the ultimate horizontal bending stress of a sheet with the
thickness e and the width b, which are measured to the direction of compression
(see the Diagram).

In this form, E is elastic module and η is Poisson’s ratio.

To normal steel with E = 210 000 N/mm2 and η = 0.3, Ole stress will be:

The ultimate horizontal bending stress is the multiple of this value, then:
+When compressing, the ultimate horizontal bending stress is:
+When cutting, the ultimate horizontal bending stress is:

and are horizontal compression factor, which depend on:

- The ratio α = a/b (two sides of the sheet);
- Vertical supporting structure along sides of the sheet;
- Load exerting within the sheet;
- The sheet is reinforced by reinforcing ribs in any way.

4.1 Ratio and

Only and in some simple cases are presented in Table 4.1 of this Appendix.
In more complex ones, it should be referred to more specialized documents.

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4.2 The Combination of compressing and cutting
Choose and calculated due to the compression and cutting, then the ultimate
comparing stress can be calculated as follows:

With determined in Table 4.1

4.3 Note
Be cautious that the above forms for calculating and are applied only
with values smaller than the proportional limit, specifically 190N/mm2 to A37
steel, 290 N/mm2 to A52 steel.
Similarly, the - identifying form can be applied only with is smaller than
the proportional limit.
If these forms produce results greater than the proportional limit, determine a
new proportional limit calculated by multiplying the calculated ultimate value
with factor ρ provided in Table 4.2. The values in this table are presented in
descending order corresponding to different calculated values of and .

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T ab le 4.1
H orizon tal b en d in g factor an d of sh eets su p p orted at th eir fou r
ed ges

No C ase or

1 Equal compression: α≥1

α≤1
2 Unequal compression: α≥1

α≤1

3 Normal bending with 2

= -1 or tension <-1 α≥3

2
α≤3
4 Bending with compression
-1< <0 In which:
K’: is with = 0 in the second
case
K’’ is in the case of normal
bending (Case 3).
5 Normal cutting: α≥1

α≤1

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T ab le 4.2

Val
uesofρandreducedul
timat
est
ress

4.4 Determining the allowable horizontal bending stress

After determining the ultimate horizontal bending stress as above, continue to
calculate the allowable horizontal bending stress by dividing the ultimate stress
by the factor vv given in 2.2.3.
Then conduct these following calculations:
Identifying the stress in each specific load in 2.2.3, then check to ensure the
calculated stress not to exceed the above allowable stress.

Note: In case of compression and tension at the same time, the ultimate
comparative stress should be compared with stress calculated in the form in
2.2.1.1.3.

4.5 Testing horizontal stress of round pillars

Thin-wall round pillars (like large-diameter round tube) should be tested with the
ability of withstanding general compression if:

In which:
t: the thickness of the tube wall
r: radius measured to the middle point of the tube wall
σE : elastic limit of the tube-made steel
E: Elastic module the tube-made steel

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The supposed bending stress can be determined according the following
form:

If is greater than the proportional limit of the structural steel, then the in
the supposed horizontal bending stress should be reduced to be equal to ρ.
At points at most 10r away from each other, arrange reinforcing ribs with the
inertia moment on the minimum cross section:

The inertia moment on the cross section of reinforcing ribs can be calculated:
1- Reinforcing rib F is arranged right at the center (horizontal centric of
reinforcing rib is in the surface of the tube thickness).

2- Reinforcing rib F is arranged off-center (horizontal centric of reinforcing rib

F2 is beyond the surface of the tube thickness 1).

Accept the calculation of corresponding and , in consideration of

geometric difference between the supposed cylindrical surface and the factual
one due to the t/2 loss in the dimensions of the general structure.

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A P P E N D IX 5
A L L O W A N C E O F L IF T IN G A P P L IA N C E S A N D R A IL

These bellowed-regulated allowances can be applied to crane, crane gate and

moveable cranes but rail crane. For crane serving temporary purposes (like in
construction), these regulations should be applied to a certain applicable extend
and supplemented by the authorities in each specific case.

5.1 Measuring method

The measuring tape, if used, should be made of steel with scale division.
Regulations related to using the tape are still in consideration. Data should be
regulated due to the sag of the tape, difference between the environmental
temperature and the standard one. All dimensions of the lifting appliances should
be measured by one tape with the same tension.

5.2 Design allowance of lifting appliance

5.2.1 The biggest difference Δs between the crane span s and the dimension in
the drawing are not allowed to exceed:
To s ≤ 15m: Δs = ± 2mm
To s > 15m: Δs = ± [2+0.15.(s -15)] mm (maximum ±15mm)
(see Diagram 5.2.1).

D iagram 5.2.1

5.2.2 Vertical beams of lifting appliances supported at the two ends should not
show any sag even when this is not mentioned in the design drawing. This helps
avoid sagging of the rail of car (crane trolley) compared with the horizontal
surface even when lifting appliances are free from loads (without car). This
requirement is applied to appliances with more than 20m span.

5.2.3 If using flat rail head, the difference between the wheel crane compared
with the horizontal surface even when lifting appliances are free from loads
ranges with +0.2% and -0.05% (see 5.2.3).

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D iagram 5.3.2

When car has not been installed on vertical beam, the load-free lifting
equipments are supported at the two ends.

5.2.4 The distance between the two moving rails of car should not be ±3mm
smaller or greater than the nominal dimension s (see Diagram 5.2.4).

D iagram 5.2.4

5.2.5 On the cross section vertical to the moving direction of cars, the altitude
difference between two opposite points should not exceed 0.15% the distance
between the two rails for cars, which means that the maximum allowable
difference is 10mm (see Diagram 5.2.5).

D iagram 5.2.5

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5.2.6 When installing the car rail, ensure that the rail surface is on a horizontal
surface with the maximum roughness smaller than ±3mm to the two 3-m wide
rail couple and smaller than ±0.1% to the two more-than-3-m wide rail couple.

D iagram 5.2.6

5.2.7 The vertical shaft of car rail should not be abaxial from that of the
vertical rail-supporting beam a distance greater than half of its thickness (see
Diagram 5.2.7).

D iagram 5.2.7

5.2.8 The vertical shaft of car rail should not be abaxial from that of the
vertical one in theory a distance greater than ±1.0 mm to a 2-m long rail section
and should not be abaxial at connection points (see Diagram 5.2.8).

5.2.11 The difference between the central plane of wheels and rail central plane
on the same railway is as much as ± 1mm. (Refer to figure 5.2.11 )

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5.2.12 If horizontal direction rolls is used, the difference between the centre
between horizontal rolls and the center of the ray is as much as ± 1mm. ( Refer to
5.2.12 )

5.2.13 Diameter tolerance of wheels shall corresponds with tolerance class h9

according to ISO standard. If the speed of driving wheels is synchronized, more
exact tolerances are required. Wheel tolerance diameter is defined on a case-by-
case basis. These tolerances are applied for driven wheels because these wheels
shall be interchanged.

5.3 The tolerance of the railway for lifting appliances.

Tolerances mentioned as follows are applied for a new railway. Under operation,
these tolerances exceed 20%, the center of the railway needs redefining. If the
movement is difficult, the center of the railway needs redefined even when
tolerances are less than 20%.

1- The largest difference between Δs and aperture s is:

When s ≤ 15 m: Δs = ± 3 mm.
When s > 15 m: Δs = ± [ 3 + 0.25 x ( s-15) ] mm. Allowed maximum: ± 25
mm.
(Refer to figure 5.2.1)

If horizontal direction wheels are equipped on only one railway, the tolerance of
the other railway could increase threefold mustn’t exceed 25 mm.
2- Supposed that a small car is at the middle of the span, deflection of
railways is approximately the same.
3- The maximum allowed tolerance of the rail surface compared to
theoretical height is ± 10 mm. Theoretical height is defined as horizontal

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position or theoretical bend( if applied).The difference in height of two
railways could be 10 mm. Height differences in the vertical direction of
the railway are 2m apart ( not exceed + 2 m)
4- The deflection of the rail surface compared to theoretical position mustn’t
exceed following values: Vertical deflection 0.3%, horizontal deflection
0.3%, refer to 5.3.1

5- The maximum allowed horizontal deflection of each rail on the horizontal

plane is ± 10 mm. The vertical bending is 2 m apart at any point (not
exceed ± 1mm ) ( Refer to 5.3b)

For lifting equipments which are directed by horizontal rolls, above values are
applied to the rail surface.
For lifting equipment which are directed on only one rail, the requirement of rail
straightness is reduced (without direction rolls) according to the agreement with
the manufacturer.
6- Not considering the axial deflection at rail joints. Recommending to use
weld joints in rails.

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A P P E N D IX 6
SU R V E Y O F M E T A L ST R U C T U R E

Item Defection Removal criteria CHECK instruction

1. Metal structure deformation, Any deformation and Check the whole length
cracking crack of total metal to identify
deformation and
cracking. Check by
magnetic powder is
needed when there is
cracking
2. Metal structure - Plane thickness: -Measure the thickness
+ Reduction by 10% in and compare the initial
thickness at any point thickness
+Reduction by 10% in -Checkers determine
thickness at local worn where the thickness is
areas which is a small part measured based on
of cross section of the practical conditions.
structure. - Checked points and
- Cross section measured values shall be
+ Reduction by 10% in the recorded on a drawing.
area of cross section for
important parts in case the
wearing is evenly
distributed on considered
cross section.
+ Reduction by 20% when
considered cross section is
a part of auxiliary
structure.
- Parts of circular
cross section:
+ Reduction by 3% in
diameter at any point on
the same cross sections.
+ Reduction by 5% in
local circular cross
section.

3. Codes for Deformation, Any deformation and Carefully check to

overhead and cracking cracking identify any
gantry cranes Deformation and
cracking. Check by
magnetic powder is
needed when there is
cracking.

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4. Codes for Wear Reduction by 10% in the Check wear after
overhead and thickness or by 5% of any cleaning the outside
gantry cranes. diameter. rust.

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A P P E N D IX 7
IT E M S F O R C H A IN A N D H O O K IN G C H A IN C H E C K

Item Defection Removal criteria Check instruction

1. Chain/ end Wear > 5% wearing in Check the chain
link the diameter and chain end
link according to
wearing limits,
especially on
bearing surfaces.
2. Chain/ Elongation > 3% elongation Measure the
coupling on 10- 20 length chain length and
of the chain. compare the
initial length.
3. Chain/ end link Deformation Any deformational Check chain and
or bending the end link
Deformation of according to
the end link. Deformation
standard.
4. Chain/ end link Notch, edge, Any notch, edge Check notch,
groove and groove edge, groove or
end link .
5. Chain/end link Cracking Any cracking Check chain or
end link to
identify cracking.
Carefully check
welded area.
Check by
magnetic powder
at chain hooks.
6. Chain/ end link Rust Any deep hole or Check chain and
> 5% rust in end link after
diameter cleaning the
outside rust.
7. Chain/coupling Twist Hook chain is Check the chain
twisted over half- twist, especially
ring on the whole under operation.
length ( 4 m)
P roof load (P L ):
- When SWL ≤ 25 t: PL = 2x SWL ( tons)
- When SWL > 25 t : PL = ( 1.22 x SWL) + 20 (tons)

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A P P E N D IX 8
N A T U R A L -F IB E R H O O K IN G C A B L E C H E C K

Item Defection Removal criteria Check instruction

1. Cable Mechanical Any visible Check cable body or
defection fastener with the
naked eye
2. Cable Fire Any damage caused Check whether damage
by fire of cable is due to
contact to fire or high-
temperature materials
3. Cable Chemical Any chemical Check whether cable
damage damage is due to
chemicals
4. Cable Mould or rotten Any mould Check the inside of
cable to identify
mould.
5. Cable Brittle Any brittleness Check whether the
brittleness of cable is
caused by wet or dry
condition.
6. Cable end Loose Any looseness of Check to ensure that
coupling coupling at cable coupling at cable end is
end tight
P roof load ( P L ): N ote:
- When SWL When SWL ≤ 25 Carefully check manual coupling
t: PL = 2x SWL ( tons) Only employ “navigation” coupling
- When SWL > 25 t : PL = ( 1.22
x SWL) + 20 (tons)

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A P P E N D IX 9
A R T IF IC IA L –F IB R E H A N G IN G C A B L E

Item Defection Removal criteria Inspection instruction

1. Cable Mechanical Any visible mechanical Check mechanical
damage damage of cable body
and cable end coupling
with the naked eye.
2. Cable Break Any broken cable body Check to identify any
or cable end coupling broken cable
3. Cable Fire Any damage caused by Check whether damage
fire of cable is due to
contact to fire or high-
temperature materials
4. Cable Chemical Any chemical damage Check whether cable is
damaged by chemicals.
The sign is faded color
and loose cable
fiber.( use figures to
loosen cable fibers)
5. Cable Frictional damage Any frictional damage Check whether cable is
damaged by external
friction at polish areas.
6. Cable Contamination Any contamination Check any
caused by lubricant caused by lubricant and contamination caused
and grease grease by lubricant and
grease.
P roof load ( P L ): N ote:
- - When SWL When SWL ≤ 1. Before using, carefully check artificial –
25 t: PL = 2x SWL ( tons) fiber cable which is frequently damaged.
- When SWL > 25 t : PL = 2. The use of artificial –fiber cable is limited,
( 1.22 x SWL) + 20 (tons) for example when light lift requirement.

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A P P E N D IX 10
S T E E L -F IB E R C A B L E C H E C K

Item Defection Removal criteria Inspection

instruction
1. Cable Break 1. When knowing the Check the whole
quantity of cable fiber: cable to identify
a/ 10% of total quantity with where any cable
the length which is 8 times as fiber breaks
much as diameter
b/ More than three adjoining
fibers

2. Cable Twist Any permanent twist Check kinds of twist

3. Cable Wear Any wear on surface of cable Check the inside of
fibers in the outside is more cable to identify
than ¾ of their initial whether cable fibers
diameter are worn.
4. Cable Diameter - 1.2 mm for ф < 19 mm Check and measure
reduction - 1.6 mm for ф = 19 mm cable diameter and
to < 32 mm compare with initial
- 2.4 mm for ф = 32 to < diameter
38 mm
- 3.2 mm for ф = 38 mm
to < 51 mm
- 4.0 mm for ф < 51 mm

5. Cable Thermal Any thermal damage Check whether

damage thermal damage is
caused by blow-
torch, electric
spark…
6. Cable Rust Remove any internally rusted Check the inside of
cable. Assess externally cable by exposing
rusted cable according to Item the surface of
3. internal strands.

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7. Cable Deformation/ All Deformation or damage Check to identify
terminal and damage under the surface Deformation or
other damage such as
connectors crush or crack
8 Cable Loose All loose parts or cable Check areas adjacent
terminal and connectors. to cable connectors
other to see whether
connectors connection between
cable and cable
connector is tight or
not.

A P P E N D IX 11
H A N G IN G L O O P A N D O T H E R C A B L E JO IN T S

Item Defection Removal criteria Check instruction

1. Assembly Twist or Any deformation Check deformation or twist
deformation from initial shape of assembly from the initial
shape, especially for
circular hanging loop.
2. Assembly Wear Any wear over 5% Check assembly wear on
of initial dimension all surfaces
3. Assembly Notch, groove, Any notch, groove, Check assembly with
crack crack affecting the naked eyes to identify any
durability of notch, groove or crack,
assembly especially those of sharp
edge.
4. Assembly Crack Any crack Check with naked eyes to
identify any crack. Check
by magnetic powder if
there is any crack.
5. Assembly Wear Any wear from Check wear of assembly
allowed wear ( > after cleaning external rust.
5% of initial
dimension)
P roof load ( P L ):
- When SWL When SWL ≤ 25 t: PL = 2x SWL ( tons)

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- When SWL > 25 t : PL = ( 1.22 x SWL) + 20 (tons)

A P P E N D IX 12
SH A K L E C H E C K

Item Defection Delete standard Check instruction

1. Shackle Wrong Remove any pin Check and compare the
dimension shackle of wrong dimension of pin and ma
types and standard dimension
according to safe working
load (SWL)
2. Pin shackle Wear Any reduction by Measure and compare the
more than 5% in dimension of shackle and
diameter from the pin with the initial
initial diameter dimension according to safe
working load (SWL).
Check the assembly
3. Pin shackle Deformation Any deformation Check shackle and pin to
identify any deformation.
4. Pin shackle Any notch, edge Any notch, edge or Check to identify any notch,
and groove groove edge or groove
5. Pin shackle wrong type Any pin of wrong Check to identify that pin
type matches Shackle
6. Worm Wear Any wear which can Check the wear of thread at

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thread/ground rush crest of thread pin and shackle pin
thread
7. Pin shackle hole nonalignment Any nonalignment Check to ensure that two
and threaded holes stands in a straight
shackle hole line.
P roof load(P L ):
- When SWL ≤ 25 t: PL = 2 x SWL ( tons)
When SWL > 25 t : PL = (1.22 x SWL) + 20 ( tons)

A P P E N D IX 13A
S U S P E N S IO N H O O K C H E C K

Item Defection Removal criteria Check instruction

1. Hook trunk Wear The thickness :> Check and measure the wear of
10% from the suspension hook
initial thickness at
A area, > 5% at B
area. ( Refer to
the following
figure )
2. Hook trunk Twist Any twist Check to identify any twist
3. Hook throat Deformation Any deformation Measure and compare the dimension
of the gap between two given centers
and initial dimension.
4. Hook trunk Crack Any crack Check to identify any visible crack.

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Check by magnetic powder if there is
any crack
5. Hook trunk Mechanical Any mechanical Check to identify mechanical damage
damage damage
6. Threaded part Wear Maximum Check and measure the wear of
on hook trunk allowed wear of threaded part on hook trunk
diameter of
threaded part :
2.5% of the initial
diameter
7. Hook eye Deformation Any deformation Check to identify any deformation of
hook eye.
Proof load(PL):
- When SWL ≤ 25 t: PL = 2 x SWL ( tons)
- When SWL > 25 t : PL = (1.22 x SWL) + 20
( tons
Note:
Check suspension hook:
1. Check dimension. All dimensions shall be over
90% of the initial dimension.
2. Bars for prevent cable from slipping (if any)
3. Threaded part on hook trunk shall be clean ( if
any)
4. Signs are readable
5. Material wear at the surface on which ball
bearing is mounted doesn’t exceed 8% of the
initial dimension.
6. Double suspension hook trial shown in
Appendix 13B
7. Dimension shall be measured for check for types
of suspension hooks in Appendix 13C
8. Suspension hook shall be checked by magnetic
powder at least once within 2 years.

A P P E N D X I 13B
D O U B L E S U S P E N S IO N H O O K T R IA L

Double suspension hook must be tried under operation (synchronous with proof
load ( PL) shown in the figure a)
Double suspension hook can be tried in two following ways:
1) Tried proof load ( PL) is vertically suspended, Figure b

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2) Tried proof load is horizontally suspended for each suspension hook,
figure c

A P P E N D IX 13C
T Y P E S O F S U S P E N S IO N H O O K S –C H E C K F O R M A IN D IM E N S IO N S

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A P P E N D IX 14

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S W IV E L E Y E C H E C K

Item Defection Delete standard Check instruction

1. Swivel eye Deformation Any deformation Check the deformation of
body swivel eye from the initial
shape
2. Swivel eye Wear Any wear exceeding Check wear from the initial
body 5% of the initial dimension
dimension
3. Swivel eye Crack Any crack Check any visible crack.
body Check by magnetic powder
if there is any crack
4.. Swivel eye Notch, edge, Any notch, edge or Check the surface of swivel
body groove groove eye to identify any notch,
edge or groove
P roof load(P L ): Note:
- When SWL ≤ 25 t: PL = 2 x SWL ( tons) Check parts of swivel eye
- When SWL > 25 t : PL = (1.22 x SWL) + 20 ( tons according to non-damage
trial within two years

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A P P E N D IX 15
R IG G IN G S C R E W A N D T E N S IO N S C R E W

Item Defection Delete standard Check instruction

1. Rigging screw Deformation Any deformation Check to identify
body which bends any mechanical
rigging screw or deformation.
prevents the
movement of
threaded parts.
2. Rigging screw Crack Any crack . Check to identify
body any visible check at
threaded parts.
Check by magnetic
powder if there is
any crack
3. Rigging screw Wear or Any wear or Check to identify
body damage damage to threaded any visible wear or
parts. damage.
4. Rigging screw Deformation Any deformation Check every rigging
head which bends screw head to
rigging screw head identify deformation.
5. Rigging screw Crack Any crack Check to identify
head any visible check at
threaded parts.
Check by magnetic
powder if there is
any crack
6. Rigging screw Wear or Any wear or Check rigging screw
head damage damage to identify wear or
damage
7. Rigging screw Repair and Any repair and Check rigging screw
body and head change change without any body and head to
permit from identify any repair or
authorities. change without any
permit from
authorities.
8. Rigging screw Wrong Any wrong Check and compare
body and head dimension dimension from rigging screw body
standard one and head with
according to safe standard dimension
working load according to safe
(SWL). working load
( SWL).
Proof load( PL):
- Tension screw:
+ When SWL ≤ 25 t: PL = 1.5 SWL

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+ When SWL > 25 t: PL = 1.2 SWL
- Rigging screw:
PL = 2 x SWL ( tons)

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A P P E N D IX 16
ST R A P A N D B E A M C H E C K

Item Defection Delete standard Check instruction

1.Loaded point Wear, Any wear, No use and the
( suspension deformation, rust deformation or whole check
point) rust affecting
operation of
appliances
2. Locking device Slack or so tight Any defection
affecting the
operation of
appliances
3. Surface of Wear Unallowable wear Maintain the
clamping cam standard surface
on the whole
surface of
clamping cam
4.Weld and main Crack Any crack Check to identify
structure any visible weld
and main
structure. Check
by magnetic
powder, if there
is any crack.
5. Pin holes Wear, expansion Any unallowable
wear or expansion
6. Jaw and swivel Excessive Any defection Check the smooth
eye tightness affecting the operation of
operation of Shakle and
appliances swivel eye
Proof load(PL):
- When SWL ≤ 25 t: PL = 2 x SWL ( tons)
- When SWL > 25 t : PL = (1.22 x SWL) + 20 ( tons

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A P P E N D IX 17
G O O D S L IF T IN G B E A M A N D L A N D IN G G E A R C H E C K

Section Defect Discarding standard Check Instruction

1. Tamper Deformation Any bended and Test total the tamper
twisted deformation length to find out
deformation, bend and
twist of tamper.
2. Tamper Crack Any crack Test the tamping
material condition with
normal eye. Check the
handing positions
withmagnetic in the test
procedure to find out
crack.
3. Last crack No or last Without or last crack Test the goods lifting
crack deformation, stop beam strength is
deformation until repair or satisfactory with the last
sufficiently equip. crack Specification or
not.
4. No or Do not have any All the compressive
Suspension abundant bolts welds to find out the
points connecting crack under the magnetic
bolts test procedure.
5.Suspension Weld bead Any crack For weld connected
points crack sections, check the weld
crack with magnetic.
Proof load (PL):
- SWL ≤ 25 t: PL= 2x SWL (ton)
SWL > 25 t: PL= (1.22 x SWL) + 20 (ton)

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A P P E N D IX 18A
S W IV E L E Y E H O O K , H A N G IN G L O O P A N D P IV O T C H E C K

HANGER Defect Discarding standard

1. Hook body Wear/rust In section A ( 13 A
appendix), Wear more than
10 % of the original length.
In section B, Wear more than
5% of the original length.
2. Hook body Twist Any twist
3. Hanging or eye Deformation Any “expansion” of hanger
twist loop or deformation of hanging
loop or manipulator.
4. Hook pivot Wear/ rust Any wear more than 5 % of
the original diameter.
5. Hook body and eye Mechanical damage Hook body shall comfort
twist with the data in section (1)
For manipulation, if wear is
more than 10 % of the
original length.
6. Hook body, ripple Crack Any crack
and manipulator.

7. Hook pivot nut Wear/ rust Top nut diameter is 5 % wear

compared with the original
diameter.
8. Cotter Wear/ rust Cotter wear is more than 5 %
in comparison with the
original diameter.
9. Cable check General damage Determine the cable check
not have any damage before
using.
10. Hook pivot for Confirm that pivot against
preventing cable from cable slipping does not have
slipping damage. Record if have no
this batten. If there is no this
batten in the approval
project, discard or repair is
necessary.

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A P P E N D IX 18 B
S W IV E L E Y E H O O K , H A N G IN G L O O P A N D P IV O T C H E C K
IN S T R U C T IO N

1. Check hook body with normal eyes to find out wear or rust. Report any
wear or rust signal in line with the depth and width remarks.
2. Check hook body with normal eyes to discovery twist deformation.
Carefully record all found deformation.
3. Measure the distance of the hanger opening “t” at the narrowest position.
Do the same with standard points marked “f” and do comparison with the
original distance. The opening of hanger outlet by wear, deformation or
rust shall be recorded. If the pully hanger group has not been tested, there
is no marked standard point. In this case, mark the position of all points,
then measure the distance and record.
4. Measure and record the maximum and minimum of the hanger post
diameter.
5. Any crack, chase, cut shall be grind clearly. Prevent increasing the
temperature too high and change the cross section of the details.
6. Check the crack depth. If it is less than the permissible depth causing by
wear, grind the crack under the authority’s agreement. Discard if the rack
depth is bigger than the permissible depth.
7. Test by magnetic or non-destructive method under the authorities’
decision.
8. Measure and set up the maximum and minimum hanger post diameter at
both the non-or ripple position. Record if discovery any wear or rust.
9. “Damage” consists of mechanic damage, rust or out of permissible wear
or not smooth operation.
Note:
1. Do not allow to grind the materials over the permissible regulations in
Article 1 and 5 in Appendix 18 A.
2. If the nut hook is welded at hanger post, discard after 2 year operation.

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A P P E N D IX 18 C
S T A N D A R D C A B L E T IE M E T H O D
Step 1:
Tie the cable check at the top cable.
Part U bends forward to the top cable.
Tighten nut.

Step 2:
Tie the second cable, the nearer the circlip, the better.
Part U bends forward to the top cable.
Light tighten the nut, do not tighten heavy.

Step 3:
Tie the left cable.
The distance between cable check is equal with that
between 2 first cables.

Step 4:
Pull and tighten all cable check comfort the required
moment.

Step 5:
Check the nut twist moment again after operating the
hanging cable.

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A P P E N D IX 18 D
S W IV E L E Y E H O O K , E Y E H O O K O R P IV O T IN G H O O K

Eye hook Swivel Pivoting Hook location test

eye hook hook Check crack or twist

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A P P E N D IX 19A
P U L L Y H A N G E R G R O U P S W IT H P IV O T E D B E A R IN G C H E C K
(A T T A C H T O A P P E N D IX 19 B A N D 19 C )

1. Pivoted bearing: test smooth shot bearing.

2. Cable brace: check to find out the damage (if do not have a cable brace,
record in the profile).
Discard or repair the non-cable brace hanger in the design.
3. Safety devices: have all the safety devices in good conditions.
Notes:
Erect the free top of the bearing cable, remember:
1. Heavy tighten cable nut as the figure in Appendix 18 C or,
2. Leave the free top of the cable about 150-225 mm length.

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A P P E N D IX 19 B
P U L L Y H O O K G R O U P S W IT H P IV O T E D B E A R IN G C H E C K
IN S T R U C T IO N

1. Check Hook body to find out the wear or rust. Record if have any signal.
2. Check Hook body to find out the twist deformation. If have any,
measure and report it.
3. Measure the size of hanger opening “t” at the smallest space. Normally,
distance between 2 standard points measured shall be compared with the original
data. Any opening by wear, deformation or rust shall be recorded. If the hanger
group has not checked for the first time, there are no standard points. In this case,
mark the standard point in the required position then take note this distance.
4. The maximum and minimum diameter of hanger post in both with and
without nipple shall measure and record.
5. Rubbing all scratches, cut. Be careful to prevent the over-heating or
much changes in cross section details. Any repair shall be recorded.
6. Check the crack depth. If it is lower than the permissible wear scope,
rub until the Crack bottom, with the authority’ agreement. Remove if its depth is
higher than the permissible level.
7. Check by magnetic powder or the non-damaged methods under the
authorities’ decision.
8. Measure and take note the maximum and minimum diameter in both
with and without nipple position. The most permissible wear of the nipple
diameter is 2.5 %.
9. Check and confirm that grease nipple is erected and works smoothly.
Measure and take note the pully side length.
10. Measure the maximum and minimum diameter of pully group.
11. Check the pully sides and pivoted bolts with magnetic powder.
12. Check the pivoted bearing with the normal eye to find out damage.
13. “Damage” consists of mechanic damage, deformation or any non –
smooth operation.
14. “Safety devices” consist of split cotters, bolts, nuts……use to connect
hanger pully group. All the axis length is sufficient and if necessary, cover with
the silver cloth to prevent wear.
Note: In all cases, do not rub the material over the wear limitation.

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A P P E N D IX 19 C
P U L L Y H A N G E R G R O U P S W IT H P IV O T E D B E A R IN G

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