Beruflich Dokumente
Kultur Dokumente
(Roatfirmod 1990)
Indian S.tandard
CODE OF PRACTICE FOR
DESIGN, MANUFACTURE, ERECTION AND
TESTING (STRUCTURAL PORTION) OF
CRANES AND HOISTS
0 Copyright 1977
( First Revision 1
Cranes and Allied Appliances Sectionsl Committee, SMDC 26
Choiman R<jmmting
SHI, D. K. N.,xm <Vhif Calcutta Pvt Limited, Calcutta
hfmbm
Da B. N. KHAN ( Afkmor< to
Shri D. I;. Nandi)
Sm, A. K.lhSD”F*DIIYAY*
0 Copright 1977
BUREAU OF INDIAN STANDARDS
Thh publication is protected under the Indian C.+iihl Arr (XIV of 1957 ) e.nd
rcpmduckm in whole or in part by any mcrnr cxccpt with wirtcn pcmiuion ofrhc
publishhcr ireI1 be deemed 10 be an infringcmcnt cf copyright under thcsaid Act.
Cutler Hammer India Limited, Faridabad
Southern Strucmrals Lid, hladra.,
Indian Crane Company Limilcd, Calcurm
Tam-Robins-Fraser Limited, Jamrbcdpur
Allnn~lr )
Bharar Heavy Elcmicals Limited, Dhopal
Hindwan Steel Limited, Durgapur
Tak Macbincry Limited, Bombay
E:~ginccring Indwry,
2
IS : 807 - I976
Indian Standard
CODE OF PRACTICE FOR
DESIGN, MANUFACTURE, ERECTION AND
TESTING (STRUCTURAL PORTION ) OF
CRANES AND HOISTS
( First Revision )
0. F 0 R E W 0 R D
0.1 This Indian Standard (First Revision) was adopted by the Indian
Standards Institution on 27 ,111gust I9iG, after the draft linalized by the
Cranes and Allied Appliances Sectional Committee had been approved by
the Structurnl and hfctnls Division Council.
0.2 This standard covers dcsign ofstructural portion of crnws and hoists
and specifics pcrmissiblc strxwc~ and other &tails of drsign in order to
ensure economy in design and reliability in operation. To dcnl with the
subject conveniently? cranes have been broadly classified into four classes
depending upon thew duty and number of hours in service per year. The
correct classification of a crane is important and shou!d be the joint
responsibility of the purchnscr and the manufacturer. For guidance a few
typical cranes have been classified and shown in Appendix A.
0.3 This standard was lirst published in 1963. In this revision the
permissible strcsscs for members subjected to fluctuations ofsrrcss have been
aligned with IS : 102%1960*, thus, introducing rhc number of cycles
of operation for fatigue calculations. The limits of camber have PISO been
specified.
0.4 This standard is the first in the series of standards relating to crana
and covers the structural design. The other standards in the se&s covering
the mechukal and electrical portions are as followsz
IS : 3177-19G5 Code of practice for design of overhead travelling
cranes and gantry cranes other than steel work cranes
IS : 4137-1967 Code of practice for heavy duty electric ovcrhcad
travelling cranes including special servike machines for use in
steel works
3
ISxDO7.1976
0.5 ‘i’l,n~ sr.w~/,~~~l kw111 iti view 11~ iliitllllf~,~:tllrillu RIMI tr.ulr: l~rwticrt
Ii,l!~wr,l iI) t1w ,:1,1:,111y it: ttw IiCI<I. ha5irtiww hiu il Iw 11CCll<hi”d hl”
~IIC I~ill8,winy pulAi~:;~liol~s
SECTION I GENERAL
1. SCOPE
1.1 This code covers the structural portion of the design manufacture,
erection, and testing of all cranes and hoists, whether riveted or welded.
1.2 This standard does not apply to:
a) lifts;
b) conveyors for the conveyance of materials by means of rubber or
other types Pr hcl!S, Ch+;‘;S $.:“I
%.-. battens or scrapers, chains with
buckets and similar other appliances; and
C) clevaton Tar the convcyancc of materials by means of bucketa and
similar other appliances.
Nwe.--It L not intcndcd that thi co-de shall apply to crane ruway girdvr
sod ~~:pporu wbicb form an cscntial part of the structur~I Iramc of a building
or structure. Tbc deign orruch girdcn should be according to the rcquiremcou of
IS:UK.:962t.
2. TERMINOLOGY
2.0 1.‘~ the purpose of this standard, the definitions given in IS : 5532-1969:
in ;uldi!ion to the fo‘ollowing, Shall apply
---.
*Rulrr for rounding oflnumcrical YDIUP ( no&d ).
t&k of pncticc for we of~rructural rtccl in general building colurruction ( rmiud).
ftxxhf oltcrmr far craIIcl.
4
2.4 Live Load - The extcrnnl stxtic load v;winblc in magnitude! position
or direction. with rcspcct to the ~ncmber of str~~turc under consideration.
Also called \\Qrking load.
2.5 Rated Lifted Load-The rated lifted load from the mechanism
design considerations shall IIICR:~ the cxtcrnal load lifted and handled by the
crane and shrill include in addition to the snfc workinS load, weight ofrope
and lifting tackles such as m:\gncts, grabs, lifting beams, book blocks, but
shall cxcludc wind load.
2.6 Dynamic Effect -The clYccts on the structure caused by inertia or
sudden load app!ication such as accclcration, dcclnration, breaking, impact
and bumping.
2.7 Safe Working Load-The maximum external load excluding the
weight of the lifting tackles under specified conditions for which the crane
may be used. This may be n variable quantity for a .jib crane. If the
grab forms an integral part of the suspended gear, then the weight of the
gear shall also bc included in the safe working load.
2.8 Wind Load -The forces p~oduccd by the velocity of wind which is
assumed to act horizontally.
2.9 Service Condition - A crane shall bc deemed to be under service
condition when it is handling in any or all of its motions, a load up to and
including the maximum load for which the crnnc hns bcon dcsigncd
and, v:here cxposcd to wind, is subjected to the strcsscs resulting from wind
velocity spccilicd for sarc opcratiun of lhc crane.
2.10 Basic and Permissible Stresses -All permissible stresses spcci-
ficd in IS: UIIO-1962*, IS : 806-1968t, IS : 816-1969:, IS: 1024-1968s and
5
I6 I 807 - 1976
IS : 4WO-1967* arc the basic strews for purpose of this code. The pert&-
sible s:rcscs in thin code arc basic ~trcsc~ multiplied by duty factor
and fiuc:uation hc!?r 3s npplivblr.
2.11 Overloading -The load in cxcc~s of safe working load cxprcsrcd as
a pcrwntagc of the latter which the crane may be subjected to during
tcsting.provided for in 13.
2.12 Slewing Load - Forces induced wth rcqcct to axis of rotation due
to dead and live loads on the rotating parts of a siewing crane.
2.13 Radius -The horizont:ll distance from the central line of the lifting
hook bcrbrc loading to the ccntrc about which the jib slews.
2.14 Reach - The horizontal distance from the centre lint of the unladen
hook to the n~nrcst point of the cllanis/undcrfranlc with rcspcct to hook.
2.15 Stability Reach -The distance .of the jib head pin from the point
of intcrscction of the ncwcst base lint and the Gcrtical plane passing
through the ccntrc line of the jib. (The dimension will vary for diffrrcnr
positions of’ the hook in the courx ofone revolution during slcwing, but for
the purpose or calculating the stability the maximum value of this dimcn-
sion is taken. )
2.16 Stability Base-The c!rcctive span of the supporting base.
2.17 Blocking-Up Base - The elfcctive span of the supporting base when
outriggers, jacks or blocks are used to increasc stability by virtue of making
contxt with the ground at points farther irom the ccntre line of the crane
than the normal wheels or tracks.
2.18 hfaio Hoist Motion -TThc motion which raises and lower; :he load
( the full load which the crane is authorized to carry) and the motor doing
this work is termed the hoist motor.
2.19 A~~siliary Hoist Motion - V,.~lcn an additional hoisting motion
smaller than the mair. hoiz::ng ::wtlo~l is embodied in a crane, it is known
as an auxiliary hoist motion and its motor is termed the auxiliary hoist
motor.
2.20 Cross Traverse Motfon - The motion of the trolley or crab acres
the crane span is known as the cross trawrse motion and the motor causing
such motion, the cross traverse motor.
2.21 Longitudinal Travel Motion - The motion of the whole crane on
iis gantry or tracks is known as the longitudinal travel motion and the
motor c:~using this motion is termed the longitudinal travel motor.
6
IS I 807 - 1976
3. GENERAL REQUIREMENTS
3.1 Materials
3.1.1 Sfrurhml Sltrl - Structural steel shall conform to IS : 2261975*,
IS: 961-19i5t or IS: 2062-19691 as appropriate.
3.1.1.1 Any structural steel other than those specified in 3.1.1 may be
used provided that the permissible stresses and other design provisions arc
suitably modified.
3.X.2 Riucfs and Bolfs - Riveu, bolts, nuts and wasben shall conform to
the following Indian Standards as appropriate:
IS: 1363-1967 Specification for black hexagon bolts, nuts and lock
nuts (dia 6 to 39 mm) and black hexagon screwy
( dia 6 to 24 mm ) (jut reoLion )
IS: 1364-1967 Specification for precision and semi-precision hcxa-
gon bolts, screws, nuts and lock nuts ( dia range ,6 to
39 mm) (jrsf revi.rion)
IS : 1367-1967 TccfmicaI supply conditions for tbrcaded fasteners
(/irsf &rim )
IS : 1929-1961 Specification for rivets for general purposes ( 12 to
4S mm dim11rtcr )
IS : 2155-1962 Specification far rivets for general purposes (below
12 mm diameter)
IS: 31361966 Specification for hexagonal bolts and nuts ( M42 to
M150)
IS : 3757-1972 Specification for high-tensile friction grip bolts
(jrrf r&&n )
IS : 6610-1972 Specification for heavy washers for steel Structures
IS : 6623-1972 Spccificntion for high tcnsilc friction grip nuts
I.S:6639-1972 Specification for hexagon bolts for steel structures
IS : 6649-1972 Specification for high tensile friction grip washers
3.1.3 Sofiamod and Hardwood Timbcrr - All titubcrs used in the construc-
tion of cranes and their supporting structures shall bc car&lly selected
from those timbers proved satisfactory in scrvicc and complying with
IS : 3629.19665.
3.1.3.1 For structures which are likely to bc cxposcd to weather, the
more durable spccirx only shall bc used.
IS t 607 - 1976
SECTION II LOADS
4. LOADS
4.1 The crane shall be designed to support the most severe combinations of
the loads.givcn in 4.2 for the section concerned which may occur simulta-
ncwsly, with the working load in the most unfavourablc position, and with
any abnormal loads which may have been included in the purchaser’s
supplemental specifications.
4.2 Each of the following items shall, whell: applicable, be taken into
zuxlxmt:
a) Dead load;
b) Live Iqad, w&k&g load (any abnormal load specified by the
purchaser shall also bc included in this);
c) Factors for dynamic effects to suit &s&cation of cranes and
hoist ( scc 4.4.4.1 );
d) Slaving effect;
c) Wind load ( in case of outdoor cranes ) ( x(cd4.7 ) ;
f) Seismic effect;
g) Erection loads ( SCL4.8 );
11) Teinpcrature ei’fccts (sa 1s: 800-19620 ); and
j) Lulling cffcct (in the case ofjib cranes).
TABLE 1 CLASSIFICATION OF CRANES ,,ND HOISTS
CL.ASSlW3TlO.u l\‘oan,sc EFPr.cmYE Dv~*nK
NO. Penloo LOAD Errecr
(1) (2) (3) (4)
I Short LOW LOW
Loon8 LOW
Short LOW
Short High
Long LOW
Long HiFh
.Sh0rt High
Hi+
Dynamic c&c~s shall be conridcrcd high for other mobile ersnc~ or mcbilc
hoist%
9
IS t 807.1976
4.4 Factors for Dynamic Effects - In order to make allowance for the
dynamic effects, the forces or loads acting upon. cranes or any portion
: thcrcof rhall be multiplied by the relevant factors shown in Table 2 accord-
ing to the classification of the crane or hoist.
The force or load thus obtained shall be used as described below for
each portion.
4.4.2 11,,p~f Ikmr - ‘1’1~ iwpwt lkt~,r ;~plhl 11) lb !w~tiw I.( Ihc
hook in LL’ vertical client iil,ll “OWLI iwrliit iiw~ca iau-ltl~lif~g nllc~~.k. 11~
calculating live loads in mcn~bcrs of the s~~ucturc, the rated lifted load
shall be multiplied by the impact factor, values of which are given in
Table 2 for the various classes of cranes. The impact factor shall not apply
to the dead weight of the crane.
4.4.3.1 Ovcrhmd frmelfing cmw -The girders of the crane sl~all have
suESent lateral strength and rigidity to enable them to withstand the
horizontal forces.
4 1830v of the sum of the safe working load and the weight of the
crab, the force being assumed to act at the level of the top of the
traversing rails in the ccntm of the span when determining the
flange load and at appropriate points of the span when determin-
ing the lateral bracing loads; and
b) &of the weight of each girder, inclusive or any attachments
thereto, such as auxiliary girders or outriggers, platform and
mechanism, the force being assumed to act z.s a uniformly distri-
buted load throughout the length of the span.
11
IS : 007 - 1976
ii) o-7
iii) 1.2
iv) 3.0
3.0
3.0
I.6
@O
I.2
1%
IS ~807. 1976
15
IS I 807 - 1976
16
IS: 8G7 - 1976
7.6 Coonections -In gcncral, clause 26 of IS: SOO-1962* applies, but for
the connections of bridge girders to end carriage in overhead cranes where
it is csscntd that the girders have latcrnl end-fisity md rcsistnncc against
torsional toads, clause 26.1.1 of IS : 800-1962’ shall be applied.
8. EFFECTIVE LENGTHS
8.1 The effective length of struts, comparison flanges of rolled beams and
plategirders, members of lattice girders and cantilever beams sha!l be as
specified in IS :800-1962’. For effective length ofjibs, see Appendix C.
9. STABILITY
9.1 General -The following clauses shall apply to the crane and structure
as a whole under the clrcctr of wind pressure and/or load lifwd. In
determining the margin of stability,. rail grips shall not be taken into
rcount.
B.2 Stability Under Stprm Conditions -The stability of a crane under
dorm conditions shal! bc such that the stnbilizing moment is at lenst 1.25
times the overturr.ing nwmcnt due ‘to the maximwn wind effects provided
for under 4.7.
9.3 Stability Urxier Service Conditions-The ratio of stabilizing
moments to the overturning moments shall be not less than the values
given below:
a) Where the crane is equippcd.with an effective d&cc 1.25
that warns the driver when stabilizing moment has
been reduced by more than IO percent
b) $Vhere the craw is qot so equipped I.50
c) hiobilc or caterpillar cranes and cranes usrd in build- 1.50
ing or constructio!l work not capable of freely
lowering their loads with sufficient speed to avert the
overturning of the crane in an emergency
9.3.1 The provisions under 9.3 are generally applicable except as
provided below.
9.3.1.1 n406ilc crow (rood whtcI or cutup&z frock mounfui) - The
margin of stability shall bc calculated for the condition when the crane is
working on hard level groun$ nnd the jib is in the position giving the
greatest overturning moment. When pncumstic types arc fitted, it shall be
assumed that these’are inflated to the correct working pressure.
17
hlaximum stability reach x 12
StTtXty base -
and shall bc not less than 50 percent on a gradient of 1 in 40.
The stability reach will vary for diffcrcnt positions of the hook in the
COII~SCof one revolution during slaving, but the maximum value of the
dimensions shall be taken when computing the margin of stability ( I(# 2.13
to 2.17 and Fig. 1 to 3).
No=.:-Tbc margin,qfrtabili!y i! tbc pcrc+agc ad$itional load roqtid to bring
it,,,, to tbc condnuon of rrppmg when zt Y handbog the ufc xorkq told at my
For a crane designed to travel with load, the whceh or tracks shall b-c
used to detcrminc the ‘ stability base’, but for cranes which require to be
blocker1 LL~when dealing with loads, the blocking up basc.shall bc deemed
to bc the bnsc of support.
9.3.1.2 Flouring nana of all !ypcs, including ponfoon bufts, squan or swim-
tndrd, Ihip-shaped, srl/spropellrd 01 dumb - The stability of hulk of floating
cranes shall be such that, under maximum condition of loading, the bulls
shall have a reasonable cxccss righting (stabilizing) moment over the
ovcrtur!ling moment imposed by the conditions of maximum loading with
the crane jib in any position.
18
REACH -
IA IS
There diagram illtutrate typical examplco but do not purport to include a:1 possible altcrationr of jibs and churis.
I l-----A RADIUS
------A
1 STABILITY REACH
MEASURED FROM
BASE LINE TO JIB
STABILITY
REACH
MEASURE0 FROM
BASE LINE TO JI6
IS ,807 - 1976
10.1 Suitable clearances shall be provided for the safe operation of the
crane.
11. RATIO OF CRANE SPAN TO END CARRIAGE WHEEL BASE
11.1 The wheel base shall bc:
a) for cranes up to and including 20 m span, not Ins than one-fifth of
the span;
b) for cranes over 20 m span and up to 25 m, not less than 4 m;
and
c) for cranes of 25 m span and over, not less than one-sixth of the
span.
12. FABRICATION AND ERECTION
12.1 The &cneral provisions in Sections V ,and VI of IS : 800-196i* arc
also applicable to the fabrication and ercctlon of cranes. Where weldjng
is adopted, reference to appropriate provisions of the relevant Indian
Standards codes of practice shall be made.
13. TESTING
13.1 Before putting the crane into operation, it shall have all motions
tested with the hook carrying (a) the safe working load, and (b) 25 percent
overload.
13.1.1 During the 25-pcrccnt overload test the geared speeds need not
be attained but the crane shall show itself capable of dealing with the over-
load without difficulty.
23
24
APPENDIX A
[ Chses 0.2 and 4.4.4.2(b) ]
TYPICAL CLASSIFICATION OF CRANES AND HOISTS, IMPACT
FACTOR AND FATIGUE FACTOR
The list of crane and hoist classifcation given below is intended to be typical only and is not to
be used for the ultimate classification, for which purpose Table 1 shall be used:
Crann dc,igncd ,-or the gcncrnl O~~rr 2 000 2 6 Y 10’ I.3 0.05
working orcargo up 1” :wd
including
3000
Severe duty (power ) vcbicular crann Over 3 o@l 2 x l(r I.4 O.OG
used in building and conrtmctional
worb
Derrick Handopmted Up to and !O' I.1 0.04
UA”CS p;kodmg
(3)
Over 4 000
ABPENDIX B
( Clause4.3.1 )
BRIEF DESCRIPTION OF SOME OF THE COMMON TYPES
OF CRANES AND EXPLANATION OF TERMS
B-l. GANTRY CRANE
B-l.1 Gantry crane is essentially an elevated horizontal runway girder (or
girders ) connected at or near both ends to vertical or inclined members,
fixed in location, OP arranged to traverse along a fixed track, and having
mounted on the girder (or girders) a trolley or crab equipped with
a means for hoisting and capable of travelling along the girder (or
girders ) .
NOTE- In addition to the usual type of gantry crane, cranr~such as the Goliath with
camihcr mm, the bridge type with overhung cmtilcvcn, radial and stationary
trampomn, or bridgn and other like appliances arc covered by this dcfiniticn.
31
Is t 807 - 1976
32
\
I I L.-- -2
Ls* 807- 1976
35
IS t 807 - 1976
The crane may be supported upon and obtain its slewing motion
from a slaving ring mounted upon a tower, or from a revolving member or
a footstep bearing within the tower.
The crane shall be capable of travclling under its own power along a
railway track with speed limitations if the load is suspended at any positton
within its area of slaving.
The larger cranes of this type, uxd for railway salvage purposq arc
gcncrally provided with outriggers.
36
Fro. 12 TOWERCRANE(~~TO~~RDERRICK CRANE)
37
Fro. 13 LOCOMOTIVE CRANE ON Rnns
IS L 807 - 1976.
APPENDIX C
( Clause 8 1 )
EFFECTIVE LENGTHS OF CRANE JIBS, CONSIDERED AS
UNIFORM STRUTS
GO. In this appendix, crane jibs arc considered as uniform struts from the
point of view of buckling in clcvation and plan. The overall slenderness ratio
(I/r) of the jib in each plane can be obtained by dividing the eff&tive
39
l8tW.1976
kngth of the jib by the least radius of gyration of the complete jib section
occurring in the middle third ofthc actual length. It should bc wtcd that
thccfTective length and the rada of gyration taken must be those applicable
to that plant of the jib for which the slendcrncss ratio is required.
The middle third of the xtuhl Icng~h of the jib cxtcndr :dong the jib
for a distance of L/3 rncasurcd from a pomt which is L/3 from the jib head.
Cl. ROPE SUPPORTED JIBS
Cl.1 The following refers only to luffing crane jibs in which the jib head
is supported by the derricking rope, and the hoist rope runs over the jib
head pulley. The side elevations of typical arrangementj arc shown in
Fig. 14 to 16.
40
IS I807 ” 1976
41
IS I 807.1976
\vherc
1 = cKcctivc Icngth of the jib ( lateral buckling ) in mctres;
I, = actual length of the jib in mctrcs;
K = ratio of load ( hTkkgf)npplicd to jib head by tllc dcrricking
rope to that q;i:licd by the non-vertical part ( M) of the
hoist rope ( 7 kgf ) ; and
C, D, H and A,, are dimensions in mctrcs shown in I:$. I+.
C-1.1.2 Special tax where the fixed pulleys for dcrrickiq rope and hoist
rope are in one vcrticnl lint ( Fig. 15 ).
‘l‘hc gcncral CS[XCESiO”above then simplifies to:
110WEA9
,:e oi LLllS
IN “03X: t
REAP “rjl$l
ROPEPULLEY
JO !S LUFFEO 8Y SOME MEANS
ACII?!:t ON IT clE,WEEN THE
JID PWOIAND JIB HEEL
43 HEEL
Fto. 17 CANTILEVER CRANE Jto WITH Hotsr ROPE PARALLEL TO Jts .&as
42
IS: 807 - 1976
43
Is t 807.1976
Wwih’iiF i I I rIIlltl
44
IS r 807 - 1976
45
AMENDMENTNO. 1 FEBRUARY1984
TO
IS:807-1976 CODEOF PRACTICE FOR DESIGN,
WNUFACTURE, ERECTIONAND TESTING (STRUCTURAL
PORTION) OF CRANESAND HOISTS
(First Revision)
Coyrbendum
es-
Page 9, Table 1, co1 3, 4th PJW) - Substitute
'Low' for 'Eigh'.
(SMLX26)