AS 1418.1-1994

1 - AS 1418.1-1994 CRANES (INCLUDING HOISTS AND WINCHES) - GENERAL REQUIREMENTS
4 - PREFACE
5 - CONTENTS
9 - FOREWORD
10 - SECTION 1 SCOPE AND GENERAL
10 - 1.1 SCOPE
10 - 1.2 NEW DESIGNS AND INNOVATIONS
10 - 1.3 INTERPRETATIONS
10 - 1.4 REFERENCED DOCUMENTS
10 - 1.5 DEFINITIONS
10 - 1.6 NOTATION
11 - SECTION 2 CLASSIFICATION OF CRANES
11 - 2.1 SCOPE OF SECTION
11 - 2.2 GENERAL
11 - 2.3 GROUP CLASSIFICATION
11 - 2.3.1 Bases of classification
11 - 2.3.2 Class of utilization
12 - 2.3.3 Load spectrum
12 - 2.3.4 Group classification
14 - SECTION 3 MATERIALS FOR CRANES
14 - 3.1 SCOPE OF SECTION
14 - 3.2 MATERIAL SPECIFICATIONS
14 - 3.3 MATERIAL PROPERTIES
15 - SECTION 4 CRANE LOADS
15 - 4.1 SCOPE OF SECTION
15 - 4.2 REFERENCE TO OTHER PARTS OF THIS STANDARD
15 - 4.3 DETERMINATION OF CRANE LOADS
15 - 4.4 CATEGORIZATION OF CRANE LOADS
16 - 4.5 PRINCIPAL LOADS
16 - 4.5.1 General
16 - 4.5.2 Dead loads
17 - 4.5.3 Hoisted load
19 - 4.5.4 Inertia loads
23 - 4.5.5 Loads induced by displacements
23 - 4.6 ADDITIONAL LOADS
23 - 4.6.1 General
23 - 4.6.2 In-service wind forces
23 - 4.6.3 Snow and ice loads
23 - 4.6.4 Forces due to temperature variation
23 - 4.6.5 Lateral forces due to oblique travel
25 - 4.6.6 Bulk material impact loads
26 - 4.7 SPECIAL LOADS
26 - 4.7.1 General
26 - 4.7.2 Loads due to off-vertical hoisting
26 - 4.7.3 Out-of-service wind forces
26 - 4.7.4 Test loads
26 - 4.7.5 Buffer forces
27 - 4.7.6 Tilting forces
27 - 4.7.7 Loads on walkways and in chutes
29 - 4.7.8 Loads caused by emergency conditions
29 - 4.7.9 Seismic loads
29 - 4.7.10 Loads during erection
29 - 4.8 CATEGORIZATION OF FREQUENCY OF CRANE LOAD COMBINATIONS
29 - 4.9 PRINCIPLES FOR DETERMINATION OF CRANE LOAD COMBINATIONS
29 - 4.9.1 Basic considerations
30 - 4.9.2 Application of load combinations
32 - SECTION 5 DESIGN OF CRANE STRUCTURE
32 - 5.1 SCOPE OF SECTION
32 - 5.2 BASIS OF DESIGN
32 - 5.2.1 Service life of crane
32 - 5.2.2 Design of structure
32 - 5.2.3 Classification of crane structures
32 - 5.3 DESIGN OBJECTIVE
32 - 5.4 METHOD OF DESIGN
32 - 5.4.1 General
32 - 5.4.2 Working stress design method
33 - 5.4.3 Limit states method
34 - 5.5 FATIGUE STRENGTH
34 - 5.5.1 General
34 - 5.5.2 Working stress design
34 - 5.5.3 Limit states design
34 - 5.6 DESIGN FOR SERVICEABILITY DEFLECTION AND VIBRATION
34 - 5.6.1 General
34 - 5.6.2 Deformation limits
35 - 5.6.3 Limits on frequency and amplitude of vibration
35 - 5.7 DESIGN OF MONORAIL BEAMS
35 - 5.7.1 Flange thickness
36 - 5.7.2 Web thickness of single-web beam
38 - SECTION 6 STABILITY
38 - 6.1 SCOPE OF SECTION
38 - 6.2 OVERTURNING
38 - 6.3 STABILITY DURING ERECTION, MAINTENANCE AND WEIGHING
38 - 6.4 SAFETY AGAINST DRIFTING
40 - SECTION 7 CRANE MECHANISMS
40 - 7.1 SCOPE OF SECTION
40 - 7.2 MECHANISMS
40 - 7.3 BASIS OF DESIGN
40 - 7.3.1 Design of mechanism
40 - 7.3.2 Design for strength
40 - 7.3.3 Design for life
41 - 7.3.4 Classification of crane mechanisms
43 - 7.4 MECHANISM LOADINGS
43 - 7.4.1 Determination of loads
43 - 7.4.2 Categorization of mechanism loads
43 - 7.4.3 Categorization of mechanism loading
44 - 7.5 PRINCIPAL LOADS
44 - 7.6 ADDITIONAL LOADS
45 - 7.7 SPECIAL LOADS
46 - 7.8 CATEGORIZATION OF FREQUENCY OF MECHANISM LOAD COMBINATIONS
46 - 7.9 PRINCIPALS OF DETERMINATION OF MECHANISM LOAD COMBINATIONS
46 - 7.9.1 General
46 - 7.9.2 Application of load combinations
49 - 7.10 MECHANICAL COMPONENTS
49 - 7.10.1 General
52 - 7.10.2 Bearings
52 - 7.10.3 Gearing
52 - 7.11 DRIVING MEDIA
52 - 7.12 BRAKING
52 - 7.12.1 Braking media
52 - 7.12.2 Size and characteristics
52 - 7.12.3 Environmental protection
52 - 7.12.4 Accessibility
52 - 7.12.5 Materials
53 - 7.12.6 Design
53 - 7.12.7 Operation
53 - 7.12.8 Hoisting motion
53 - 7.12.9 Travel and traverse motions
54 - 7.12.10 Luffing motion
54 - 7.12.11 Slewing motion
54 - 7.13 MOTION LIMITS, INDICATORS AND WARNING DEVICES
54 - 7.13.1 Provision of limits
54 - 7.13.2 Range of limitation of motion
54 - 7.13.3 Operation of motion limit
54 - 7.13.4 Indicators and warning devices
55 - 7.14 DRUMS
55 - 7.14.1 Materials
55 - 7.14.2 Design
56 - 7.14.3 Diameter of drum
56 - 7.14.4 Actual thickness of drum shell
56 - 7.14.5 Theoretical thickness of drum shell (abbreviated method)
58 - 7.15 SHEAVES
58 - 7.15.1 Materials
58 - 7.15.2 Design
58 - 7.15.3 Diameter of sheave
58 - 7.15.4 Sheave guard
58 - 7.16 DRUM AND SHEAVE DIAMETERS
58 - 7.17 ROPES AND REEVED SYSTEMS
58 - 7.17.1 Ropes
59 - 7.17.2 Components
59 - 7.18 GUYS, OTHER FIXED-ROPE SYSTEMS, AND STATIONARY ROPES
59 - 7.19 REEVED SYSTEMS
59 - 7.19.1 Wire rope
60 - 7.19.2 Wire rope selection procedure
61 - 7.19.3 Fleet angle from drum or sheave
61 - 7.19.4 Rope anchorages
61 - 7.19.5 Rope equalizers
61 - 7.19.6 Overhauling weight
61 - 7.19.7 Fibre rope
61 - 7.20 WHEELS AND RAILS
61 - 7.20.1 Selection of wheels and rails
61 - 7.20.2 Wheel loading
62 - 7.20.3 Wheels
64 - 7.20.4 Tyres
64 - 7.20.5 Side guide rollers
65 - 7.20.6 Rails
70 - 7.20.7 Rail fastening
71 - 7.20.8 Rail joints
71 - 7.20.9 Rail alignment
71 - 7.20.10 Runway flanges -Lateral support
73 - SECTION 8 ELECTRICAL EQUIPMENT AND CONTROLS
73 - 8.1 SCOPE OF SECTION
73 - 8.2 MATERIALS AND EQUIPMENT
73 - 8.3 INFORMATION RELEVANT TO DESIGN OF ELECTRICAL SYSTEM
73 - 8.4 MOTORS
73 - 8.4.1 Enclosure and duty type
73 - 8.4.2 Rated output and performance characteristics
74 - 8.4.3 Resistors for motor power circuits
74 - 8.5 MOTOR CONTROL
74 - 8.5.1 Control systems
74 - 8.5.2 Electrical braking
74 - 8.5.3 Motor control circuit
75 - 8.6 CONTACTORS
75 - 8.7 CONTROLLERS
75 - 8.7.1 Means of control
75 - 8.7.2 Pendant control station
77 - 8.7.3 Pendant cord
77 - 8.7.4 Whole-current controller
77 - 8.7.5 Master controller or combination controller
77 - 8.7.6 Radio control
79 - 8.7.7 Electronic control
81 - 8.7.8 Automatic control
82 - 8.7.9 Infra-red control
83 - 8.8 LIMIT SWITCHES
83 - 8.8.1 Purpose
83 - 8.8.2 Mandatory and optional limit switches
83 - 8.8.3 Working-limit switch
83 - 8.8.4 Final-limit switch
84 - 8.8.5 Operation of limit switches and associated electrical relays
84 - 8.8.6 Design and construction
85 - 8.8.7 Application
85 - 8.9 CONTROL-CIRCUIT TRANSFORMERS
85 - 8.10 ELECTRICAL ISOLATION
85 - 8.10.1 Purpose
85 - 8.10.2 Arrangement of isolation
87 - 8.10.3 Main isolator
88 - 8.10.4 Crane isolator
89 - 8.10.5 Access isolators
89 - 8.10.6 Service isolator
89 - 8.10.7 Accessory, ancillary and auxiliary isolators
89 - 8.10.8 Emergency isolation
90 - 8.11 ELECTRICAL PROTECTION
90 - 8.11.1 Purpose
90 - 8.11.2 Overcurrent protection
91 - 8.11.3 Motor overtemperature protection (overload protection)
91 - 8.11.4 Earthing
91 - 8.12 HIGH-VOLTAGE SUPPLY TO CRANES
92 - 8.13 LIGHTNING PROTECTION
92 - 8.14 CRANES WITH MAGNET ATTACHMENTS
92 - 8.14.1 General
92 - 8.14.2 Lifting capacity
92 - 8.14.3 Magnet controllers
92 - 8.14.4 Application of magnets
92 - 8.14.5 Emergency batteries
93 - 8.14.6 Magnet circuits
93 - 8.14.7 Rectifiers
94 - 8.14.8 Magnet leads
94 - 8.14.9 Magnet couplings
94 - 8.14.10 Magnet attachments
95 - 8.14.11 Magnet testing
95 - 8.15 WIRING AND CONDUCTORS
95 - 8.15.1 Materials and installation
95 - 8.15.2 Multi-outlet electrical supply
95 - 8.15.3 Crane collector systems
96 - 8.15.4 Collector rings
96 - 8.15.5 Electrical supply cables
96 - 8.15.6 Flexible cable
97 - 8.16 ACCESSIBILITY
97 - 8.16.1 General
97 - 8.16.2 Servicing platforms
97 - 8.17 ELECTRICAL EQUIPMENT MARKING AND INSTALLATION DIAGRAMS
97 - 8.17.1 Marking
97 - 8.17.2 Diagrams
98 - SECTION 9 HYDRAULIC EQUIPMENT AND CONTROLS
98 - 9.1 SCOPE OF SECTION
98 - 9.2 MATERIALS
98 - 9.3 BASIS OF DESIGN
98 - 9.3.1 General
98 - 9.3.2 Braking
98 - 9.3.3 Emergency stop
98 - 9.3.4 Tubes, hoses, fittings and fluid passages
98 - 9.3.5 Safety features
99 - 9.4 CIRCUIT DIAGRAM
99 - 9.5 COMPONENTS
99 - 9.5.1 Accumulators
99 - 9.5.2 Cylinders
99 - 9.5.3 Filters and strainers
99 - 9.5.4 Hydraulic controls
100 - 9.5.5 Hydraulic pumps and hydraulic motors
100 - 9.5.6 Hydraulic tubing, hoses, fittings and fluid passages
100 - 9.5.7 Reservoirs
100 - 9.6 INSTALLATION
100 - 9.7 TESTING
100 - 9.8 MARKING
101 - 9.9 INSPECTION AND MAINTENANCE
101 - 9.9.1 General
101 - 9.9.2 Replacement parts
102 - SECTION 10 PNEUMATIC EQUIPMENT AND CONTROLS
102 - 10.1 SCOPE OF SECTION
102 - 10.2 MATERIALS
102 - 10.3 BASIS OF DESIGN
102 - 10.3.1 General
102 - 10.3.2 Braking
102 - 10.3.3 Emergency stop
102 - 10.3.4 Tubes, hoses, fittings and air passages
102 - 10.3.5 Safety features
103 - 10.4 CIRCUIT DIAGRAM
103 - 10.5 COMPONENTS
103 - 10.5.1 Cylinders
103 - 10.5.2 Filters
103 - 10.5.3 Pneumatic controls
103 - 10.5.4 Pneumatic motors
103 - 10.5.5 Pneumatic tubing, hoses, fittings and air passages
104 - 10.5.6 Receivers
104 - 10.6 INSTALLATION
104 - 10.7 TESTING
104 - 10.8 MARKING
104 - 10.9 INSPECTION AND MAINTENANCE
104 - 10.9.1 General
104 - 10.9.2 Replacement parts
105 - SECTION 11 OPERATIONAL DESIGN
105 - 11.1 SCOPE OF SECTION
105 - 11.2 CONTROL CABIN
105 - 11.2.1 Location of control cabin
105 - 11.2.2 Space for driver/operator
105 - 11.2.3 Seating of driver/operator
105 - 11.2.4 Controls and indicators
105 - 11.2.5 Visibility from the cabin
106 - 11.2.6 Ventilation
106 - 11.2.7 Lighting
106 - 11.2.8 Thermal environment
106 - 11.2.9 Noise exposure criteria
106 - 11.2.10 Communication
106 - 11.2.11 Fire extinguisher
107 - 11.2.12 Emergency entry to control cabin
107 - 11.3 PENDANT CONTROL STATIONS AND PENDANT CORDS
107 - 11.3.1 Pathway for crane driver
107 - 11.3.2 Operating level of controls
107 - 11.4 DRIVER CONTROLS AND INDICATORS
107 - 11.4.1 Crane motions
107 - 11.4.2 Operation of controls
107 - 11.4.3 Interlocking of controls
107 - 11.4.4 Controls and indicators for ancillaries
107 - 11.5 WARNING DEVICES
108 - SECTION 12 MANUFACTURE AND CONSTRUCTION
108 - 12.1 SCOPE OF SECTION
108 - 12.2 MATERIALS
108 - 12.3 FABRICATION AND ASSEMBLY
108 - 12.4 REWORK
108 - 12.5 FINISH
108 - 12.6 DRAINING
108 - 12.7 ACCESS AND CLEARANCES
108 - 12.7.1 General
108 - 12.7.2 Access to crane driving position
108 - 12.7.3 Access and servicing facilities
109 - 12.7.4 Clearances
109 - 12.8 REPAIRS
110 - SECTION 13 ACCESS FOR SERVICING
110 - 13.1 SCOPE OF SECTION
110 - 13.2 ACCESS FOR SERVICING
110 - 13.2.1 Servicing
110 - 13.2.2 Access for servicing
111 - SECTION 14 INSPECTION, TESTING AND MARKING
111 - 14.1 SCOPE OF SECTION
111 - 14.2 INSPECTION
111 - 14.3 TESTING
111 - 14.4 MARKING
111 - 14.4.1 General
111 - 14.4.2 Marking on lifting means
112 - SECTION 15 OPERATING ENVIRONMENT
112 - 15.1 SCOPE OF SECTION
112 - 15.2 INDOOR INSTALLATION
112 - 15.2.1 Normal service conditions
112 - 15.2.2 Special service conditions
113 - 15.3 OUTDOOR INSTALLATION
113 - 15.3.1 Normal service conditions
113 - 15.3.2 Special service conditions
113 - 15.4 MAINTENANCE
114 - APPENDIX A - ORGANIZATION OF AUSTRALIAN STANDARD FOR CRANES
118 - APPENDIX B - LIST OF REFERENCED DOCUMENTS
122 - APPENDIX C - FATIGUE DESIGN OF MECHANISMS
122 - C1 INTRODUCTION
122 - C2 DEFINITIONS
122 - C2.1 Alternating stress
122 - C2.2 Endurance limit (or fatigue limit)
122 - C2.3 Endurance ratio
122 - C2.4 Fatigue life
123 - C2.5 Fatigue strength
123 - C2.6 Finite life
123 - C2.7 Fluctuating stress
123 - C2.8 Frequency of stress cycle
123 - C2.9 Infinite life
123 - C2.10 Linear damage law
123 - C2.11 Maximum and minimum stress
123 - C2.12 Mean stress (or steady stress component)
123 - C2.13 S-N diagram
123 - C2.14 Stress amplitude
123 - C2.15 Stress cycle
123 - C2.16 Stress range
123 - C2.17 Stress ratio
123 - C3 DESIGN PROCEDURE
123 - C3.1 General
124 - C3.2 Selection of materials
124 - C3.3 Detail design
124 - C3.4 Fatigue strength design
125 - C3.5 Fatigue life design
125 - C3.6 Factor of safety
125 - C4 WELDED FABRICATED COMPONENTS
125 - C5 REFERENCES
126 - APPENDIX D - TYPICAL CRANE APPLICATION CLASSIFICATION
128 - APPENDIX E - OBLIQUE TRAVEL FORCES-DETAILED ANALYSIS
128 - E1 GENERAL
128 - E2 GENERAL METHOD OF CALCULATION APPLICABLE TO ALL BRIDGE AND GANTRY CRANES
132 - APPENDIX F - TYPICAL CRANE DRIVE DIAGRAMS
134 - APPENDIX G - TYPICAL METHODS OF BRAKING OPERATION
134 - G1 BRAKE APPLICATION
134 - G2 BRAKE RELEASE
135 - APPENDIX H - GUIDANCE ON GROOVE PROFILES FOR ROPE DRUMS
137 - APPENDIX I - THEORETICAL THICKNESS OF CRANE DRUM
137 - I1 APPLICATION
137 - I2 NOTATION
139 - I3 PERMISSIBLE STRESSES
139 - I4 LIMITATIONS ON DRUM-SHELL THICKNESS
139 - I5 STRESSES IN SINGLE-LAYER DRUM
140 - I6 STRESSES IN MULTILAYER DRUM*
141 - I7 DRUM DESIGN FACTORS
148 - APPENDIX J - GUIDANCE ON GROOVE PROFILES FOR WIRE ROPE SHEAVES
151 - APPENDIX K - REEVED SYSTEMS-ALLOWANCE FOR FRICTIONAL EFFECTS
153 - APPENDIX L - NOISE LEVELS
154 - APPENDIX M - MAINTENANCE WORK PROCEDURES
154 - M1 INTRODUCTION
154 - M2 RESTRICTION OF ACCESS
154 - M3 AUTHORIZATION FOR ACCESS
154 - M4 WARNING TO OTHER PERSONNEL
154 - M5 WORK NEAR CRANES AND CRANE RUNWAYS
154 - M6 WORK ON CRANES
154 - M7 LOCKOUT OF MAIN ISOLATOR OR CRANE ISOLATOR
154 - M8 OVERHEAD MAINTENANCE WORK
155 - M9 MAINTENANCE WORK IN ELEVATED POSITIONS
155 - M10 HEAD PROTECTION
156 - APPENDIX N - STANDARDS FOR COMPONENTS USED IN LIFTING SYSTEMS

The Standard specifies the general requirements for cranes. The Standard includes the design of cranes by the traditional working stress method and also allows design by the limit states design method. The partial load factors necessary for crane design by the limit states method have not been provided. Major technical changes include revisions towards harmonization with ISO Standards, development of crane loads, crane structure, stability, electrical and controls including automatic controls, radio controls and infra-red control. The Appendices have also been revised.

This Standard specifies the general requirements for cranes (including hoists and winches), as defined in AS 2549, and appliances intended to carry out similar functions. In recognition of the publication of AS 4100, the limit states design method has been included in this Standard along with the traditional working stress design method to AS 3990. The partial load factors referenced in Clauses 4.9.2.3 and 7.9.2.3 for limit states design have not been given as these have not yet been provided for in any internationally recognized crane Standard. Where the limit states design method is used, cranes shall be designed to give a degree of safety not less than that given in this Standard for the working stress design method for strength, buckling, deflection, torsion, fatigue and the like.NOTES:1 Specific requirements for particular types of cranes are specified in other Parts of AS 1418; these requirements take precedence over corresponding requirements in this Standard where any difference exists.2 Requirements for the selection and operation of some types of cranes are given in AS 2550.3 A chart showing the structure of the Crane Code and its parts is given in Appendix A.

AS 1418.1 first published as part of AS CB2-1938.
Second edition 1960.
Revised and redesignated in part as AS 1418.1-1977.
Second edition 1986.
Third edition 1994.