As 4324.1-1995 Mobile Equipment for Continuous Handling of Bulk Materials General Requirements for the Design

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AS 4324.1—1995

Australian Standard Mobile equipment for continuous handling of bulk materials Part 1: General requirements for the design of steel structures

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This Australian Standard was prepared by Committee ME/43, Bulk Handling Equipment. It was approved on behalf of the Council of Standards Australia on 1 June 1995 and published on 5 September 1995.

The following interests are represented on Committee ME/43: Association of Australian Port and Marine Authorities Association of Consulting Engineers, Australia Australasian Institute of Mining and Metallurgy Australian Mining Industry Council Bureau of Steel Manufacturers of Australia Department of Minerals and Energy, Qld Department of Minerals and Energy, W.A. Department of Occupational Health, Safety and Welfare, W.A. Institution of Engineers, Australia Metal Trades Industry Association of Australia University of Wollongong WorkCover Authority of N.S.W. Work Health Authority, N.T.

Review of Australian Standards. To keep abreast of progress in industry, Australi an Standards are subject to periodic review and are kept up to date by the issue of amendments or new editi ons as necessary. It is important therefore that Standards users ensure that they are in possession of the latest edit ion, and any amendments thereto. Full detail s of all Australi an Standards and related publications wil l be found in the Standards Australia Catalogue of Publications; this information is supplemented each month by the magazine ‘The Australi an Standard’, which subscribing members receive, and which gives details of new publications, new editi ons and amendments, and of withdrawn Standards. Suggesti ons for improvements to Australian Standards, addressed to the head offi ce of Standards Australia, are welcomed. Noti fi cati on of any inaccuracy or ambiguity found in an Australi an Standard should be made without delay in order that the matter may be investigated and appropriate action taken.

This Standard was issued in draft form for comment as DR 87245.

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AS 4324.1—1995

Australian Standard Mobile equipment for continuous handling of bulk materials Part 1: General requirements for the design of steel structures

PUBLISHED BY STANDARDS AUSTRALIA (STANDARDS ASSOCIATION OF AUSTRALIA) 1 THE CRESCENT, HOMEBUSH, NSW 2140 ISBN 0 7262 9889 1

AS 4324.1 — 1995

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PREFACE This Standard was prepared by the Standards Australia Committee on Bulk Handling Equipment.

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This is the first Part of what is planned to be a four-part series dealing with mobile equipment for continuous handling of bulk materials, with Part 2 to deal with mechanisms, Part 3 to deal with electricals and Part 4 to deal with manufacture, construction, commissioning, operation and inspection. Also planned is a Standard for such machines that operate intermittently instead of continuously. This Standard is based largely on the German Code for structural design, BG 1986 Regulations, Calculations and dimensioning of large machines in open cuts and the International Standard ISO 5049-1:1994, Mobile equipment for continuous handling of bulk materials— Part 1: Rules for the design of steel structures, but includes a number of variations to provide coverage of a more comprehensive range of machinery, as well as options for nominating the latest fatigue and strength assessment procedures that are included in AS 4100, Steel structures. This Standard also includes specific reference to the latest Australian Standards for wind loads and earthquake loads. This Standard has been drafted so that designers may adopt almost interchangeably the limit state approach in accordance with AS 4100 or the permissible stress approach in accordance with AS 3990, Mechanical Equipment—Steelwork , when undertaking strength assessment of structural and mechanical components. This was considered to be essential, because of the different ways structural and mechanical components are normally assessed. Irrespective of the Standard adopted for undertaking strength assessments, this Standard requires fatigue of structural members and joints to be assessed in terms of a stress range approach based on working stresses and a detailed set of charts relating the stress range to the life of the equipment. AS 4100 is the preferred Standard for assessing strength and fatigue capacity of structural members and joints. Another significant inclusion in this Standard is a reference to the process of using an independent structural audit as a means of increasing the confidence level while obtaining machinery that satisfies the requirements of the nominated design rules. Additional explanatory notes on the drafting of this Standard are given in Appendix A. The terms ‘normative’ and ‘informative’ have been used in this Standard to define the application of the appendix to which they apply. A ‘normative’ appendix is an integral part of a Standard, whereas an ‘informative’ appendix is only for information and guidance.

 Copyri ght

STANDARDS AUSTRALIA

Users of Standards are reminded that copyri ght subsists in all Standards Austr alia publi cati ons and software. Except where the Copyri ght Act allows and except where provided for below no publications or software produced by Standards Austr alia may be reproduced, stored in a retr ieval system in any form or transmitt ed by any means without prior permission in writ ing from Standards Australi a. Permission may be conditi onal on an appropri ate royalt y payment. Requests for permission and informati on on commercial soft ware royalti es should be dir ected to the head off ice of Standards Australi a. Standards Austr alia will permit up to 10 percent of the technical content pages of a Standard to be copied for use exclusively in-house by purchasers of the Standard wit hout payment of a royalty or advice to Standards Austr alia. Standards Austr alia wil l also permit the inclusion of it s copyright material in computer software programs for no royalty payment provided such programs are used exclusively in-house by the creators of the programs. Care should be taken to ensure that materi al used is fr om the curr ent edit ion of the Standard and that it is updated whenever the Standard is amended or revised. The number and date of the Standard should therefore be clearly identif ied. The use of materi al in print form or in computer software programs to be used commercially, with or without payment, or in commercial contracts is subject to the payment of a royalty. This policy may be vari ed by Standards Austr alia at any ti me.

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AS 4324.1 — 1995

CONTENTS Page

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SECTION 1 SCOPE AND GENERAL 1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 INNOVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 REFERENCED DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 NOTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 BASIC DIGGING PARAMETERS FOR BUCKET WHEEL MACHINES . . . 1.8 CORROSION PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 6 6 6 6 6 8 8

SECTION 2 MATERIALS 2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2 LIMITATION ON USE OF BRITTLE MATERIALS . . . . . . . . . . . . . . . . . . 9 SECTION 3 LOAD ASSUMPTIONS 3.1 BULK DENSITY . . . . . . . . . 3.2 LOAD GROUPS . . . . . . . . . . 3.3 MAIN LOADS . . . . . . . . . . . 3.4 ADDITIONAL LOADS . . . . . 3.5 SPECIAL LOADS . . . . . . . . 3.6 FATIGUE LOADS . . . . . . . . 3.7 LOAD CASES . . . . . . . . . . .

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11 11 11 15 20 27 29

SECTION 4 OVERTURNING AND DRIFTING 4.1 STABILITY AGAINST OVERTURNING . . . . . . . . . . . . . . . . . . . . . . . . . 32 4.2 RESISTANCE AGAINST DRIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SECTION 5 STRUCTURES 5.1 LOADS AND LOAD CASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 FATIGUE LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 STEELS HAVING A HIGH YIELD TO ULTIMATE TENSILE STRENGTH RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 DESIGN METHODS TO ALLOW FOR STRENGTH AND SERVICEABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 FATIGUE STRENGTH OF STRUCTURAL COMPONENTS AND JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 BOLTING AND RIVETING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 STEEL WIRE ROPES, STRAPS AND STAYS, AND HYDRAULIC CYLINDERS IN TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 SLEWING RACE SAFETY HOOKS TO PREVENT SEPARATION AT THE SLEW RACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 MASS AND CENTRE OF GRAVITY OF MACHINE . . . . . . . . . . . . . . . . 5.10 LIFTING BEAMS AND LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 33 33 33 44 46 46 48 49 49

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AS 4324.1 — 1995

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Page APPENDICES A EXPLANATORY NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 B INFORMATION THAT SHOULD BE SUPPLIED WITH A PURCHASE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 C REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 D QUANTITY SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 E TYPICAL TYPES OF MOBILE CONTINUOUS BULK HANDLING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 F BASIC DIGGING PARAMETERS FOR BUCKET WHEEL MACHINES . . . 80 G LOOSE MEASURE VOLUMETRIC CAPACITY OF DIGGING ELEMENTS 87 H TYPICAL BULK DENSITIES OF HANDLED MATERIAL . . . . . . . . . . . . 90 I LIVE LOADS ON CONVEYORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 J DE-RATING FACTORS FOR PLATE BUCKLING . . . . . . . . . . . . . . . . . . 100 K FUNCTIONS FOR A DESIGN AUDIT ENGINEER DURING AUDIT OF A STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 FIGURES 3.4.6 3.5.2.4 3.5.8 3.5.9 3.5.13 E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 F1 F2 F3 F4 G1 G2 I1 I2 I3

LATERAL SKEW REACTIONS FOR MACHINES ON RAILS . . . . . . TYPICAL UP-LIFT OF A BUCKET WHEEL . . . . . . . . . . . . . . . . . . . REACTIONS FROM A LATERAL COLLISION OF A STACKER-RECLAIMER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . REACTIONS FROM AN END-ON COLLISION OF A STACKER-RECLAIMER BOOM DURING TRAVELLING . . . . . . . . . TYPICAL BURYING OF A BUCKET WHEEL . . . . . . . . . . . . . . . . . BUCKET WHEEL EXCAVATORS AND BUCKET CHAIN EXCAVATORS — CRAWLER MOUNTED . . . . . . . . . . . . . . . . . . . . RECLAIMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STACKER-RECLAIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRIPPER-STACKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCRAPER-RECLAIMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STACKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELT WAGON — CRAWLER MOUNTED TYPE . . . . . . . . . . . . . . . . SHIP CONTINUOUS LOADERS . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIP UNLOADERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONVEYOR DRIVE HEADS AND THEIR TRANSPORTERS . . . . . . BUCKET WHEEL EXCAVATOR — TYPICAL TERRACING CUT . . . BUCKET WHEEL RECLAIMER — FIRM STANDING STOCKPILE . . BUCKET WHEEL EXCAVATOR — SLICE CENTROID . . . . . . . . . . . BUCKET WHEEL RECLAIMER — FREE FLOWING STOCKPILE . . . CARRYING VOLUMES OF A BUCKET ON A BUCKET WHEEL . . . CARRYING VOLUMES OF A BUCKET ON A BUCKET CHAIN . . . . CROSS-SECTIONAL AREA OF MATERIAL ON A FLAT BELT . . . . CROSS-SECTIONAL AREA OF MATERIAL ON A TWO-ROLLER BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CROSS-SECTIONAL AREA OF MATERIAL ON A THREE-ROLLER BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 21 24 25 27 71 72 73 74 75 76 78 78 78 79 83 84 85 86 88 89 93 94 95

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AS 4324.1 — 1995

Page I4 I5

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CROSS-SECTIONAL AREA OF MATERIAL ON A FOUR-ROLLER BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 CROSS-SECTIONAL AREA OF MATERIAL ON A FIVE-ROLLER BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 TYPICAL MAXIMUM CROSS SECTIONS . . . . . . . . . . . . . . . . . . . . 98

First publi shed as AS 4324.1— 1995.

AS 4324.1—1995

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STANDARDS AUSTRALIA Australian Standard Mobile equipment for continuous handling of bulk materials Part 1: General requirements for the design of steel structures

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S E C T I O N

1

S CO P E

A N D

G E NE R A L

1.1 SCOPE This Standard specifies general requirements, design loads and specific requirements for structures of mobile equipment for continuous handling of bulk materials, including appliances and machines that are intended to carry out similar functions (e.g. excavators, stackers, reclaimers, ship loaders, ship unloaders). It is not intended that this Standard be applied to the following equipment, but may be applied to parts of such equipment: (a) Feeders, fixed conveyors, bucket elevators and storage structures with through flow of materials. (b) Intermittent operation bulk handling equipment (i.e. equipment that handles or excavates material on a cyclic basis, such as draglines and power shovels). NOTES: 1

Explanatory notes on the drafting of this Standard are given in Appendix A.

2

Information that should be supplied with a purchase specification is given in Appendix B.

1.2 APPLICATION This Standard may in some instances be applied to the design of certain stationary plants. It is not intended that this Standard be applied to equipment that was designed before the publication of this Standard. 1.3 INNOVATION It is not intended that the Standard should impose unnecessary restrictions on the use of new or unusual materials or methods. 1.4 REFERENCED DOCUMENTS The documents referred to in this Standard are listed in Appendix C. 1.5 NOTATION The quantity symbols used in this Standard are listed in Appendix D. Where possible, the quantity symbols used are generally similar to those in AS 4100 and AS 3990. Due to inconsistencies between the quantity symbols used in these codes, an exact equivalence is not possible. 1.6

DEFINITIONS For the purpose of this Standard, the definitions below apply.

1.6.1 Crowding board —a board placed near the edge of a conveyor belt to either increase the carrying capacity or to prevent spillage. NOTE: Crowding boards are sometimes referred to as skirt plates. Other devices (e.g. closely spaced wire ropes) that achieve the same effect should be treated as though they are crowding boards.

1.6.2 Design audit engineer — a suitably qualified engineer who undertakes independent checks of the design (also known as a proof engineer). COPYRIGHT

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AS 4324.1-1995, Mobile equipment for continuous handling of bulk materials General requirements for the design of steel structures

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