Technical Specs - Rev01

Performance Description
Bridge Crane TKCSA

ThyssenKrupp CSA
Project TKCSA Status 2007/05/25
THYSSENKRUPP CSA
Technical specifications for the TKCSA bridge cranes
Item Crane Designation Location Support Load Range

no. rows capacity [t] [m]
1 S 100 Hot metal charging crane * Charging hall A/B 530/180 23,75
2 S 200 Steel pouring ladle transport crane* Ladle handling C/D 530/100 23,75
3 S 300 Steel pouring ladle transfer crane* Loading hall D/E 530/100 23,75
4 S 110 Scrap charging crane Charging hall A/B 180/100 23,75
5 S 210 Repair crane Ladle handling C/D 180/60/10 23,75
6 S 310 Ladle transport crane** Loading hall D/E 180/60/10 23,75
7 S 320 Tundish crane** Casting bay E/F 180/60 27,25
8 S 330 Tundish crane** Casting bay E/F 180/60 27,25
* These cranes transport molten masses regularily

** These cranes transport molten metal occasionally (S310 up to 20t), technical requirements for
molden metal handling are written in the relevant chapters of this technical specification.
Project drawings for the specified cranes
Item Crane Drawing no. Status Crane runway Wheel

no. measurement load
specifica-
tions
1 S 100 SCA-S100-002P after crane runway assembly None
A plant overview with the arrangement of all the cranes in top view is presented in the
directory of enclosed documents.
Inquiry crane TKCSA V1 1 EA-AT-RS

Bridge Crane TKCSA
ThyssenKrupp CSA
8.3.7.3.1 Steel grades for bolted components-----------------------------------------------------------------------30

8.3.7.3.2 Steel grades for welded components----------------------------------------------------------------------30
8.3.7.3.3 Selection criteria----------------------------------------------------------------------------------------------30
8.4.1.7.1 Rail form-------------------------------------------------------------------------------------------------------36
8.4.1.7.2 Steel quality---------------------------------------------------------------------------------------------------36
8.4.1.7.3 Rail joints------------------------------------------------------------------------------------------------------36
8.4.1.7.4 Fixing of rails-------------------------------------------------------------------------------------------------37
9.2.14.2.2 Quality requirements-----------------------------------------------------------------------------------------62
9.2.14.2.3 Corrosion protection-----------------------------------------------------------------------------------------62
9.2.14.2.4 Inspection openings------------------------------------------------------------------------------------------62
9.2.14.2.5 Part joints------------------------------------------------------------------------------------------------------62
9.2.14.2.6 Tapered pins, pressure threads-----------------------------------------------------------------------------63
9.2.14.2.7 Ventilation-----------------------------------------------------------------------------------------------------63
9.2.14.2.8 Lifting points--------------------------------------------------------------------------------------------------63
9.2.14.2.9 Installation-----------------------------------------------------------------------------------------------------63
9.2.14.2.10 Gear transmissions-------------------------------------------------------------------------------------------63
9.3.1.5.1 Diameter and design-----------------------------------------------------------------------------------------69
9.3.1.5.2 Rope attachment and safety turns--------------------------------------------------------------------------69
9.3.1.5.3 Rope drum articulated connections------------------------------------------------------------------------70
9.3.1.5.4 Rope drum bearings------------------------------------------------------------------------------------------70
9.3.1.5.5 Gear limit switches-------------------------------------------------------------------------------------------70
9.3.2.4 Track wheels--------------------------------------------------------------------------------------------------72
9.3.2.5 Guide Rollers--------------------------------------------------------------------------------------------------73

Bridge Crane TKCSA
ThyssenKrupp CSA
1. General
This specification directory contains the mechanical and electrical equipment

descriptions, the assembly and commissioning instructions and the documentation
requirements for 8 cranes for the TKCSA Brazil project.
1.1 Object description
Located in Brazil, a new integrated iron and steel plant is to be built under the
designation TKCSA (ThyssenKrupp CSA Companhia Siderúrgica) by the owners
ThyssenKrupp Steel AG (TKS) and Companhia Vale do Rio Doce (CVRD). The annual
capacity of this new iron and steel plant will be 5 million tons of steel.
The crane units described in these specifications will be engaged in the steel works
area of this iron and steel plant. The requirements for availability and ease of
maintenance placed on these cranes are especially high, as the failure of one of these
cranes cannot be compensated for by another crane.
Furthermore, the construction of the cranes should be designed such that the number
of necessary spare parts is minimized by an optimized selection of components and
assemblies. With this in mind, the classifications and load capacities of the cranes were
selected such that only 4 sizes of hoisting gear are required.
1.2 Instructions for order processing
1.2.1 Projecting phase
After a contract is granted, the supplier must name a responsible transaction manager,
who is constantly available to the project manager of ThyssenKrupp CSA (referred to in
the following as TKCSA) during the development of the project.
The design meetings are conducted in the English language.
An arrangement drawing by the crane supplier must be submitted in draft at the design
discussions. Before site preparation begins, all working drawings with parts lists must be
submitted for approval, in due time and in duplicate. In due time means here that
constructive improvements by TKCSA will not lead to a delay in delivery.
For the approval of the drawings, a period of 2 weeks from receipt of the drawings to
their dispatch should be calculated. Approval drawings must be marked with the
drawing number and the date they were last worked on. Where drawing checks are
necessary, mechanical engineering and static calculations must be provided with the
relevant drawings. TKCSA reserves the right to make design changes in the drafts and
working drawings.
In the projection phase, any sub-suppliers for the steel engineering, mechanical
engineering and electrical engineering must be checked with TKCSA, and approved by
TKCSA in writing. Where there has been a previous negative experience, or justified
doubts about the sub-supplier's qualification, TKCSA reserves the right to reject them.

Bridge Crane TKCSA
ThyssenKrupp CSA
The main contractor bears the sole and immediate responsibility for all work done. He
must ensure that the subcontracted work is supervised in a suitable fashion and that the
quality requirements are met.
Components for mechanical and electrical equipment must be presented in tabular form
for the approval of TKCSA. This does not include components already included in the
task description.
The transport routes outside and inside the TKCSA works site are to be checked for
deliveries. Official objections to special transportation or deficiencies in the use of public
roads and seaways must be reported at the latest 10 weeks after the contract is
granted. Obstacles that must be overcome within the TKCSA works site must be
specified 6 weeks before delivery.
Dimension specifications given in the attached project drawings are mandatory as

regards the positioning of hooks and crossbeams, starting dimensions, crane runway
heights, distances between hooks, crane buffer heights and operator cab positions.
Smaller starting dimensions are permissible. The overall heights and crane lengths over
buffers must not be exceeded. Smaller wheel bases are also possible. The top beams
and crane ascents must not be designed any wider than shown in the project drawings.
For the crossbeams shown, the lengths given are the maximum permissible
measurement.
In the framework of the project development, further restrictions to the clearance gauge
shown may yet arise, as the works planning has not yet reached its final status. For this
reason, the main system dimensions and the adherence to the safety clearances from
fixed parts of the environment and from neighboring cranes or gantry cranes must be
checked by the contractor after the contract is granted. The dimension specifications for
the conductor rails and the position of the earthed conductor must also be checked by
the contractor.
At the latest 10 weeks after the contract is granted, the contractor must present a
weekly grid time schedule with the following contents:
- Allocation schedule for major components, e.g. steel structures, gear units, rope
drums, electrical systems etc., indicating the agreed sub-suppliers.
- Scheduled dates for inspections of production sites and components
- Production deadlines for the major components
- Scheduled dates for inspections of materials and components
- Scheduled dates for preliminary acceptances
- Shipping date
- Delivery date
At the latest 6 weeks before assembly begins, a time schedule with an hourly grid must
be presented for:
- Arrival of main and partial deliveries in the harbor

- Arrival of main and partial deliveries at the TKCSA works site
- Unloading of the crane girders and trolleys
- Site-internal transportation
- Preparatory work on the works site
- Construction work, such as the removal of obstacles from the works
- Filling in and solidifying the mobile crane area, if necessary
- Assembly and disassembly of the mobile crane
- Sequence and procedure of the moves
- Durations for closures of rails or roads, and other functional limitations

Bridge Crane TKCSA
ThyssenKrupp CSA
- Durations for electrical shutdowns

- Construction site preparation and clearing
- Assembly procedures for the new cranes
- Supply of working materials such as e.g. oil
- Quality control of necessary weld joints
- Commissioning cranes
- Function tests
- Inspections
This time schedule should include the activities of all subcontractors and any other
companies involved, separately and organized by trade and activity.
Taking into consideration necessary measures for the assembly of the cranes when
planning the halls (e.g. openings in the roof), a rough assembly conception must be
presented by the contractor approx. 10 weeks after the contract is granted.
In case of discrepancy with sect. 17, sect. 17 will govern
1.2.2 Construction phase
1.2.2.1 Production monitoring
Discussions for production monitoring are conducted in the English language. Chapter
11 applies to the documentation of production monitoring
During the construction phase TKCSA will commission specialist departments to carry
out the following tests at the contractor or its sub-supplier:
- Qualification of suppliers to manufacture the respective components

- Dimensional accuracy of components or assemblies
- Material and component inspections
- Professional execution
- Adherence to the welding specifications
- Execution of the electrical installation
- Checking of the quality documentation
The scheduled dates on which the inspections of the production sites and the affected
components may take place are to be entered in the time schedules in accordance with
section 1.2.1. Timely information (min. 10 working days in advance) on possible
inspection dates is especially important for components that will not be accessible or
able to be readily inspected at a later date, or where compensation delivery in case of
rejection is time-critical.
For the holes bored in the saddle housings of the track wheel links and the orientation of
the trolley rails to be checked, the bridge girders must be pre-assembled before they
are dispatched and arranged in the sequence in which they are later to be used. The
connecting rods are to be installed for these measurements. The track wheel links must
not be installed at this time. The measurement of the saddle housing takes place
without carriages. The carriages with wheels are subsequently to be installed for further
measurements. To this end, the carriages are to be installed in the same position that
they will have in the final assembly.
For the checks on the supports between the trolley carriage frames and the hoisting
gear frames of cranes S100, S200 and S300, these components are to be aligned and
assembled together. The components required for the horizontal fixing of carriage

Bridge Crane TKCSA
ThyssenKrupp CSA
frames and hoisting gear frames are to be adjusted to their final positions. The
measurement of the saddle housing takes place without carriages. The carriages with
wheels are subsequently to be installed for further measurements. The carriages are
then to be installed in the same position that they will have in the final assembly.
The measurements of the remaining crane trolleys incl. auxiliary trolleys initially takes
place without track wheel carriage or track wheels installed, and then subsequently with
wheels installed.
For all track wheel carriages, measurement protocols are to be created by the
manufacturer by running the carriage on the NC horizontal boring mill. The track wheel
carriages are to be labeled clearly and unambiguously.
All dimensional controls are initially to be carried out by the contractor. He must then
document the results of the inspections. If the test results are not within the required
tolerance range, TKCSA must always be consulted.
Details of the measuring method, the tolerances to be adhered to and the

documentation of test results may be found in section 11.8.
Overlay welding and remachining must only take place with the written agreement of
TKCSA.
The contractor must demonstrate that the superimposition of the tolerances determined
for the trolley rail and trolley track wheel positions will not lead to secondary bending
when running.
Only when the prescribed condition is achieved shall TKCSA carry out the confirmatory
measurement. Retests that may be attributed to the contractor shall take place entirely
at his expense, including repeat travel costs for the inspection personnel.
For the following components and their substructures, it must be demonstrated that they
have been so oriented that the tolerances required by the manufacturers for the drum
couplings, shaft couplings, crowned tooth couplings, brake drums and gear limit
switches for the fitting condition are adhered to:
 Pedestal bearing for the rope drum

 Rope drums
 Top pulleys
 Drum reduction gear unit
 Jack shafts
 Motor reduction gear
 Operation brakes and Eldros
 Emergency stop brakes
 Hoisting gear motors Motors
Over and above this, the requirements for drive units in accordance with TH-N 565 144
and DIN 740 must be met.
The axial displacement, radial displacement, angled displacement, radial true run and
axial true run must be verified. The radial and angled displacement are to be determined
by rotation tests.
Deformations of the supporting framework when loaded are to be considered along with
the installation tolerances if this could influence the useable tolerance range.

Bridge Crane TKCSA
ThyssenKrupp CSA
For cranes with emergency stop brakes, the rope drum flanged discs must adhere to
the tolerance specifications of the brake manufacturer.
When setting up and fixing the carriage and hoisting gear frames for cranes S100, S200
S300 and S310, it must be ensured that the installation and operational tolerances of
the load cells are adhered to under all deployment conditions.
All components that will be removed after the alignment are to be affixed with dowel
pins.
1.2.2.2 Test runs
Test runs of the installed motors and gear units for the hoisting gear of cranes S100,
S110, S200 and S300 are to be carried out by the contractor before shipping. The test
runs are to take place without loads. For this, the gear units are to be filled with slushing
oil. The maximum test rotation speed for the oil type used is to be specified by the gear
unit supplier. The test runs are to take place in the presence of a representative of
TKCSA. The dates should, if possible, be scheduled consecutively and are to be
registered approx. 2 weeks before the tests are carried out.
1.2.3 Assembly and commissioning
The complete assembly and commissioning of the cranes ordered fall within the scope
of supply. This also includes all necessary tools and auxiliary aids such as e.g. mobile
cranes, lifting platforms, scaffoldings etc. If additional measures or roof openings should
be necessary, then these must already be listed in the quotation.
The contractor must appoint a responsible installation manager for the installation and
commissioning tasks. The site coordination meetings will be conducted in English or
Portuguese. The contractor must inspect the construction site before commencing
installation work, to determine any deficiencies and impediments, and to report them to
TKCSA in good time. The contractor is liable for any costs and delays traceable to
ignorance of the construction site.
The installation manager must hold coordinating meetings with the project and works
management. He is further obliged to ensure that the construction site regulations are
adhered to by his engineers. The valid version of the construction site regulations will be
provided as ANNEX F by the purchasing department. TKCSA does not provide any
changing or common rooms. It is the responsibility of the contractor to provide these
facilities.
In order to shorten the assembly time, bridge girders are to be completed as far as
possible before being placed on the crane runway. This applies especially to the
electrical installation.
In the work area of TKCSA, the operating voltage is 460V. Electric appliances, lamps,
welding machines etc. are to be selected accordingly. The contractor must otherwise
bring appropriate transformers.
For work in confined spaces, only electric devices with safety low voltage may be used.
The contractor must also bring transformers for this purpose. Adequate ventilation and
the presence of a security post must also be ensured.

Bridge Crane TKCSA
ThyssenKrupp CSA
Should external personnel be engaged for the crane assembly, the written consent of
TKCSA must be obtained.
Daily action reports must be written for the entire assembly and commissioning
personnel.
1.2.4 Transportation
All supplies are to the point of use. Transportation within the work and construction site
is to be carried out by the contractor with his own means. Where the use of intermediate
transport such as mobile cranes, hoisting tackle or fixtures is required, this is a
performance of the contractor.
Where intermediate storage outside the TKCSA site takes place, the contractor must
take sufficient measures to prevent theft and weathering.
Any necessary intermediate storage on the TKCSA site is to be organized by the

contractor. All auxiliary aids such as bases, tarpaulins etc. are to be brought by the
contractor.
A transport insurance for covering all possible transport damage and the resulting
consequences must be concluded by the contractor.
The costs for approval of special transports and the expenditures for accompanying
vehicles are borne by the contractor.
Intermediate storage devices within or outside the TKCSA works terrain must be
insured by the contractor against theft, damage, fire etc.
The costs for approval of special transports and the expenditures for accompanying
vehicles are borne by the contractor.
The transport routes outside and inside the TKCSA works site are to be checked for the
delivery of the cranes before these are dispatched.
For delivery by ship, all goods are to be packaged in a seaworthy manner. Unpainted
components must be protected against weathering by sea air.
For deliveries which exceed the loading gauge, the loading sketches must be submitted
to the customer for approval.
1.2.5 Acceptance in accordance with BGV D6, Art. 25
The acceptance of the two-girder bridge crane will take place after a loading test, in
accordance with BGV D6, Art. 25 and in accordance with DIN 15030. Written evidence
of stability under a test load must be submitted. The acceptance test will be carried out
by an expert appointed by TKCSA. The contractor's specialist personnel responsible for
the electrical and mechanical systems of the crane must be present during the
acceptance test. Following the acceptance, the supplier will calibrate the excess load,
differential load and slack rope deactivation.

Bridge Crane TKCSA
ThyssenKrupp CSA
1.2.5.1 Loading tests
After assembly work is completed, and after all the contractor's performances are
contractually complete, the loading test takes place. The determination of the effective
test load takes place in accordance with TH-N 560 500 T 2. The necessary loading
weights are to be provided by TKCSA free of charge for the contractor. The unloading,
suspending and reloading of the loading weights and the provision of the hoisting tackle
are done by the contractor. The test load may be suspended only in the presence of a
person appointed by the customer.
1.2.5.2 Acceptance and transfer
Handover and commercial acceptance are effected individually for each crane after
completion of a two week fault free test period. The test period begins after the
successful completion of the BGV D6 acceptance. Should a defect arise during the test
period, the test period of 2 weeks begins again when the defect has been rectified.
Rectification of all defects that may have arisen is a prerequisite for our declaration of
acceptance. If inspections during the production sequence are requested at the time of
ordering or by company standards (TH-N), or if it will no longer be possible to carry out
inspections at the time of acceptance, the contractor must ensure that the customer can
perform these inspections in good time. The guidelines according to TH- N 080 100 and
DIN 15030 for the crane acceptance test must be complied with. Defects established at
the time of acceptance or within the test period that are not remedied by the contractor
before payment of the final installment will lead to retention of payment.
1.2.5.3 Service on call
After a crane is accepted and approved, a continuous callout availability period of 10

calendar days begins for this crane. During this period, competent specialist personnel
of the contractor with corresponding knowledge must be available for control alterations,
and must be able to arrive at the construction site within 2 hours of being contacted by
telephone. This requirement applies 24 hours per day. It must be possible to inform the
callout team in either the English or Portuguese languages.
1.2.6 Warranty
The exact duration of the warranty period will be agreed with the purchasing department
at the time of contract award. Furthermore, the conditions for the begin of the warranty
will be described by the purchasing department. The warranty also applies without
restriction to the components indicated in the framework of the current technical
specification. For components that must be replaced after failing during the warranty
period, the contractually agreed warranty begins again.
1.2.7 Training
Training of the operating and maintenance personnel falls within the scope of supply.
Training sessions are given in English and Portuguese. The personnel to be trained will
be defined by TKCSA. The localities for the training dates will be specified by TKCSA.

Bridge Crane TKCSA
ThyssenKrupp CSA
Per crane type, there will be 3 instruction sessions of approx. 4 hours for operating
personnel and 3 instruction sessions of approx. 8 hours for the maintenance personnel.
The necessary documentation, such as operating and maintenance instructions is thus
also to be distributed by the supplier. The documents are to be presented in the same
language as the training.
1.3 Tender contents
Complete, functional cranes are to be offered, as described in this performance

description.
Complete fulfillment of this performance description must be confirmed

explicitly in the tender. If deviations from this performance description are made
for compelling reasons, they must be clearly indicated and justified in the
enclosed annex (List of deviations). The deviations must furthermore be
described such that a technical and economic evaluation is possible on the part of
the customer.
The tender should also contain all relevant technical data, as well as a tender drawing
with crane and trolly travel dimensions, the upper and lower hook positions, the
clearance diagram and a wheel load table with all vertical and horizontal loads.
The tender should also indicate the extra cost of 3-shift assembly and the surcharges
for work on Sundays and holidays.
Should the assembly of the cranes require roof openings or similar performances at the
construction site, these should already be indicated in the tender. Notes for which
"normal or readily accessible assembly conditions" are required are not valid. As far as
is possible from the attached drawings, the space conditions for assembly must be
considered when tendering offers.
1.4 Pricing
Fixed prices are to be quoted, which cover the scope of supply in accordance with
section 3. All individual prices are also to be quoted in the annex table (Cost
Breakdown). Additionally, the total price for simultaneous provision of all the cranes is to
be quoted.
Individual prices for the options described are also to be presented.
All prices are quoted in US Dollar [$].
1.5 Terms of delivery and regulations to be considered
When a contract has been awarded, deviations from the technical specification are
permitted only with the written consent of the customer.
Supplementarily to the stipulations in sections 8 to 11 of these specifications and the

regulations presented therein, the following EC directives, standards and accident
prevention regulations must be adhered to during the construction, manufacture,
assembly and commissioning of the cranes. The sequence of regulations corresponds
to the sequence of the enumeration titles. All regulations are to be applied in the latest
valid version (except DIN 15017, which was not passed into law).

Bridge Crane TKCSA
ThyssenKrupp CSA
For standards that have been reworked or replaced, the new version or the replacement
version is valid. References to other standards are to be taken into consideration.
EC Directives
Machinery Directive 98/37/EC as from 01/01/1995 (9th GPSGV - Machine Ordinance)

EMC Directive 89/336/EEC as from 01/01/1996 (EMC act)
Low Voltage Directive (LVD) 73/23/EEC as from 08/20/1974 (1st GPSGV)
Noise Emission Directive 2000/14/EC
Work Equipment Ordinance 89/655/EEC as from 01/01/1997 (AMBV)
95/63/EC and 2001/45/EC (Ordinance on Operational Safety))
Harmonized Standards (compliance with the applicable / latest version)
DIN EN 292 T1 Safety of machinery; basic concepts, general principles for

design; basic terminology, methodology
DIN EN 292 T2 Safety of machinery; basic concepts, general principles for
design; technical principles and specifications
DIN EN 294 Safety of machinery; safety clearances to prevent danger zones
being reached by the upper limbs
DIN EN 349 Safety of machinery; minimum gaps to avoid crushing of parts of
the human body
DIN EN 418 Safety of machinery; emergency stop equipment
DIN EN 811 Safety of machinery; safety clearances to prevent danger zones
being reached by the lower limbs
DIN EN 954 T1 Safety of machinery; safety-related parts of control systems;
general principles for design
DIN EN 1037 Safety of machinery; prevention of unexpected startup
DIN EN 1050 Safety of machinery; principles for risk assessment
DIN EN 12077 T2 Cranes safety; requirements for health and safety; limiting and
indicating devices
DIN EN 12644 T1 Cranes; information for use and testing; instructions
DIN EN 12644 T2 Cranes; information for use and testing; marking
DIN EN 13135 T1 Cranes; safety; design; requirements for equipment;
electrotechnical equipment
DIN EN 13135 T2 Cranes; safety; design; requirements for equipment; non-
electrotechnical equipment
DIN EN 13155 Cranes; non-fixed load-carrying equipment
DIN EN 13557 Cranes; controls and control stands
DIN EN 13586 Cranes; access
DIN EN 14492 T2 Cranes; power driven winches and hoisting gears
DIN EN 60204-32 Safety of machinery; electrical equipment of machines;
requirements for hoisting machines
DIN EN 61000-6-2 Electromagnetic compatibility; generic standards; immunity for
industrial environments
Accident prevention regulations

Bridge Crane TKCSA
ThyssenKrupp CSA
BGV A1 Principles of Prevention

BGV A3 Electrical installations and operating material
BGV A8 Safety and health-protection marking at the workplace
BGV B3 Noise
BGV D6 Cranes
BGV D8 Winches, lifting and pulling devices
BGV D36 Ladders and steps
VBG 5 Power driven equipment
VBG 9a Load-carrying equipment
Technical regulations
DIN 4132 Craneways; steel structures; principles for calculation, design and
construction (valid for a selection of permissible stresses
dependent on material, loading group, stress relationship and
notch condition)
DIN 15017 T1 Standards draft of Nov. 1975; customer specifies that this is to be
considered binding for calculation of otherwise unspecified drive
elements.
DIN 15018 T1 Cranes; steel structures; verification and analyses
DIN 15018 T2 Cranes; steel structures; principles of design and construction
DIN 15019 Cranes; stability
DIN 15020 Hoisting machines; principles relating to rope drives
DIN 15030 Lifting equipment; acceptance testing of crane units; Principles
DIN 18800 Structural steelwork; (if not stipulated by specification and DIN
15018 T1 to T4)
DIN 18800 T7 Structural steelwork; execution (if not stipulated by specification
and DIN 15018) and constructor's qualification
DIN EN 15011 Draft - Cranes; bridge and gantry cranes (valid subordinately to
DIN 15018)
DIN 31001 T1 Safety devices; concepts, safety clearances
VDI 3423 Availability of machines and equipment
VDI 4412 Cableless control of cranes
VDI 3575 Path limiters for cranes
VDI 3570 Overload safeguards for cranes
VDI 3571 Manufacturing tolerances for bridge cranes
BGR 117 Working in confined spaces
BGR 149 Equipment safety regulations for the cableless transmission of
control commands
BGG 905 Testing of cranes
BGG 956 Examination book for winches, lifting and pulling equipment
ZH 1/547 Guidelines for radio remote control systems of cranes
SEB 660 035 Crane with cableless control
SEB 664 035 Crane and crane runway; tolerances for the track wheel-rail
transport system (tolerance class 3 is valid when not otherwise
indicated in the forms for the TH-N measurement protocols)

Bridge Crane TKCSA
ThyssenKrupp CSA
Local Standards
Local Safety Regulations will be applied in case they are stronger than the regulation as
specified before.
1.6 Declaration of conformity / Risk analysis

Bridge Crane TKCSA
ThyssenKrupp CSA
A declaration of conformity must confirm in writing that the cranes to be delivered

adhere to the following standards:
Machinery Directive 98/37/EC as from 01/01/1995 (9th GPSGV - Machine Ordinance)
EMC Directive 89/336/EEC as from 01/01/1996 (EMC act)
Low Voltage Directive (LVD) 73/23/EEC as from 08/20/1974 (1st GPSGV)

DIN EN 60204-32 Safety of machinery; electrical equipment of machines;
requirements for hoisting machines
DIN 15020 Hoisting machines; principles relating to rope drives
DIN 15018 T1 Cranes; steel structures; verification and analyses
DIN 15018 T2 Cranes; steel structures; principles of design and construction
Under the EC Machinery Directive, the manufacturer of the cranes is obliged to conduct
a risk assessment to determine all the risks associated with his machinery. He must
design and construct the cranes in the light of this assessment.
If the cranes are supplied from the EC economic zone, CE markings are to be placed on
the crane and the control unit.
1.7 Employment of subcontractors
Subcontractors for the electrical or steel construction works may be employed only after
stating the names of the companies and with the approval of TKCSA. For this purpose,
qualification certificates DIN 18800 T7 class E8, welding and procedure tests must be
submitted. Furthermore, we reserve the right to carry out an inspection of the production
facilities. Where there has been a previous negative experience, or justified doubts
about the sub-supplier's qualification, TKCSA reserves the right to reject them.
1.8 Date scheduling
Part of commercial contract.

Ready f.
Item Crane.No. Order Delivery Erection Commissioning Operation
1 S100
2 S110
3 S210
4 S310
5 S100
6 S330
7 S200
8 S300
Table 1
2. Tasks
2.1 Tabular listing of crane activities and crane control systems

Bridge Crane TKCSA
ThyssenKrupp CSA
Crane Control Activities Load Load dimensions /

no. designation drawings
S 100 fixed operator cab transport and tipping of full hot metal ladles C.ACV0.SL.1261-
with shaft suspension, and empty hot metal ladles; M0000/EIZ100
view of converter, i.e. filling converter; assembly See drawings
support row B work; repairs, specified in sect. 2.2
S 200 fixed operator cab transport and tipping of full steel pouring ladles C.ACV0.SL.241-
with shaft suspension, and empty steel pouring M000/EIZ001
view of crane S210 ladles; transport of vacuum
vessels; assembly work;
repairs
S 300 fixed operator cab transport and tipping of full steel pouring ladles C.ACV0.SL.241-
with shaft suspension, and empty steel pouring M000/EIZ001
view of crane S310 ladles, charging and removal
of ladles in the turret;
assembly work; repairs
S 110 fixed operator cab in transport and tipping of full scrap containers C.ACV0.SL.1334-
region of top beams and empty scrap containers; M000/EIZ001
support row A with filling converter; transport steel pouring ladles C.ACV0.SL.241-
view of converter and tipping of empty steel M000/EIZ001
support row B, pouring ladles; assembly
work; repairs C.ACV0.SL.251-
M000/EIZ001
S 210 fixed operator cab transport of vacuum vessels; vacuum vessels

centrally beneath assembly work; repairs
crane bridge with view
of crane S200; radio
remote control
S 310 fixed operator cab transport and tipping of steel pouring ladles C.ACV0.SL.241-
centrally beneath empty steel pouring ladles; M000/EIZ001
crane bridge with view assembly work; repairs
of crane S 300;radio
remote control
S 320 fixed operator cab transport of empty and full tundish troughs C.ACV0.CB.222-
centrally beneath tundish troughs; changing M1000/ZAE001
crane bridge with view molds, assembly work; moulds
of crane S330; radio repairs
remote control dismounting chain
S 330 fixed operator cab transport of empty and full tundish troughs C.ACV0.CB.222-
centrally beneath tundish troughs; changing M1000/ZAE001
crane bridge with view molds, assembly work; moulds
of crane S320; radio repairs
remote control dismounting chain
Table 2
2.2 General task description
The cranes listed under section 2.1 serve for the execution of transport processes within
the TKCSA steel works. This also includes such tasks as the conveyance of the entire
production capacity of 5 million tons of pig iron and steel annually, and also the handling
of ladles, vacuum vessels, tundish troughs, moulds etc. The pertinent drawings of the
various load-carrying equipment (ladles, scrap containers, vessels etc.) may be found

Bridge Crane TKCSA
ThyssenKrupp CSA
either in the table above or in the overview of enclosed appendices. In order to ensure
the perfect functioning of this load-carrying equipment, the carrying gear (hooks and
crossbeams) and the characteristics of the cranes should be adjusted accordingly.
Additionally, for cranes S100 and S110 the examination of the converter filling process
must be taken into consideration as shown in drawing C.ACV0.SL.21/EIZ050 through
EIZ055, in order to allow problem-free emptying of ladles and molds. At construction
phase the contractor will reduce the width of ladle beam in the lower area as much as
technically feasible. In this respect, the crane operator's field of view must also be
factored in.
During operation in iron and steel plants, cranes are subjected to exceptional stresses
by dust, heat and radiant heat. During the design of the cranes described here, the
deployment conditions specified under section 4 must fully be taken into consideration.
2.3 Control systems / Operation
The various kinds of control system can be found in the table under 2.1. It must be
possible to safely reach or exit an operator cab in every crane and trolley position.
Unambiguous direction markers for control system elements at crane operator seats or
radio remote control systems must be mounted in the form of permanent symbols or
text in the local language. In the case of radio remote control systems, the direction
markings for crane and trolley traversing must be executed so as to be visible from a
range of over 50 m, in accordance with SEB 660 043.
3. Scope of supply
The scope of supply includes the following performances on the part of the contractor
as regards the 8 bridge cranes listed on page 1:

Bridge Crane TKCSA
ThyssenKrupp CSA
- Design and structural analysis of the cranes and carrying gear, taking into consideration
the complete specification directory
- Supply and assembly of the complete steel and mechanical structure for the cranes and
the carrying gear, taking into consideration the complete specification directory
- Dimensioning, supply, installation and commissioning of the complete electrical
equipment including control systems and the laying of cables, as described in these
specifications
- Emergency stop brakes for the cranes of groups G1, G2 (S301 only) and G4, in
accordance with section 9.2.15.2
- Air-conditioning of the switchgear rooms and operator cabs in accordance with section
10.17
- Heat protection measures in accordance with section 8.4.7
- Overload measurements by means of measuring bolts in accordance with Sections
9.3.1.8 and 10.12 for the cranes
- Weighing facilities in accordance with section 10.12 for cranes S100, S200, S300 and
S310
- Systems for distancing from neighboring cranes in accordance with section 10.2
- Electrical start and end limit stops before the craneway stops in accordance with section
10.2
- Electrical positioning aids in accordance with section 10.16
- Mechanical positioning aids for crane and trolley traversing in accordance with section
8.4.9
- Communication facilities in accordance with section 10.14
- Rope overrun check according to Section 10.9.1
- Ladle underweight triggering for crane S100 according to Section 10.12
- Current supplies in accordance with sections 10.3.1 and 10.3.2
- Fault signaling devices in accordance with section 10.11
- Documentation as described in these specifications (chapter 11)
- Measuring and protocoling the machinery and steel structures in accordance with Section
11.8
- Inspection certificates according to Section 11.7
- Corrosion protection in accordance with chapter 13
- Fire protection measures in accordance with chapter 14
- Test run hoisting gear drive for cranes S100, S110,S200 and S300 in accordance with
section 1.2.2.2
- Training in accordance with section 1.2.7
- Transport in accordance with section 1.2.4
- Site facilities and safeguarding in accordance with section 1.2.3
- Time schedules for the production sequence and assembly in accordance with Section
1.2.3
- Setting the overload safeguard systems and calibration of the weighing system
- Compilation of all mechanical and electrical set values
- Callout availability during a 2 week test period in accordance with section 1.2.5.3
- Risk assessment of all cranes, including the crane vicinity
- Design of setting down arrangement for crossbeams that may be walked on (one for
each crane with crossbeam) in accordance with section 8.4.5
- Platforms for inspection of horizontal guide rollers and in accordance with section 8.2.3.2
- Platforms for inspection of craneway girders and in accordance with section 8.2.3.2
Options:
- Hook opening sensors in accordance with Sections 8.4.6 and 10.7 and 10.10
- 2 programming devices for the elimination of error messages.
- Repair winches for rope changes in accordance with section 9.5
- Threading rolls for rope changes on the 530 t hoisting gear in accordance with section
8.4.5
- Repair cars for dismounting devices in accordance with section 8.2.3.2

Bridge Crane TKCSA
ThyssenKrupp CSA
- Fire fighting system according to National Fire Protection Association for all electrical
equipment room
- Automatic tooth crown lubrication in accordance with section 9.3.2.3
- Platform for maintenance of hall lighting in accordance with section 8.4.10
4. Deployment conditions
4.1 Temperatures / Humidity / Dust load
Crane Hall Temperatu Temperatu Relative Dust load mm

no. re max. re min. humidity max. impacted dust
[°C] [°C] [%] per month
S100 Charging hall A-B 60 10 95 20
S110 Charging hall A-B 60 10 95 20
S200 Ladle handling C-D 60 10 95 20
S210 Ladle handling C-D 60 10 95 20
S300 Loading hall D-E 60 10 95 20
S310 Loading hall D-E 60 10 95 20
S320 Casting bay E-F 60 10 95 20
S330 Casting bay E-F 60 10 95 20
Table 3
Alongside the deployment conditions listed in the table, cranes S100, S200, S300, S320
and S330 are placed under especial stress by the radiation heat from the molten
masses, as well as the hot air rising from the ladles and tundish troughs. This also
applies to a lesser extent to cranes S210 and S310 when transporting empty but still
red-hot ladles.
The highest thermal stress occurs during charging with cranes S100 and S110.
Extremely hot rising air, flame development, deflagrations and high splashes of molten
hot metal and pieces of scrap must be reckoned with here. The technical design in
respect of mechanics, steel structure, electrical engineering and air-conditioning must
be arranged in accordance with the deployment conditions specified above. All
components that might suffer damage under these deployment conditions, or whose
function might be prejudiced, must be protected with heat protection measures or dust
protection devices.
For electrical and mechanical components, the deployment conditions might require
tropical design versions. Therefore, these deployment conditions must definitely be
communicated to the suppliers of these components. This applies, among other things,
to the selection of types of enclosure, insulation classes, seals, corrosion protection etc.
4.2 Weathering
All cranes will be operated in halls. Occasional precipitation from condensed steam,
leakages in the roofs and water entry through the hall ventilation openings cannot be
ruled out. This must be taken into consideration when selecting the protection class for
electrical components outside the electrical operating rooms and for the drives.

Bridge Crane TKCSA
ThyssenKrupp CSA
5. Capacity utilization / Classifications
All cranes are operated in 3 shifts on approx. 360 working days per year. The following
categories result from the number of load cycles and the length of the hoisting heights
and travel distances.
Classification of rope drives in accordance with DIN 15020
Classification of rope drives for main hoists of S100, S200 and S300 in accordance with
FEM 1.001 from 10/01/1998
.
Crane Hoisting Load capacity Weight class Running Classifi-

no. gear [t] time cation
class
S100 Hoist 1 530 L3 T9 M8*
Hoist 2 180 heavy V1 2m*
S200 Hoist 1 530 L3 T9 M8*
S300 Hoist 2 100 heavy V1 2m*
Hoist 1 180 light V3 2m
S110
Hoist 2 100 light V3 2m
Hoist 1 180 medium V2 2m
S210
S310 Hoist 2 60 medium V2 2m
Hoist 3 10 medium V2 2m
Table 4
* When determining rope diameters it must be remembered that it is a hazardous

transportation
Classification of drives in accordance with FEM 1.001 from 10/01/1998
Crane Drive group Weight class Running Drive Power-on

no. time period [%]
Hoist 1 L3 class
T9 M8 40
Hoist 2 L3 T7 M8 25
S100 Trolley 1 L3 T6 M7 25
Trolley 2 L3 T6 M7 25
Crane traversing L4 T8 M8 40
gear
Hoist 1 L3 T9 M8 40
S200 Hoist 2 L3 T7 M8 25
S300
gear
Hoist 1 L1 T9 M8 40
Hoist 2 L1 T9 M8 40
S110
gear

Bridge Crane TKCSA
ThyssenKrupp CSA
Hoist 1 L2 T9 M8 40
Hoist 2 L2 T7 M7 40
S210 Hoist 3 L2 T7 M6 25
S310 Trolley L2 T6 M6 25
gear
Shifting gear L2 T6 M6 25
Hoist 1 L2 T9 M8 40
S320 Hoist 2 L2 T7 M7 40
S330 Trolley L2 T6 M6 25
gear
Table 5
Supporting frameworks
The supporting frameworks are to be classified in accordance with the following table.
Supporting framework classification in accordance with DIN 15018
Crane Supporting Weight class Stress range Classification

no. framework DIN 15018 DIN 15018* Hoist class Stressing group DIN
DIN 15018 15018
Crane bridges heavy S3 N4 H2 B6
S100 Trolley 1 heavy S3 N4 H2 B6
S200 Trolley 2 heavy S3 N4 H2 B6
S300 Carrying gear heavy S3 N4 H2 B6
Crane bridge heavy S3 N4 H2 B6
Trolley 1 heavy S3 N4 H2 B6
S110
Trolley 2 heavy S3 N4 H2 B6
Carrying gear heavy S3 N4 H2 B6
Crane bridges medium S2 N2 H2 B4
Trolley 1 medium S2 N2 H2 B4
S210
S310
Carrying gear medium S2 N2 H2 B4
Crane bridges medium S2 N2 H2 B4
S320
S330
Carrying gear medium S2 N2 H2 B4
Table 6
* Stress range N over 25 years
6. Availability
. Details on the availability to be expected are specified in Annex F.
6.1 Reaction time in the case of functional disturbances

Bridge Crane TKCSA
ThyssenKrupp CSA
In the event of any operating faults occurring that have to be rectified as a matter of
guarantee or warranty by the supplier, a period of 6 hours maximum from the telefax
communication or e-mail being received to the arrival of a competent engineer shall
apply. Inasmuch as no engineer arrives within that period of time, a fault rectification will
be carried out by TKCSA or third parties and the costs charged to the contractor.
These requirements apply on 7 days per week and 24 hours per day. The response
time will be charged to the downtime.
6.2 Fault remedying
The rectification of a single fault may take 12 h max. (including response time) from the
fax communication or e-mail being received. If this period is exceeded, faults will be
rectified by our maintenance department or by third parties, and the costs will be
charged to the contractor.
Inasmuch as a fault causes production restrictions or downtimes, the customer reserves

the right to rectify any such damage immediately by the use of his own personnel. In
this case, the costs for the rectification of any such damage the damage will be claimed
from the contractor on the basis of a verifiable documentation.
6.3 Inventory of spare parts
As factory measure to ensure availability, spare parts will be stocked in accordance with
the specifications of the crane supplier. For this purpose a comprehensive list of spare
parts must be submitted by the contractor 6 months, for spare parts with a delivery time
more than 6 month list to be submitted 2 months, after award of the contract for the
cranes. The documentation for the cranes must be designed such that all wear and
spare parts are listed and can be ordered or produced according to the parts lists and
working drawings. Components obtained from sub-suppliers must be described such
that they can also be ordered by TKCSA directly from the manufacturers.
7. Technical data
The following geometric data for the cranes may be obtained from the crane project
drawings listed on page 1. This applies to:
- Track center gauge,

- Height of top edge of crane rail,
- Rail head width,
- Height to lower edge of roof truss or repair-way or other interfering edges,
- Clearance between crane rail and roof beams,
- Upper hook position for main and auxiliary hoists (operational end position) relative
to middle hook position,
- Lower hook position for main and auxiliary hoists (operational end position) relative
to middle hook position,
- Trolley traversing dimensions for main and auxiliary hoists relative to middle of
crane rail
- Hook clearance between main and auxiliary hoists (with shifting gear when
adjustment distance is given)
- Hook clearance relative to crossbeam lengthwise

Bridge Crane TKCSA
ThyssenKrupp CSA
- Crane end approach

- Buffer height
- Lower edge of crane bridge or of heat shield under crane bridge
- Maintenance basket
- Position of conductor rails (to be filled in later in the course of the project, should
separate guide rails be planned for)
- Arrangement and line of vision of the driver's cabin with respect to mounting, and
height of the operator cab in respect to field of vision
Considering the constructive prescriptions to be assured characteristics, adherence to

the specifications in the project drawings is to be guaranteed. Restrictions to or
deviations from these specifications must be indicated directly at the tendering stage.
The specifications for the hoisting heights are the required operational end positions.
Hoisting and lowering paths, up to the point of the emergency limit switch and the final
backup limit switch, are to be taken into consideration here.
The following table contains further technical data that must be adhered to, which are
not recognizable in the project drawings.
Mechanical / steel construction Unit Group G1 Group G2 Group G3 Group G4

S100 S210 S320
S200 S110 S310 S330
S300
1. Crane structure
maximum bending by test load in accordance with section mm 1/1000 1/1000 1/1000 1/1000
1.2.5.1
lowest natural frequency of crane bridge Hz ≥4 ≥4 ≥4 ≥4
2. Speeds and accelerations of carriages

Max. speed crane traversing gear m/min 80 80 80 80
Mean acceleration and delay crane traversing gear m/s² 0,2 0,2 0,25 0,25
Max. speed trolley traversing gear m/min 30 30 30 30
Mean acceleration and delay trolley traversing gear 0,15 0,15 0,15 0,15
Max. speed shifting gear for trolley 2 (only S310) m/min - - 15 -
3. Track wheels (as per sect. 9.3.2.4)

Minimum number and diameter of crane traversing gear track no. / mm
wheels
Minimum number and diameter of trolley 1 carriage track no. / mm
wheels
Trolley rail for trolley 1 in accordance with DIN 536 -
Minimum number and diameter of trolley 2 carriage track wheels no. / mm

Bridge Crane TKCSA
ThyssenKrupp CSA
Trolley rail for trolley 2 in accordance with DIN 536 -
4. Hoisting gear
Carrying capacity of hoist 1, (classification DIN 15020) t 530 180 180 180
Carrying capacity of hoist 2, (classification DIN 15020) t 180 (S100) 100 100 60 60
(S200/S300)
Carrying capacity of hoist 3, (classification DIN 15020) t - - 10 -
Hoisting speed, hoist 1 m/min 9 9 12 12
Hoisting speed, hoist 2 m/min 9 9 12 12
Hoisting speed, hoist 3 m/min - - min. 12 -
Differential load to be taken into operational consideration t 120 30 30 30
between the opposite hooks of hoist 1 for the layout of the
hoisting gear and the supporting frameworks
Maximum differential load to be taken into consideration t 150 50 50 50
between the opposite hooks of hoist 1 (The maximum load in
the hook is 50% of the load carrying capacity)
Overload switch off at a total load on hoist [1/2/3] t 560 / 190 200/110 200 / 65 / 11 200 / 65
Switch off at a differential load between opposite pulley blocks t 120 30 30 30
in hoist 1
Release slack rope hoist [1/2/3] at weight carrying gear minus t 30 / 3 10 / 2 / 10 / 1 / - 10 / 2
5. Electrical system
Operating voltage of the hoisting gear components V 460±15% 460±15% 460±15% 460±15%
Control voltage V 220 - 250 220 - 250 220 - 250 220 - 250
Signal voltage / PLC V 24 24 24 24
Current supply V 460±15% 460±15% 460±15% 460±15%
Frequency Hz 60 60 60 60
Type of protection in electrical room - ≥ IP20 ≥ IP20 ≥ IP20 ≥ IP20
Type of protection for components located outside (tropicalized - ≥ IP55 ≥ IP55 ≥ IP55 ≥ IP55
version)
Table 7
8. Steel engineering
8.1 Calculation
8.1.1 Fundamentals of calculation
The calculation of the steel supporting framework must be carried out in accordance
with DIN 15 018 and according to the customer's specifications. The calculation must
conform to the approved rules of statical design and strength theory, as well as to the
latest state of technology.
The maximum differential load requirements in accordance with section 7 must be

verified in the appropriate classifications, and this must be taken into consideration
during design and manufacture
The attachment of electrical components to carrying parts must be taken into

consideration in the operational stability proof of the structural analysis.
Stresses to the rope drum caused by shifting shocks after rope failure or by the tripping
of the emergency stop brake (with and without load) must be verified for the least
favorable conditions.

Bridge Crane TKCSA
ThyssenKrupp CSA
8.1.2 Structure and sectioning of the calculation
A detailed list of contents must be included at the front of the static calculation
document. The pages must be numbered consecutively. The calculation must verify, in
clearly sectioned synoptical form, the stability, strength and security of the individual
components as well as of the complete supporting framework including the hoisting gear
frame and supporting means. The calculation must be self-contained. A new calculation
is permitted only as supplement to the previous one. To facilitate checking, the
calculation must contain the necessary explanatory notes, drawings and sketches in
adequate scope. If the calculation is carried out partly or entirely with electronic
computing systems, the computing system must be specified. We reserve the right to
have the calculation checked by TKCSA or by a test specialist for statical calculations.
Any calculation errors discovered must be rectified by the contractor free of charge. If
the affected components have already been manufactured, the cost of alterations or
new production is to be borne by the contractor.
8.1.3 Stress values, cross sections, profiles
The stress values must be determined from the limit values of the forces at the cross
section to select the cross sections and profiles. These determined stress values must
be compared with the tolerated stress values. Stresses resulting from off-center
conditions, force diversions by deflection, kinks, openings and breakouts, as well as the
stresses at load application points, must also be considered and verified.
8.1.4 Load specifications for the crane runway calculation
The calculation must contain in a clear form an overview of all forces which must be
known for calculating and dimensioning the crane runway, for both trolley end positions.
This includes the following:
-Vertical wheel loads for all wheels: Rmax, Rmin

-Forces from off-track running: Smax, y1/1 to y2/16
-Gravitational forces from drive units: Ka, Kr, HM
-Buffer end forces: Pu from crane and trolley traverse
The calculation must also contain all relevant dimensions. This includes:
-Wheel bases,
-Length across the buffers
-Buffer height
The calculation must also specify the stress group and the height of lift class.
Important! The calculation of off-track running forces is to use the maximum track
clearance that can occur, in accordance with the specifications of section 9.3.2.1.
Machining allowances for wear on the rail head and the guide gear are to be added to
the track clearance determined in accordance with DIN 15018.
8.1.5 Verification of the tolerable exceptional loads
The test load determined in accordance with section 1.2.5.1 is to be verified for all
cranes. The permissible stress values for the steel supporting frameworks in

Bridge Crane TKCSA
ThyssenKrupp CSA
accordance with DIN 15 018 Part 1 must not be exceeded in any component when
suspending the loading weights.
8.1.6 Natural frequency
The natural frequencies of the lifting gear must be taken into consideration for designing
the supporting girders. Disturbing superimpositions on the natural frequencies of the
supporting girders must be avoided. The lowest permitted natural frequency of the
crane bridge under load is specified in section 7.
8.2 Design and construction form
The supporting framework must be designed such that smallest possible notch effects
appear at weld joints, cross section changes, etc. If the approval drawings contain
constructions which according to our experience lead to early damage, we reserve the
right to request correction free of charge.
8.2.1 Standards to be observed
For construction and design, DIN 15 018 Part 1 and Part 2 applies in addition to these
technical specifications
8.2.2 Conditions for the running characteristics of the crane and trolley traversing gear
8.2.2.1 Load distribution
The load must be distributed as evenly as possible between the wheels.
8.2.2.2 Observation of the crane runway and trolley rail deviations
Flawless running characteristics and flawless performance characteristics must be

guaranteed for the cranes and crane trolleys for the expected tolerances of the crane
runways. Taking into account the crane runway deviations, the crane must be designed
such that the stress values and wheel loads increase by no more than 10 % and that
the driven wheels do not spin when starting or when applying the brakes. It must be
guaranteed that all track wheels stay on the rails which is to be achieved by constructive
measures. At least one top beam must be provided with a joint for this purpose.
Calculated verification must be provided. Due to the geological properties of the
construction site TKCSA exceptionally large craneway tolerances must be expected.
The craneway tolerances according to SEB 664 035 tolerance class 3 must therefore be
taken into account as a minimum requirement.
In addition to above mentioned tolerances, a deviation of rail gauge +/- 40mm due to
deflection of the building columns has to be considered.
8.2.2.3 Construction precision
Prerequisite for compliance with the tolerances for vertical deviations and track
deviations is that all welding tasks on the steel construction must have been completed
before the track wheel bores are marked out and machined. The tolerances for

Bridge Crane TKCSA
ThyssenKrupp CSA
construction precision are to be obtained from the test protocols in accordance with
section 11.8 . The measurements of the track wheel drillings are to be reported in good
time (see section 1.2.2.1) and will take place in the presence of test personnel
commissioned by TKCSA.
8.2.3 Design stipulations
8.2.3.1 Access to control stands
During the design and execution of access routes to control stands, DIN EN 13586 must
be adhered to.
The ascent from the crane runway to the crane must be possible with one step.
Additionally, the crane bumpers are to be placed high enough (2200 mm over top edge
of crane rail), that persons can climb beneath the buffer. On the crane bridges there
shall also be platforms directly next to or above the crane rail that permit quick and safe
access. Every crane shall have four of the ascents described here at the external
corners. For the expansion of wheels or guide rollers, the platforms shall be able to be
folded away in the respective areas. On four-girder cranes, the ascents to the central
bridge girder shall take the form of ladders that are fitted with a step and trapdoors at
the top. These ladders shall be fitted with ladder guards that prevent reaching out with
expanded metal or metal sheets. The ascents to the operator cabs shall take the form
of stairs. The operator cab platforms shall be designed such that when the crane
traversing end position is reached it is also possible to descend via a stairway installed
gable-end in the hall.
8.2.3.2 Service platforms and dismantling devices
All components affected by maintenance or inspection work, e.g. top pulleys,

compensation rollers, rope drums, ropes, rope fixed points, brakes, couplings, universal
joints, motor guide drums (for main power suppliers and crossbeams), grease nipples,
gear units including the viewing hatches and filling level indicators, current collectors,
switchboxes, terminal boxes, etc., must be visible and safely accessible. The platforms
required for this purpose must be provided and equipped with ascents, hand, foot and
mid-rails as well as automatically closing flap doors at the ascents. If is should be
necessary to use ladders to access walkways or service platforms, these access routes
shall have steps and trapdoors. Ladder descents must be secured with sufficiently large
hatchways, min. 800 mm x 800 mm. As a safety precaution against falling, all
hatchways shall have railings on 3 sides. All hatch covers shall have recessing handles
and automatic locking. All ladders above 2200 mm shall have ladder guards. If ladders
are directly next to platforms, additional protection against falling must be provided (e.g.
higher railings).
All components of the hoisting gear and the traversing gear must be arranged such that
they are readily accessible and can be exchanged with suitable aids and placed ready
for removal. Should easy disassembly with an onsite repair winch (in the hall roof) not
be possible, extension devices (e.g. job booms or trolley girders) must be employed.
These girders are to be arranged such that the dismounting and remounting of the
affected components is possible by chain hoisting, without the necessity of inclined
pulling. The necessary hoisting gear is to be offered individually (see section 3, options).
For access to the 10 t underrunning trolleys (hoist 3) of cranes S210 and S310, service
platforms under the bridge girders must be provided. These must facilitate access to the
trailing cable system, the rope drive and all electrical equipment.

Bridge Crane TKCSA
ThyssenKrupp CSA
For inspections of the throat seams between the crane runway upper frame and the
web plates, inspection possibilities must be provided. Inasmuch as current collector
baskets exist (cranes of group G4), these must be designed accordingly. On the
respectively opposite side of the current collector baskets and in the case of the cranes
in groups G1, G2 and G3, additional maintenance baskets must be provided.
8.2.3.3 Accessibility of electrical equipment
All control cabinets and terminal boxes must be safely accessible by walkways or
platforms. The doors of the control cabinets and terminal boxes open wide enough that
all necessary electrical work can be carried out. Open doors must not block escape
routes. Drives, Eldros, traversing and gear limit switches, distancing equipment, load
cells, transformers etc. must be accessible safely and without auxiliary aids. Cable
ducts that can be walked on must be sufficiently stable and have level, non-slip covers.
For platforms, service platforms and the ascents to them, the specifications of section
8.2.3.2 apply.
8.2.3.4 Accessibility of air conditioning system
For the maintenance of air conditioning units, platforms are to be provided that are
accessible from 3 sides. For platforms, service platforms and the ascents to them, the
specifications of section 8.2.3.2 apply.
8.2.3.5 Rope inspection platforms
All cranes with crossbeams shall have platforms for the purpose of rope inspections that
run continuously between the pulley blocks opposite. The platforms shall have an
ascent with a hatch that opens inwards on one of the long sides. In addition to its rope
inspection function, access to the underside and the lube nipples for the rope pulley
bearing must be guaranteed. The platforms may need to be arranged around the lower
pulley block.
8.2.3.6 Occupational safety
All rotating parts must be protected to avoid accidental contact with parts of the human
body. Should the enclosure of these parts not be possible, the relevant areas are to be
closed off with railings and ascent doors and marked with warning signs reading
"Danger Rotating Parts".
In areas where surfaces that can be walked on rise above the surrounding level, these
barrier railings are to be raised correspondingly.
Railings shall have a minimum height 1100 mm. In areas where surfaces that can be
walked on rise above the surrounding level, the barrier railings are to be raised
correspondingly.
Service platforms shall have railings with foot and mid-rails and automatically closing
trapdoors, which are to be equipped with steps of min. 600 mm in the case of ascent
ladders.
Openings for rope passthrough (e.g. on the rope drum or at the rope attachment points)
must be secured with railings.

Bridge Crane TKCSA
ThyssenKrupp CSA
Hatch covers which are located above descent ladders must be equipped with
recessing handles. As a precaution against the danger of falling, hatch covers must be
surrounded by railings (except on the access side). The hatch covers must
automatically lock in the open position. Handles must be provided at a suitable height
for safe descent.
Safety clearances must be observed in accordance with UVV BGV D6.
Stumbling hazards caused by different platform levels must be avoided. If high steps
are unavoidable, these are to be equalized with sheet metal and marked in color.
The regulations listed in section 1.5 must be complied with.
8.3 Description of general steel structure
8.3.1 Construction notes
It must be ensured that the steel construction and paint coatings are conveniently
accessible for inspection. Concealed weld seams which cannot be inspected are not
permitted on supporting components. Exceptions to this are weld seams in bridge
girders, which are to be covered with insulation. Dirt corners, stumbling edges and water
traps must be avoided. Inaccessible cavities must be hermetically sealed by welding or
bolting. No parts which are not planned in the approved drawings and calculations may
be welded onto supporting components, even if these parts are only intended for
temporary use, e.g. for installation tasks, and would later be removed again. Openings
in the support structure for cables are to be adequately flanged and to be covered at the
friction points so that the cables cannot be damaged. All machinery parts attached to
the trolley frame with bolted connections, including the drum bearing trestles, are to be
secured against loosening with counter-nuts (full height) and fixed with pins. Further
notes on design are to be found in sections 8.3.7.3.2 and 8.3.8.3.
8.3.2 Connecting elements
Hexagon head bolts with nuts must be used. Bolts without nuts are permitted only for
attaching hand hole covers. All bolts must be secured, with the exception of friction-grip
highly pretensioned bolted connections (non-slip connections) with a clamp length to
diameter ratio of > 5:1. Only galvanized bolts, nuts, washers etc. may be used. The
exception to this is the fixtures of stainless steel components, for which the quality of
the connecting elements must correspond to the higher quality of the material.
8.3.3 Cable routes and penetrations
Cable routes (e.g. conduits, troughs, trays) and penetrations must be defined already
during the design phase and entered in the production drawings.
8.3.4 Assembly joints

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Assembly joints may be provided with the approval of the customer only in the places
where they are required for transport or assembly reasons. Assembly joints must be
indicated directly at the tendering stage. Assembly joints must be executed as precision
body-fit bolt connections. The use of SFG connections is permitted only after agreement
with the customer. Proper seating must be ensured for body-fit bolts. All joints must be
fitted together without play, as in the final state, and linked with dowel pins and bolts,
before finish-turning the track wheel bearing seats.
8.3.5 Accessibility of the bolted connections
For the supporting construction, it must be ensured that fixing bolts for attaching the
machine parts and electrical operating material are readily accessible and detachable. If
this cannot be ensured, hand holes with a diameter of at least 125 mm must be
provided. The hand holes must be closed with rubber covers.
8.3.6 Walkways, ascents, passages, protecting hoods
8.3.6.1 Walkways and ascents
Walkways such as catwalks, maintenance platforms, steps, etc. must be covered with
gratings. The maximum permissible mesh size for gratings is 20 x 20 mm. The bracing
strip selected must have a minimum height of 30 mm. Catwalks must have a width of at
least 500 mm. Access routes to control stands must be at least 600 mm wide. All
platforms, covers and top beams must be equipped with foot strips which have a height
of at least 100 mm above the top edge of the catwalk. The height of the railings must be
at least 1,100 mm everywhere. The railings must be made of round steel pipes. The
pitch of stairways must not exceed 47°. The steps must be of nonslip design. Profile
rungs must be used for ladders (e.g. from Graepel). Fine mesh corrugated wire
protective grids must be fitted in the vicinity of danger points. The corrugated wire must
be mounted in a separate frame inserted into the protective wall.
8.3.6.2 Protecting hoods
Protecting hoods, e.g. for gear wheels, couplings, universal joints and brakes must be of
fold-open design, or they must have inspection port covers of adequate size and which,
as far as possible, close securely under their dead weight. Removable protecting hoods
must be of an easily manageable weight (max. 20 kg per segment). The inspection
ports must be large enough to allow monitoring of all parts which are subject to wear or
which must be checked for firm seating. Protecting hoods which are installed in the
traffic and working area must permit walking in and they must not constitute any
stumbling hazard. Hinged protecting hoods are to be attached with strong hood holders
and strap hinges, and shall have limit switches that bring about the shutdown of the
relevant drive unit.
8.3.7 Materials
Only materials with conformity markings and clear material certificates may be used.
Components which lose their conformity marking by separation must be remarked by

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qualified personnel. The proof of equivalence must be presented in accordance with

DIN 18200.
8.3.7.1 Steel grades to be used
For structures that will not be exposed to heat stress, steel grades are to be used as
described in DIN EN 10025 and DIN EN 10164. Components that will be exposed to
temperatures above 100 °C, (e.g. crossbeams) are to be manufactured from heat
resistant pressure vessel steel in accordance with DIN EN 10028. Fine-grained
structural steel with a strength of over 355 N/mm² may only be used with the agreement
of the customer. SEW 088 must be observed when machining fine-grained structural
steel. Special conditions apply to lamella hooks in accordance with section 8.4.6. The
steel grades selected and their characteristics must be certified with inspection
documents 3.1 under EN 10204 in accordance with section 11.7 , in so far as no other
more extensive requirements are specified in the following sections. The cross section
of a supporting element may be welded together with steels of various grades and
quality groups, only with the approval of the customer.
For equipment manufactured in Brazil, a list of equivalent Brazilian materials will be
prepared by the supplier for approval by TKCSA (3 weeks).
8.3.7.2 Welding filler metals
The weld filler materials must be matched to suit the basic materials to be welded, so
that the properties of the welded material correspond to those of the base materials as
closely as possible. Subject to this condition, it is permissible to build up the weld seam
with various weld filler materials, even if the welding method is thereby changed.
8.3.7.3 Selection of steel grades
8.3.7.3.1 Steel grades for bolted components
For bolted components (holes bored) materials of quality above S235JR in accordance
with DIN EN 10025 or above P235NH in accordance with DIN EN 10028 are permitted.
8.3.7.3.2 Steel grades for welded components
For welded components the material S235JRG or higher quality is permitted in

accordance with DIN EN 10025. For components that will be exposed to heat stress,
the material P235NH or higher quality is permitted in accordance with DIN EN 10018-3.
As regards the limit values for chemical composition in accordance with DIN EN 10025,
for materials up to a minimum yield strength of 275N/mm², the max. limit on the
proportion of sulphur and phosphor 0.025% applies. For materials up to a minimum
yield strength of 355N/mm² the max. limit on the proportion of sulfur and phosphor is
0.015%, and of carbon is 0.18% applies (with the addition of Ti, Ni or V, C ≤ 0.03% is
permissible). These requirements must be passed on to the steel suppliers. The
requirements for the chemical composition of steel in accordance with DIN EN 10028
remain unaffected by this.

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8.3.7.3.3 Selection criteria
The following influencing factors must be taken into consideration for selecting the
materials:
- Accumulation of weld seams in confined regions,

- Places in the construction where major stress peaks cannot be avoided,
- Components in which two dimensional or three dimensional stress conditions cannot
be avoided during operation, e.g. components with crossing seams when both
seams carry large longitudinal or transverse stress values, and the mostly rounded
transitions from high to low girder parts at the ends of crane bridge girders,
- Places where concentrated forces act, e.g. at the end truck components for taking
up the traversing gear,
- Large cross-section alterations,
- Connections which can only be made under high stress.
Components that are thus placed under additional stress are to be manufactured from
materials of a correspondingly higher quality. The same applies to components which
have a direct effect on the safety or serviceability of the crane.
The selection of steel quality group for welded components must be made in
observance of DASt directive 009 in connection with the conformity directives for steel
engineering. The influencing factors assumed here (input temperature, stress condition,
strain rate, degree of cold reduction, production thickness, safety requirements, non-
homogeneity of toughness) must be documented in an annex to the draft for purposes
of traceability. The material requirements determined by the draft author, and the
resulting material tests and the necessary material test certifications must be noted in
the parts lists.
The DASt Guideline 014 must be observed to avoid lamellar tearing of components
which are stressed in the thickness direction. Plates which are stressed in the thickness
direction with a thickness > 30 mm must always be tested for doubling and made from
plates for which a test certificates from weld bead bend tests has been issued. Sheets
that are stressed in through-thickness direction in a whole or partially, need a certificate
about a tensile test in through-thickness direction, quality grade Z 35 following
DIN EN 10164.
8.3.8 Technical requirements for welding
8.3.8.1 Requirements imposed on the manufacturer
The manufacturer must be in possession of a manufacturer's qualification in accordance

with DIN 18800-7 Class E with a scope of application in accordance with DIN 15018 and
the corresponding welding method qualifications in accordance with DIN EN
ISO 15614-1.
Manufacturers qualification may be in accordance with ASME-Code provided the
requirements are equivalent with the classification as asked for in the specification.

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Details to be agreed by welding experts of both parties at later stage. Sample of welding
process and welder qualification will be sent.
8.3.8.2 Quality assurance
The standard DIN EN ISO 3834-2 applies to the quality assurance of welding work
taking in account about ASME-Code above.
8.3.8.3 Drawings
Symbols, joint forms and dimensioning have to be carried out following DIN EN ISO
9692-1 and DIN EN 22553. The welded seam quality groups following DIN EN ISO
5817 must be indicated in the drawings. Classification group D is not permitted. When
selecting the classification groups, the recommendations of the DVS sheet 0705 have to
be taken into account.
If the drawings do not specify anything to the contrary, DIN EN ISO 13920 applies with
regard to the general tolerances in the welded construction:
Linear measure group B

Degree and flatness group F
Flame cuttings must be carried out in accordance with DIN EN 9013:
Dynamically loaded designs Grade 1

Primarily statically loaded designs Grade 2
All drawings with details of welded seams are to be checked and signed by a welding
supervisor. This welding supervisor must be qualified in accordance with DIN EN 719
and belong to the production department.
All drawings with welded constructions must contain information about the seam
thicknesses of non-dimensioned weld seams.
Inasmuch as heat treatments must be carried out in welded constructions, the drawings
must contain the relevant details.
Test certificates for welded constructions must be completed in accordance with Annex
QM10.
8.3.8.4 Tests
After being cut to length, the belts must be subjected to edge zone and center zone
testing in accordance with DIN EN 10160, and quality classes E4 and S2 must be
tested with ultrasound. The test results must be documented.
Before technical weld processing, web plates must be subjected to a peripheral US test
pursuant to DIN EN 10160, Quality Class E4. The test results must be documented.
Where no further requirements are stated in this performance specification or the

production drawings, at least 10% of the weld seams of all supporting components must

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be subjected to ultrasound and metallic powder testing, in accordance with DIN 18800
part 7.
If nondestructive testing is carried out, then the standard DIN EN 12062 applies.
Ultrasonic tests must be carried out in accordance with DIN EN 1712 method 2, and
DIN 1714. Reflections below the registration limit that, due to their linear expansion,
lead one to suspect an error of procedure are to be assessed by opening the welded
seam in sample test locations and carrying out an evaluation in accordance with DIN EN
ISO 5817 class B.
Radiographic examination following DIN EN 1435, test classification B, radiograph

quality classification B. Permissible limit values are to be taken from EN 12517.
Dye-penetrant inspections are to be carried out in accordance with EN 571-1.
Magnetic particle testing is to be carried out in accordance with EN 1290 and EN1291.
The evaluation of errors must take place in the specified assessment groups
DIN EN ISO 5817.
8.3.8.5 Production monitoring
In supplement to section 1.2.2.1 it is to be noted that TKCSA reserves the right to

inspect welding of every kind with means considered appropriate. If nondestructive
testing discovers faults, the weld seams affected are to be opened by the contractor at
various points for spot checks. If the fault is confirmed, the contractor is to open the
entire seam. It must subsequently be agreed with TKCSA whether restructuring of the
failure points is possible or whether new manufacturing is necessary. In either case, the
costs are to be borne by the contractor.
8.4 Description of specific steel structures
For purposes of simplification, the cranes will be organized in groups for the following
chapters and sections
Group Description applies to:

GA all cranes in this performance specification
G1 S100, S200, S300
G2 S110
G3 S210, S310
G4 S320, S330
Table 8
8.4.1 Crane girders

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8.4.1.1 Type and manner of construction of the crane girders
General description for all crane girders (group GA)

All crane girders must be designed as welded internally passable box girders. Apart
from the central girders of the 4 support cranes, all crane girders shall have 2 ascent
doors. Electrical rooms in crane bridges have separate, dustproof doors. The areas in
front of the traversing drives of the cranes are similarly to be enclosed and fitted with
doors. Adequate air supply for the traversing drives is to be ensured with ventilation
grates. All crane girders must be designed such that they may be walked on from
above. The catwalks on the crane girders must be equipped with foot rails, two mid-rails
and hand rails on both sides. Halved I rolled sections with 100 % UT and MT inspected
full penetration welds are to be fitted under the crane trolley track rails. The weld seams
between the top and bottom booms and the web plates must be made as double SFG
seams. The similarly passable central girder of crane S110 shall have ascent hatches in
the upper frame beam.
The connections between the crane girders and the top beams must be made with
bends. Adequate numbers of stiffeners are to be welded into these bends (see figure 1).
Plate thickness jumps in this area are to be executed with crossovers in a ration of 1:4.
Fig. 1
The supports of the festoon cable systems must be designed such that contact between
the trailing cables and the supports is prevented under all accelerations and
decelerations encountered during normal operation. For the protection of the trailing
cable in cases of contact with exceptional delay, e.g. impact against the buffer, the
supports shall have additional deflectors. The support feet are to be welded to the upper
frame beam with stiffeners. In the area of the support feet, bulkhead plates or stiffeners
must be provided under the upper frame beam. Above the weld joint, the supports shall
have a flanged joint with bolts.
All traversing drives shall be fixed to brackets with anchor rails. The anchor rails must
be selected in accordance with the dimensions of TH-N 441 360 and must permit
displacement in the direction of the motor axle.
In addition to this general description, the following stipulations apply to the individual
groups.

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Group G1
The cranes of this group shall be manufactured as 4 support bridge cranes. The two
central bridge girders must thereby be so manufactured that the auxiliary trolley may
traverse under the main trolley. The two central crane girders shall each have 2 trolley
rails (one for trolley 1 and one for trolley 2) . The trolley rails for the main and auxiliary
trolleys shall both be at the same height level. The clearances of the bridge girders shall
be selected such that the ropes and lower pulley blocks do not impact against the bridge
girders, either under normal operating conditions or in the case of emergency stop
braking and impact against the buffer.
Group G2
As for G1, however the central girders shall only have one trolley rail for trolley 2.
Additionally, the height levels of the trolley rails for main and auxiliary trolleys may differ.
Group G3
Manufacture as two-girder bridge crane for one trolley with 2 hoisting gears. On each of
the bridge girders, an I section shall be bolted onto the underside as a traversing track
for the 10 t underrunning trolley. The bolts must be secured against loosening. Stops
with rubber buffers must be mounted on the ends of the traversing track.
Group G4
Manufacture as two-girder bridge crane with one trolley.
8.4.1.2 Crane bridge camber and deflection
The crane bridge girders must be cambered such that they have the specified camber
subsequently, after mounting them on the crane runway in the non-loaded state (trolley
in the starting position without load). This camber must be depicted in the drawings and
entered in a measuring record in accordance with TH-N 236 500. The superelevation is
to be selected such that it corresponds to the bending of half the useful load and the
weight of the trolley, including carrying gear. Use the test load calculated in accordance
with TH-N 560 500 for determining the deflection. The maximum permitted deflection
specified in section 7 must not be exceeded.
8.4.1.3 Accommodation of the electrical equipment
As far as possible, the electrical equipment of the crane must be installed in a box girder
taking DIN EN 60204-32 into consideration. An enclosed, dustproof contactor room,
insulated on all sides, is to be installed in this box girder, which must have closeable
doors on both sides. The doors must open from inside at all times (panic locks).
Alternatively, the crane electrical systems may be installed in a separate container, for
which the conditions stated above apply in the same manner. The possibility of
disassembling the largest electrical components must be ensured through the
placement of hatchways.
Electrical equipment rooms must be provided with non-slip electrically insulating floor
coverings made of rubber or PVC.

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Electrical resistors must be located on the box girder or on special platforms. The hand
rails as well as the knee and foot rails must be continued behind these components to
exclude the danger of falling when carrying out repairs.
8.4.1.4 Lining strip holders
Holders must be attached for the removable lining strip in front of the switching plants.
The lining strip must be secured in accordance with DIN EN 60204-32.
8.4.1.5 Passages and bulkhead openings
The free passage height must be at least 2000 mm. The bulkhead openings must not
be smaller than 1600 mm x 700 mm. Opening must be provided in the bulkheads for the
cable penetrations.
8.4.1.6 Access and disassembly hatches in the box girders
The box girders are equipped at both ends with entrance doors with closures. If the
traversing gear is accommodated in the girder, additional dismantling hatches must be
provided in the top frame beam. The size of these hatches must be large enough to
permit replacement of the driving gears and frequency transformers without difficulty.
The dismantling hatches must be equipped with recessed handles and locking levers.
The bolt fittings of the hatch covers must not protrude upwards. The flap doors must be
provided with warning signs reading "Warning! Danger Rotating Parts!"
8.4.1.7 Rails for crane trolleys
8.4.1.7.1 Rail form
Rails of Form A in accordance with DIN 536 must be used. The shapes may be
obtained from the project drawings. The trolley rails do not count as part of the
supporting cross section.
8.4.1.7.2 Steel quality
Crane rails of Form A in accordance with DIN 536 Part 1 made of steel with a tensile
strength of at least 690 N/mm 2 must be used.
8.4.1.7.3 Rail joints
The trolley rails and operator cab rails should be delivered as far as possible as single
continuous rolled sections. If joints are unavoidable in longer runs, they should be made
by thermite welding. Directive SEB 368 100 must be observed.

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8.4.1.7.4 Fixing of rails
The trolley rails must be installed on an elastic support with steel core. The rail supports
are to be manufactured in accordance with the wheel loads determined and the
temperatures stated. All rail clamps used are to consist of two parts with adjustable top
parts. The lower parts of the clamps are to be fixed to the rolled section installed on the
crane girder upper frame beam with through-bolts. The adjustable top parts of the
clamps are to be selected with elastic hold-down devices. The dimensioning and the
clearances of the rail clamps must take place under the stipulation that the off-track
running force of the trolleys is only transmitted by one trolley track wheel. Before the
fixing holes are bored, the trolley rails must be laid and aligned. The adjustment range
of the rail clamps allows later resetting. The bolted connections of the lower clamp parts
must be secured against loosening.
Eccentric clamps are not permitted.
When insulating bridge girders, it should be remembered that seeing into the areas in
which the rail clamp bolts are located must be possible. For this purpose, it must be
possible to remove and replace the insulation in the relevant areas without damaging it.
As protection against displacement of the trolley rails in the longitudinal direction, cams
must be attached on the crane girders in front of the rail ends.
8.4.2 Top beams
The following applies to the top beams of all cranes in group GA:
Bolted joints that are fitted to the top beams must be fixed with dowel pins. All highly
pretensioned bolted connections on the top beams must be secured. Hand holes must
be closed.
The top beams shall have hydraulic buffers on both sides to absorb the kinetic energy
from an impact at 100% crane traversing speed with the trolley in starting position. The
buffer damping shall be hydraulic. The reaction force is to be supplied by a nitrogen
spring. The stroke distance of the buffer must be min. 600 mm. The buffer heights
specified in the project drawings must be adhered to.
The dimensioning of the top beams must take place for the maximum attainable buffer
end force.
The top beams must be equipped with brackets or recesses for lifting the crane. The
required bracket height must be agreed with the customer. The press application points
must be made strong enough to permit lifting of the crane in any position of the trolley.
The press application points must be marked with the maximum supporting forces.
Wheel break supports with a vertical distance of 30 mm from the crane rail must be
attached to the top beams. These must be dimensioned such that if a track wheel,
carriage or upper link breaks, no consequential damage to the crane results. The wheel
break supports are to be attached to the top beam with bolted joints, so that a change of
track wheels is possible after disassembly.
On the conductor rail side, massive deflectors are to be mounted under the top beams
for the protection of the conductor rails. These must securely prevent a collision of main
and auxiliary hoist ropes, hooks and crossbeams with the conductor rails.

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groups.
Group G1
These cranes shall have top beams to take 16 track wheels on each side. The
calculation of the track wheel diameter is to be determined in accordance with section
9.3.2.4 ; the minimum requirements of section 7 are to be adhered to however.
2 track wheels are to be mounted into each track wheel link, in accordance with TH-N
565 651. Two of these track wheel links are to built into each upper link. Supports are to
be provided under the top beams to prevent the upper links from turning over if a track
wheel or track wheel carriage fails.
In group G1, the top beams shall have jointed connections with connecting rods on both
crane runway sides. The connection joints shall have exchangeable bushes and it shall
be possible to relubricate the pins.
The bearings and axles of the carriages, upper links and connecting rods and the
connecting rod beams must be constructed such that the maximum off-track running
forces can still be transmitted as operating load under the least favorable possible crane
runway tolerance conditions.
The lubricating pipes of the connecting joints and wheel bearings are to be arranged
such that relubrication can be carried out from one of the crane walkways. As many
lubricating points as possible are to be arranged centrally in a block. Every end user
shall have its own pipe. Branching points are not permitted.
It is to be ensured that every track wheel carriage can be removed quickly and without
separating the top beam or dismantling the connecting rods.
For the laying of cables, cable ducts with 15% reserve space are to be provided in the
top beams. In the area of the connecting joints, the cable ducts shall have transitions
that can follow the compensatory movements of the top beams. In the cable ducts, heat
resistant mats are to be laid under the cables. The cable ducts are to be covered with
removable sheets that are secured against falling.
In accordance with section 8.4.6, the cable ducts are to be protected by heat resistant
plates.
Group G2
Execution as for G1, however with the number and size of the carriage wheels as
indicated in section 8.4.4. Whether connecting rods are to be used, and then how many,
is to be agreed with TKCSA, dependent on the design of the top beam. If connecting
rods are deployed, these must not be put under stress by vertical transverse forces
(e.g. from the wheel load of trolley 2).
G3 and G4
Execution as for G1, however with the number and size of the carriage wheels as
indicated in section 8.4.4. Only one side of the end carriage shall have 2 connecting
rods. The selection of joint sides is to be agreed with TKCSA.

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8.4.3 Trolley frames
The following applies to all trolley carrying gear (group GA):

Trolley frames must be manufactured as torsionally stiff welded structures. The trolley
frames and the trolley buffer stops must be dimensioned such that the buffer impact
force can be absorbed when the trolley runs onto the buffers at 100% traversing speed.
The buffers are to be dimensioned such that they can absorb the kinetic energy thus
arising. The buffer damping shall be hydraulic. The reaction force is to be supplied by a
nitrogen spring. The load must be distributed as evenly as possible between the wheels.
The driven wheels must take up at least 25% of the entire load in every loaded state.
The trolley frames are to be completely covered, except for the rope openings.
Openings for ropes must be provided with foot rails. The size of openings for ropes
must be selected such that even in the case of pendulum motion the ropes do not come
into contact with the trolley frame. The edges must be designed such that no ropes will
be damaged even in the case of pendulum motion resulting from buffer impact or
oblique pulling.
Negative notch conditions are to be avoided for the trolley designs. This applies in
particular to the corners of the trolley frame.
Surfaces on which mechanical components are mounted must be prepared by

machining.
The cross sections of the driving arms of the festoon cable system must be
dimensioned such as to avoid vibrations. They must be provided with vertical
compensation permitting lifting of the trolleys for replacement of track wheels without
dismantling on the driving arm.
The trolley frame must be equipped with brackets or recesses for lifting the trolleys. The
required bracket height must be agreed with the customer. The press application points
must be marked with the maximum supporting forces. The distance between the rail top
edge and the trolley frame must be at least 30 mm. Wheel break supports with a vertical
clearance of 30 mm must be attached underneath the trolley frame. The press forces
necessary for lifting must be indicated on signs.
Wheel break supports with a vertical distance of 30 mm from the crane rail must be
attached to the top beams of the trolley frame. These must be dimensioned such that if
a track wheel, carriage or upper link breaks, no consequential damage to the trolley or
the crane bridge results. The wheel break supports are to be attached to the top beam
with bolted joints, so that a change of track wheels is possible after disassembly.
The crane trolleys (hoisting gear frame) shall have railings all around and ascents from
2 crane girders. In the case of group G1, the ascents over both traversing gear frames
to the hoisting gear frame shall be accomplished with stairways. The passable areas of
the traversing gear frame (group G1) shall likewise be equipped with railings. It must be
ensured that the traversing drive is accessible. If necessary, descents from the hoisting
gear frame shall be provided for this purpose. The ascents shall have self-closing
trapdoors.
Cable routes that are laid in the passable areas shall be designed with stable, non-slip
covers. Cable ducts shall be laid out with heat resistant mats.
It must be possible to reach or exit all crane trolleys at either side and in any trolley
position.

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All machinery parts attached to the trolley frame with bolted connections, including the
drum bearing trestles, are to be secured against loosening with counter-nuts (full height)
and fixed with pins.
The lubricating pipes of the wheel bearings are to be arranged such that relubrication
can be carried out from the bridge walkways or hoisting gear platforms. As many
lubricating points as possible are to be arranged centrally in a block. Every end user
shall have its own pipe. Branching points are not permitted. The same applies to the
lubrication of the rope pulley bearings in the top pulley blocks and the central pins of the
compensation link. Lubrication takes place here, however, from accessible points on the
hoisting gear platform.
The compensation rockers are to be protected against accidental interference with

removable covers or cages. For the inspection of the rope fixing points and the
lubrication of the pins, lockable openings in the cages are to be provided.
Rotating parts of the trolleys such as e.g. universal joints, crowned tooth couplings and
brakes are likewise to be protected from accidental interference with protective cages.
In the case of universal joints and jack shafts, these cages are to be fixed to
substructures that simultaneously serve as support and safeguards.
All traversing drives shall be fixed to brackets with anchor rails. The anchor rails must
be selected in accordance with the dimensions of TH-N 441 360 and must permit
displacement in the direction of the motor axle. All hoisting gear motors are to be
assembled on 2 pairs of consecutively stacked anchor rails, one oriented toward the
motor axle and one perpendicular to it. For the orientation of the drive units, cleats with
adjusting bolts are to be provided at the mounting positions. All mechanical components
in the hoisting gear are to be set on spacers that are min. 15 mm thick and allow
subsequent height adjustment.
The diameter and number of the track wheels are to be determined in accordance with
section 9.3.2.4; the minimum requirements of section 7 are to be adhered to however.
The heat protection measures specified in section 8.4.6 must be observed.
groups.
Group G1 / Trolley 1
The following additionally applies to group GA:
The trolley frames consist of 3 assemblies, which comprise 2 traversing gear frames
and one hoisting gear frame.
In one side of the traversing gear frame, two track wheel links are housed whose
wheels run on the outer trolley rails of the central bridge girder. To compensate for
irregularities in the runway, the opposite side of the traversing gear frame shall have an
upper link in a jointed bearing to take 2 further track wheel links whose wheels run on
the trolley rails of the outer bridge girder. The upper links shall have supports to prevent
consequential damage from resulting if the track wheels or traversing gear carriage fail.

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In those areas in which ropes could impact against the traversing gear frame, wear-
resistant plastic liners or plates are to be mounted. Prominent edges in these areas are
to be blunted by mounting them with ¾ pipe sections.
The pressure plates for taking the load cells shall be located on the traversing gear
frame (see section 10.12). The pressure plates are to be suitable for the load cells and
must allow the load cells to be able to follow the maximum possible horizontal and
vertical displacements between the traversing gear frame and the hoisting gear frame.
The bends in the contact surfaces between the pressure plates and load cells must be
selected such that the load cells are automatically returned and centered. The horizontal
fixing between the traversing gear frames and the hoisting gear frames shall be
achieved with 6 transverse guides per trolley. To secure the position of the hoisting
gear, every hoisting gear frame shall have one transverse guide in the direction of
trolley traversing and 2 transverse guides in the direction of crane traversing. To avoid
squeezing from deformation of the hoisting gear platform, arising from bending under
loads, the transverse guides are to be placed as close as possible to the load cells. The
subplates of the transverse guides shall be attached with secured bolted connections
and pins. All transverse guides shall have clevises that can be relubricated on both
sides. The alignment of the guides shall be achieved with lining plates at least 15 mm
thick. The lining plates, the subplates for the transverse guides and the connecting
brackets on the hoisting and traversing gear frames are to be mechanically machined.
After the alignment, the lining plates are to be attached. For the dimensioning of the
transverse guides, all influences from the operational loads must be taken into
consideration, as well as shaft breakage in the hoisting gear, rope breakage, emergency
stop braking of the hoisting and traversing gear, and crane and trolley buffer impact. For
exchanging load cells, setting points for presses must be arranged and marked.
The hoisting gear frames sit on the load cells with pressure plates in the manner
described above. The hoisting gear frames are to be manufactured in rigid torsion proof
steel sheet design. In a loading test with a test load, in accordance with section 1.2.5.1,
the bending of the hoisting gear frame must measure max. 1/1000 of the length
between the detectors. The hoisting gear frames must be manufactured such that
vibrations coming through the hoisting gear drive unit do not give rise to resonances.
The welding sequence and manufacturing tolerances for the hoisting gear frames must
be selected such that an accumulation of steel structural tolerances does not negatively
influence the positioning of mechanical components, and such that a symmetrical rope
run-off can be guaranteed The complete hoisting drive shall be constructed on the
hoisting gear platform. This also includes the top pulley blocks and compensation rocker
assemblies with the rope fixing points. The compensation rocker assemblies shall have
retaining blocks with hydraulic damping systems in accordance with DIN EN 1449-2.
These retaining blocks, and all other carrying gear elements, are to be dimensioned
both for the loading of the rope rocker assembly from operational compensation
movements and for the loading arising from the shifting impact after rope failure under
the least favorable conditions. The complete absorption of the kinetic energy for the
shifting impact at maximal deflection of the compensation rocker assembly must be
verified by calculation. The vertical heat protection (converter side) of the crane S100
shall have doors that allow the lateral disassembly of the hoisting gear motor.
Trolley 1 shall be designed with 2 rope drums, under whose flanged discs massive
supporting rollers are to be mounted that can catch the rope drum in the event of the
pulley journal breaking under full load. These supporting rollers shall be so long that the
rope drums can be placed on them, in a pulled-out state, when the drum coupling is
being changed and do not need to be dismounted. The rest of the steel structure must
be accommodated to such a repair.

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The pivots of the rope drums shall lie parallel to the crane bridge girders. The axes of
the top pulley blocks and compensation rocker assemblies shall lie parallel to the
direction of crane traversing.
For mounting the emergency stop brakes for the rope drums, there shall be brackets
that provide a stable and easily accessible position for the brakes. It must be possible to
shift the brakes down in order to change the drum couplings.
For pulling up the rope fixing points when the ropes are changed, locking facilities for
the electric winches must be provided next to the compensation rocker assemblies, in
accordance with section 9.5. Furthermore, in front of the run-out side of the rope drums,
where the rope grooves begin and end, there must be lifting lugs to which load ropes
can be attached during rope changes.
Group 1 trolley 2
These trolleys are to be fabricated as welded constructions. In addition to the
descriptions under 8.4.3 group GA, the following also applies to group G1 trolley 1 in
regard to:
 Rope protection measures

 Construction with hydraulic damping of the compensation rocker assembly
These trolleys shall each have one rope drum, whose axis is aligned in the direction of
crane traversing. The same applies to the rope pulleys of the top pulley block and the
compensation rocker assembly. Where the wheel calculations in accordance with
section 9.3.2.4 permit, these trolleys should be constructed in a 4-wheel design. If the
required wheel diameter is > 1000 mm, an 8-wheel design with track wheel links should
be used.
Group 2 (S110) trolley 1

As for group 1 trolley 2, however, the position of the rope drum axis may be varied. The
position of the rope pulleys in the top pulley block remains the same.
The carriage is to be placed on stands in order to make sufficient space for trolley 2.
The crane trolley is to be equipped with 8 wheels. The track wheel diameter is to be
determined in accordance with section 9.3.2.4 and must fulfill the minimum
requirements of section 7. The track wheel bearing is to have track wheel links in
accordance with section XXX. For the trolley traversing drive, passable platforms are to
be mounted at the 4 corners of the crane trolley.
Group 2 (S110) trolley 2

As for group 1 trolley 2, however in 4-wheel design and with compensation rocker
assembly and rubber buffers.
Group 3 (S210 and S310)

As for group 1 trolley 2, but with two sets of hoisting gear on one crane trolley and with
compensation rocker assemblies and rubber buffers. The pivots of both rope drums and
of the rope pulleys in the top pulley block lie in the direction of crane traversing. The
crane trolleys are to have 6 or 8 wheels. The track wheel diameters are to be
determined in accordance with section 9.3.2.4 and must fulfill the minimum

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requirements of section 7. If track wheel links are used, these are to be selected in
accordance with section 8.4.4. The 10 t auxiliary hoists shall have underrunning trolleys
Group 3, addition only for S310

The structure of the crane trolley on crane S310 is to be designed as a double frame for
the installation of 4 loading cells. Paragraph 4 from group 1 trolley 1 applies to the load
cells, pressure plates and transverse guides. It is also possible to set up the main
hoisting gear mechanism on a double frame.
For tipping the ladles, crane S310 shall have a motor-adjustable top pulley block (at
crane S310 the horizontal adjustment between the hook blocks can be carried out
alternatively by placing the aux. trolley on the main trolley). This top pulley block shall
stand on its own carriage frame, which shall travel with 4 flanged wheels on a frame
below the trolley frame. For access to the top pulley block and the actuators, a passable
platform is to be mounted underneath the trolley frame. The descent to this platform is
to be covered by a hatchway. The flanged wheels are to be selected in accordance with
section 9.3.2.4 and are to run on rails in accordance with section 8.4.1.7. The track
length is to be selected such that a change of the hook clearance between hoist 1 and
hoist 2 from 3200 mm to 4200 mm is made possible. Mechanical end limits with rubber
buffers are to be provided for the carriage.
Group 4
As for group 3 (S210 and 310)
8.4.4 Track wheel links and upper links
All track wheel links are to be manufactured as fabricated constructions in accordance

with TH-N 565 651 and the standard drawings contained therein. The principle of link
bearings can be adopted for the upper links, but it requires appropriate dimensioning.
The load introduction points must be reinforced with thick-walled sheets.
A track wheel link design in solid-web construction is also possible after consulting
TKCSA, provided the dimensions in accordance with TH- N 565 651 are retained. As a
suggested solution here, example drawing F13-1045 can be applied.
8.4.5 Crossbeams
All load-bearing crossbeams are to be manufactured as steel sheet constructions. In

accordance with the rough stresses of the iron and steel plant and the collisions to be
expected, the crossbeams are to be robustly manufactured. When designing the
crossbeams for crane S100, the converter filling situation is to be taken into
consideration. The geometric dimensions must be selected such that any collision with
the converter exhaust system is avoided.
For the design and manufacture of crossbeams for the cranes in group G1, SEB
666151 is to be adhered to. It must be assumed here that the residence time of
onloading ladles and teeming ladles in the lamella hooks may be longer than an hour. In
the structural analysis and the operational strength verification of the crossbeams,
universal joints and lamella hooks, the weakening of the materials deployed under the
temperatures that will be reached must be taken into consideration. Instead of the
materials prescribed in SEB 666 151 with the old designations StE 285, WStE285 and
WStE355, creep-resistant steel is to be used in accordance with DIN EN 10028-3, e.g.

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P235NH, P265NH, P295NH, P355NH. The same applies to universal joints and lamella
hooks. The lamella hooks are to be protected on both sides with chain curtains.
For the crossbeams of the other cranes, it is to be determined by the contractor,

dependent on the tasks section 2 and deployment conditions section 4.1, to what extent
the specifications of SEB 666151 are to be applied.
When designing the crossbeams, the field of vision of the crane operators should be
taken into consideration, as far as possible. In this respect, the contractor must present
explanatory drawings which could perhaps lead to alterations in the positioning of the
operator cabs.
The pins for attaching the lamella hooks and the hook slings are to be manufactured
from the material 42CrMo4V and hardened to 60-62HRC. The hardness penetration
must measure 3-4 mm.
To reach the required hoisting heights, it could be necessary to crimp the middle part of
the crossbeams. In such a case it must be ensured that the center of gravity of the
crossbeams lies sufficiently far below the center of the rope pulley, also when not
loaded.
The openings in the lower frame beams of the crossbeams must be selected sufficiently
large that the universal joints do not strike them under normal operating conditions.
Where crossbeams are passable inside, the openings of the manholes must be at least
600 mm wide.
In areas where the hooks of auxiliary hoists could strike the crossbeams, collision
protection plates must be mounted.
For the cranes of groups G1 and G2, lifting points are to be provided that allow the
suspension of the crossbeam from the auxiliary hoist.
The crossbeams shall have heat protection sheets in accordance with section 8.4.6 that
provide the supporting structure with sufficient protection from radiation heat.
The crossbeams shall have data plates with details of factory number, manufacturer,
year of construction, dead weight and carrying capacity.
All crossbeams are to be passable on top, in accordance with section 8.2.3.5.
The crossbeam lengths specified in the project drawings are maximum values.
Inasmuch as this is possible, the crossbeams must be designed to be shorter.
Design for the setting down of carrying crossbeams, appropriate setting-down

mechanisms is included. 2 mobile set-down bases shall be provided per crossbeam.
The set-down bases shall be fitted with platforms that are laid around the lower pulley
blocks in a U-shape. The platforms shall have railings all around and a ladder ascent
with a hatchway. The following quantity has to be considered:
2 pair of set-down bases for crane group G1

1 pair of set-down bases for crane groups G2 and G3
2 pairs of setdown stands for the bottom pulleys of the cranes in groups G1, G2, G3
and G4

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Fabrication of this set down bases by TKCSA. The set-down bases must be equipped
with lifting points for transport with stackers or cranes. The standing surface of the
bases must be selected sufficiently large that there is no risk of them falling over and
that the loads are distributed over a sufficient floor area.
In order to facilitate rope changes, the crossbeams of the cranes in group 1 are to be
supplied with assistance mechanisms in the form of 4 threading rolls. With the aid of
these rolls, new load ropes can be threaded from coils on the ground without grinding
on the edges of the crossbeam. These rolls are to be made of plastic and as light as
possible. The threading rolls shall have a rope groove that fits the load rope and has
extended edges. The roll diameter shall measure 700 mm for a rope with a diameter of
approx. 40 mm. Before a rope change, the threading rolls shall be suspended at the
height of the lower pulley blocks with a matching carrier arm and secured there with
bolts. Appropriate connections are to be provided on the crossbeams.
8.4.6 Lamella hooks
Lamella hooks are to be manufactured in accordance with DIN 15407. Regarding the
hook dimensions, however, the specific tasks to be performed by the individual cranes
and the design of the carrying gear (ladle suspensions, tipping suspensions, scrap
containers, vacuum vessels etc.) must be taken into consideration. These requirements
will probably lead to deviations from the hook dimensions and possibly the hook
materials from DIN 15407. For these deviant lamella hooks, as for the hammer hooks of
the auxiliary hoists, structural analyses and operating strength certification must be
presented. Weakening through the influence of temperature must be taken into
consideration here. For the calculation of stress, the attached TH-N 565 873 may be
used as an aid. The curved points of the lamella hooks must be as small as possible
(approx. 30 mm), to prevent collisions with the bail trunnions. The lamella hooks for
crane S100 are to be designed in a lengthened form, in order to achieve unimpeded
converter filling.
In its unloaded state, the inclination of the lamella hook in the main hoist may be
max.10° and in the auxiliary hoist (after calibration) max. 2° from the vertical.
The width (including protection layer in supporting surface) of lamella hooks must not
exceed 325mm.
All lamella hooks for the main hoists of the cranes in group G1 shall have a central
dummy lamella plate, in which the cable routing for the optional hook opening sensors
may be housed. The dummy lamella plate is not to be calculated into the load-bearing
cross section. The width of the lamella hook must not exceed the dimension b2 from
DIN 15407 for the respective load carrying capacity class. In order to realize this
requirement the load supporting lamellas must be made from materials with higher
strengths.
The lamella plates are to be manufactured from the materials already listed under
section 8.4.5 in accordance with EN 10028-3. The rolling direction of the plates must be
selected along the hooks' lengthwise axis. The lamella hooks must not be welded. The
lamella plates are to be connected with rivets.
All lamella hooks shall have hook openings that are to be welded on the top side with
austenitic manganese steel. A buffer layer is to be included between the parent metal
and the austenitic manganese reinforcement. If the optional hook opening sensors are
included in the design, the hook openings are to be manufactured in accordance with
the drawings and welding instructions of the licenser (BFI). Example drawings (for 580t
hoisting gear) may be requested under drawing numbers B51-4239 and B50-4240.

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All lamella hooks in the main hoists (except those of the cranes in group G4) shall have
impact protection on the inside of the hook opening and on the outside of the hook
point. The size and design of these protection devices shall be selected such that
operational impacts against the suspension loops or bail trunnions, occurring during
threading of the lamella hooks, do not lead to damage of the lamella plates.
Lamella hooks in auxiliary hoists shall have a hook opening on the main hoist side that
is to correspond to the tipping trunnions of the ladles. The opposite side is to be
designed such that load-carrying equipment for repair work can also be suspended. An
example drawing is enclosed as an example. The hook size and the shaft length must
be agreed with the respective operational use, i.e. with the relevant load suspension
device.
8.4.7 Heat protection measures
For the crane bridges, top beams, crane trolleys, crossbeams and operator cabs, heat
protection measures are to be provided in accordance with the following table:
Crane Gr. Crane girders Top beams Trolley 1 Trolley 2 Operator cab Crossbeam
S100 all lower frame complete complete underside; all complete underside; all underside as far complete
beams; all web enclosure on web plates on the web plates on the as field of vision underside;
plates of the the converter internal sides; vertically internal sides; vertically permits; both; plate
internal beams side on the converter side on the converter side armored glass sides;
and the inner die approx. 2.5m high; as high as possible splash guard lamella
web plates of laterally on carriages hooks;
the external and links
G1
beams; both
trailing cable
systems
S200 all lower frame - complete underside; complete underside; underside complete
beams underside;
beams underside
S110 all web plates complete complete underside; all complete underside; underside as far complete
and all lower enclosure on plates; vertically on the vertically on the as field of vision underside
frame beams; the converter converter side approx. converter side as high permits; armored both plate
G2
trailing cable side 2.5m high; laterally on as possible glass splash sides;
systems carriages and links guard lamella
hooks
beams underside
G3
beams underside
S320 - - - - - complete
underside
G4
S330 - - - - - complete
underside
Table 9
The heat protection plates of the main and auxiliary trolleys for the cranes S100 and
S110 are to be designed in cartridge form. The cartridges shall consist of 4 layers
 Underside of high-alloy grade, heat-resistant steel sheets (e.g. Thermax) in

accordance with DIN EN 10095; min. thickness 2 mm.
 Fire protection plates with galvanized steel plate support (e.g. Durasteel,
temperature stable to 1200°C); approx. thickness 10 mm
 Trapezoidal sheet e.g. 35 x 207
 Top side steel sheet thickness min. 1 mm

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The cartridges are to be mounted such that, except for the rope openings, there are no
spaces into which hot air may rise. As far as possible, the rope drums, top pulley blocks
and gear units are to be covered by the heat protection. The fixings of the cartridges
must be able to withstand the shock waves from the deflagrations in the converter. It
must be possible to replace individual cartridges without disassembling the entire heat
protection. It must be possible to inspect bolted connections without disassembling the
cartridges.
It must be lastingly ensured that no accidental detachment or loosening of the heat

protection plates occurs under the influence of vibrations and crane activity.
Furthermore, the various expansions of heat protection plates and cartridges must be
constructively taken into consideration, and must not lead to stress or deformation.
For the crane trolleys of the cranes S200, S300 and the crane trolleys of group G3 and
for the bridge girders and operator cabs of groups G1/G2/G3, the heat protection plates
are to be manufactured from galvanized trapezoidal plates. The heat protection plates
are to be attached in frames. It must be possible to replace individual plates. The size of
the frame and the spacing of the supports must be selected such that vibration,
buckling, and bending of the heat protection plates may definitively be avoided under all
operating conditions. In addition to the formfitting support of the frame, these heat
protection plates are also to be secured against falling out with bolts. These bolted
connections must allow for expansion when the heat protection plates are warm. It must
be possible to visually inspect the bolted connections of the heat protection plates and
fixture frame without disassembling the heat protection plates.
On the crane bridges of cranes S100 and S110, vertical heat protection plates made of
steel plate are to be erected to protect the cable trailing devices for the main and
auxiliary trolleys.
The undersides of all crossbeams and the web plates on the crossbeams of cranes
S100 and S110 are to be protected from the affects of the heat with heat-resistant steel
plates in accordance with DIN EN 10095 (e.g. Thermax). The thickness of the sheets
shall be min. 10 mm. For purposes of reinforcement, the ends of the plates shall be
folded and welded in the corners. Ribs of the same material are additionally to be
welded in. The suspension of the heat protection plates shall be achieved with chains
on the reinforcement ribs. The minimum chain size to be selected is 16x48 in
accordance with DIN 5687. All chains shall have transition pieces and shackles at the
ends, which must correspond to the chain size and quality. The chain intervals may be
max. 0.8 m. The chains and the suspension fixtures must be constructed such that the
failure of every second chain can be compensated for. At the same time, the weakening
of the chains through loss of temper under heat effects must be taken into
consideration.
The heat protection plates on the top beams (converter side) of cranes S100 and S110
must also be manufactured from heat-resistant steel plates in accordance with
DIN EN 10095 and reinforced in the manner described above. These plates must
likewise be attached with chains, in accordance with the above description. Differing
expansions of heat protection plates and crossbeams must constructively be taken into
consideration.
All cable ducts that do not run along the top of the structures shall have heat protection
plates on the underside.

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8.4.8 Current collector baskets
For the attachment and maintenance of the current collectors, a current collector basket
is to be mounted on the conductor rail side of group 4 cranes. The current collectors
shall be attached to doors that, when opened, automatically first lift the current
collectors off the phases. When closing the door, the phase current collectors shall
make contact last. Every current collector basket shall have two doors with current
collectors, so that 2 collectors are deployed for each conductor rail. The current
collector doors must be secured additionally by means of lock bolts.
The current collector baskets are to be designed such that when the current collector
doors are closed there is no access to the conductor rails.
The closing and opening of the doors is to be facilitated by the use of threaded rods with
handwheels.
The cables for the current collectors must not scrape against the steel structure, either
when the doors are closed or when they are being opened.
The current collector basket must be equipped with a descent ladder, in the vicinity of
which the height of the railings must be increased.
At the descent to the current collector basket, a warning sign must be mounted to
indicate the danger of death if the conductor rails are touched.
Maintenance basket for crane girder inspection to be delivered instead.
8.4.9 Operator cabs
The operator cabs are to be designed as closed and all-around insulated full-vision
cockpits with the following minimum geometric measurements:
Width (exterior) at ground: approx. 2,300 mm

Clear width (interior): approx. 2,100 mm
Depth (length): 2,300 mm
Height: approx. 2,100 mm
Clear headroom: 2,000 mm
The walls are to be designed using the following components:
Exterior steel sheet thickness min. 3 mm

Mineral wool thickness min. 60 mm
Interior steel sheet thickness min. 1.5 mm
Sound insulating mineral fiber matting thickness min. 40 mm
Perforated plate thickness min. 1.0 mm
All sides of the operator cabs shall be glazed at top and bottom. The doors shall
likewise have windows at top and bottom. For an optimal field of vision, the windows are
to be as large as possible and the frames as narrow as possible. The floor in the front
portion shall be tilted upwards and shall also be glazed. The remainder of the floor shall
be constructed from:

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Heat protection plates in accordance with section 8.4.7

Steel plate min. thickness 3 mm
Mineral wool thickness min. 100 mm
Cable cavity, cable floor approx. 50 mm
Eternit plate, rubber matting thickness approx. 20 mm
The floor trough is to be fitted out as a cable shaft. It should be possible to lay cables
there without obstruction. It is closed from above with plates that may be unscrewed.
In order to achieve a sufficient degree of insulation and protection, the glazing of the
operator cabs must consist of the following components:
ESG 6 mm – coated on one side

SZR 16 mm
VSG (TVG) 10 mm
Compound safety glass (VSG) made of 2 x TVG 5 mm

Total thickness of glass approx. 32 mm
K-value: approx. 1.6 W/m²K
It must be possible to safely clean panes that cannot be reached from the operator cab
platform from within the operator cab. For this purpose, a corresponding number of
windows must be equipped with opening mechanisms.
The ceilings of the operator cabs must permit a sufficient distribution of the air-
conditioning supply. Vent slides are to be fitted at the exhaust ports. There are to be air-
conditioning ducts for air supply and extraction.
The operator cab doors are to be self-closing shock resistant doors with all-around
sealing and locking with panic function.
The operator cabs are to be supplied with the following equipment:

Holders with hinged arms for displays and monitors, where these are present
Fire extinguisher with wall mounting bracket
Door fastener
Additional folding seat
Desk surface
Ash tray
Coat hook
Lighting
Double socket
The operator cabs of cranes S100 and S110 shall have an additional pane of armored
glass on the left or right side outside the cabin, arranged with a frame, 24 mm thick –
clear, quality Allstop B2-12 EH 2 tested or equivalent. The size of the total glazing shall
cover the seating position of the crane operator and shall be positionable from the crane
control panel in the cockpit. It shall be possible to bring the pane forward to the front
edge of the cockpit during the charging process, using an electrically driven lifting
spindle.
The crane cabin, including the suspension, must be designed to withstand all braking
and impact loads. The supporting structure for the operator cab and its air-conditioning
system must be as free from vibrations as possible. Additional vibration dampers are to
be installed at the lifting points of the operator cab. It must be possible to inspect the

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suspension. Tension bolts are not permitted. Additional claws must be welded onto the
crane girder bottom boom as protection against falling.
Air-conditioning of the operator cab see section 10.17.
Design of the control seat see section 10.7
Sufficient cable ducts and terminal boxes must be provided for the connection of the
electrical cables.
The ascent to the operator cabs takes place by stairways, in accordance with 8.2.3.1,
on a platform located next to the operator cab. In addition to the ascent stair, a further
ascent is to be provided that allows a direct crossover from the crane runway ascents.
The position of these doors can only be determined during the course of the project.
These doors shall have electric interlocking that definitively prevents operation of the
crane with open doors.
The positions and lines of vision of the operator cabs are to be obtained from the
following crane project drawings. The cranes of groups G1 and G2 shall have shaft
mountings for which the requirements of chapter 8 apply. It should be possible to install
air conditioning units for the operator cabs in an upper level, and thereby to air-condition
further upper levels for calculation rooms or weighing technology.
8.4.10 Mechanical positioning aids
For the cranes of groups G1, G2 and G3, markers are to be mounted under the trolleys
and under each other the top beams in order to facilitate positioning of the trolleys and
cranes. The markers are to be made of steel sheet and must be identifiable from the
operator cabs. The positioning markings on the crane bridge and crane runway shall be
placed there by the contractor. The markers are to be secured against falling.
8.4.11 Service platforms for lighting installation and maintenance
For one crane per hall, a platform is to be offered for the installation and maintenance of
the hall lighting. These platforms shall be located on the trolleys and shall be reached by
ladders. The height of the platforms is to be in accordance with the height of the roof
structure. The platforms shall have railings all around and, for the ascent, one trapdoor
that opens inwards. Between the handrail and the roof, a safety clearance of 0.5 m is to
be observed. A warning sign with indications of the danger from the roof structure is to
be mounted on the ladder ascent.

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9. Description machinery
For the description of the machinery, the group divisions described in section 8.4 shall
be used.
9.1 Fundamentals of calculation
The "fundamentals of calculation for drive units in hoisting equipment", (draft DIN
15017) issued as special report by the standards committee for machinery construction,
conveying systems section, in the DIN Deutsches Institut für Normung e.V., Beuth-
Verlag publisher apply for the calculation of driving gear components. If other
fundamentals of calculation have to be used beyond this, for which no definition is given
in this specification document, the calculations must be carried out in accordance with
FEM or the relevant technological rules.
For purposes of service life calculation, a total service life of 25 years is to be assumed
under the conditions set forth in chapters 5 and 6.
For the calculation of the rope pull forces and drum torque, TH-N 560 560 applies,
inclusive of the degrees of efficiency specified in this standard for rope pulleys, pulley
blocks, rope drives and rope drums. These degrees of efficiency must also be observed
when designing the layout of the hoisting gear motors, gear units, couplings and brakes.
For the deployment of the emergency brake, the total power trains from the drives to the
crossbeams are to be verified and dimensioned as multiple-mass oscillators, taking non-
linearities into account, especially when running through tooth and coupling play. These
verifications must be carried out for the following load conditions:
 Emergency stop braking on the basis of one application per day for test
purposes or in the event of power failure
Mechanical braking (operational brakes and emergency stop brakes) from
maximum lowering speed to standstill, without payload, with maximal wear play
in the drum coupling and the toothed couplings of the jack shafts from motor
and drum reduction gears.
 Braking system layout

Mechanical braking from maximum lowering speed to standstill, with payload,
for the investigation of the brake equipment
 Braking with operational brakes from lowering with full payload
 Braking with emergency stop brakes from lowering with full payload
 Braking with both brake systems from lowering with full payload
The maximum braking distances for these load conditions must be determined
 Gear unit shaft breakage on the basis of one application per year
Mechanical braking (operational brakes and emergency stop brakes) from the
startup process to standstill, with full payload, after breakage of a main drive
shaft. This investigation is to be completed by the determination of the
maximum stopping distances in the event of damage.

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 Drum shaft breakage on the basis of one application per year

Mechanical braking (operational brakes and emergency stop brakes) from
maximum hoisting speed to standstill, with full payload, after breakage of a
drum shaft. This investigation is to be completed with the determination of the
maximum stopping distances and maximum crossbeam misalignment in the
event of damage. The maximum crossbeam misalignment that may be reached
must not lead to spillage of molten steel from a full teeming or onloading ladle.
For the investigations described above, the complete power trains with all mechanical
components are to be modeled.
The calculation of the emergency brakes of S310, 320, 330 acc. to the multiple mass
oscillation procedure will done at same time of the equipment fabrication. If this calc.
shows a design problem, BARDELLA and TKCSA should find a solution together.
The calculations of the torques arising under the load conditions described above shall
take place on the basis of the lower wear limits (100% of the permissible wear) of
couplings and brakes. Furthermore, the maximum reaction times before the application
of the brakes and the largest possible lowering speed reached by that point are to be
used. The wear limits and set values used for the operational brakes, emergency
brakes and couplings are to be documented.
The layout of the operation brakes must be independent of the functioning of the
emergency stop brake, such that the failure of any given operation brake can be
compensated for without any reduction in safety; i.e. in the event of an emergency stop,
the braking torque of the still functioning operational brakes guarantees a sufficient
delay under all conditions (without motor braking).
When all operational brakes are functioning, these must achieve a delay time ≤ 0.8
seconds under the least favorable conditions and without motor braking. The delay
values to be set later will be approx. 1.8 -2.2 seconds, independent of this.
During the mechanical engineering calculations, the operational differential loads in

accordance with the specifications of section 7 are to be observed.
For the layout of buffers on crane and trolley traversing gear, and for shifting gears and
rope compensation rockers, the conditions specified in chapter 8 and the following
sections are to be observed.
The determination of track wheel diameters is to take place in accordance with

DIN 15070. The minimum diameters from chapter 7 must be adhered to however.
The entire machinery design must be documented in a form which can be checked.
9.2 Description of general mechanical equipment
9.2.1 Materials
The materials to be used must be selected according to their purpose, and should be in
accordance with the following standards.
9.2.1.1 Steels
The steel grades must be selected from:

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- DIN EN 10025, hot-rolled products of unalloyed structural steel grades; S185 =

1.0035 (previously St 33) is not permitted
- EN 10083-1 to EN 10083-3 heat-treatable steel grades
- DIN 17 210 casehardening steel grades, preferentially 16 MnCr 5 = 1.7131 and
l7CrNiMo 6 1.6587
Suitability for welding must be certified for steel grades which are to be used for making
welded components.
9.2.1.2 Cast steel and cast iron
DIN 1681 applies to the selection of cast steel. Steel castings must be normalized
before machining. Gray cast iron and malleable cast iron are not permitted. Speroidal
graphite cast iron (modular iron) in accordance with DIN 1693 is permitted only for
special purposes with the consent of the customer.
9.2.2 Lubrication
9.2.2.1 Lubricants and process materials
The following lubricants and process materials are allowed:

- Lube oil CLP 320 for gear units (oil temperatures to max. 80° C)
- Lube oil ESG 220 for gear units (oil temperatures over 80° C)
- Lubricating grease G 0 F for slow turning toothed couplings (traversing drives)
- Lubricating grease e.g. Longlife Grease for fast turning toothed couplings (hoisting
gear)
- Lubricating grease K 3 K for anti-friction bearings in electric motors,
- Lubricating grease KP 2 K for anti-friction and plain bearings, guide, articulated
joints, wheel flange lubrication
- Hydraulic oil HLP 46 for Eldro equipment
The lubricating and process materials must be included in the delivery made by the
crane supplier. Filling-in and lubrication before the acceptance test must be carried out
by the company commissioned with the crane installation. Anti-friction bearings must
already be provided with sufficient lubricant at the time of installation.
9.2.2.2 Lubricating instructions, lubricating schedule
Documents in accordance with the lubricating instructions template TH-N 507 021 must
be included with the delivery for every lubricating point.
9.2.2.3 Manual lubrication points
Manual lubrication points with lubrication intervals shorter than 2 months are permitted
only with the approval of the customer. Grease lubrication points shall have large button

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head lube nipples A-G 1/4-22 in accordance with DIN 3404. The lubrication points must
be readily accessible. If necessary, e.g connecting hoses or pipe extensions should be
mounted. As far as possible, lubricating points must be combined centrally on strips with
corresponding markings.
9.2.2.4 Gear system lubrication
Section 9.2.17.3 of this specifications document applies to the lubrication of gear units.
9.2.2.5 Marking of lubricating points
Lubrication points must be marked with red paint.
9.2.3 Shafts, axles
Shafts, shaft shoulders, shaft ends and axles seated in plain or anti-friction bearings, or
which serve for connecting couplings, gearwheels, track wheels and other wear
components, must comply with the diameter selection in accordance with SEB 601 110.
It must be ensured that all gearwheels and similar parts are seated on shoulders of the
shafts, axles, etc. which have a diameter at least 2 mm larger than the bearing point or
than the seat of the removable machine part located in front. The transitions from the
shaft shoulders must be designed such that the notch effect is as small as reasonably
possible according to technical and economic aspects. The following standards apply
for the design of transitions:
- DIN 509 Clearance cuts

- DIN 250 Radii of curvature
- DIN 5418 Anti-friction bearing dimensions for incorporation.
The transitions must be manufactured with surface quality Ra = 1.6 µm in accordance

with DIN IS0 1302 and SEB 055501.
Because the operating strength depends on the roughness depth, the surface quality
must be chosen according to the operating strength calculation for places which are
endangered by the notch effect.
9.2.4 Fits
The selection of fits must be made in accordance with:

- DIN 7157 Recommended selection of fits; tolerance zones; allowances; fit tolerances
- DIN ISO 286 ISO system for limit dimensions and fits
- SEB 055 650 Anti-friction bearings; installation tolerances
9.2.5 Tolerances
The following standards apply to dimensions without specified tolerances:

- DIN 1680 Part l Rough castings; general tolerances and machining allowances
- DIN 1683 Part l Rough steel castings; general tolerances and machining allowances
- DIN 1685 Part l Rough castings of speroidal graphite cast iron; general tolerances
machining allowances
- DIN 7168 General tolerances; degree of accuracy and tolerance class mS

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- DIN 7526 Steel forgings; tolerances and admissible deviations for drop forgings
- DIN 8570 General tolerances for welded structures
- Technical requirements for drive systems in accordance with TH-N 565 144
9.2.6 Surface quality
The surface condition of a part must be specified to suit its function in accordance with
DIN ISO 1302 and SEB 055501.
9.2.7 Separable and other connections
9.2.7.1 Bolts, nuts and accessories
Suitable commercial bolts nuts and accessories must be selected in accordance with
the DIN, DIN EN and DIN ISO standards and in accordance with the plant engineering
requirements. Avoid using bolts < M 10. Give preference to through-bolts. Galvanized
bolts, nuts and washers are to be selected.
9.2.7.2 Bolt securing devices
Give preference to locknuts as bolt securing devices. Washers with tab (locking plates),
castellated nuts with splints and other bolt securing devices may be used only subject to
the consent of the customer.
9.2.7.3 Fitting keys, wedges, splined shaft and toothed shaft connections
Fitting key connections must be designed such that only one groove is required. Other
designs must be agreed. DIN 6885-1 applies to the selection of fitting keys. Flat, hollow,
inset and tangential keys are not permitted. Jib-head keys in accordance with DIN 6887
must be locked. If plant engineering requirements necessitate the use of wedges and
splined shaft connections, a corresponding agreement must be made with the
customer. The connection types must be selected in accordance with DIN ISO 14 and
DIN 5480.
9.2.7.4 Frequently separated connections
An easily separated, but economically efficient, construction, such as a manually

actuated locking handle, must be attached to connections which have to be separated
frequently, e.g. for inspection hatch covers, protecting hoods and quick make/release
couplings.
9.2.7.5 Securing rings
Standard design securing rings are permitted in accordance with DIN 471 for shafts and
DIN 472 for bores.

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9.2.7.6 Spring pins
Spring pins in accordance with DIN EN 28752 (ISO 8752) may be used.
9.2.7.7 Frictional connections
Frictional connections are to be manufactured in accordance with DIN 7190. Oil

pressure frictional connections in accordance with DIN 15 055 are only permitted if
agreed on. Pressed joints are not allowed for hoisting gears, except for rope drum
trunnions on the fixed bearing side.
9.2.7.8 Axle holders
DIN 15 058 applies to the design and configuration. Axle stop plates are to be set at 90°
to the axle's main direction of stress. In safety-related applications, under high stress, or
with turning, the axle stop plates are to be designed as split rings that may be
connected with a larger, closed ring.
9.2.8 Welded constructions
The processing instructions for the respective material must be complied with for
making welded joints. For ensuring the quality of the steel grades, the following apply,
among others: DIN EN ISO 3834, DIN EN 288, DIN EN 719, DIN EN 729. Drawings
must be carried out in accordance with DIN EN 12345. In addition, the following must be
specified:
- Welding method
- Weld seam quality in accordance with EN ISO 5817 (classification group)
- Auxiliary welding material
- Welding sequence
- Preheating and working temperature
- Heat treatment.
The drawings for welded constructions must be created in cooperation with a welding
specialist. Drawings with statically and dynamically loaded subassemblies must be
checked and signed by a welding engineer.
For gear housings, the requirements of sections 8.3.8 to 8.3.8.4 apply.
9.2.9 Bearings
For rotating parts, antifriction bearings are to be selected preferentially. The selection
shall take place in accordance with SEB 601 303. Preference should be given to closed
anti-friction bearings instead of bearings with loose parts. For the calculation of the
antifriction bearings and ball bearing slewing rim, a service life of at least 40,000
operating hours under full load and continuous duty must serve as the basis. For
hoisting classification equal or lower M8 and drive classification equal or lower M7, the
calculation is based on 20,000 operating hours. Antifriction bearings must conform to
the dimensions of the relevant standards. The tolerance classes for the installation of
antifriction bearings must be selected in accordance with DIN 5425.

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Only antifriction bearings from manufacturers with a certified quality management

system in accordance with ISO 9001 may be used. Proof of certification must be
submitted within the framework of the quality documentation.
The bearing seats for the inner and outer rings must be at least as wide as the bearings.
This requirement must also be fulfilled for the full utilization of all component tolerances
e.g. interior dimensions of gear boxes.
9.2.10 Sealing rings
DIN 3760 (Radial shaft sealing rings) and DIN 3771 (0-Rings = round sealing rings)
apply for selection and incorporation. Shaft sealing rings > 320 mm and other kinds of
seal are subject to agreement with the customer.
Radial rotary shaft seals are to be installed with stiffening plates and spring loaded
sealing lips. Other forms of execution are only permissible after prior approval by the
customer. All seal rings are to correspond to the deployment conditions described in
chapters 5 and 6. When selecting the seal rings, in addition to the ambient temperature
and the oil temperature, the frictional heat on the sealing surface must also be taken
into account. Therefore, the operational use of the seal rings for temperatures up to 80°
C is not sufficient for some applications. In these cases, sealing materials for higher
temperature ranges must be used, e.g. Viton seals. Additionally, resistance to the
lubricant to be used must be ensured. This must especially be considered when
synthetic or partially synthetic lubricants are used (e.g. ESG 220). Seal rings must also
correspond to the oil temperatures to be expected, bearing in mind the heat balance in
accordance with section 9.2.14.4.
Radial rotary shaft seals are always to be deployed in pairs with the seal on the gear
unit interior. Between the seal rings, a spacer ring must be provided that ensures
sufficient room for a permanent grease filling. The radial rotary shaft seals must be
secured against axial shifting. To protect seal rings from contamination, dust seals
against the gear unit exterior should be provided. A separate seal ring can be used for
this. When selecting the seal ring dimensions it should be allowed for that the external
radial rotary shaft seal may later be exchanged for a split seal ring of the same
dimensions. The application of further spacer rings should ensure that the sealing lips of
the split replacement rings do not run in the same track as the radial seal ring of the first
set. All seal rings must run on hardened bushes that can be replaced if required.
Round section joint rings in covers are to be preferentially deployed to prevent damage
during installation.
9.2.11 Couplings
Only the following types of couplings may be used. For the installation tolerances and
other documentation, section 1.2.2.1 applies. For bolted couplings, the installation
tolerances must be complied with in accordance with section 9.2.11.2.
9.2.11.1 Rigid shaft couplings
Stiff shaft couplings with/without protective edging are to be selected in accordance with
SEB 601 431, SEB 601 432 and forms B and C in accordance with DIN 116. The
coupling halves are shrunk to fit, with the exception of those in the hoisting gears.

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9.2.11.2 Flexible shaft couplings
Only elastic shaft couplings with coupling pins, forms A and B, secured against free-
turning in accordance with TH-N 270 130, are permitted. For the installation tolerances,
TH-N 565 144 must be adhered to.
9.2.11.3 Gear-type couplings
If it is necessary to use angle and longitudinally variable couplings to cope with statically
indefinitely seated shafts, gear-type couplings should be chosen. Inspection monitoring
of the tooth flank wear must be possible without dismantling the coupling. Gear
couplings must be selected such that interchangeability with crowned tooth couplings
manufactured by Renk is guaranteed. The jack shafts of crowned tooth couplings are to
be manufactured as die-forgings. When mechanically machining the jack shafts, cross-
section steps and transitions must be as notch-free as possible. The flanged joints of
the jack shafts and couplings must be drilled together. For the installation and alignment
of the gear couplings, section 1.2.2.1 must be observed. When assembling the crowned
tooth coupling it must further be observed that all the lube nipples of each drive group
must be reachable in one shaft position.
9.2.11.4 Friction clutches
To protect against overloading, the drives of shifting units are to be equipped with
friction clutches. The transferable torque must be adjustable. It must be possible to
adjust the friction torque to double the load torque.
9.2.11.5 Shaft couplings for gear limit switches
Gear limit switches on the rope drums or the gear units of the hoisting gear must be
attached with appropriate spring washers or gear couplings. The couplings and gear
limit switches must be protected with removable and safely passable coverings.
9.2.11.6 Drum couplings
see section 9.3.1.5.3
9.2.12 Universal joints
The TH-N 270 080 must be taken into consideration for connecting articulated shafts
and connecting flanges. For the dimensioning of universal joints, the maximum friction
torque of the track wheels is to be used as the continuous load for reverse operation.
Universal joints must be secured against dropping down. It must be ensured that the
lubrication points are accessible. If necessary, the lube nipples must be brought to the
exterior with the help of extension piping. It must be possible to take out universal joints
from above.

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9.2.13 Gear wheels
All gear wheels and the associated shafts must be made from forged steels. Welded
gearwheels are not permitted.
9.2.13.1 Calculation
The load carrying calculations for gear wheels must be made in accordance with DIN
3990 and included with the delivery made by the contractor. The minimum pitting
resistance as a function of the fatigue strength S H min and the minimum tooth breaking
strength as a function of the fatigue strength S Fmin must be taken from the following
table.
Component Safety Application factors Ka

devices
Gearbox S H min S F min Input shaft Interme- Planetary Output shaft
diate gear stage
stages
Hoist 1,3 1,8 1,7 1,5 1,5 1,2
Group G1, G4
cranes
Hoist 1,1 1,4 1,5 1,3 1,3 1,1
Group G2, G3
Cranes
Crane 1,1 1,4 1,5 1,3 - 1,1
traversing
all cranes
Trolley 1,1 1,4 1,5 1,3 - 1,1
all cranes
Table 10
For the calculation of gears and shafts and other mechanical components, the largest
torque arising from the following load conditions is to be used, in accordance with draft
DIN 15017. To this end, the application factor K a is to be used for the values φa and φb.
For crane and trolley traversing gear, and for shifting gear
 Greatest torque from acceleration MBS as continuous operational load
 Greatest torque from delay MBR as continuous operational load
 Greatest torque from buffer impact M So as special load condition
 Greatest torque MBS or MBR in the event of symmetrical failure of 50% of the
traversing drive in emergency operation
For hoisting gears

 Greatest torque from lifting the load M Ah as continuous operational load
 Greatest torque from acceleration MBS as continuous operational load
 Greatest torque from delay MBR as continuous operational load
 For hoisting gears with emergency stop brakes, the torque values calculated in
accordance with section 9.1 are to be verified, along with the given number of load
plays.
 Torque arising from operational differential loads in accordance with section 7 as
continuous operational load.

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 Torque arising from maximum differential loads in accordance with section 7 as

special load condition.
 Torque test load in accordance with section 1.2.5.1 as special load condition.
The material selection and material mating are determined by the above load carrying
calculation.
9.2.13.2 Gearing
In respect of the tolerances of spur gear toothing, DIN 3961 (Fundamentals) and DIN
3962 (Tolerances for deviations of individual fundamental quantities) apply . Terms and
fundamental quantities must be selected in accordance with DIN 3960. For the
processing of gearwheels, the minimum requirements of the tool reference profiles
according to DIN 3972 category III or IV must be complied with. For this purpose, tools
with a protuberance profile must be used if the tooth form must be generated with
regard to a grinding process to be carried out. This means that the grinding process
must not cause any notches to occur within the area of the cross-section of the gear
tooth base. This form suitable for grinding is achieved by pre-toothing with
protuberance profile tools.
The measurement of all gearwheels must take place on appropriate testing systems. All
measurement data must be documented in accordance with Section 11.7. If the
tolerances are exceeded, the affected gearwheels are to be rejected. The toothing data
must be specified in accordance with TH-N 205 430. Load grinding is only permissible
with the consent of the customer.
In accordance with the specifications in Section 11.7, contact pattern tests and tests for
overheating caused by grinding must be carried out and documented.
9.2.14 Gear unit design/ Drive unit layout
Gear units of hoisting gear group G1 trolley 1

Motor reduction gear (1 per hoisting gear)
For these hoisting gears, spur gear units are to be used for which the power summing of
the drive motors takes place via a planetary gear stage. The gear unit has 2 input
shafts, each with 2 motors of the same kind. When the drive shaft is stopped, it must
still be possible to continue with half hoisting speed and full torque. The power output is
to be transferred over 2 output shafts that are each connected to a drum reduction gear
with crowned tooth couplings. The gear unit bearing is to be at the hub of the output
shafts.
Drum reduction gears (2 per hoisting gear, construction type: CUW or CMW DIN 15053)
Both rope drums of each hoisting gear are to be driven by one drum reduction gear. To
this end, two-stage spur gear units are to be employed that are attached to the rope
drums with drum joint connections, in accordance with section 9.3.1.5.3. The input
shafts of the drum reduction gear are to be connected to the drive shafts of the motor
reduction gear with crowned tooth couplings. The bearing of the drum reduction gear is
to be at the hub of the drive shaft, on a support under the input drive.
Gear units of hoisting gear group G1 trolley 2

The drive units for these hoisting gears are to be one planetary gear drive each. The
gear unit has 2 input shafts, each with one motor. The two motors are identical. When
the drive shaft is stopped, it must still be possible to continue with half hoisting speed
and full torque. The position of the planetary gear drive may be selected centrally
between two rope drums or frontally on a rope drum that extends right through. The
connection to the rope drums is to be achieved with a drum joint connection, in

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accordance with section 9.3.1.5.3. The bearing is to be selected in a foot mounting

design.
Crane drive gear unit group 1 (construction type CUV/CMV/CSV/CZV DIN 15053)
Every crane in this group shall have 8 identical crane drive gear units. These gear units
shall have spur gear toothing. These gear units shall be arranged upright. The power
transmission to the wheel shafts shall be achieved with universal joints in accordance
with section 9.2.12. The traversing gear unit bearings shall be at the hub of the output
shafts and shall have a torque support.
Trolley drive gear units group 1 trolley 1 (construction form CHV in accordance with
DIN 15053)
The main trolleys of this crane group shall each have 4 trolley drive gear units. These
gear units shall have spur gear toothing. Each trolley drive gear unit shall have two drive
motors that are connected to both ends of the input shaft. Emergency operation with
one motor per trolley drive gear unit must be guaranteed. These gear units shall be
arranged upright. The position of the trolley drive gear units shall be centrally between
the outer rails of the inner crane girder and the trolley rails of to outer crane girder. The
power transmission to the wheel shafts of the trolley wheels on the inner and outer
bridge girders is to occur through crowned tooth couplings with jack shafts, in
accordance with section 9.2.11.3. The drive gear unit bearings shall be at the hub of the
output shafts and shall have a torque support.
Trolley drive gear units group 1 trolley 2 (construction form CHV in accordance with
DIN 15053)
These crane trolleys shall each have a trolley drive gear unit. These gear units shall
have spur gear toothing. Each trolley drive gear unit shall have two drive motors that are
connected to both ends of the input shaft. Emergency operation with one motor per
trolley drive gear unit must be guaranteed. These gear units shall be arranged upright.
The trolley drive gear units should preferably be positioned centrally between the trolley
rails. The power transmission to the wheel shafts shall be achieved with 2 universal
joints each in accordance with section 9.2.12. The drive gear unit bearings shall be at
the hub of the output shafts and shall have a torque support.
Gear units of hoisting gear 1, groups G2, G3 and G4

As for gear units of hoisting gear group G1 trolley 2
Gear units of hoisting gear 2, group G2

As for gear units of hoisting gear group G1 trolley 2
Gear units of hoisting gear 2, groups G3 and G4

As for gear units of hoisting gear group G1 trolley 2, however with an input shaft instead
of a planetary gear stage. The drive power may be created with a motor or optionally
even with 2 motors on a drive shaft.
Crane drive gear unit groups G2, G3 and G4 (construction type CUV/CMV/CSV/CZV
DIN 15053)
The cranes in these groups shall each have 4 identical crane drive rsing gear units, as
described for crane drive gear units group 1.
Trolley drive gear unit group G2 trolley 1 (construction type CUV/CMV/CSV/CZV

DIN 15053)

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Crane S110 shall have 4 trolley drive gear units for the main trolley. These gear units
shall have spur gear toothing. These gear units shall be arranged upright. The trolley
drive gear units should preferably be positioned on platforms next to the track wheels.
The power transmission to the wheel shafts shall be achieved with universal joints in
accordance with section 9.2.12. The traversing gear unit bearings shall be at the hub of
the output shafts and shall have a torque support.
Trolley drive gear units group G2 trolley 2 and the trolleys of groups G3 and G4
(construction type CHV in accordance with DIN 15053)
These crane trolleys shall each have a trolley drive gear unit. These gear units shall
have spur gear toothing. Each trolley drive gear unit shall have two drive motors that are
connected to both ends of the input shaft. Emergency operation with one motor per
trolley drive gear unit must be guaranteed. These gear units shall be arranged upright.
The trolley drive gear units should be positioned centrally between the trolley rails. The
power transmission to the wheel shafts shall be achieved with 2 universal joints each in
accordance with section 9.2.12. The drive gear unit bearings shall be at the hub of the
output shafts and shall have a torque support. The trolleys with 6 or more track wheels
should, if possible, be driven on the wheels with the highest wheel pressure.
Shifting gear crane S310 (construction type CYV/CNV/CUV/CMV/CSV/CZV DIN

15053)
For the traversing drive that shifts the top pulley block, a spur gear unit is to be
employed. This gear unit shall be arranged upright. The power transmission to the
continuous wheel shaft shall be achieved with universal joints in accordance with
section 9.2.12. The traversing gear unit bearing shall be at the hub of the output shafts
and shall have a torque support.
All drive motors shall be attached with bolted couplings, in accordance with section
9.2.11.2. The brake drums shall be mounted on the bolted couplings, in accordance with
section 9.2.15.2. For carriages, at least one brake per drive motor must be provided.
Every hoisting gear motor shall have at least 2 brakes. In this respect, the motor-side
coupling half shall also be fitted out as a brake drum.
9.2.14.1 Selection
For the selection of spur gear units as regards fitting dimensions, limit dimensions and
drive torque values, DIN 15053 applies. For the planetary gear drive, these
specifications are to be adhered to as far as possible.
9.2.14.2 Gear housing
9.2.14.2.1 Material and design
Gearboxes must be made of steel as appropriate rigid welded constructions. The

planetary gear carriers are to be deployed in forged form.
9.2.14.2.2 Quality requirements
The center distances and tolerances in accordance with DIN 3964 apply to gearboxes.

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9.2.14.2.3 Corrosion protection
Gearboxes must be provided inside and outside with anticorrosion protection that is
resistant to oil and aging. Gearwheels, with the exception of the toothing surfaces, shall
likewise have anticorrosion protection that is resistant to oil and aging.
9.2.14.2.4 Inspection openings
In the gear units of hoisting gears, all gear unit stages shall have lockable inspection
openings of adequate size. These inspection openings must be closed with sealed
covers provided with manually actuated locking handles
9.2.14.2.5 Part joints
The parting lines of the hoisting gear casings (drum reductions gears excluded) must be
installed horizontally. The surface of the parting line must correspond to the roughness
class Ra = 6.3 in accordance with DIN ISO 1302 for all gears. The part joints must
not be ground, so that they can be properly sealed with a thin fluid removable sealing
compound such as Teroson-Atmosit or a similar product.
9.2.14.2.6 Tapered pins, pressure threads
The gearbox top parts and bottom parts must be fixed with respect to each other by
tapered pins with threaded stems in accordance with DIN EN 28737. Pressure threads
closed with blind bolts must be present in the gearbox top section. The blind bolts must
be secured with locknuts.
9.2.14.2.7 Ventilation
Each gearbox must be equipped with at least one venting filter. Oil sprayed upwards
must not emerge through the venting filter.
9.2.14.2.8 Lifting points
The lifting points on gearboxes must be located on the top and bottom part such that
the total weight of the gear system can be taken up and it is just suspended when lifting.
If eye bolts are used, they must be selected in accordance with DIN 580.
9.2.14.2.9 Installation
Tolerances must be specified for the installation and connecting dimensions to ensure
that the gearboxes can be replaced. The reference line is the center of the drive shaft.
The mounting locations on the steel structure must be prepared mechanically. If
additional lining pieces (shims) are provided, they must have a thickness of approx. 10
to 15 mm and must be fixed by tacking.
9.2.14.2.10 Gear transmissions
As far as possible, the transmission ratios of spur gear sections should not exceed 1:6.3
for single stage gear systems, 1:31.5 for two stage gear systems and 1:125 for three

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stage gear systems. The ratios of the number of teeth in the individual stages should
not be an even number.
9.2.14.3 Lubrication
Section 9.2.2 must be taken into account for the lubrication of gear systems. Lubrication
of gear wheels must normally be by oil splash lubrication, and the bearings should be
lubricated with the oil which is flung up by the gear wheels. It must be possible to check
the oil level with a readily accessible oil dipstick. A gear wheel oil pump must be
provided on gearboxes for which adequate lubrication is not ensured by immersion of
the gear wheels. A non-return valve with suction basket must be attached to the end of
the suction line. Filters are to built into the oil circulation system with max. 40µm filter
mesh size and adequate filtering capacities. The functioning status of the gear wheel oil
pumps must be indicated by sight glasses or pressure gauges in the oil lines. Circulation
lubrication for the cranes of group G1 shall have a pressure monitor with a display in the
operator cab. A readily accessible drain valve with pipe thread must be provided at the
lowest point of the gearbox for draining the oil. The screw thread size will be specified
after contract award.
9.2.14.4 Oil coolers
For all gear units of hoisting gears, a heat balance must be achieved, after
consideration of the deployment conditions in accordance with chapter 4, capacity
utilization in accordance with chapter 5 and the power dissipations of the gear units. If
the results lead to temperatures that are above the permissible sustained temperatures
for the planned oils (e.g. max. 80 °C for mineral oils) adjustable oil coolers must be
deployed. The design and cooling capacities must correspond to the deployment
conditions. If fans are deployed, the dust load must be taken into consideration.
9.2.14.5 Labeling
A sign plate must be permanently attached to the gearbox with the following clearly
legible information:
- CE labeling
- Manufacturer
- Type, production number, production year
- Drive power with respect to the drive rotation speed
- Gear ratio
- Maximum permitted drive torque
- Empty weight of the gear system with inserts and cover
- Oil volume.
A designator for the required oil type must be marked on the gearbox.
9.2.14.6 Alignment surfaces
All drum gear units shall have mechanically machined surfaces at the hub of the drive
shaft for the alignment of the rope drums. On the rope drum flanged discs, the surfaces
must also be mechanically machined to the same radius.

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All gear units of hoisting gear shall have cleats at the front, at the height of the
separation joints, with markings for the alignment and measurement of the gear units.
These markings are to be etched on in the same clamping in which the separation joints
are marked.
9.2.14.7 Mechanical preparations for the vibration monitoring system
For a possible retrofitting of a vibration monitoring system, the relevant points on the
gear units of the hoisting gear (only cranes of group G1) are to be provided with
mechanically machined surfaces for vibration measuring devices.
9.2.14.8 Oil level and oil temperature monitoring systems
The gear units of the hoisting gear of cranes in group G1 shall have oil level and oil
temperature monitoring systems. If the oil level or temperature should move outside the
normal operational range, displays in the operator cabs should activate. If critical values
are reached, the affected drive units should automatically shut down.
9.2.15 Brakes and brake releasing equipment
9.2.15.1 Fundamentals of calculation
The service brakes must be calculated in accordance with DIN 15434 for the respective
highest speeds, least favorable thermal stress and maximum switching frequency. The
conditions and delay times specified in section 9.1 apply.
Hoist mechanism may have disc brakes. Manufacturer and type of disc brakes has to
be approved by TKCSA. Horizontal mechanisms must have drum brakes. In the case
disc brakes are used for hoist mechanisms the drum brakes should not be used (to
avoid mixture of brake types).
The brakes of the crane trolley traversing gears must be dimensioned and executed as
holding brakes. Here, it must be taken into account that, in the case of the incidence of
the brakes, there is still a speed of travel which exists at 5 Hz rotary frequency of the
drive motors. A suitable deceleration when the emergency stop function is triggered
(without any electrical braking effect) must be assured under the most unfavorable
conditions.
Hoisting gear brakes must be dimensioned and executed as holding brakes. Here, it
must be taken into account that, in the case of the incidence of the brakes, there is still
a raise or lower speed, which exists at 5 Hz rotary frequency of the drive motors. A
suitable deceleration in the event of three immediately subsequent triggerings of the
emergency stop function (without any electrical braking effect) must be assured under
the most unfavorable conditions.
The calculations for the brakes, in accordance with DIN 15434, are also to be supplied.
All set values are to be listed in the documentation.
The instructions of the brake system manufacturer must be complied with.

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All brakes are to be designed as drum brakes. The braking torques calculated are to be
taken into consideration when performing calculations for the gear units.
9.2.15.2 Design of the service brakes and brake releasing equipment
Only eccentric drum brakes may be deployed, without return springs in the case of
Eldro devices. Installation dimensions and shape and housing deviations of the joints
relative to each other are to be selected in accordance with DIN 15435 Part 1. It must
be possible to relubricate all housing positions, and they must all have spring steel
bearing bushes. The brake levers are to be deployed in cast steel design. The
replaceablility of all individual components must be guaranteed. Brake shoes are to be
designed in accordance with DIN 15435 Part 2. Only inspected and asbestos-free
coverings whose suitability has been verified under the existing conditions may be
deployed as brake linings, in accordance with DIN15435 Part 3. The brake linings
deployed must fulfill all requirements of DIN 15436.
The brake drums are to be designed in accordance with DIN 15437. Only cast drums
made of GS-60, GS 42CrMo4V or forged drums made of C60 or 42CrMo4V may be
deployed. The brake drums are to be designed as bolted couplings.
Every operational brake shall have two non-contact brake monitors that serve to identify
the open or closed brake status.
For installation purposes, the setting values of the brakes must be marked indelibly and
clearly legible on a sign on the brake.
Brake lifting devices deployed are to be electrohydraulic in design. Interchangeability

with the brake lifting devices of EMG must be guaranteed. The brake lifting devices are
to be designed for a power-on period of 100%. The deployment conditions specified in
chapter 4 are to be taken into consideration. Seals must be selected in Viton design. If
necessary, the brake lifting devices must be designed with stator grouting.
Eldro assignment for Eldros manufactured by EMG:
D 200; Ed 23/5 to Mb 200 Nm

D 250; Ed 23/5 to Mb 250 Nm
D 315; Ed 30/5 to Mb 450 Nm
D 400; Ed 80/6 to Mb 1400 Nm
D 500; Ed 80/12 to Mb 1700 Nm
D 630; Ed 185/16 to Mb 4100 Nm
D 710; Ed 301/12.1 to Mb 7350 Nm
9.2.15.2 Emergency brake
All cranes in groups G1 and G4 as well as crane S310 are to be equipped with
electromagnetic emergency stop brakes in the main hoisting gear. The design of the
emergency stop brakes must adhere to the descriptions given in section 9.1. These
brakes work directly on the rope drum flanged discs and are to be installed on separate
and easily accessible brackets.
The number (group G1 min. 4 brakes per drum) and size of the brakes is to be
determined in accordance with the loading specifications of section 9.1. Taking into

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consideration the reaction times of rotation speed monitors and switching devices, and
the rotation speed reached before the brake engages, max. braking distances of 0.5 m
(measured on the lowering path of the lamella hooks) are to be guaranteed under the
least favorable loads.
At 530t hoists, number of emergency brakes per drum can be reduced to 3, provided
the calculation by the crane/brake manufacturer shows adequate safety and subject to
approval by TKCSA.
The brakes and switching devices are to be selected with reverse current systems that
bring about a reduction in peak when the brakes engage.
The suitability of the emergency stop brake for the deployment conditions described in
chapter 4 and the switching frequency described in section 9.1 must be confirmed by
the manufacturer.
It must be possible to control the ventilation of the emergency stop brakes for
emergency lowering after the brakes are engaged. It must therefore necessarily be
possible to adjust both the number of brakes being bled and the braking torque. In
addition to this, a rotation speed monitor is to be provided that raises the braking torque
again if critical speed is reached, and reengages bled brakes. The operating devices for
emergency lowering shall take the form of control blocks that may be connected to the
trolley with a cable route of approx. 15 m.
9.2.16 Motors
Squirrel-cage motors suited to frequency inverter operation are to be deployed. All

motors and all frequency inverters must be obtained from the same manufacturer. All
drive units are designed in accordance with insulation class B but executed as insulation
class F. The type of protection must be at least IP 55. All motors shall have external
cooling units. The assembly of all motors shall be achieved with anchor nuts on motor
slide rails in accordance with TH-N 441 360. Hoisting gear motors shall have motor slide
rails for alignment in the X and Y axes.
The performance of the motors must be calculated for the following conditions:
 Gear mechanisms for the acceleration performance from the specifications

according to Table 7 at full load with the most unfavorable trolley position and a
switch-on duration according to Table 6.
 For carriages at half nominal speed and with symmetrical failure of 50% of the
drive units, and at 60 % operating factoracc. to table 6
 Hoisting gear mechanisms for the steady-state performance at full load and with
an operating factor according to Table 6.
 For hoisting gears with test load, in accordance with section 1.2.5.1 and at 25%
operating factor
 All calculations taking into consideration the maximum temperatures given in
chapter 4
 All calculations taking into consideration the classifications in accordance with
chapter 5
 All calculations with at least 10% additional charge for the operation with
frequency converters
 Degrees of efficiency of gear units are to be calculated using the following
factors:
ηZ = 0.995 per tooth meshing
ηL= 0.99 per pair of bearings

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ηD= 0.98 per shaft for sealing and lubrication

 The degrees of efficiency of couplings or universal joints must be taken into
consideration.
 Rope pull forces and degrees of efficiency are to be calculated and applied in
accordance with DIN 15020.
The performance calculations are to be submitted with the specified factors within the
framework of the mechanical engineering calculations.
Carriage drive units may be selected with max. 1800 RPM. For hoisting gear drives, the
maximum rotation speed is 1200 RPM. For motor types to be used in the hoisting gears
of the cranes in group G1, the performance capability must be verified by making
references to casting cranes with similar applications.
9.3 Description of specific mechanical equipment
9.3.1 Hoisting gears
9.3.1.1 General
Rope deflection angles must not exceed 3°. Smaller rope deflection angles should
always be the aim. The rope drive must be designed such that the largest rope
deflection angles on the rope pulleys appear with slow rotation speeds. Counter bending
changes are not allowed. Right hand wire ropes must be wound on left hand drums, and
left hand wire ropes must be wound on right hand drums.
In case rope counter bending causes problems for trolley hook approaches, TKCSA
will be contacted
In the case of the cranes S100, S200 and S300, the additional requirements of EN
14492-2, Annex B, for the transportation of molten masses must be observed.
9.3.1.2 Reevings
With the exception of the 10t auxiliary hoisting gears, all hoisting gears are to be
designed with winches. The following reevings are to be selected, and the maximum
rope diameter may be 40 mm:
Group G1 hoist 1: 4 x Y/1 (e.g. 4x 14/1)

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All rope drives are to be designed with compensation rockers in accordance with section
8.4.3. The calculation of the rope drives and the arrangement of the diameters of rope
drums, compensation rollers and rope pulleys must be in accordance with DIN 15020
respectively FEM for the main hoists of group G1.
Ropes with higher metallic cross-sections may not be deployed to reduce the rope
diameter.
9.3.1.3 Hoist ropes
Uncompressed 8-strand round-stranded ropes are to be used, with plastic layering

between the steel rope core and the external strands. The selection of rope diameters
must be in accordance with DIN 15020 respectively FEM for the main hoists of group
G1. When determining rope diameters for the affected cranes, correction value c for
hazardous (molten) transportation must be used. Long-lay ropes must be utilized. The
rope end connections must use flemish eyes and full thimbles in accordance with DIN
3091. Ferrules are to be deployed in accordance with DIN 3095 form Z type A. In
addition to the required rope certificates, inspection certificates for the ferrule materials
are to be supplied in accordance with DIN 10204 class 3.1. Furthermore, the pressure
sleeves must be subjected to ultrasonic testing. This must be documented. The
examiner must demonstrate qualification of at least class 2 in accordance with EN 473.
9.3.1.4 Rope attachment points
The rope attachment points must be gimbal suspensions. It must also be ensured that
the bolts and bearings are accessible for inspection. The forks and bars of the rope
fixing points are to be manufactured from forged solid material in minimal notch design.
9.3.1.5 Rope drums
9.3.1.5.1 Diameter and design
The minimum rope drum diameter is to be calculated in accordance with DIN 15020, or
shall be determined by the length of the rope to be spooled. The design of the rope
drums shall be in accordance with SEB 666211. As for all other winding, the security
winding also runs in rope grooves. A minimum of 3 security windings are to be provided.
Drum flanged discs facing the gear unit drive shafts shall have mechanical machining
on this side in accordance with section 9.2.14.6.

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For the deployment of the emergency stop brakes, the affected rope drum flanged discs
of the cranes in groups G1 and G4 are to be correspondingly enlarged. The flanged disc
thickness and the axial and radial eccentricity tolerances are to be guaranteed through
mechanical machining to correspond to the specifications of the brake unit
manufacturer.
For cranes in group 1, the flanged discs are to be designed such that, in the event of a
drum trunnion breakage, support can be provided by the supporting rollers in
accordance with section 8.4.3.
When performing the calculations for the rope drums, their flanged discs and the rope
drum bearings, the forces arising from the engagement of the emergency stop brakes
must be taken into consideration. The same applies to the dimensioning of all
components in the power train.
9.3.1.5.2 Rope attachment and safety turns
The rope attachment on the rope drum must be designed in accordance with SEB
666212. All rope drums of a hoisting gear must have the rope fixtures in the same
position on the rope drum circumference. A corresponding instruction must be noted on
the assembly drawing. 3 security windings are to be provided.
9.3.1.5.3 Rope drum articulated connections
The power transmission from the gear unit drive shafts to the rope drums shall take
place through rope drum jointed connections. The quality and load carrying capacity
must correspond to the products of Messrs. Malmedie, type NTT or TTX or Messrs.
Flender, type ZAPEX. For the calculation, design and dimensions of the rope drum
jointed connections SEB 666212-1 to -5 applies. The rope drum jointed connections are
to be equipped with wear monitors for the axial and radial backlash. It shall be possible
to relubricate the rope drum jointed connections. To this end, each rope drum jointed
connection shall have 2 pipelines that extend to the outer rim of the flanged disc. The
lubricant and the seals are to correspond to the deployment conditions specified in
section 4.
9.3.1.5.4 Rope drum bearings
On the trunnion side, the rope drum bearings must be seated in self-aligning roller
bearings. The bearings must be provided with facilities for relubrication. In hoisting gear
with emergency stop brakes, the pulse transmitters of the rotation speed monitors are to
be attached to the shaft extensions of the drum trunnions with couplings. The pulse
transmitters shall have dust and impact protection.
9.3.1.5.5 Gear limit switches
The deactivation function for the highest and lowest positions of the carrying device
must be implemented with gear limit switches. It must be ensured that adequate run-out
distance is available. To this end, at least one rope drum of each hoisting gear shall
have a gear limit switch with at least 4 contacts. The connection of the gear limit switch
to the rope drums or hoisting gears shall always be achieved with couplings, to
compensate for shaft misalignment and angular displacement. The gear limit switches

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may also be attached to the gear units of the hoisting gear. The cranes of group G1
shall have at least two gear limit switches that monitor each other.
9.3.1.6 Rope pulleys
The rope pulleys must be selected in accordance with TH-N 565 763. Cast or forged
rope pulleys of quality 42CrMo4V or GS-42CrMO4V may be deployed. It must be
possible to relubricate the rope pulley bearings. The rope pulleys must be arranged in
an easily accessible fashion. A one side bearing support is not permitted. The rope
pulleys must be seated in cylindrical roller bearings which are sealed with radial shaft
sealing rings.
The rope pulley axles must be designed according to the calculation fundamentals for
drive systems in hoisting gears (draft DIN 15017).
9.3.1.7 Top and bottom blocks
The lubricating lines for the rope pulleys must be brought together at one point on the
top pulley block. The accessibility of all rope pulleys and the possibility of a simple rope
pulley replacement must be guaranteed. Disassembly aids are to be provided if
necessary.
The bottom pulley blocks must be encapsulated as far as possible. Openings for dirt,
water or grease must be provided facing downwards. Where necessary, the bottom
pulley block must be equipped with rope back-up rollers and rope ridges to prevent the
ropes from jumping off the rope pulleys
9.3.1.8 Overload and slack rope switches
For the cranes of group G1, overload and slack rope deactivation in the main hoisting
gear must be triggered by load calculation in the load cells, in accordance with section
10.12.
For all other hoisting gears (except 10t auxiliary hoists), the load calculation for the
overload and slack rope deactivation is achieved with measuring pins in the
compensation rocker bearings or the rope fixing points in the compensation rockers.
The thimbles must not be in direct contact with the measuring pins, but must have their
bearings on separate pins, with connecting bars or universal joints. Universal joints must
here be manufactured from forged materials.
All measuring pins must be equipped with redundant measuring circuits. Strength
analyses for the measuring pins must be supplied along with these.
For hoisting gears with crossbeams, the evaluation of the measuring pins must be such
that both total and differential loads may be determined.
The measuring pins are to be installed as stipulated. Special significance must be

accorded to the avoidance of measuring errors that might arise from squeezing of the
pins due to insufficient axial play.

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9.3.2 Traversing gears
9.3.2.1 Lateral forces due to off-track running
The lateral forces arising from off-track running must be calculated for relevant
components in accordance with DIN 15018 - 1.
For the calculation of the off-track running angle , the following values are to be
added:
f = off-track running angle from 75 % due to the actual track play between the
rail and the guide gear.
v = off-track running angle from wear. Minimum 10 % of 120 mm
0 = 1‰ off-track running from tolerances of the crane and the crane runway
9.3.2.2 Track guidance
The track guidance of all crane and trolley traversing gear and of the S310 shifting gear
is achieved with flanged track wheels.
9.3.2.3 Wheel flange lubrication
To reduce friction between rail head and wheel flange, automatic lubricating systems
are to be installed on one crane per hall. Here, the lubricant (e.g. KP2K) is distributed by
2 spring-loaded coils on either side of the rail head. The lubricant quantity and the
frequency of lubrication must be adjustable.
9.3.2.4 Track wheels
The following standard specifications apply for the crane and trolley track wheels:
-TH-N 565 600 drive running sets with wheel flange (for trolleys)
-TH-N 565 601 mountings with wheel flange (for trolley)
-TH-N 565 605 drive running sets without wheel flange (for crane bridge)
-TH-N 565 606 mountings without wheel flange (for crane bridge)
Wheel diameter 900 can be applied for this project.
The minimum track wheel diameters specified in section 7 must be complied with.
Should the calculations for the track wheels in accordance with DIN 15070 result in
higher pressures than 690N/mm², the wheel size or the number of wheels is to be
increased. The track wheel diameter must not exceed 1000 mm. The enlargement of
rail profiles is only permissible for crane trolleys.
As a rule crane track wheels with wheel flanges are provided with a track wheel bore of
140 mm for the crane rail profile A120 being used here. For adaptation to the increased
craneway tolerances according to Section 8.2.2.2, it is recommended to increase the
track wheel bore on one crane side each. In this case the widths of the track wheels

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from TH-N 565 600 and TH-N 565 601 must be increased by that amount by which the
usual wheel flange bore of 140 mm is exceeded. The track wheel drawings must be
adapted. For reasons of spare parts, identical track wheel widths must be provided on
both hoist gear mechanism sides of a crane in spite of differing track wheel bores.
For the crane trolleys of cranes S210, S310, S320 and S330, variations in track wheel
sizes are possible in order to balance out the asymmetrical load distribution. To this
end, track wheel diameters of sizes 630, 800 and 1000 mm may be combined.
Furthermore, track wheels of the same size may be paired in track wheel links.
Certification for rail in accordance with DIN 15070 for pressures ≤ 690N/mm² must be
supplied.
All track wheels must be of tempered design. The following materials may be employed:
42 CrMo 5-04 (from ASCOMETALL for Valdunes)

34 CrNiMo 6
33 NiCrMo 7 4 4
33 NiCrMoV 14 5
30 NiCrMo 8 5
35 CrMoV 10 4 V
50 CrMo 4
The track wheel materials must fulfill the following technical values:
Rm : 850 - 1000 N/mm²
Re : 700 – 800 N/mm²
A5 : 10%
AV : 30%
The track wheel axles must likewise be made of heat-treatable steel.
9.3.2.5 Guide Rollers
All cranes have to be equipped with two inside and two outside guide roller pairs. The
column row for the position of the guider roller has to be chosen during the construction
phase. In each case, one inside and one outside guide roller pair are seated in a rocker. Also
it is possible to arrange 4 guider rollers in one centre rocker.
The preferred position of the rockers have to be arranged as close as possible to the first
and the last crane wheel in order to keep the width of cranes above buffers as low as
possible.
For changing the wheels the bracket of the guider rollers have to be removable by bolted
connections.
The vertical position of the guide rollers can be varied upwards through at least
15 mm by inserting spacers, compared with the setting in the new condition. Insertion of the
spacers must be possible without dismantling the centre trunnion. The centre trunnions
must be provided with relubrication facilities for the bearings. Eye bolts must be screwed on
the centre trunning for dismantling.
The horizontal play of the guide rollers is adjusted with eccentric axles which must be
incorporated in all guide rollers. For locking the setting, the eccentric axles must be provided
at the top with a collar with toothing and specification of the eccentric setting. The toothing
engages in a screw attached sector gear disk. In the new state the horizontal play must be

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set to 2 x 2.5 mm. The possible range of readjustment must be at least ± 10 mm. The
bearings of the guide rollers must be made floating, with two self-aligning roller bearings for
each guide roller. The bottom edge of the guide roller and of the eccentric trunnion and of
other components of the guide roller must not lie more than 2 mm below the rail head of the
crane runway (dimension h3 DIN 536) in the new state. The eccentric axles must have
relubrication facilities for the bearings and a threaded bore for screwing in the mounting eye
bolts.
The material of the guide rollers must be choosen accordingly to the material the crane
wheels in paragraph 9.2.3.4 of crane specification from 16.02.08.
Quantity and diameters of guide roller
Crane Quantity Diameters [mm]

S100 8 630
S200 8 630
S300 8 630
S110 8 400
S210 8 400
S310 8 400
S320 8 400
S330 8 400
For protection of the maitinance personal and the crane operators the the guide rollers have
to be covered by hoods.
9.4 10 t auxiliary hoist for cranes S210 and S310
For these hoisting gears, electric rope pulleys with underrunning trolleys of classification
2m (DIN 15020) are to be deployed. The reeving selected must be 2/1, 4/1, 2/2 or 4/2.
The hoisting gears shall have a gear limit switch with the following features:
1 switch contact pre-deactivation for the reduction of hoisting speed before the upper
operational limit switch
1 switch contact upper operational limit switch (with bridging for inspections)
1 switch contact upper emergency limit stop
1 switch contact lower operational end position
The hoisting gears shall have an overload deactivation system. The slow hoisting speed
(min. 20% operating factor) shall be achieved by pole-changing, frequency converters or
slow hoisting motors.
The underrunning trolley shall have electric pre-deactivation and limit stop systems, as
well as a mechanical limit with a rubber buffer.
The current supply may be designed with insulated small contact lines or with a trailing
cable system. The current supply and the auxiliary hoisting gears are to be protected
from the effects of heat.
The drive units shall have temperature monitors and thermistor type motor protection,
as well as fusing with load-break switches.
Inspection books, declarations of conformity and maintenance and operating

instructions shall be included in the hoisting gear documentation.

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The operating voltages shall be selected in accordance with section 7.
9.5 Repair winches for rope changes
To pull the rope fixing points, 2 winches with a load-bearing capacity of 500 kg each are
required. The winches may be designed for irregular coiling. The specified load-bearing
capacity must however be reached in the top winding. The winches shall have a speed
control and an overload safeguard system.
The winches are to be equipped with a substructure that permits quick and secure
attachment to the trolleys of the cranes in group G1. The pulling of the rope ends with
the fixing points shall take place via deflection and guide rolls that are slung in the
gallows of the rope rockers. The tensile forces of up to 50 kN that then arise must be
conducted from the substructure of the winches into the trolley structure.
The operating voltages shall be selected in accordance with section 7.
The winches shall have transport lugs. Inspection books, declarations of conformity and
maintenance and operating instructions shall be included in the winch documentation.
10. Electrical design

10.1 Power supply
Supply voltage: 6,6 kV for all cranes

Voltage fluctuations: ± 15 %
Frequency: 60 Hz
Operating Voltage for drives: 460 V
Control voltage: 220 - 250V AC 60 Hz
Signal voltage / PLC: 24 V AC /DC
Type of protection switchgear unit in E-rooms at least IP 20 or IP 30
Type of protection switchgear units outside E-rooms at least IP 55
10.2 General overview
Division of the plant groups:
Crane supply = Plant group 00

Special current = Plant group 01
Safety power circuit = Plant group 02
Weighing technology = Plant group 04
Air conditioning technology = Plant group 05
Radio control system = Plant group 09
Crane traversing gear = Plant groups 10 to 18
Hoisting gear = Plant groups 20 to 26
Trolley traversing gear = Plant groups 40 to 46

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Design of the control system / electrical system with the following components:
Control cabinets on the bridge girders and crane trolleys must be equipped with double
doors opening to 180 degrees, indoor lighting by door contact and an equipment
connection socket for each drive group. They will be equipped with separately bolted
mounting plates. The doors are to be equipped with locking devices fitted with fasteners
allowing the doors to be arrested at the top and at the bottom.
In the E-rooms according to Section 8.4.1.3, open switchgear racks must be fitted on
rubber-metal vibration dampers. The switchgear racks and the components mounted
thereon must not restrict the passage widths of the passages as prescribed according to
Section 8.3.6.1 and 8.4.1.5. All life parts without standard contact protection must be
covered in accordance with BGV A3. To the extent possible, transparent materials,
such as Macrolan must be used for this purpose.
The floors of the E-rooms are to be laid with rubber floor coverings approved for
switchgear units up to 1000V.
The regulations pursuant to Section 1.5 apply to the electric execution and design. In
particular, DIN EN 60204 Part 1, 26 and 32, EN 294, 418, 811,60947(VDE 0113 Part
1,32,VDE 0100 Part 410, 610,726, VDE0105-100) EN13155 must be complied with
completely.
NR-10 (Brazilian law to safety operation on electrical installation) and ABNT NBR-5410
(Technical Specification to electrical installations on law voltage plants) have to be
considered additionally.
Furthermore, the EMC Directives 89/336/EEC and EN 50081 as well as EN 50082 for
protection against the emission and incident of electromagnetic interferences when
selecting equipment, cables and cable laying must be fully complied with. The EMC
version of switchgear units and switching devices, high HF damping, must be
implemented during project planning.
For all electric components a spare part supply must be ensured for a period of 10
years.
Those contactors, auxiliary contactors, automatic circuit breakers, full motor protection
devices are to be used whose interchangeability with the Siemens or Schneider brands
is ensured.
Fuse load-break switches must be implemented with safety monitoring.
Plug melting fuses must not be used.
Crane circuit breakers on the crane bridges must be designed as a cabinet combination
with lockable manual levers according to EN 60204.
The infeed and special current plant assemblies will be equipped with a voltmeter for
each phase in order to visibly indicate the separation point.
The crane isolating switches are designed as circuit breakers in accordance with DIN
EN 60204-32. The cables for the infeeds and outfeeds are routed via insulated CU
contact rails. The crane isolating switches are mounted in the immediate proximity of
the ascents and descents to the crane cabs. The design of the crane switches must be
selected as bar contactors complete with non-welded contacts or as a circuit breaker
version in accordance with VDE 0660 Part 107. The outfeeds at the bar contactors or

Bridge Crane TKCSA
ThyssenKrupp CSA
circuit breakers are executed as a CU rail system. The cable outfeeds for all drive units
are connected to the rail system by means of single conductors.
For each crane, the crane lighting consists of at least 8 crane lights 400 W –HIT/DE
including adapting equipment and illuminant halogen metal vapor lamps under or on the
crane bridge and 2 lights of 400W each under each crane trolley. All illuminants must be
selected such that they feature a stainless steel design. The suspension consists of a
swiveling bow, fixing clamps and vibration reducing elements according to DIN 50976.
The illuminant holder must be fitted with a twin base. A good and hazard-free
accessibility of the lamps and illuminants must be ensured. All lamps are fitted with drop
safety devices.
All E-rooms, walkways, service platforms and operator cab access points are fitted with
illumination devices for add-on connection; such devices are to be suitable for use in
damp locations / long field light version made of break-proof PVC, 2x36W / 1x58W, with
removable lamella troughs. An illumination of at least 50 Lux must be ensured in these
areas. At the hoisting gear platform, each crane trolley is fitted with 2 off glass/steel
reflector lamps 2 x 58 W in a stainless steel design. It is attached by means of
adjustable fastening angles.
Each control panel is to be fitted with a socket outlet that will be designed for measuring
and operating units only and protected by a 2 ampere fuse. Each crane bridge girder will
be fitted with a socket outlet on both sides. The operator cab will also be fitted with a
socket outlet. All socket outlets are fitted with a differential-current switch circuit
breaker.
All illuminations must be assigned to the plant group = 02 (special current).
Each crane is fitted with an acoustic (hooter) signaling device having a loudness of at
least 100 dB complete with an electronic signal adjustment device.
In the switchgear units and the operator cabs and the radio remote controls, any fault
messages will be displayed according to Section 10.11.
In addition to fault messages in the operator cab according to Section 10.11, cranes
equipped with a radio control system are also additionally fitted with 2 lights under the
crane bridges or platforms, which signal the following conditions:
 excess load,
 limit switch,
 air conditioning system,
 collective fault message
The light systems must be clearly visible from the mill floor line and secured against
dropping down.
For parameter entry and the read-out of data in the PLC, 2 off input device /
programming devices with associated programming software are to be offered
optionally.
An interface for remote analysis or a data exchange (teleservice) for each programming
unit must be provided for each crane. The associated input devices are included in the
scope of supply.

Bridge Crane TKCSA
ThyssenKrupp CSA
All trolley traversing gears (including shifting gears) are fitted with electric advance and
limit stops for both directions. The circuits and the components used must correspond
to the safety category 3 according to EN 954-1 and the requirements of EN 12077. The
same conditions apply in respect of the crane traversing gear for the travel movement in
buffer stop direction.
For crane travel in the direction of the neighboring cranes spacer systems must be fitted
complete with advance and limit stops. The circuits and the components used must
correspond to the safety category 3 according to EN 954-1 and the requirements of EN
12077. Optical systems must only be used with self-cleaning optical devices.
For the crane traversing gears, all cranes are fitted with 4 rail blowers each as well as 4
rail blowers for each crane trolley to remove impurities from the rails. When the
respective traversing mechanism is operated, the rail blowers will be activated and run
for approximately 5 minutes after the travel movement has been stopped. With regard
to the noise emission of the rail blowers, Noise Emission Directive 2000/14/EC must be
taken into account.
For cable trolleys, cable trailers for I – profiles must be selected. All cable trolleys are
fitted with lateral guide rollers. The track rollers and guide rollers must be used in a steel
version with a diameter of at least 80 mm. For cranes of group G1, rollers with a
diameter of at least 120 mm are to be used. All cable trolleys are fitted with stop buffers.
Between the cable trolleys, strain relief clamps must be tensioned. When moved
together, the cables must not come into contact with each other. For the operational
conditions stated in Chapter 4, neoprene flat conductors must be used. The cable
trolleys must be loaded symmetrically. 15% reserve wires must be taken into account,
which need to be connected to terminals. The carriers of the cable trolley devices are
fitted with a height adjustment device which provides for a lifting of the crane trolleys
without any removal of the carriers.
Transition boxes are to be equipped with double doors and a locking system (by
agreement with TKCSA). The dimensions of the cabinets must be at least 1200 x 1200
x 300 mm and they are to be mounted on a vibration-proof substructure.
All cables and conductors as well as all components on the crane shall have conductor
markings.
All electrical components must be marked according to plant and location. To this end,
heat-resistant plates must be bolted onto the components and their respective base, or
mounting plates. In the case of fuse load-break switches the current intensities of the
fuses inserted must be entered in plain text format. The same applies to set values of
motor-protection circulation breakers.
All cabinets, transition boxes and control elements must be marked with a warning
against live parts in accordance with EN 60204-32.
All electrical components are fitted with a visible equipotential bonding.
The electrical circuit diagrams must be kept in welded foils in a compartment in the
control cabinet. In the switchgear unit, a storage shelf for a programming unit is fitted
and adapted.
10.3 Current supply
10.3.1 Current supply for the cranes in groups G1, G2, G3 and G4

Bridge Crane TKCSA
ThyssenKrupp CSA
For their main power supply, all cranes are fitted with a motor cable drum featuring
helical winding. The infeeds are effected with a 6600 V medium voltage respectively
from the craneway center ±20m. The supply and assembly of the necessary infeed
hoppers are included in the crane supplier's scope of supply. The supply of the motor
cable drum including cable and guide roller system underneath the motor cable drum is
also included in the crane supplier's scope of supply.
The dimensioning of the motor cable drums and the cables as well as the switches and
transformers must be effected for the sum of the nominal currents of all loads on the
respective crane. For all cranes in group G1, the same components must be used as
well as for all cranes in groups G2, G3 and G4.
For current supplies, drum-capable cables of type Protolon SM-K 6 /10KV in
accordance with DIN VDE 0250 part 813 must be supplied. The cable lengths must be
determined from the workshop lengths, the position of the infeed hoppers and the
position of the motor cable drums on the crane. At least 2 reserve windings on the
motor cable drum must be taken into account here.
The current supply up to the infeed hoppers is effected by TKCSA. The consoles for the
cable trays are supplied by TKCSA.
Examples for the motor cable drums, roller guides and infeed hoppers are found in the
annexes.
For the cranes in the charging shop (S100 and S110), 3 infeed hoppers must be fitted
as a further crane may possibly be retrofitted in this shop. For the ladle handling and
charging shop, 2 infeed hoppers must be fitted respectively. The enclosed crane project
drawings show on which side the infeed hoppers must be mounted.
When selecting the motor cable drums, the operating conditions according to Chapter 4
must be taken into account. The drive motors must be selected for 100% operating time
under the conditions according to Chapter 4. In addition, the drive motors are fitted with
full motor protection and PTC thermistor sensor with triggering devices. The frequency
converters for the motor cable drums and for hook sensor technology must be selected
whilst taking into account Section 10.4. The frequency converters must be arranged
with 100% redundancy (i.e. 2 FC per drive unit) in the fully air-conditioned switchgear
rooms. The cable routing to the drive units is effected complete with screening.
The cable routing to the drive units of the motor cable drums is effected by means of
cables such as described under Section 10.5 , i.e. EMC-suitable cabling with screening.
The motor performance drums are fitted with limit switches for both travel directions as
well as an automatically acting shutoff in the roller guides as protection against any
excess or underrun of the cable pull force.
The 6.6 kV supply line is connected to the terminals in the associated high voltage
terminal boxes of the motor cable drum. From these terminal boxes the cable is routed
to the 6.6kV / 460 V transformer.
The installation, connection and commissioning is effected in accordance with the
directives:
 DIN VDE 0101- Power installation with nominal alternating voltages in excess
of 1 kV,
 EN 50110 Operation of electrical installation
 EN 60332 Cable testing
 EN 50267 Part 1-3 General test procedures for the behavior of cables
 Standard EN 60076
 EN 60255-6 Electrical relays
 EN 60694 Common provisions for high-voltage switchgears
 EN 61219 Working with live voltages...

Bridge Crane TKCSA
ThyssenKrupp CSA
 EN 61230 Working with live voltages…

 EN 61330 Factory-ready stations for high voltage / low voltage
In accordance with the operating conditions on cranes, transformers must be supplied in

a shockproof design. Transformers are to be mounted on vibration dampers. The
transformers are installed in steel sheet casings on the crane bridges. When selecting
the type of protection, the operating conditions according to Chapter 4 must be taken
into account. With the present air humidity, the generation of condensation water must
be expected. In addition, the enormous dust generation as well as the incidence of
splash water must be noted. The transformers are fitted with temperature monitoring
devices, voltage monitoring devices, insulation and contact protection in accordance
with the above-stated regulations.
Accidental contact with live parts must be prevented in accordance with BGV A3 and
BGV D6.
.
From the secondary outputs of the transformers, the infeed lines must be fed to the
isolating switches. The isolating switches must be located in the operator cab access
areas. The execution of the crane circuit breakers in connection with the special electric
circuit is effected by means of load-break switches in accordance with their required
performance. The switches are fitted and cabled in a control cabinet. The outputs to the
crane switch contactor is effected by means of a CU rail system. A unique optical
separation of the switch positions for On and Off in accordance with the switch positions
according to EN 60204 Part 32 in connection with phase voltmeters must be ensured.
10.3.2 Current supply for the cranes of group G4 (S320 and S330)
For the main power supplies of these cranes, contact line systems are routed
underneath the crane rails and along the tracks. These are not included in these
specifications.
The sides along which the contact lines are routed are indicated in the crane project
drawings. The exact position and dimensioning of the contact rails are indicated during
the course of the further object processing. The conductor rail system consists of an
earthed conductor and three phases with 460V each. The earthed conductors are
always positioned at the top.
The full copper rails of Messrs. Vahle F45/600, with a transferable continuous duty
current intensity of 1432 A each, are used.
The associated current collectors:
 GSV 8/S MI PH and

 GSV 8/S MI PE- insulated
are included within the crane supplier's scope of supply. For each contact line, 2 current
collectors must always be used. Each of the two current collectors must be capable to
transmit the full connected power on its own. Further details on the current collector
basket are provided in Section 8.4.8..
The infeed of the contact rails is effected centrally and, in addition, with 2 infeeds
approximately L/10 from the ends of the contact rails.
In the case of this infeed, in addition to the nominal voltage tolerance of ±15% stated in
Section 10.1, a further contact rail voltage drop is to be expected.

Bridge Crane TKCSA
ThyssenKrupp CSA
10.4 Electrical specifications for the drive units on the crane.
Squirrel-cage rotor asynchronous motors in accordance with the specifications from

9.2.16 are to be used. The motors must comply with the requirements of the Machinery
Directive 98/37/EC, EMC directive 89/336/EEC.
The performances of the frequency converters must be adjusted to the drive power. In
so doing, the frequency converter design should be selected according to TKCSA
experience such that the frequency converter performance is:
 for traveling gears: at least 1.6 times the acceleration rating of the motors
 for lifting gears: at least double the acceleration rating of the motors
 for motor cable drums: at least 1.6 times the acceleration rating of the motors
with the operating time being the same in all cases. The factor is the ratio of the
converter current to the current for acceleration or deceleration of the drive units.
Electrical drive units and frequency inverters must be obtained from the same
manufacturer.
The occurring brake energy is carried away via regenerative units. brake / chopper units
and brake resistors. Installation of the resistors according to Section 8.4.1.3.
Alternative devices for the dissipation of brake energies can be offered complete with
the submission of a technical description.
The brake resistors must be fitted with a contact protection device. The cable routing to
the resistors must be effected by means of single wire routing.
All cranes will be equipped with regenerative systems.
The redundancy of the individual drive assemblies hoisting gear, crane traversing gear
1+2, as well as the trolley traversing gear, must be assured.
Overview of the number of motors and frequency converters
Group Hoisting gear Crane Trolley Shifting gear Cable drum

Hoist 1 / 2 / 3 traversing traversing gear
gear Trolley 1 / 2
Motors FC Motors FC Motors FC Motors FC Motors FC
G1 4* / 2* / - 4/2 8 4 4/2 2/1 - - min. 1 2
G2 2* / 2* / - 2/2 4 2 4/2 2/1 - - min. 1 2
G3 2 / 1 or 2 2/1 4 2 2/2 1 / 1 1 (S310) - min. 1 2
G4 2 / 1 or 2 2/1 4 2 2/2 1/1 - - - -
Table 11

Bridge Crane TKCSA
ThyssenKrupp CSA
In the event of an inverted rectifier (IR) or an infeed unit failing, the following
switchovers / redundancies for maintaining the crane operation are necessary:
The distribution of the drive units across the infeed units must be selected such that, if
one component fails, crane operation can be maintained using reduced parameters.
Infeed unit failure : covered by an even distribution of the inverted

for crane G1 and G2 rectifiers (IR) across two infeed units
Failure of IR hoisting gear 1 : crane G1, G2 covered by the planetary gear
drive
Failure of IR hoisting gear 2 : crane G1, G2 covered by the planetary gear
drive
Failure of IR crane traversing gear : G1 Operation with three IR possible (extended
ramps), G2, G3, G4 with one IR possible
(extended ramps)
Failure of IR trolley 1 : G1, G2 Operation with one IR possible
(extended ramps)
Failure of IR trolley 2 : G1, G2 one IR can be switched from trolley 1 to
trolley 2
Failure of IR conductor drum : Switchover from the second frequency
converter
All drive units are fitted with a temperature monitoring device PT100 complete with an
associated evaluation unit.
The setting of the start up curves and the speeds for the various individual running
steps is effected during commissioning in accordance with the specifications of the
crane operators.
The drive units and drive controllers of the hoisting gears must be designed such that, if
required, all technical prerequisites exist and are available for an oversynchronous
traversing mode of the lowering movement.
Should supplier wish to deviate from the TKCSA experience stated on the electrical
specifications for the frequency converters, the following is agreed between the parties:
The cabinets for the frequency converters should be designed in such a way that
enough space is reserved for a potential later substitution of the frequency converters
with the next bigger sized model of the same manufacturer.
Should any frequency converter stop working, including but not limited to short-term
temporary shutdowns for cooling down, on three days in any 30 day period, supplier
agrees to substitute, without any additional costs to TKCSA, the frequency converter
with the next bigger sized model of the same manufacturer. It is further agreed that
such substitution must be effected, after TKCSA’s written request, within a regular
repair shift (max. 16h). If the replacement time exceeds said 16h, TKCSA may at its
own discretion hire a qualified third-party to do the works. All duly evidenced costs
related to this will be borne by the supplier of the cranes.
10.5 Electrical installations

Bridge Crane TKCSA
ThyssenKrupp CSA
The routing of electrical cables and components must be effected in accordance with
the following basic principles:
 Cables must be laid in covered cable troughs or in cable ducts made of

galvanized steel. Here, space reserves of at least 15% must be taken into
account.
 In accessible areas, the cable ducts must be designed in a non-crush fashion

complete with a slip resistant surface.
 Cable ducts shall be laid out with heat resistant mats.
 Cable ducts exposed to radiation heat from below are fitted with heat protection
panels (see e.g. Section 8.4.2).
 The cable ducts must be included in the equipotential bonding.
 For the protection of the cables, the edges at the ends of the cable ducts or
cable ducts must be covered. In relation to the further cable routing, additional
measures such as cable hoppers, pipe bends, transitions, beading of the pipe
ends etc. may be necessary.
 For the cable entries into control cabinets, transition boxes and the
breakthroughs in the bridge girders, the following applies: for round cables
metric metal boltings and for flat cables special flat cable introductions must be
used.
 Trolley traverse limit switches must be fitted to sufficiently fastened C-rails with
a length of approximately 3 m length. The cable infeed to the limit switches is
effected from the crane bridge.
 The welding of holders onto supporting elements is not permissible without any
static verification.
 For trolley power infeeds, transition boxes must be provided.
 The connections of electrical components must be routed such that it is

possible to remove these components without opening cable routes or
withdrawing extended lengths of cable. If necessary, terminal boxes must be
installed for this purpose.
 PROFIBUS bus cables for use with enforced flexible movement operations (e.g.
trailing systems, FC trailing cable):
Execution and setup for electrical networks (RS485), according to DIN 19245
and EN50170 complete with screened and twisted two-wire cables and circular
cross-sections. The cables must be hardly inflammable (IEC 60332-1) and free
from halogen. Bending radii for moving bus cables on machine parts, single
bending radius > 60mm, multiple bending >120 mm. For bus cables capable of
being trailed, the following requirements apply: at least 3 million bending cycles
with the specified bending radius and an acceleration of 4m/s2 maximum.
 The following cable types must be provided for the installation of the control
system and the electrical drive units:
o Neoprene flat or circular cables NSHT or CORDAFLEX for cable trolley

operation, screened in accordance with VDE 0250 Part 809,

Bridge Crane TKCSA
ThyssenKrupp CSA
temperature of up to + 90 degrees Celsius, nominal voltage of 500V,

minimum bending radius 5x line diameter
o Flexible control cables, transparent, EMC suitable according to VDE
0245, 0250, and 0281 CU screened and transparent, temperature up to
+ 90 degrees Celsius, nominal voltage of 500V, wire color black with
continuous number printing, earthed conductor in the color green/yellow
o Motor connection cables, EMC suitable, double screening, transparent,
in accordance with VDE 0250, temperature up to 90 degrees Celsius,
nominal voltage 600/1000V, minimum bending radius, flexibly routed
12-20mm outside diameter bending radius > 7.5x outer diameter, >
20mm - 20x cable diameter
o Temperature-resistant control cables in the external area for casting
cranes EMC-suitable and free from halogen according to VDE 0295
cl.5, up to +180 degrees Celsius, for a short period up to 250 degrees,
minimum bending radius 10x cable diameter, execution with steel wire
arming
o Cable for mean voltage 6600V
10.6 Isolating switch on the crane =00 ,=01 , =02
The isolating switch on the crane for the 460 V supply connection and for special
currents must be designed in accordance with Section 10.2.
10.7 Crane driver seats and electrical systems in the operator cab =00 ,=01 , =02
On the inside of the cab, a lockable terminal box must be provided for all incoming
cables. The terminal strip must be designed such that all drive assemblies have their
own plant distribution and numbering. The terminal strip is located behind a lockable
door. Ensure that the cable ducts are sufficiently dimensioned. Furthermore, the cab
must be equipped with indoor lighting, a socket outlet, and a thermostat for air
conditioning.
The operator cabs are equipped with crane operator seats featuring a swiveling range of
at least 300 degrees. The seats must be designed with hydraulic damping. In addition,
the height of the seats can be adjusted continuously. Also, continuous adjustment for
the backrests must be provided for. The seat surfaces and backrests must be designed
from an ergonomic point of view. The width of the seat and the backrest must be at
least 450 mm. In order to support the feet, pipes, grids or step surfaces must be
provided. For supporting an operator's arms, adjustable rests complete with plastic or
leather coverings must be installed.
The control boxes and their substructure must be made from steel sheet and provided
with corrosion protection. The control box covers must be foldable and lockable in their
position in order to provide access to the equipment. The marking of the equipment,
operating elements and switching movements must be clearly legible and permanently
engraved into the cover plates. The lateral covers of the control boxes must be
removable.
The arrangement of the operator seats is to provide the crane driver a good overview of
the working area of the crane and to keep the physical stress as low as possible. The
positioning and designation of the operating elements must be effected by agreement
with TKCSA. However, in general it must be ensured that the operating elements can
be operated fast and without confusion. Depending on the actual model of the crane,
footswitches are also used. These must be protected against any accidental operation.

Bridge Crane TKCSA
ThyssenKrupp CSA
The signal horns are activated at knee-height by means of large switches. Emergency
stop switches must be marked in accordance with the standard.
All traversing and lifting movements are controlled via master switches with a spring-
return mechanism and circuit 4-0-4. The output signals are received in input assemblies
and passed on to a safety PLC via PROFIBUS cables. The emergency stop control
elements are wired in directly via a cable connection and PLC safety monitors.
The equipment must be wired in accordance with the circuit and handling of the
customer and routed to plug-in type terminals within the connection area underneath the
seat. The control cables must be fitted at the base of the controller, so as to ensure that
the rotation and height adjustment take place within the duct. From the base plate of the
controller, the control cables must have a length of at least 3 m.
Indications for the optionally inquired hook aperture sensor mechanism are effected by
means of 2 lights for each sensor, at the top, on the cab front.
Monitoring displays must be hung on articulated support linkages from the ceiling or the
side walls. Fault signaling displays are fitted on the operator cab side walls or on
brackets. Accessibility from the operator chair must be ensured.
In the operator cab, communication devices according to Section 10.16 will be installed.
To this end, a swan-neck microphone will be fitted next to the control devices. The
loudspeaker and the selection keys for the stations are also located next to the
operating elements.
The output of crane weighing machine data is effected via the fault signaling displays.
When predefined trolley and crane travel positions (e.g. for converter filling) are reached
with the assistance of the positioning devices, this is indicated by optical signals in the
operator cab.
The splash protection for the cranes S100 and S110 is activated from the operator seat.
10.8 460V feed-in on the crane =00
The power distribution is effected in accordance with EN 660204 Part 32 into the groups
Infeed, Special Power Circuit and Safety Circuit.
The control circuits in the individual assemblies are equipped with ground contact
monitoring and circuit breakers according to BGI 954 for work in confined spaces.
The infeed subdivision across the cranes is effected in accordance with the enclosed
circuit diagram (TH-NZ 415 601)
10.9 Special electrical functions
In addition to the general descriptions of the above-mentioned paragraphs, the following

electrical functions for the respective cranes must be provided in addition, and in
relation to the individual crane groups. The functions marked by *3 must be
executed in accordance with safety category 3 DIN EN 954-1. In addition to a
corresponding control setup, this means that for the electrical components used
a suitability for this control category must be verified and documented.

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ThyssenKrupp CSA
10.9.1 Special electrical functions for all cranes (group GA)
All cranes must be equipped with the following electrical functions.
 Operation limit switch, top hook position for all hoisting gears *3
 Emergency stop switch, top hook position for all hoisting gears *3
 Emergency stop switch, top hook position for all hoisting gears *3
 Bridging the operation limit switches (top hook position) by switches in the
operator cab and, if necessary, on the remote control. The operation of the
bridging is indicated optically (fault signal display). Further lifting at low speed
only. If the crane switch contactor is operated again, the bridge will be
deactivated *3
 Bridging the operation limit switches (top hook position) by switch, installed in
the electrical switchgear room and, if necessary, on the remote control unit
complete with key-operated switch. The operation of the bridging is indicated
optically (fault signal display). Further lifting at low speed only. If the crane
switch contactor is operated again, the bridge will be deactivated *3
 Operation limit switch bottom hook position *3
 Slack rope circuit
 Overload shutdown according to Section 10.12 *3
 Load spectrum memory
 Spacing device to any neighboring crane with advance and limit stops *3
 Electrical advance and limit stops for crane traversing to the buffer block end *3
 Electrical advance and limit stops for trolley traversing *3
 Communication facilities in accordance with section
 Door monitoring of air-conditioned rooms with visual display (fault signaling
display) and shutdown of the air conditioning system
 Temperature monitoring of all drive units. Shutdown when limit temperature is
exceeded.
 Motor protection circuits
 Fault diagnosis systems with fault memory for a 2 week operating period
 Monitoring of rope overrun by means of 2 antenna changeover switches per
rope on the rope drum
 Remote diagnosis system with the option to carry out program changes via a
modem connection
 Monitoring of all hoisting gear and traversing gear brakes
10.9.2 Special electrical functions for cranes S100, S200 S300 (group 1)
 Add-on synchronization of main and auxiliary hoisting gear

 Optional hook aperture sensor mechanism according to Section 10.10
 Difference load switchoff in hoisting gear 1 *3
 2 off electrical bypass locking according to Section 10.15
 4 off electrical positioning aids for the trolleys according to Section 10.16
 Temperature monitoring of all hoisting gear mechanisms with optical
advance warning and hoisting gear shutdown if the temperature continues to
increase
 Pressure monitoring of all hoisting gear mechanisms with optical advance
warning and hoisting gear shutdown if the pressure continues to drop
 Filling level monitoring of all hoisting gear mechanisms with optical advance
warning and hoisting gear shutdown if the filling level continues to drop
 Monitoring equipment for the oil cooling of gear units, if these are used
 Control devices for the emergency stop brake in the hoisting gear

Bridge Crane TKCSA
ThyssenKrupp CSA
 Operating controls for the emergency lowering device in the main hoisting
gear according to Section 9.2.15.2 *3
 Monitoring for drum shaft fracture, transmission shaft fracture or motor shaft
fracture *3
 Weighing device according to Section 10.12 *3
 Inclined position monitoring of the crossbeam in hoisting gear 1 with shutoff
 Limit position monitoring of the rope compensation rockers in hoisting gear 1
with optical pre-warning and hoisting gear switchoff in the event that a limit
value is permanently exceeded
10.9.3 Special electrical functions for crane S110 (group G2)
 Add-on synchronization of main and auxiliary hoisting gear *3

 Add-on synchronization of the crane trolleys *3
 2 off electrical bypass locking according to Section 10.15
 Temperature monitoring of all hoisting gear mechanisms with optical
advance warning and hoisting gear shutdown if the temperature continues to
increase
 Pressure monitoring of all hoisting gear mechanisms with optical advance
warning and hoisting gear shutdown if the pressure continues to drop
 Filling level monitoring of all hoisting gear mechanisms with optical advance
warning and hoisting gear shutdown if the filling level continues to drop
 Monitoring equipment for the oil cooling of gear units, if these are used
10.9.4 Special electrical functions for cranes S210 and S310 (group G3)
 Advance and limit stop shifting gear (only S310)

 Weighing device according to Section 10.12 *3 (only S310)
10.9.5 Special electrical functions for cranes S320 and S330 (group G4)
 Limit position monitoring of the rope compensation rockers in hoisting gear 1

with optical pre-warning and hoisting gear switchoff in the event that a limit
value is permanently exceeded
 Operating controls for the emergency lowering device in the main hoisting
gear according to Section 9.2.15.2 *3
 Monitoring for drum shaft fracture, transmission shaft fracture or motor shaft
fracture *3
10.10 Hook aperture sensor mechanism
For the main hoisting gear of the cranes S100, S200 and S300 (Group 1), as well as for
the crane S310, monitoring of the ladle receivers is to be offered optionally. To this end,
the hook aperture sensor mechanism according to the BFI (Betriebsforschungsinstitut,
Sohnstraße 65, D-40237 Düsseldorf) system must be used, complete with two sensors

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for each lamella hook. The wirings of the sensors with heat resistant cables and
connections to protected terminal boxes on the crossbeam are included in the scope of
supply and must be executed in accordance with BFI specifications. The scope of
supply also includes the further cable routing from the crossbeam, the evaluation units,
the motor cable drums including service platform, any necessary cable guides, the
integration into the control systems and the displays in the operator cab, as well as the
license fees to BFI. In the case of crane S100, due to the ambient conditions whilst
charging, it is not possible to route any cables from the crossbeam to the trolley. In this
case the sensor occupations are passed via a safe wireless data connection from the
crossbeam to the crane bridge.
The motor cable drums must be offered with spiral-type winding. They are driven by
means of a standstill motor with 100% ON period. A minimum of 2 security windings are
to be provided. In the case of cable route, the absolute bottom most hook position
(repair position) must be taken into account. For the selection of drum-capable cabling,
the cable manufacturer must be informed about the operating conditions as specified in
Chapter 4, to ensure that these are taken into account. In addition the cables must be
executed complete with a strain relief device. From the transition box trailing system to
the switchgear room, cabling is effected by means of pair-drilled screened cables.
Note Section 8.4.6 with regard to sensor fitting and cable routing within the lamella
hooks.
The control systems of the hook aperture monitoring are accommodated in the
switchgear rooms, preferably within the weighing technology area. Control is effected in
accordance with the BFI circuit diagram. There will be an indication (green or red) for
the sensor occupation in the operator cab and a shutdown of the hoisting gear in the
event that not all four sensors of a hoisting gear signal an occupation.
If the option 'hook aperture sensor mechanism' should be executed, then the sensor
occupation signals must be processed jointly with the values from load measurement
according to the block diagram (see annex).
10.11 Operating and fault messages
The control of the fault messages and operating messages is indicated by means of a
programmable logic controller on the touch panels (fault message displays) in the
switchgear room or the switchgear rooms and in the operator cab. In the operator cab,
fault messages are additionally displayed via a collective fault message and, if available,
separate indicator lamps. Inasmuch as the option 'hook aperture sensor mechanism'
becomes relevant here, 4 red and 4 green indicator lamps must be additionally fitted in
the case of the cranes from group G1.
For cranes from the groups G1 and G2, the volume of the fault messages is
approximately 200 messages and for the other groups approximately 100 messages.
Below, some fault messages are listed by way of example.
- Transmission oil monitoring with filling level, temperature and shutdown

- Rope rocker monitoring
- Rope roller overrun complete with status message and shutdown
- Operating brake indicator Open and Closed
- Emergency stop indication and shutdown of hoisting gear
- Hook aperture sensor mechanism - status message and shutdown

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- Vibration monitoring
- Weighing technology
- Overload switch off
- Out-of-balance load detection
- Ladle underweight triggering
- Slack rope
- Door contacts
- Air conditioning system
- Drive units
- Brakes open / closed
- Moved into operation limit switch
- Operation limit switch bridged
- Motor cable drum (exceeding / underrunning cable pull, limit switch)
Additional fault messages will be agreed with the customer after contract award.
The fault messages must be visualized. To this end, the respective assemblies must be
shown schematically in the display. When the fault has been removed, the crane
operator may acknowledge the fault message. The fault memory stores the faults for a
period of at least 2 weeks.
For the retrieval of stored fault messages and the processing of fault message
indications, two programming units must be supplied complete with software. An
interface for a remote analysis / data exchange (teleservice) via PG must be provided.
The associated input devices are included in the scope of supply.
In the switchgear units and in the operator chair, the fault/operating messages are
shown on touch panels with a size of at least 10“.
The radio-controlled cranes of group G4 are additionally fitted a quadruple fault

message display for each bridge girder; this fault message display has the form of a
traffic light and can be seen from ground level. The following cases are indicated here:
Overload, limit switch, air conditioning system safety event
10.12 Weighing device / Overload and slack rope shutdown
The main hoisting gear of the cranes S100, S200, S300 and S310 are to be equipped
with weighing technology. Inasmuch as this weighing technology corresponds to the
safety category 3 according to DIN 954-1, it can also be used for the overload shutdown
and slack rope detection of the hoisting gear. In addition to the necessary circuit setup,
load cells with 2 independent measuring circuits as well as safe entry assemblies and
safe evaluation units must be used. The suitability of the components for use according
to safety category 3 must be verified and documented.
In the case of these cranes, if these specifications are not met, additional load
measurement bolts must be used at the rope fixed points for overload shutdown and
slack rope detection. The use of the load measurement bolts described below is also
specified for the auxiliary hoisting gears of the cranes S100, S200, S300 and S310
(according to build type), as well as for the main and auxiliary hoisting gears of the
remaining cranes S110, S210, S320 and S330. This does not apply to the 10 t electric
rope tractions of the cranes S210 and S310.
Specifications for the weighing device or overload /slack rope shutdown of cranes S100,
S200, S300 and S310:

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Measuring technology data S100, S200, S310

S300
Measuring precision 530 kg 180 kg
Relative error 0,1 % 0,1%
Data for excess load, slack rope, differential load S100, S200, S310
S300
Relative error 2% 2%
Min. detectable differential load 10 t 4t
Shutdown for raising and lowering in the event of any 30 t 10 t
discrepancy*
Shutdown for raising and lowering in the event of any 80 t 30 t
out-of-balance load
Shutdown for raising in the event of any overload Σ 550 t Σ 200 t
Shutdown for lowering in the event of any slack rope Σ -5.0 t Σ -2.0 t
Shutdown for lowering in the event of any slack rope on - 3.0 t - 1.0 t
one side
Table 12
*Difference between the two measuring circuits of a load cell
Load-carrying capacity of load cells
For selecting the measuring range and the load carrying capacity of the load cells, the
criteria below must be taken into account:
Operating load case :

 minimum load-carrying capacity * 1.2 for dynamic influence from mass inertias
whilst raising and lowering, as well as shocks from crane and trolley traversing
 in the event of any non-symmetrical load cell arrangement, the uneven load
distribution of the hoisting load must be taken into account
 weight hoisting gear frame including all superstructures, taking into account the
load distribution
 uneven load distribution from component tolerances of the trolley frames, crane
bridges and craneways
Special and additional load cases :

 Loading tests with test load according to Section 1.2.5.1 (Caution>> 125%)
 Incidence of the emergency stop brakes
 Buffer shock crane and trolley traversing
When selecting the load cells and its cables, the operating conditions according to
Section 4 must be particularly taken into account. The load cells must be screened
against heat radiation.
Section 8.4.3 applies to the fitting the load cells and the take-up of horizontal loads. The
fitting tolerances of the load cells must be selected such that the occurring steel
structure tolerances and structure deformations (e.g. caused by a bending of the trolley
frame) are taken into account.

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If measuring bolts are used for the overload function, the specifications stated below
shall apply:
 The load measuring bolts are mounted on the rope fixed points. So as not to
cause wear to the measuring bolts, the thimbles of the load ropes must not rest
directly on the measuring bolts (see Section 9.3.1.8.)
 The components used and the circuit arrangement must comply with the safety
category 2 according to EN 954-1.
 A sufficient strength of the measuring bolts must be proven in accordance with
DIN 15017 or FEM 1001 for the present loads.
 Each measuring bolt is fastened unilaterally by means of 2 axle holders
 The mounting position of the measuring bolts must be clearly marked.
 The construction of the measuring bolt bearing must be designed such that no
secondary bendings occur.
How out-of-balance load detection functions for all traverse cranes

(Block diagram, see annex)
If during load take-up (there was no load on the hook during the last 20 seconds) the
out-of-balance load signal occurs, raising will be locked! The crane operator now has 20
seconds to remove the out-of-balance load situation by lowering the out-of-balance load
and thus enabling a new load take-up attempt in the "raise" direction.
If it should not have been possible to remove this out-of-balance load within these 20
seconds, then raising remains locked and lowering will also be locked. After checking
the cause, these lockings can only be removed by specialized personnel using a key-
operated switch in the E-room.
If during load setdown (there was a load on the hook during the last 20 seconds) the
out-of-balance load signal occurs, lowering will be locked! The crane operator now has
20 seconds to remove the out-of-balance load situation by raising the out-of-balance
load and thus enabling a new load take-up attempt in the "lower" direction.
If it should not have been possible to remove this out-of-balance load within these 20
seconds, then lowering remains locked and raising will also be locked. After checking
the cause, these lockings can only be removed by specialized personnel using a key-
operated switch in the E-room.
All messages must be displayed as fault messages.
Ladle underweight triggering for crane S100

In order to prevent any unintended demounting of the hot metal ladles by setdown on
the converter edge, during charging a further "lower" after underrunning the own weight
of the ladle must be locked.
10.13 Radio controls = plant group 09
The cranes of groups G3 and G4 are also operated by means of radio remote control.
The changeover switches for the cockpit and radio remote controls are accommodated
in the operator control chair. The radio remote controls consist a.o. of transmitters and
reserve transmitters, 2 aerials, receivers, return shippers, accumulators and reserve
accumulators and 2 charging stations. For radio remote controls, the make Theimeg is
to be used. The types EC40 or TC200 are to be used here. The fault messages of the
crane must be shown in plain text on the display of the transmitter. The coupling of the
radio remote control to the cockpit control system and the drives are effected by means
of a 24 V coupling relay.
The passive emergency stop period (i.e. the response time after a dropping of the
transmitter signal) may be max. 1 second.

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The markings of the drive movements must be effected in accordance with SEB 660
040 and SEB 660 043.
The radio transmitters must be supplied complete with adjustable carrying straps.
10.14 Communication systems
For communication, wireless intercom systems must be provided at the following points:
 at all crane access points excepting the center girder of groups G1 and G2
 in all electric switchgear rooms
 in weighing technology rooms
 on the trolleys
 in the operator cab
 at the crane infeed
The communication devices on the cranes must also offer the option to establish
speaking contact with the ground staff (e.g. strikers) that is equipped with mobile radios.
These mobile radio devices are not included within the scope of supply of the cranes.
The design of the intercom device must be effected in industrial quality and correspond
to the operating conditions according to Chapter 4. The voltage supply to the
intercommunication systems is effected via the special power circuit.
10.15 Bypass lockings
The bypass lockings are accessed by using a magnetic locking switch to shut down the
traversing movement.
In the locked work areas, a differentiation must be made between continuous lockings
or such lockings that only become activated in the event of certain specific trolley or
hoisting gear positions. Such continuous lockings can only be removed by bridging
using a key-operated switch in the electric switchgear room. The remaining lockings
only remain active for as long as critical conditions - due to certain specific trolley and
hoisting gear limit positions - apply. Here, after traversing a locked area, the hazardous
movements - e.g. hoisting gear or trolley traversing - must be locked inasmuch as this is
necessary.
The shutdown of traversing movements is always effected by means of advance and
limit switch stops. The components and controllers must comply with the safety
The hoisting gear positions must be detected by means of the gear limit switches.
The movements and positioning of the crane complete with the limit stop switches and
bypasses are shown in the displays as a static graphic.
10.16 Electrical positioning aids
For the repeated movement of trolleys into certain specific positions (e.g. tilt positions
S100) mechanical positioning aids according to Section 8.4.9.10 are fitted. These
markings will be designed into the electrical control systems / the PLC by means of two
electromagnetic pre-limit switches each for both directions of travel and one limit stop
each for the exact positions. When the pre-limit switch is reached, flashing messages
will be output to the displays in the operator cab, and when the position limit switch is
reached, it is indicated by static messages e.g. „Tilt-over position reached“.

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The magnetic limit switches are to be adjusted and mounted on approximately 1 cm

long guide rails. The magnets themselves are bolted and fitted to the solid part of the
bridge.
The shutdown of traversing movements is always effected by means of advance and

limit switch stops. The components and controllers must comply with the safety
The movements and positioning of the crane complete with the limit stop switches and
bypasses are shown in the displays as a static graphic.
10.17 Air conditioning system
The necessary cooling capacity of the temperature control units for electrical switchgear
rooms and the operator cab must be calculated for the most unfavorable operating
conditions according to Section 4 and the power dissipation at a maximum load
according to Section 5. In the electrical switchgear rooms, the temperature may be
35°C max. In the operator cab, the temperature must be controlled to be within the
range 18 – 26°C. For electrical switchgear rooms, the cooling capacity determined must
be distributed across 3 air conditioning units each. These must be designed such that in
the event of one air conditioning unit failing crane operations may still continue without
any restrictions (50% redundancy). The air-conditioning of the operator cab must be
effected by a further air conditioning unit. For the present operational case, all air
conditioning units must be selected such that they feature a vibration-proof design.
Inasmuch as the plant groups 00 and 01 are installed in the subcarrier, temperature
control by means of a further air conditioning unit must be provided for this switchgear
room also. Here, no redundancy is required.
The installation of the air conditioning units and vaporizer is effected outside the
electrical switchgear rooms. Fresh air must be supplied to the electrical operating rooms
or to the operator cab by means of ducts made of galvanized steel sheet. Within the
switchgear rooms, the air conditioning ducts must be routed such that a fresh air supply
is achieved which is as even as possible.
During any such installation it must be ensured that the air conditioning units are easy to
access (from 3 sides).
No plug-type fuses may be used in the temperature control system. The control system
for the air conditioning systems must provide potential-free contacts for fault message
input and the signal exchange with the PLC. Faults occurring on air conditioning
systems must be indicated as fault messages.
All air conditioning ducts must be mounted on consoles such that they are vibration-
proof and they must be secured against shifting by a clamp. It is not permissible to
mount the air-conditioning ducts on the sheets from any insulation.
Control cabinets that are fitted onto the crane bridge must be separately temperature-
controlled if necessary. Non-tempered switchgear racks / control panels comprise a
sufficient number of ventilation systems so as to ensure a safe functioning under the
conditions stated in Section 4.
Electrical room will have a thermometer to send a control information to the air condition
system. Air condition system will be able to send information to PLC of the crane in
case of failure.

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11. Documentation
All drawings, calculations, operating instructions, spare part offers, circuit plans,
component lists etc. must be prepared in the English and Portuguese languages. This
also applies to the documentation of all mechanical and electrical bought parts. The
quality documentation and measuring reports must be prepared in the English language.
11.1 Responsibility
The contractor is responsible for ensuring that his drawings and other documents, as
well as the drawings from subcontractors, are correct, even after these documents have
been approved by the customer.
11.2 Arrangement drawing
Before commencing the actual construction work, detailed forward planning drawings, in
which all important details can be seen for approval, must be submitted to the customer
in duplicate. In these scheduling plans, the wheel loads must be shown in accordance
under Section 8.1.4 . Furthermore, the environment of the cranes such as e.g.
craneway, shop supports, roof frameworks, roof trusses and repair lines must also be
inserted into the forward planning available. Any distances to these facilities must be
measured.
All forward planning drawings must be stored as PDF, TIF or DWG files in the Internet
platform „CONJECT“ in the version as currently amended. There, these documents can
be inspected and printed out by authorized persons. In order to be able to operate this
software, it is necessary to participate in an instruction session.
11.3 Drawings during the project planning phase
In addition to the forward planning drawings, the following drawings must be submitted
before approval of the execution drawings described at 11.4 .
- Illustration of the rope runs with marking of the run angles

- Drawings for determining the visibility
11.4 Execution drawings
All drawings must be created on sheet formats A4 to A0. A format with height A4 must
be used for all electrical circuit diagrams, block diagrams, etc. Execution drawings,
including structural analysis, circuit diagrams etc., must be submitted to the customer in
duplicate for his approval before commencing any work in the workshop, so that it may
be possible to implement any changes without delaying the actual date of delivery.
These drawings must show all dimensions, selected materials, surface markings, fits,
hardness depths, heat treatments, tempering etc. as well as all details necessary for
any welding or weld seam inspection and, in the case of mechanical engineering
drawings, complete parts lists. If any changes are made in these documents after
approval of drawings and parts lists by the customer, this must be reported to the
customer without delay. The drawings and parts lists must be marked with a
modification note and an index number appended to drawing number, and then
submitted again for approval. In the case of modifications during the warranty period, all
document must be kept updated correspondingly by the contractor. This also applies to
the disposition drawings. Complete lists of parts and parts lists of the drawings in which

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all drawings are contained, sorted according to construction groups, must be included in
the supply. A list must be attached to the drawing directories showing the main data of
the cranes.
All execution drawings must be prepared subject to compliance with the following
standards:
DIN EN ISO 128-20 General foundations of representation, lines, basic rules

DIN EN ISO 1302 Geometric product specification, surface conditions
DIN EN ISO 3098-0 to -06 Technical product documentation, fonts
DIN EN ISO 5457 Technical documentation, formats and design
DIN EN ISO 7200 -2 Technical product document., data fields in the font areas
DIN EN ISO 128-24 General foundations of representation, lines in drawings
DIN EN ISO 128-30 General foundations of representation, basic rules for views
DIN EN ISO 128-34 General foundations of representation, views, in drawings
DIN EN ISO 128-40 General foundations of representation, basic rules for cuts
DIN ISO 286-1 u. -2 Dimensional limits for fits
DIN ISO 1100 Technical drawings, form and position tolerance
DIN ISO 2203 Technical drawings, representation of gear wheels
DIN ISO 2768-1 a. -2 General tolerances, dimensions, form a. position
DIN ISO 5455 Technical drawings, scales
DIN ISO 6410-2 u. -3 Technical drawings, threads and threaded parts
DIN ISO 6411 Technical drawings, centering bores
DIN ISO 509 Technical drawings, undercuts
DIN 3966-1 to -4 details for gearing in drawings
DIN 6771-2 Forms for technical documents, parts list
DIN 6771-6 Forms for technical documents, drawings
All length dimensions must be stated in millimeters. Only pipe threads may be stated in
the unit Inch. All angles must be specified in degrees, minutes and seconds.
Each crane is provided with its own full set of drawings. This also applies in the case
that there are same drawings for other cranes.
Each drawing is allocated its own drawing no. There must never be several sheets
under one drawing no. .
All drawings with welded constructions must meet the specifications in accordance with
Section 8.3.8.3 and 8.3.8.4.
Inasmuch as TKCSA hands out forms for drawing formats and parts lists, these are to
be used. For the allocation of the layers and font styles in CAD drawings, the
specifications by TKCSA must also be noted.
All execution drawings must be stored as PDF-, TIF- or DWG files in the Internet
platform „CONJECT“ in the version as currently amended. There, these documents can
be inspected and printed out by authorized persons.
For the electrical documentation the following standards must be taken into account:
DIN EN 60617 Electrotechnical switching symbols

DIN EN 61082 T 1- 4 Preparation of electrotechnical documents / documentation
DIN EN 61175 Marking of signals
DIN EN 61346 Structural principles and reference marking
DIN EN 61355 Classification + marking of documents

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11.5 Lettering
All drawings and corresponding documents must be marked with the following
information in the vicinity of the legend field:
- The plant number assigned by the customer
- The customer's order number
- The contract number of the crane supplier
- The customer's place of utilization, e.g. "steel works casting bay" (in English and
Portuguese language)
- Plant designation e.g. „S 100 “
- Plant group, e.g. main hoisting gear with a four-digit number (see explanation)
- The component, e.g. rope drum diameter
- For subcontractors, the manufacturer or brand and type of the plant section
Inasmuch as there are no other specifications, the plant groups must be subdivided as
follows:
0XXX crane scheduling

1XXX all drawings for crane bridges, top beams, crane traversing gear, operator cabs
2XXX all drawings for trolley 1 (chassis and hoisting gear frame)
3XXX all drawings for trolley 2
4XXX hoisting gear 1 incl. crossbeam and carrying gear
5XXX hoisting gear 2 incl. carrying gear
6XXX hoisting gear 3 (if present)
7XXX reserved for rotating mechanisms (not available here)
8XXX reserved for special permanently sheared carrying gears (e.g. slab handling
tongs)
9XXX for load-carrying equipment associated with a crane
Example for a crane drawing no. for a bridge girder on crane S100
S – S100 – 1001
S = work area
S100 = crane no.
1001 = plant group (here the first drawing for the crane bridge)
11.6 Drawings for production monitoring
In addition to the production drawings, the following drawings must be provided for
production monitoring purposes:
Coordinate system of the hoisting gear

For all hoisting gears, drawings complete with coordinate systems must be submitted.
Here, the coordinates of all mechanically processed surfaces such as e.g. for
transmission supports, rope drum frames, top pulleys, rope compensation rockers,
brakes, motor rails load cells, and rods, including their mountings, must be stated. The
tolerances necessary for ensuring the exact fit and functionality must be stated herein.
For orientation, reference points must be attached to the hoisting gear frame; these
must be stated in the drawings.
Coordinate system 'Trolley' for cranes of group G1

For the trolleys of this crane group, drawings complete with coordinate systems must be
submitted which detail the relative position of the hoisting gear and the chassis frame

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toward one another. In addition to the dimensioning of the processed surfaces of rods,
load cells, track wheel vibrations, the dimensions and tolerances of the track wheels
must be stated that are necessary for a trolley run free from secondary bending.
11.7 Workpieces with test certificates
Test certificates must be supplied in accordance with table 12. In addition, test
certificates resulting from the requirements of Section 8.3.8.3 must be executed in
accordance with DIN EN 10204 in the category 3.1. The test scope and the
designations of 29 different test certificates is explained in Table 11. Forms for the test
certificates QM1 to QM17 are enclosed as an annex.
The contractor must deliver all test certificates of the manufacturer for workpieces for
which tests are stipulated.
Radiographic examination reports and other documents for the tests required according
to DIN 15018 must be delivered together with a plan and a summary. The customer
reserves the right to commission an independent testing organization.
no. Inspection Designation / extent of inspection

certificate
1 QM1 Gearing test
2 QM2 Chemical composition quenched and tempered or case-hardening steel
3 QM3 mechanical properties for quenched and tempered steel
4 QM4 Hardness testing for quenched and tempered steel
5 QM5 Checking fro surface cracks
6 QM6 Checking for internal separation
7 QM7 Checking for an internal separation in respect of workpieces made of cast
steel
8 QM8 Heat treatment for case-hardened tooth flanks
9 QM9 Heat treatment stress relieved batch annealings
10 QM10 Welding
11 QM11 Dimension inspection
12 QM12 * Forgings made of fine-grained structural steel, strength grades M or P
13 QM13 * Forgings made of fine-grained structural steel, strength grades S or T
14 QM14 * Forgings made of heat resistant fine-grained structural steel, strength grades
S or T
15 QM15 * Rolled fine-grained structural steel, strength grades M or P
16 QM16 * Rolled fine-grained structural steel, strength grades S or T
17 QM17 * Rolled, heat resistant fine-grained structural steel, strength grades S or T
18 SEB 666212 T4 Rope drum joint connection - Acceptance test certificate according to DIN EN
10204
19 DIN 7190 Press fits Annex C, but as Certificate 3.1 according to DIN EN 10204
20 VDI/VDE 2609 Checking the contact pattern
21 DIN EN 10204 Checking for overheating when grinding according to ANSI / AGMA 2007 –
3.1 test B92
certificate
22 DIN EN 10204 Rope certificates with ordering information, rope-Ø, length, weight, rope
3.1 test construction, surface, insert, impact direction, rated tensile strength,
certificate calculated breaking force, minimum tensile strength, end connection,
ultrasonic test according to Section 9.3.1.3 and magnetic powder test of the
pressure sleeves
23 DIN EN 10204 on the chemical composition (14 item analysis) complete with analysis
3.1 test specifications according to DIN EN 10025 or DIN EN 10028, material
certificate specifications, handling status, agreement marking, manufacturer's and
charge details, delivery dimensions, order information
24 DIN EN 10204 mechanical properties with details about the minimum yield strength,

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3.1 test minimum tensile strength, elongation value and comparison of the minimum
certificate values according to DIN EN 10025 or DIN EN 10028, 3 notched bar impact
test complete with sample forming and temperature, agreement marking,
manufacturer's and charge details, delivery dimensions, order information
25 DIN EN 10204 mechanical properties with tensile test in through-thickness direction
3.1 test according to DIN EN 10164 with 3 test results from the fracture elongation
certificate and their mean value, manufacturer's and charge details, delivery
dimensions, order information.
26 DIN EN 10204 mechanical properties with details on the minimum yield strength, minimum
3.1 test tensile strength, hardness and penetration depth, notch impact samples with
certificate sample form and temperature, agreement marking, manufacturer's and
charge details, delivery dimensions, order information
27 DIN EN 10204 on the chemical composition (14 item analysis) complete with comparison of
3.1 test analysis specifications according to DIN EN 10095, material specifications,
certificate handling status, manufacturer's and charge details, delivery dimensions,
order information
28 DIN EN 10204 on the weld bead bend test according to SEP 1390
3.1 test
certificate
29 DIN EN 10204 on the testing for lamination according to DIN EN10160
3.1 test
certificate
* These quality sheets will first be updated with regard to the new material designations
Table 13 Abbreviations for test certificates

Scope of the test certificates to be supplied
Components
Cranes
S100, S200, S110 S210 S310 S320
S300 S330
Mechanical engineering hoisting gear
Brake drums 5,7,11 5,7,11 5,7,11 5,7,11 5,7,11
Board disk for emergency stop brake 23.24 23.24 23.24
Gear casing 9,10,11 9,10,11
pinion shafts forged and quenched and 1,2,3,4,6,11, 1.4 1.4 1.4 1,2,3,4,6,11
tempered 20,(21) 20,(21)
Gearwheels forged and quenched and 1,2,3,4,6,11 1.4 1.4 1.4 1,2,3,4,6,11
tempered 20,(21) 20,(21)
Gearwheels forged and case-hardened 1,2,5,6,8,11 1,2,5,6,8,11 1,2,5,6,8,11 1,2,5,6,8,11 1,2,5,6,8,11
20,21 20,21
Shafts 4,2,3,6,11 4 4 4 4,2,3,6,11
Planetary gear carriers 2,4,6,11 2,4,6,11 2,4,6,11 2,4,6,11 2,4,6,11
Axles and bolts 2,3,6 2,3,6
Rope drum jointed connections 18 18 18 18 18
Spacers for toothed couplings 12 or 13 - - - -
Rope drums 6,10,19,23,24 19,23,24 19,23,24 19,23,24 6,10,19,23,24
Wire ropes 22 22 22 22 22
Tie-rods, universal joints for rope fixed points 12 12 12 12 12
Suspension fixtures for lamella hooks 12 12 12 12 12
Rope rolls, guide rolls (cast version) 7 7 7 7 7
Mechanical engineering chassis

Brake drums 5,7,11 5,7,11 5,7,11 5,7,11 5,7,11
pinion shafts forged and quenched and
tempered
Pinion shafts forged and case-hardened
Gearwheels forged and quenched and
tempered
Gearwheels forged and case-hardened

Bridge Crane TKCSA
ThyssenKrupp CSA
Shafts
Track wheels 26 26 26 26 26
Steel engineering
Top beams for crane and trolley 23,24 23,24 23,24 23,24 23,24
Bridge girder including its rollformed profiles 23,24 23,24 23,24 23,24 23,24
Trolley frame (traversing and hoisting gear 23,24 23,24 23,24 23,24 23,24
frame)
Track wheel vibrations, harmonic oscillations 23,24 23,24 23,24 23,24 23,24
Compensation rockers and pedestals 23,24 23,24 23,24 23,24 23,24
Connecting rods 23,24 23,24 23,24 23,24 23,24
Track rails 23,24 23,24 23,24 23,24 23,24
Operator cab shafts 23,24 23,24 23,24 23,24 23,24
Heat protection panels, unalloyed or with a 23,24 23,24 23,24 23,24 23,24
low alloy
Heat protection panels made of heat- 26 26 26 26 26
resistant steels
Components with multi-axle tension 25 25 25 25 25
conditions
Sheets with thickness ≥ 30 mm 27,28 27,28 27,28 27,28 27,28
Crossbeams 10,23,24
Load hooks forged - - 12 12 12
Lamella hook 15 or 16 15 or 16 15 or 16 15 or 16 15 or 16
Lamella hook suspension fixture made of 15 15 15 15 15
panels
Load introduction points, thickness jumps, 10 10 10
force guiding, cross-sectional changes
Table 12 Scope of the test certificates to be supplied
11.8 Documentation for measuring / alignments
The measuring of the crane girders and their crane bridge chamber must be
documented in accordance with the form TH-N 236 500 A. The tolerances stated in this
standard must be complied with. For 4 carrier cranes, the figures and tables must be
amended by the supplier accordingly
The measuring of harmonic oscillations and track wheel carriages is effected by moving
along NC machinery units. For the documentation of the measurement results, the
supplier may select the form of the protocols. However, the tolerances of these
boreholes must be selected such that, with the rockers in a fitted condition, the track
wheel tolerances specified in accordance with TH-N 236 500 A are complied with.
Boreholes for coupling joints must be added in the figures and tables.
The dimensioning of the trolleys must be documented in accordance with TH-N 236 500
Form C. The measuring of harmonic oscillations and track wheel carriages is effected
by moving along NC machinery units. For the documentation of the measurement
results, the supplier may select the form of the protocols. However, the tolerances of
these boreholes must be selected such that, with the rockers in a fitted condition, the
track wheel tolerances specified in accordance with TH-N 236 500 C are complied with.
In addition, for the trolleys of group G1, the drawings prepared according to Section
11.6 for the coordinate system 'trolley' must be used for documenting the measurement
results. Here, the nominal and actual values of the prefitted hoisting gear and traversing
mechanism frames must be compared. All dimensions in relation to the rods, rod
consoles (including chuck), load cells and oscillation bores must be stated.
Furthermore, the track wheel bores of all prefitted carriages must be stated with all
tolerances (track gauge, parallelism, track and camber).

Bridge Crane TKCSA
ThyssenKrupp CSA
For all hoisting gears, the dimensions of the mechanically machined surfaces must be
entered into the drawings for the coordinate system 'hoisting gear' complete with
nominal and actual values.
In accordance with Section 1.2.2.1, the alignment of existing hoisting gear components
must be verified for all cranes.
 Pedestal bearing for the rope drum

 Rope drums
 Top pulleys
 Drum reduction gear (if applicable)
 Jack shafts (where present)
 Motor reduction gear
 Operation brakes and Eldros
 Emergency stop brakes (if applicable)
 Motors
11.9 Lubrication schedules
When submitting the drawings for approval, the contractor must also provide a summary
plan in which all lubricating points, lubricants, qualities, quantities and relubrication
intervals have been entered. Lubricant qualities and quantities must also be included in
the assembly drawing of the respective gear unit and bearing.
11.10 Spare parts offer
Parts with long delivery times 12 weeks, commercial offer of spare parts 24 weeks,
after the placing of order an offer must be submitted to the customer for all spare parts
which according to the contractor's opinion should be kept in stock to ensure continuous
operation of the crane. Here, the drawing and item numbers of the parts offered, as well
as the individual prices and the individual weights, must be stated. Standard parts must
be named according to the designation example. For nonstandard parts, the exact
designation, type and manufacturer must be stated.
11.11 Documents provided by the customer
Drawings and other documents made available to the contractor remain the property of
the customer. They must be checked by the contractor of the hoisting hear for correct
application. No changes may be made in the working drawings provided by the
customer. They need not be submitted for approval, but they must be included in the list
of drawings and in the assembly drawings under the customer's drawing numbers.
11.12 Documents to be included with the delivery
One set of the following drawings listed under 11.12.1 and 11.12.2, in durable mounting
and capable of being copied must be delivered, independently of the already delivered
approved drawings, not later than 4 weeks after acceptance of the crane. Documents
which cannot be copied must be delivered in triplicate. All drawings must be delivered in

Bridge Crane TKCSA
ThyssenKrupp CSA
a bend-proof packaging and sorted in accordance with the directory list of drawings. All
drawings must additionally be submitted as a CAD file (DWG format) burnt on CD. The
associated parts lists and drawing lists must be submitted in the form of EXCEL files.
The quotation must state for which parts and for what reasons working drawings are not
supplied (if applicable).
For all gear units, in addition to the schedule drawings and detailed drawings,
subassembly drawings must also be submitted for each gearbox shaft. These drawings
are to allow spare parts to be ordered for complete shafts, including all fitted
components such as gears, bearings, spacer disks, seals etc..
11.12.1 Steel and mechanical constructions
Documentation to be supplied:
- Overview drawing of the crane and the trolleys

- All other overview drawings
- All drawings and parts lists as well as working drawings sorted according to
construction groups
- Subassembly drawings for all gearbox shafts
- Drawings for determining the visibility
- Illustration of the rope runs with marking of the run angles
- The calculations for all supporting structures
- The calculations for all machine parts
- Schematic overviews of the individual drives with specification of the respective
working drawings
- Functional descriptions and operating instructions with depiction of the functional
principles of all exceptional components and novelties
- Certificates of material tests under section 11.7
- Radiographies (only one copy)
- Irradiation and test records (only one copy)
- Irradiation plans and other test schedules (only one copy)
- Measuring protocols according to Section 11.8
- External part drawings
- Dispatch drawing
- Structural analyses
- Weight calculation
- Pipeline plans and production drawings for the pipelines
- Lubrication schedules
- Lubrication and maintenance instructions
- List of all utilized anti-friction bearings and shaft seal rings with specification of the
installation location
- List of all utilized lubricants (with lubricant designations under DIN51502)
- Hazard analysis for cranes
11.12.2 Electrical systems
Drawings of existing plants or plant components where changes are made must be
amended or prepared again. We provide the original drawings.
The electrical documentation must be sectioned according to the drives.

Bridge Crane TKCSA
ThyssenKrupp CSA
The contractor must make a drawing of the components on the supporting structure.
This drawing must be approved by the customer.
Documentation to be supplied:
- Overview circuit diagrams

- Circuit diagrams according to DIN EN 60617 with specification of the lengths and
cross sections of the conductors
- Construction group plans
- Cable and terminal plans
- Cable lists
- Component part lists
- Internal circuit diagrams of unusual devices
- Drawings of the arrangement of the electrical equipment units
- Functional plan
- Data flow chart
- Program sequence plan
- Backup copies of all programs
The entire documentation of the electrical equipment must be created with the CAD
system EPLAN. Consultations with the customer are necessary before starting to create
the documentation. The supply on appropriate CD-ROMs with all associated files, and
one original printed set and 3 sets of copies, belongs to the scope of supply.
The drawing formats and title blocks must be agreed with the customer. For CAD
drawings, the legend fields for diskette and project number must be provided
additionally in the region of the drawing number, and filled out.
The drawing numbers must be entered by the contractor on all drawings supplied.
After commissioning, one set of all drawings manually corrected in red must be
available on site at the time of commencing production. The complete documentation
must be delivered four weeks before commissioning.
11.12.3 General documentation
Documentation to be supplied
- Operating instructions
- Operating manuals
- Maintenance and repair instructions
- Tables with the settings for mechanical components such as e.g. the brakes
- Program backups of all control systems
- Tables with the settings for electrical components
11.12.4 Crane test logbook
Contents:
- Master sheet with the chief data and categorization of the crane, as well as the hook
and rope test documentation
- Test certificates for all utilized wire ropes, hooks, chains and supporting and load-
carrying devices

Bridge Crane TKCSA
ThyssenKrupp CSA
- Declaration of conformity
12. Sign-posting
12.1 Factory and load rating signs
All cranes will be provided with load capacity signs and factory plates according to UVV
BGV D6 (VBG 9). These signs must be mounted in a clearly visible position on 2
external sides and in a sufficient size. The factory and load-carrying capacity signs must
be delivered in enameled design. The CE marking must be attached to the factory plate.
The load capacity and factory plates must be attached in metal frames on the crane
bridge such that they are safe from dropping off.
12.2 Warning signs
All hazard points must be marked by warning signs. The signs must have a minimum
size of 200 mm x 300 mm and printed in a permanent fashion. Inasmuch as this is
possible, the hazards must be shown by way of an image or a symbol on the signs, and
they should be supplemented by texts in the Portuguese and English languages.
 No access for unauthorized persons!

 Crane! Inform crane operator before entry (at all access points)
 Crane access! Caution when ascending and descending (at all access points)
 Important! When leaving the operator cab switch off the crane switch inside the
operator cab and the separating isolating switch on the crane bridge.
 Crushing hazard caused by "Name of the hazard“
 Danger of crushing parts of the body! Enter only after shutdown of "Name of the
hazard“
 Important! Rotating parts
 Low building construction
 Voltage warning signs
 High voltage
 Contact with the conductor rails is a danger to life
 Electrical operating room
 Close door after leaving
 Special power circuit! Live even when isolating switch is off
12.3 Information signs

Bridge Crane TKCSA
ThyssenKrupp CSA
All information signs must have been printed in a permanent fashion. Below, there
follow some examples for information signs. The texts must be printed in Portuguese
and English.
 Crane isolating switch

 Isolating switch for special power circuit
 Hard points for hydraulic lifting presses (complete with force details)
 Activate air conditioning system only when the cab is closed
 UVV information, operating regulations for cranes BGV D6 § 28 to 43 size
 Marking of fire extinguisher
 Marking of emergency stop switch
12.4 Unit designations
Signs for electrical equipment and machinery parts as well as the type specification
plates for electrical devices and machinery parts must be delivered with permanent
clearly legible lettering. To avoid problems when replacing equipment units, the signs
should not be attached to the devices and machines, but instead on fixed structural
components. Type plates are excepted. All designation and notice signs must be made
of Resopal with engraved lettering. The signs must be attached with tallow-drop screws
and nuts.
12.5 Wire marking
All conductors connected to the operating equipment units and terminal strips must be
marked.
13. Corrosion protection
13.1 General
The scope of delivery of the contractor includes the derusting and basic and top coating
of all steel and machinery constructions. For derusting and coating in steel and machine
engineering DIN EN ISO 12944 (corrosion protection of structural steelwork by coating
systems) Parts 1 to 8 applies.
Manufacturers may change the corrosion protection for a system with same quality if
this system is supplied for approval to TKCSA.

Bridge Crane TKCSA
ThyssenKrupp CSA
13.2 Derusting
All steel and mechanical parts must be derusted before painting, by sandblasting in
accordance with DIN EN ISO 12944, section 4. The degree of preparation results from
the annexes to Section 13.3. The prime coat must be applied to the blasted surfaces on
the same day if possible.
13.3 Coating systems
For the corrosion protection of the cranes, there are 3 different classes that are
enclosed with this inquiry at the annexes A/i, A/T and B:
The coating structure according to A/i must be selected for all steel and machine
components that will be exposed to temperatures of 130° C max. This coating structure
also applies to electrical and mechanical components such as e.g. engine
compartments, brakes, Eldros, external gear unit faces, rope pulleys, rope drums, track
wheels, air conditioning systems etc. inasmuch as these do not accept any
temperatures above 130° C. This coating structure also applies for painted control
cabinets, E-containers and the insides of walk-on crane girders or crossbeams
The coating structure according to B must be selected for all steel and machine
components that are exposed to temperatures in excess of 130° C. This coating
structure also applies to electrical and mechanical bought components such as e.g.
engine compartments, brakes, Eldros, external gear unit faces, rope pulleys, rope
drums, track wheels, air conditioning systems etc. inasmuch as these accept
temperatures above 130° C.
The insides of non-accessible hollow components such as top beams or smaller

crossbeams are given a coating structure according to annex A/T
The RAL colors are defined by TKCSA after contract award. In respect of the remaining
steel and mechanical engineering components, separate colors are defined for the
following components:
 Railing
 Crossbeams
 Boom, running profile and carrier of the trolley power infeeds
 Bottom and top pulleys
 Control cabinets and terminal boxes
 Inside of switchgear rooms
 Electrical mounting plates
 Operator cab
 Air conditioning units
The front faces on the top beams of the crane bridges and trolleys as well as the
crossbeams and hook pulleys will be provided with a black/yellow tiger pattern
according to DIN 15026
13.4 Corrosion protection of components without any coating
Bearings, bearing seals, grease nipples, brake surfaces, etc. must not be painted. Bare
machinery parts must be cleaned and treated with a suitable preservative such as

Bridge Crane TKCSA
ThyssenKrupp CSA
Ferrolit Special or a similar product with suitable consistency as protection against

corrosion.
14 Fire prevention
The following fire protection measures must be taken for all cranes and are included in
the scope of supply of the crane supplier:
 Early fire detection within the area of the electrical operating rooms of the crane
units complete with connection to cabin, the works fire brigade and the control
room of the steelworks. Radio transmission of the message.
 As an option: Small fire extinguishing system with fully automatic triggering for
the electrical operating rooms of the crane systems. (Recommendation due to
the potential risk of fire: gas fire extinguishing system using the extinguishing
medium NOVEC 1230TM from 3MTM)
The type and number of the fire extinguishing units can only be defined when
the plant layout has been finalized.
 Powder fire extinguishers (complete with bracket) for all operator cabs
15. Annexes
Project drawings
1. Shop cut, drawing no.: C.ACV0.SL/LAY210
2. Shop overview, drawing no.: C.ACV0.SL/LAY110
3. Crane project drawings according to the overview on page 1 of these specifications
4. Investigation converter filling (drawing still missing) but situation shown in the
general drawing for crane S100
5. Crane lay out drawing - shop cut: C.ACV0.SL.76/LAY200
6. Crane lay out drawing - shop overview: C.ACV0.SL.76/LAY100
Drawings load-carrying equipment and carrying gear

1. Teeming ladle drawing no.: C.ACV0.SL.241-M0000/FPA001
2. Hot metal ladle drawing no.: C.ACV0.SL.1261-M0000/FPA001
3. Scrap box drawing no.: C.ACV0.SL.1334-M0000/EIZ001
4. Vacuum vessel drawing no.: C.ACV0.SL.3611-M2000/EIZ001
5. Proposal SVAI on the design of the laminated hooks in the auxiliary hoists
Technical details
Block diagram out-of-balance load detection
Block diagram hook aperture sensors
Example for data sheet motor cable drum for Ø3800 mm Drwg. G-4352-00-V-2
Example for data sheet motor cable drum for Ø3300 mm Drwg. G-4351-00-V-2
Example for data sheet guide rollers Drwg. 119-06-059601/0
Example for data sheet infeed hopper Drwg. 219-55-056838/1
Inspection documents
QM1 to QM17
Corrosion protection
A/i steel and mechanical components up to 130°C

Bridge Crane TKCSA
ThyssenKrupp CSA
A/T insides of hollow sections

A/i steel and mechanical components over 130°C
Annexes to be completed by the supplier

Equipment prices
Annex: Component list complete with sample for a track wheel
List with deviations from the description
TH Standards
TH-N 080 100 Acceptance guidelines
TH-N 205 430 Spur gear involute gearing, specification in drawings
TH-N 236 500 Test certificate for crane girders and trolley frames
TH-N 270 130 Elastic shaft coupling with coupling pin
TH-N 270 080 Universal joints and connection flanges
TH-N 441 360 Motor slide rails, anchor nuts and shim
TH-N 507 021 Lubricating instructions
TH-N 560 500 Test loading and determining bending
TH-N 565 144 Technical requirements for drive systems
TH-N 565 560 Rope drive units
TH-N 565 600 Driven axle and wheels with wheel flange
TH-N 565 601 Following axle and wheels with wheel flange
TH-N 565 651 Track wheel rocker
TH-N 565 763 Rope pulleys and compensation rollers
TH-N 565 873 Lamella hooks
TH-NZ 415 601 ff Crane supply circuit diagram

Annexes Purchase
16. Performance Guaranties
The following technical instructions are to be taken into account in the technical proposal and
fulfilled:
- Max. wheel load 16 x 700 kN for cranes in group G1.

- Compliance with the (external) measurement of the cranes, as per drawings to be approved by
TKCSA.
- Approaches of crane and trolley as well as higher and lower hoisting limits to be complied with,
as per drawings to be approved by TKCSA.
- Compliance to the driving and lifting speeds at nominal load, as per Technical Specifications
(table 7).
- Maximum deflection of the crane bridge with the test load as per Technical Specifications
(paragraph 1.2.5.1)
- Lowest vertical resonance frequency of the crane bridge girder shall be >= 4 Hz..
- Weighing precision shall be 0.1 %, relative to the payload
- Non-availability max. 25 h/year per crane. This is the time after the contractor has been notified
for failures which the contractor is responsible.

Bridge Crane TKCSA
ThyssenKrupp CSA
17. Time Schedule
Arrangement Trolley and
+/- 10%
Drawings2)
Visibility from Cabin3)
Long Travel4)
Drawings5) + Pre-statical
Finalised Sub-supplier list
General Arrangement
Arrangement for Cable
calculation of steel structure
Power consumption of each
Component list
Cable list + cable routing

Wheel Load Diagram1)
(preliminary)
Drum/Tray
Calculation of mech. Parts
drive permanent consumers
Single line diagram +

+4 +8 +16
S100 +3 weeks +3 month +6 weeks +6 weeks +8 weeks +10 weeks +13 weeks +13 weeks weeks weeks weeks
+4 +8 +16
+4 +8 +16
+4 +8 +16
+4 +8 +16
+4 +8 +16
+4 +8 +16
+4 +8 +16
1) Wheel Loads and Wheel Base, Skewing Forces, Inertia Forces due to drives, Buffer forces, Tension Force by Cable
Drum with location of acting force

Bridge Crane TKCSA
ThyssenKrupp CSA
2) incl. Size of hooks

3) Location of plant equipment provided by TKCSA 3 weeks before
4) incl. Rope reeving system, gearbox arrangement, accessibility for maintenance
5) Main dimensions and criteria for the stress analyses
6) Capacity Calculation for A/C, Arrangement of air-ducts incl. Arrangement of electr. equipment inside girder
Detailed fabrication drawings: 2 weeks prior to start of fabrication

Risk analyses: 8 weeks prior to shipment
Detailed time schedule for engineering and manufacturing (incl. Milestones for approval): 4 weeks after contract
award
Detailed time schedule for transport,erection and commissioning / testing: 12 weeks after contract award
Air-conditioning6): +16 weeks
Documentation as per 10.12.1 through 10.12.4: 4 weeks prior to shipment
As-built documentation: 4 weeks after acceptance

Technical Specs - Rev01

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Performance Description

Bridge Crane TKCSA

Project TKCSA Status 2007/05/25

Technical specifications for the TKCSA bridge cranes

Item Crane Designation Location Support Load Range

* These cranes transport molten masses regularily

Project drawings for the specified cranes

Item Crane Drawing no. Status Crane runway Wheel

Inquiry crane TKCSA V1 1 EA-AT-RS

Project TKCSA Status 2007/05/25

8.3.7.3.1 Steel grades for bolted components-----------------------------------------------------------------------30

Inquiry crane TKCSA V1 2 EA-AT-RS

Project TKCSA Status 2007/05/25

This specification directory contains the mechanical and electrical equipment

1.1 Object description

1.2 Instructions for order processing

1.2.1 Projecting phase

Inquiry crane TKCSA V1 3 EA-AT-RS

Project TKCSA Status 2007/05/25

Dimension specifications given in the attached project drawings are mandatory as

- Arrival of main and partial deliveries in the harbor

Inquiry crane TKCSA V1 4 EA-AT-RS

Project TKCSA Status 2007/05/25

- Durations for electrical shutdowns

In case of discrepancy with sect. 17, sect. 17 will govern

1.2.2 Construction phase

1.2.2.1 Production monitoring

- Qualification of suppliers to manufacture the respective components

Inquiry crane TKCSA V1 5 EA-AT-RS

Project TKCSA Status 2007/05/25

Details of the measuring method, the tolerances to be adhered to and the

 Pedestal bearing for the rope drum

Inquiry crane TKCSA V1 6 EA-AT-RS

Project TKCSA Status 2007/05/25

1.2.2.2 Test runs

1.2.3 Assembly and commissioning

Inquiry crane TKCSA V1 7 EA-AT-RS

Project TKCSA Status 2007/05/25

Any necessary intermediate storage on the TKCSA site is to be organized by the

1.2.5 Acceptance in accordance with BGV D6, Art. 25

Inquiry crane TKCSA V1 8 EA-AT-RS

Project TKCSA Status 2007/05/25

1.2.5.1 Loading tests

1.2.5.2 Acceptance and transfer

1.2.5.3 Service on call

After a crane is accepted and approved, a continuous callout availability period of 10

Inquiry crane TKCSA V1 9 EA-AT-RS

Project TKCSA Status 2007/05/25

1.3 Tender contents

Complete, functional cranes are to be offered, as described in this performance

Complete fulfillment of this performance description must be confirmed

All prices are quoted in US Dollar [$].

1.5 Terms of delivery and regulations to be considered

Supplementarily to the stipulations in sections 8 to 11 of these specifications and the

Inquiry crane TKCSA V1 10 EA-AT-RS

Project TKCSA Status 2007/05/25

Machinery Directive 98/37/EC as from 01/01/1995 (9th GPSGV - Machine Ordinance)

Harmonized Standards (compliance with the applicable / latest version)

DIN EN 292 T1 Safety of machinery; basic concepts, general principles for

Accident prevention regulations

Inquiry crane TKCSA V1 11 EA-AT-RS

Project TKCSA Status 2007/05/25