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IS 807 (2006): Design, erection and testing (structural

portion) of cranes and hoists - Code of practice [MED 14:
Cranes, Lifting Chains and Related Equipment]

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Satyanarayan Gangaram Pitroda

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.-

Indian Standard
DESIGN, ERECTION AND TESTING ( STRUCTURAL
PORTION ) OF CRANES AND HOISTS
CODE OF PRACTICE

(Second Revision )

ICS 53.020.20

0 BIS 2006

BUREAU

OF

INDIAN

STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002
April 2006

Price Group -15

Cranes, Lifting Chains and Its Related EquipmentSectional Committee, ME 14

FOREWORD
This Indian Standard ( Second Revision) was adopted by the Bureau of Indian Standards, after the draft finalized
by the Cranes, Lifiing Chains and Its Related Equipment Sectional Committee had been approved by the Mechanical
Engineering Division Council.
This standard covers design of structural portion of cranes and hoists and specifies ,permissible stresses and
other details of design. In order to ensure economy in design in reliability in operation: To deal with the subject
conventional Iy, cranes have been broadly classified into eight classes depending upon their duty and number of
hours in service per year. The correct classification of a crane is important and should be joint responsibility of
the producer and the manufacturer.
This standard was first published in 1963. In the first revision the permissible stresses for members
subjected to fluctuations of stress have been aligned with IS 1024: 1999 Code of practice for use of welding in
bridges and structures subject to dynamic loading, and AWS D 14.1 introducing the number of cycles of
operation for fatigue calculations. The limits of camber have also been specified, in the current revision.
[n the current revision, the following points are added:
a)

The classifications of the cranes are based on operating time and load spectrum and classification from
Mlto M8,

b)

State of loading is based on the hoist spectrum,

c)

The various loads have been explained elaborately and notch effect,

d)

The fatigue and notch effect have been dealt elaborately,

e)

The welding joint design, welding procedures and inspection of welding for industrial cranes have been
.
explained in detail, and

t)

The design of bolts, quality of bolts, bolts tightening and effective friction surface has been dealt elaborately.

,,

The composition of the Committee responsible for formulation of this standard is given in AnnexC.
This standard is the first in the series of standards relating to cranes and covers the structural design. The other
standards covering the mechanical and electrical portion are as follows:
1s3177: 1999

Code of practice for overhead traveling cranes and gantry cranes other than steel work
cranes ( second revision )

1S4137 :-1985

Code of practice for heavy duty electric overhead traveling cranes including special service
math ines for use in steel work (first revision )

1S 807:2006

CONTENTS
Page

Scope

References

Terminology

Materials

-4

Classification of Cranes

5.1

Class of Operating Time

5.2

Load Spectrum

5,3

State of Stress Stress Spectrum

State of Loading

6.1

Loads to be Considered

Loads Due to Climatic Effects

10

Miscellaneous Loads

12

8.1

Loads Carried by Platforms

12

8.2

Seismic Load

12

8.3

Amplification of Load -

13

8.4

Case of Loading (Combination of Loads)

8.5

Transportation and Erection

13
... ,
14

Allowable Stress

14

9.1

Fundamental Allowable Stress

14

9.2

Structural Members and Welds

14

9.3

Rivets, Bolts and Pins

9.4

Conventional Number of Cycles and Stress Spectrum

14

10 Stability against Overturning

21

10.1 Special Measures

21

10.2 Safety against Movement by the Wind

21

11 Calculation of Tension Members

21

12 Calculation of Compression Members

26

13 Calculation of Box Girder Subjected to Bending and Torsional Stresses

13.1 Bending

26

13.2 Torsion

27

14 Calculation of Members Subjected to Bending by Force in the Direction of Axis

27

15 Calculation of Welded Joints

27

15.1 Stresses on Joints under Tension, Compression or Shear Force

27

15.2 Combined Stresses on Joints under Bending and Shear Moment

i

27

IS 807:2006
Page
28

16 Calculation of Local Buckling of Plates

16.1 Compressive Stress or Shear Stress Acts Independently

28

16.2 Normal Stress and Shear Stress Acts Simultaneously

29
29

17 Designs of Structural Members Subject to Axial Forces

17.1 Net Sectional Area of Tension Member

29

17.2 Slenderness Ratio

29

17.3 Limit for Slenderness Ratio

36

17.4 Compressive Members with Variable Height

36

17.5 Combined Compressive Members

37

17.6 Shear Stress Acting on Combined Compressive Members

38
38

18 Detailed Design of Girders Subjected to Bending

18.1 Rivets or Bolts for Joining Girder

38

18.2 Rivets, Bolts or Welded Directly Subjected to Wheel Load

40

18.3 Web Joint of Plate Girder Receiving Bend

40

19 Welding of Industrial and Mill Cranes

42

20 Limiting Deflection

42
42

21 Camber~
.,, ,

22 Diaphragms and Vertical Stifl%ess

42

22.1 Diaphragms

42

23 Girder and Connection

42

24 Bridge Trucks

42

24.1 Ratio of Crane Span to End Carriage Wheel Base

42

24.2 Bridge and Gantry Rails

42
42

25 Welded Box Girders

25.1 Girder Proportion

44

25.2 Height Thickness Ratio of Web Plate

44

25.3 Compression Stress

44

A?WEX A

45

Classification of Joints

45

A-1 Design of Bolted Joints

A-1. 1 Co-efficient of Friction (p)

45

A-1.2

Bolts Tightening

45

A-l.3

Value of the Tensile Stress Area of the Bolts

45
45

A-1.4 Quality of Bolts

ANNEX B

Weld Joint Design, Welding Procedures and Inspection of Welding for

Industrial and Mill Cranes
ii

48

IS 807:2006
Page

B-1 Allowable Stress

48

B-2 Base Metal

48

B-3, WeJd Metal

48

B4

48

Fatigue

48

B-5 Weld Joint Design

B-5.1

General Requirements

48

B-5.2

Groove Welds

48

B-5.3

Intermittent Groove Welds

48

B-5.4

FiIlet Welds

48

B-5.5 Intermittent Fitlet Welds

48

B-5.6

Staggerad Intermittent Fillet Welds

55

B-5.7

Plug and Slot Welds

55

B-6 Weld Joint Categories

55

B-7 Welding Process

55

B-7.1

Tolerances for Groove Weld Joint Preparations for Arc Welding

66

B-8 Control of Distortion and Shrinkage Stresses

66

B-9 Nominal Number of Loading Cycles

66

ANNEX C

69

Committee Composition

...

IS 807:2006

Indian Standard
DESIGN, ERECTION AND TESTING ( STRUCTURAL
PORTION ) OF CRANES AND HOISTS
CODE OF PRACTICE

(Second Revision )
IS No.

1 SCOPE

This standard covers the code of practice for design,

manufacture, erection and testing ( structure) of EOT
cranes, goliath, shear legs and derricks.

1364

The following standards contain provisions, which

through reference in this text constitute provisions
of this standard. At the time of publication, the editions
indicated were valid. All standards are subject to
revision and parties to agreements based on this
standard are encouraged to investigate the possibility
of applying the most recent editions of the standards
indicated below:
1S No,

Hexagon head screws ( size range

M 1.5 to-M 4 ) ( third revision )

(Part 3):2002

Hexagon nuts ( size range M 1.5 to

M 64 ) ( third revision )

( Part 4 ): 2002 Hexagon thin nuts ( chamfered )

( size range M 1.5 to M 64 ) ( third
revision

revision

1367

Code of practice for design loads

( other than earthquake ) for
buildings and structures:

(Part 5):1987

loads
load
Special
and
combinations ( second revision )

961:1975

Structural steel ( high tensile )

( second revision)

1363

Hexagon head bolts, screws and

nuts of product grade C:

Technical supply conditions

threaded steel fasteners:

for

( Part 2 ): 2002 Tolerances for fasteners Bolts,

screws, studs and nuts Product
grades A, B and C ( third revision)

(I?art 3): 1987 Wind loads ( second revision )

Snow loads ( second revision )

(Part 1): 2002 General requirements for bolts,

screws and studs ( third revision )

( Part-2): 1987 Imposed loads ( second revision)

(Part 4):1987

( Part 5 ): 2002 Hexagon thin nuts ( unchamfered )

( size range M 1.5 to M 64 ) ( third

Code of practice for generaI

construction
in steel ( second

(Part l): 1987 Dead loads Unit weights of

building
material and stored
materials ( second revision )

( Part 3 ): 2002 Mechanical properties of.fasteners

made of carbon steel and alloy
steel Bolts, scf.ews and studs
(fourth revision )
( Part 5 ): 2002 Mechanical properties of fasteners
made of carbon steel and alloy
steel Set screws and similar
threaded fasteners not under tensile
stresses ( third revision )

( Part 1 ) :2002 Hexagon head bolts ( size range

M 5 to M 64 ) (fourth revision)

(Part 6): 1994 Mechanical properties and test

methods for nuts with specified
proof loads ( third revision)

( Part 2 ) :2002 Hexagon head screws ( size range

M 5 to M 64) (fourth revision)
(Part 3):1992

(Part2 ):2002

Title

revision

875

Hexagon head bolts, screws and

nuts of product grades A and B:

( Part 1 ): 2002 Hexagon head bolts ( size range

M 1.5 to M 64 ) ( third revision )

2 REFERENCES

800:1984

Title

(Part 7): 1980 Mechanical properties and test

methods for nuts without specified
proof loads ( second revision)

Hexagon nuts ( size range M 5 to

M 64 ) ( third revision)
1

IS 807:2006

IS No.

IS No

Title

( Part 8 ): 2002

1893:1984

Prevailing torque type steel

hexagon nuts Mechanical and
performance properties ( third
revision

Surface discontinuities, Section 1

Bolts, screws and studs for general
applications ( third revision )

( Part 9/See 2 ) :
1993

Surface discontinuities, Section 2

Bolts, screws and studs for special
applications ( third revision )

Criteria for earthquake resistant

design of structures ( fourth
revision

( Part 9/See 1 ) :
1993

Title

1929:1982

Specification for hot forged steel

rivets for hot closing ( 12 to 36 mm
diameter ) (first revision)

2062:1999

Steel for general structural

purposes Specification (Jjih
revision

2155:1982

Specification for cold forged solid

steel rivets for hot closing ( 6 to
16 mm diameter ) (first revision)

coatings ( third

3138:1966

Specification for hexagonal bolts

and nuts ( M42 to M150 )

(Part 12):1981

Phosphate coatings on threaded

fasteners ( second revision )

3737:1966

Leather safety boots for workers

in heavy metal industries

(Part 13):1983

Hot-dip galvanized coatings on

(second
threaded
fasteners

6610:1972

Specification for heavy washers

for steel structures

revision)

6623:1985

Stainless-steel threaded fasteners

( second revision)

Specification for high strength

structural nuts (first revision )

6639:1972

Specification for hexagon bolts for

steel structures

6649:1985

Specification for hardenetf and

tempered
washers for high
strength structural bolts and nuts
(first revision )

( Part 14/Sec 2 ) : Mechanical

properties
of
2002
corrosion-resistant
stainless
steel fasteners, Section 2 Nuts
( third revision)

8500:1991

Structural steel ( microalloyed )

( medium and high strength
qualities ) Specification (,firsf

( Part 14/Sec 3 ) : Mechanical

3 TERMINOLOGY

( Part 10): 2002

Surface discominuities Nuts

(~hird revision)

(Part 11 ):2002

Electroplated
revision

(Part 14):1984

( Part 14/Sec 1 ) : Mechanical

properties
of
2002
corrosion-resistant stainless steel
fasteners,
Section 1 Bolts,
screws and studs ( third
revision

revision

properties
of
corrosion-resistant stainless steel
fasteners, Section 3 Set screws
and sim iIar fasteners not under
tensile stress ( third revision )

2002

( Part 6 ) :2002

Designation system for fasteners

( third revision)

( Part 7): 1996

Inspection,
acceptance
revision

3.1 .Bogie A short end truck attached to the end

of one girder ( or to a connecting member, if more than
one bogie is used per girder). This type of end truck
is used when more than four wheels are required on
a crane due to the design of the runway.
Bogie Equalizing A short end truck which
is flexibly connected to one girder ( or connecting
member ) by means of a pin upon which the truck
can oscillate to equalize thq loading on the two truck
wheel.

3.2

and
sampling
procedure ( third

( Part 8):

996

Packaging ( third revision )

( Part 9):

997

Axial load fatigue testing of bolts,

screws and studs

( Part 20 ) :1996

Torsional test and minimum

torques for bolts and screws with
nominal diameters 1mm to 10 mm

3.3 Bogie Fixed A short end truck which is rigidly

connected to one girder.
Bridge That part of a crane consisting of
girders, trucks, end ties, walk way and drive
mechanism which carries the trolleys traveling along
the runway rails.

3.4

IS 807:2006

and control panels. The dead load deflection is fully

compensated for in the girder camber.

3.5 Bumper ( Buffer ) - An energy absorbing

bumper or energy dissipating ( buffer ) device for
reducing impact when a moving bridge or tralley
reaches the end of its permitted travel. This device
may be attached to the bridge trolley or runway stop.

3.20 Deflection ( Live Load ) The vertical

displacement of a bridge girder due to the weight of
the trolley plus the rated load.

3.6 Cranes A specially designed structure

equipped with mechanical means for moving a load
by raising and lowering by electrical or manual
operation and whilst the load is in such a state ofmotion
or suspension transporting it.

3.21 Diaphragm A vertical plate ( or channel )

between the girder webs, which serves to support
the top cover plate and bridge and to transfer the
forces of the trolley wheel load to the webs rail.
3.22 Dynamic Effect The effects on the structure
caused by inertia or sudden load application such as
retardation/acceleration
breaking impact due to
collision.

3.7 Cab The operators compartment on a crane.

3.8 Camber The slight, upward, vertical curve
given to girders partially compensate for deflection
due to rated load and weight of the crane parts.

3.23 End Tie A structural member, other than the

end truck, which connects the ends of the girders to
maintain the squareness of the bridge.

3.9 Clearance The minimum distance from any

part .of the crane to the point of nearest obstruction.

3.24 End Truck ( End Carriage) An assembly

consisting of structural members, wheels, bearings,
axles, etc, which supports the bridge girders.

3.10 Cover Plate The top or bottom plate of a box

girder.
3.11 Crane Cab Operated A crane controlled by
an operator in a cab attached to the bridge or trolley.

3.25 Foot Walk A walk way with hand rail and toe
boards, attached to the bridge or trolley for access
purpose.

3.12 Crane, Floor Operated A crane which is

controlled by means of suspension from the crane
with the operator on the floor or on an independent
platform.

3.26 Gauge The horizontal distance between

centre-to-centre of the bridge rails.
3.27 Hoist A machinery unit that is used for Iiftiug
and lowering a load.

3.13 Crane, Gantry A crane similar to an overhead

crane except that the bridge is rigidly supported in
two or more legs.

3.28 Hoist Auxiliary A supplemental hoisting unit

used to handle light loads.

3.14

Crane, Hot Molten Material

Handling
( Ladle ) An overhead crane used for trans-

3.29 Hoist Main The primary hoist mechanism

provided for lifting and lowering the rated load of the
crane.

porting or pouring molten material.

3.15 Crane, Manually Operated A crane whose
hoist and travel mechanism are driven by manual
operation.

3.30 Hook Approached ( End ) The minimum

horizontal distance, paral Iel to the runway between
the centre line of the hook(s) and theface of the wall
(-or columns ) at the end of the building.

3.16 Crane, Semi-gantry A gantry crane with one

end of the bridge supported on one or more legs and
other end of the bridge supported by an end truck
connected to the girders and running on an elevated
runway.

3.31 Hook Approach ( Side ) The minimum

horizontal distance, perpendicular to the runway,
between the centre line of a hook ( main or auxiliary )
and the centre line of the runway rail.

3.17 Cross Traverse Motion The motion of the

trolley or crab across the crane span is known as cross
traverse motion.

3.32 Live Load A load which moves or varies

relative to the member being considered. For the
trolley, the live load consists of the rated load plus
the weight of the block. For the bridge, the live load
consists of the rated load plus the weight of the trolley,

3.-18 Dead Load The weight of the crane structured

steel work moving on crane runway girder with
all material fastened there to and supported
permanently.

3.33 Over Load Any hook load greater than the

rated load.

3.19 Deflection ( Dead Load ) The vertical

displacement of a bridge girder due to its own-weight
plus the weight of parts permanently attached
thereto, such as foot walk, drive mechanism, motor

3.34 Longitudinal Travel Motion The motion of

the whole crane on its gantry or tracks is known as
the longitudinal travel motion.
1

IS 807:2006
3.35 Rated Lifted Loads The rated lifted load
from the mechanism design consideration shall
mean the external load lifted and handled by the crane
and shall include in addition the safe working load,
lifting tackles such as magnets, grabs, lifting beams,
but shall exclude wind load.

4.2 Structural steel shall conform to IS 2062 or IS 8500

as per designers suitability or as mutually agreed to
between the purchaser and the manufacturer
permissible stress shall be related to yield stress of
the material used.
4.3 Materials for pins, rivets and bolts including high
strength bolts and nuts shall be as given in Table 1.

3.36 Radius The horizontal distance from the

centre line of the lifting hook before loading to the
centre about which the jib slews.

4.4 Material characteristics shown in Table 2 may be

used for design purpose.

3.37 Reach The horizontal distance from the centre

line of the laden hook to the nearest point of the chassis/
under frame with respect to hook.

4.5 Table 1 contains the different material grade for

principal load bearing members and also rivets, pins
and bolts, high strength bolts and nuts. The physical
characteristics of steel are given in Table 2.

3.38 Runway The assembly of rails, girders, brackets

and frame work on which the crane operates.

NOTE No black bolts shall be used forthe principal

3.39 Rail Sweep A mechanical device attached
to the end truck of a bridge or trolley.

load bearing members in the crane.

Table 1 Rivet and Bolts

3.40 Span The horizontal distance between centreto-centre of the runway rails.

( Clauses 4.3 and4,5

3.41 Stability Base The effective span of the

supporting base.
3.42 Stability Reach The distance of the jib head
pin from the point of intersection of the nearest base
line and vertical plane passing through the center line
of the jib.

S1 No.

Product

Ref to Fndian
Standard

(1)

(2)

(3)

Rivets

2155
1929

ii)

Pins and bolts

1364 ( Parts 1 to 5 )
3138

iii)

High strength bolts and

nuts

6639
6623
6649
3757

i)

3.43 Stop A member to physically limit the travel

of the trolley orbridge. This member is rigidly attached
to a fixed structure and normally does not have energy
absorbing ability.

Table 2 Physical Properties

3.44 Web Plate The critical plates, connecting the

upper and lower flanges or cover plate of a girder.

( Clauses 4.4 and4.5

S1 No.

3.45 Wheel Base The distance from centre-tocentre of the outer most wheels of the bridge or trolley,
measured parallel to the rail.

(1)

Parameter

Values
(3)
2. IXI05

Modulus of elasticity in
shear (G), in N/mmz

8.1 x104

iii)

Poissons ratio (I/m)

0.3

iv)

Co-efficient of linear
expansion (a)

1.2X 10-f

Specific gravity (y)

7.85

v)

5 CLASSIFICATION

3.48 Wheel Load Trolley The vertical force

( without impact) produced on any trolley wheel by
the sum of the rated load and trolley weight.

of Steel

(2)

ii)

3.47 Wheel Load Bridge The vertical force

( without impact) produced on any bridge wheel by
the sum of the rated load, trolley weight and bridge
weight, with the trolley so positioned on the bridge
as to give maximum loading.

.,,,

Modulus of longitudinal
elasticity ( E ), in N/mm2

i)

3.46 Wind Load The forces produced by the

velocity of the wind which is assumed to act
horizontally.

OF CRANES

There are two factors to be taken into consideration

for Ihe purpose of determining the group to which
the cranes belong are the class of utilization and the
state of loading, that is:

4 MATERIALS
4.1 The mat~rial of structures shall be in the form of

a)

Class of operating time; and

plate, sheet and rolled sections.

b)

Load spectrum.

IS 807:2006
5.1 Class of Ope&ing

a)

Class of operating time indicates the average

period per day;

b)

Two hundred fitly working days per year shall

be considered; and

c)

Higher classes of operating time for more than

one shift per day.
Class of utilization

5.1.1

There are four states of loading, designated by the

vahres P= 1, P=213, P= 1/3 and P= Oare shownon
the curves. These curves represent the four sets of
conventional spectra corresponding to the number
of cycles to class of utilization are shown in Table 4.

Time

takes
of one of the cranes as

account

5.3 State of Stress Stress Spectrum

The state of stress are defined in the same manner
on those of the hoisted loads with same -spectra
according to Table 5, Table 6 and Table 7.

of the

a whole when in
service. This concept could be represented by the
number of working cycles, which the crane would
accomplish during its life ( see Table 3 ). The classes
of utilization are used as a basis for the design of the
structure.
frequency

6 STATE OF LOADING
6.1 Loads to be Considered

The following loads shall be considered in the

calculation of the steel structural parts of the cranes.
6.1.1 Principal

5.2 Load Spectrum

5.2.1
State
Spectrum

of Hoist

Loading

Hoist

Loads Exerted

on the Structure

The loads due to the dead weight of the

components ( crane girders, end carriage, plate forms,
LT machinery and electrical items panel, resistance
boxes ).

6J.I.1

Load

The state of hoist loading determines the extent

to which the crane lifts the maximum load, L~a or only
a lesser load, L, This idea is illustrated by a spectrum
of hoist loads showing the number of cycles of
operation during which a certain fraction of the
maximum load is reached or exceeded. It is one of the
important factors determining the severity of the
duty of the cranes.

6.1.2 Lifted Loads

loads ( hook loads ) comprise the useful
load and the self weights of members designed to
carry the useful load, for example, the bottom block
spreader bar, the grab, the lifting magnet and also a
proportion of the carrying means such as ropes.
The lifted

.,. ,

Table 3 Classes of Utilization

(Clause
S1 No.

Class of Utilization

5.1.l )

Frequency of Utilization
Hoisting Motion

of the

Conventional
Hoisting

(.I )

(2)

Irregularoccasionaluse followed by long

idle periods

(3)

of

(4)

ii)

Regular use on intermittent

iii)

Regular use on intensive duty

iv)

Intensive,
shiftlday

duty

6.3 X

104

2 x 105
6.3 X 10s

heavy duty more than

Table 4 State of Loading

Number
Cycles

one

2x 106

( Clause 5.2.1)
S1 No.

State of Loading

(1)

(2)

(3)

(4)

Very light

Cranes which hoist SWL exceptionally

and, normally, very Iight loads

P=o

ii)

Light

Cranes which only hoist the SWL and

normally loaded about one-third of SWL

P= 1/3

iii)

Moderate

Cranes which hoist the SWL fairly

frequently and normally loads between
1/3 to 213 of SWL

P = 2/3

iv)

Heavy

Cranes which are regularly loaded close

to the SWL

Definition

Corresponding

P=l

Spectrum

IS 807:2006

LIL max.

L/L max.

1.0

1.0

0.8

0.8

0.6

0.6

0.4

0.4

0.2

0.2

0
10

102

104

103

FIG. 1 GRAPHICAL REPRESENTATIONOF CLASS OF

UTILIZATIONA

10

FIG.

6.3 x 104CYCLES

L/L max.

103

102

104

1(-)5

2 GRAPHICALREPRESENTATIONOF CLASS OF
UTILIZATIONB 2 x 105 CYCLES

L/L max.

1.0

1.0

P=

0.8

0.8

0.6

0.6
0.4

0.4
\
F&
0.2

0.2

0
1

FIG.

10

102

103

104

105

10

3 GRAPHICALREPRESENTATIONOF CLASSOF
UTILIZATION
C 6.3 x 105 CYCLES
Table5

FIG.

102

103

104

105

106

4 GRAPHICALREPRESENTATIONOF CLASS OF
UTILIZATIOND 2 x 106 CYCLES

States of Stress

( Clause 5.3)
S1 No.

State of Loading

(1)

(2)

i)

Very Iight

Definition

Spectrum
(4)

(3)
Components

subjected

exceptionally

to its

P=o

maximumstress and normally to light

ii)

Light

Components rarely subjected to its maximum

stress but noskslly about 1/3 of maximum stress

P = 113

iii)

Moderate

Components

P = 2/3

iv)

Heavy

frequently

. subjected

to its

maximumstress and normally stress vary from

1/3 to 2/3 of the maximumstress
Components regularly subjected to its
maximumstress

P=l

._

_..

-.,!_

_________

__

IS 807:2006
Table 6 Group Classification

of Cranes

( Clause 5.3)
S1 No.

State of Hoist Loading

or State of Stress

(1)

Class Utilization

ii)

of Hoisting

Cycles

.,

6.3 X 104

2x Iof

6.3 X 10s

2 x I ()(

(3)

(4)

(5)

(2)
i)

and Number

(6)

Very light, P = O

Ml

M2, M3

M4

M5

Light, P = i/s

M2

M3, M4

M5

M6

iii)

Moderate, P = 2/3

M3

M4, M5

M6, M7

iv)

Heavy, P = I

M8

M4

M5

M6, M7

M8

Table 7 Examples of Classification

of Cranes

( Clause 5.3)
S1 No

Type of Cranes

(1)
O

Applications

(2)
Over head travei]ing

cranes

iii)

iv)

v)

Gantry cranes

Jib cranes

Derrick

(4)

(5)

(3)

Group
(6)

o-1

MI-M2

2. Cranes
for
warehouse,
stocking
yard, machine
and
assembly shop and cranes for
general use

I -2

M2-M3-M4

3. Store room cranes, workshop

cranes

B-C

1-2

M4-M5-M6

4. Grabbing over head traveling

C-D

M6.M7-M8
M6-M7-M8

5. Cranes for steel works

C-D

6. Ladle cranes

C-D

M7-M8

M7-M8

7. Stripper
cranes

Gantry cranes

State of
Loading

1. Hot cranes, cranes for power

station, cranes for repair shops

cranes, magnet cranes

ii)

Class of
Utilization

cranes,

soaking

pit

8. Charging cranes

C-D

M7-M8

9. Forging cranes

M7-M8

1. Cranes for power station

and cranes for repair shop

o-1

M1-M2

2. Cranes for stocking yard

B-C

1-2

M3-M4

1. Cranes for-container

B-C

M4-M5-M6

2. Cranes with grab, magnets

B-C-D

M7-M8

1. Stocking yard cranes, repair

shop, assembling shop

A-B

1-2

MI-M3
M3-M4-M5

handling

2. Wharf cranes

B-C

2-3

3. Grabbing and magnet cranes

C-D

2-3

M5-Mti-M7

4. Unloaders

M7-M8
M1-M3

5. Cranes for building construction

1-2

1. Derrick for heavy load

A-B

0-1

MI-M2

2-3

M3-M4

2. Derrick for construction

-building

and

3. Floating cargo crane

A-B

M5-M6

4. Floating grabbing crane

A-B

M5-M6-M7

IS 807:2006
to the speeds to be reached maybe chosen according to
the three following working conditions:

6.1.3 The loads due to horizontal motion areas follows:

a)

Inertia effects due to acceleration ( .or

deceleration ) of the traverse, travel, slewing
or luffing motions. These effects can be
calculated in terms of the value of acceleration
(or deceleration ) and its values are given in
Table 8;

a)

Cranes of low and moderate speed with great length

of travel;

b)

Cranes of moderate and high speed for normal

application; and

c)

High speed cranes with high acceleration.

6.1.3.2

b)

Effects of centrifugal force;

c)

Transverse horizontal reaction resulting from

rolling action; and

d)

Buffet effects.

Force due to slewing

and luffing motion

For slewing and luffing motions the calculation

shall be based on the acceleration ( or deceleration )
torque applied to the motor shaft of the
mechanism. The rates of acceleration shall depend
upon the cranes. For a normal crane a value
between 0.1 m/s2 and 0.6m/s2, according to the speed
and radius, may be chosen for the acceleration at
the jib head so that an acceleration time of 5 to
10 second @achieved.

6.1.3.1 fnertia force

The forces of inertia resulted from the acceleration
and deceleration of the traverse motion, travel motion,
level luffing motion and slewing motion of the crane
shall generally be considered as ~ times of the weight
of the moving parts and the hoisting load, and be given
by the following formula:

6.1.3.3 Effects of centrlfixgalforce

The centrifugal force shall be the force, wldch is acting
outwards in the direction of slewing radius, resulted
tlom the slewing radius and slewing motion and shall
be obtained from the following formula:

For level luffhg motion, ~ = 0.1 h

For transverse travel motion, ~ = 0.01 W
For slewing motion, ~ = 0.006 W
where v is the speed of respective motion, in m/min.

However, in case of traverse motion and travel motion

by the wheel drive, it shall be taken as 15 percent of
the load of the driving wheel at maximum.

=&
gR

where
F

.,. ,
= centrifugal force, in kgf or N;

W = hoisting load, in kgf or N;

Moreover, for the slewing motion, it shall be considered

that the load is acting at the end point of the jib.
NOTE If the speed and acceleration values are not
specified by the user, acceleration times corresponding
Table 8 Acceleration

= acceleration of free fall, in rn/s2;

= slewirtg radius, in m; and

= peripheral speed, in mls.

Time and Acceleration

Value

( Clause 6.1.3 )
SI
No.

(1)

Speed
to be
Reached,
in m/s
(2)

Low and Moderate Speed

with Long Travel
Acceleration
Time, in s

Acceleration,
in mls2

Moderate and High Speed

( Normal Applications)
Acceleration
Time, ins

Acceleration,
in m/s2

High Speed with

High Acceleration
Acceleration
Time, in s

Acceleration,
in m/s2

(4)

(5)

(6)

(7)

(8)

i)

4.00

(3)

8.0

0.50

6.0

-0.67

ii)

3.15

7.1

0.44

5.4

0.58

iii)

2.5

6.3

0.39

4.8

0.52

iv)

2.0

9.1

0.22

5.6

0.35

4.2

0.47

v)

1.50

8.3

0.19

5.0

0.32

3.7

0.43

vi)

1.00

6.6

0.15

4.0

0.25

3.0

0.33

vii)

0.63

5.2

0.12

3.2

0.19

viii)

0.40

4.1

0.098

2.5

0.16

ix)

0.25

3.2

0.078

x)

0.16

2.5

0.064

1S807 :2006
Transverse

6.1.3.4

reactions

the outer two guide rollers shall be tpken as the effective

wheel base.

due to rolling action

The lateral force on wheel shal I be the horizontal force

acting at right angles with the traveling direction of
the wheels and shall be given from Fig. 5 by the ratio
of the span and the effective wheel base.

6.-I.3.5 Buffer effects

The impact due to collision with buffers may b.eapplied
on the structure or on the suspended load.
A distinction maybe drawn between:

0.15
0.10

a)

The case in which the suspended load can

swing; and

b)

That in which rigid guides prevent swing.

For 6.1.3.5(a) the following rules shall be applied:

0.05

For horizontal speed below 0.7 m/s, no account

shall be taken of buffer effect,
For speed exceeding 0.7m/s, account shall be taken
of reactions set up in the structure by collisions
with buffers. However, for higher speed ( greater
than 1 m/s) the use of decelerating device which
act upon approach to the ends of the track is
permitted provided the action of these devices
is automatic and they produce an effective
deceleration on the cranes which always reduces
the speed to the predetermined lower value before
the buffers are reached.

02468
I
%

Fi~. 5 RATIOOF SPA:, AND EFFECTIVE WIIEEL BASE

versus SIDE FORCE CONSTANTON WHEELS
SF=X,R

where
s,

lateral force on wheels, in kgf or N;

L=
//.

wheel load, in kgf or N;

1=

span, in m; and

a=

wheel base, in m.

side force constant on wheel;

6.1.3.6 Collision

The loads can be computed by considering that

horizontal force applied at the level of the load is
capable of causing two of the crab wheels to lift.

wheel base shall be taken from Fig. .6A,

Fig. 6B and Fig. 6C. Moreover, when the horizontal
guide rollers are provided, the centre distance between
I

I
.

.
I

6A Four Wheels on a Rail

load

Impacts due to collision between the load and fix.ad

obstructions are taken into account only for cranes
when the load is rigidly guided.

The effective

effects on the suspended

66 Eight Wheels on a Rail

I
-

6C Over Eight Wheels on a Rail

FIG. 6 METHOD FOR TAKING EFFECTIVE WHEEL BASE

9

IS 807:2006

7 LOADS DUE TO CLIMATIC

component parts of the girder on a plane

perpendicular to the direction of the wind;

EFFECTS

7.1 The loads due to climatic effects are those resulting

from the action of the wind, from snow loads and from
temperature variations.
7.1.1

9=

aerodynamic pressure, in kgf/m2; and

(J.

aerodynamic coefficient which takes the

increased and reduced pressure on the
various surface and depends upon the
configuration of the girder. The values of
C are given in Table 10.

Wind Action

a)

b)

It shall be assumed that the wind can blow

horizontally in all directions. The action of
the wind will depend essentially upon the
shape of the cranes; and

7.1.4 Case of Several

Another

It res-ults in increased and reduced pressure

whose magnitude are proportional to the
aerodynamics pressure.

The aerodynamic pressure, q is given by the general

formula:
VW2.

visible area ( area of solid portions );

A=

. density, in kglm~;

A, = enveloped area ( solid portion + voids );

pressure, in kgffmz;
9=
Vw= wind velocity, in m/s; and
. gravitational acceleration, in m/s2.
g

Calculating

h=

depth of the girder;

b=

distance between the surfaces facing each

other; and
. aerodynamic pressure, in kg/m2.

The values of wind velocity and pressure are given

in Table 9.
7.1.3

One

&

where

16g

where
P

Behind

When a girder or part of a girder is protected from

the wind by the presence of another girder, the wind
force on the protected part of the girder is determined
by applying a reducing coefficient q to the force
calculated in accordance with the formula P = rl.A.q. C.
The value of this coefficient q is depends upon b
and h and on the ratio of A/Ae ( see Fig. 7 ).

7.1.2 Wind Pressure

9=

Girders Located

In case of lattice girders, the ratio Q = A/Aeis.awter

than 0.6, the reducing coefficient shall be the same
as that for a solid girder. The configuration of girders
is given in Fig. 7 and values of coefficient are given
in Table 11.

Wind Effects

The wind exerts a force against a girder, and the

component of this force resolved along the direction
of the wind is given by the relation:

7,2 Values of the Reducing Coefficient

P= A.q. C

7.2.1

Wind Load for Suspended

(q)

Load

where
The wind action on the suspended load
shall be determined by taking account of the
greatest area which can face the wind and its values
given in Fig. 8.

7.2.1.1

p.

resultant load, in kgfi

A=

area presented to the wind by girder

( in m-2)that is, the projected area of the

Table 9 Wind Velocity and Pressure

( Clause 7.1.2)
I

S1 No.

Height of Member
Above Ground

&

Limiting

Working

Velocity, Vw
mls

Wind
Aerodynamic
Pressure, q

kmlh

Maximum Wind
(Crane Out of Service)
Aerodynamic
Pressure, q

Velocity, Vw

kgf/m2 or

kmth

mls

kgf/m2 or

N/m*

N/m2

(3)

(4)

(5)

(6)

(7)

(8)

20

72

25

36

130

80

ii)

20 to 100

doldoldo

iii)

Over 100

do

14211501

do

I
10

do

46

110

165

130

..

..

1S 807:2006
Table 10 Values of the Aerodynamic

Coefficient

lrl...
\ GLUUJC n~ 1 9 J\
/.l..J

S1 No.

Type of Girder

Type of Girder

Variable

(1)

(2)

(3)

(4)

(5)

i)

Truss of rolled sections

1.6

i
h

ii)

Plate girder or box girder

h~
iii)

c ylindrical member or truss

of cylindrical member

d in m where q in kgf/m2

d~<l

1.2

d~>l

0,7

d
t

11
b

FIG.

7 DISTANCEOF CONFORMITYGIRDERS

The resulting force shall be calculated taking C = 1

for the value of aerodynamic coefficient.

be-precisely determined by the user, the values may

be assumed as lm2per t for the part up to 5 t. 0.5m2
per t for that part from 5 t to 25 t. The basic wind
pressures for different regions in India shall be taken
fkom 1S875 ( Part 3 ).

Ho-wever, for the handling of miscellaneous loads

less than 25 t, where the wind facing area cannot
11

..

IS 807:2006

Table 11 Values of Coefficient

q in Terms of Q =A/A, and b/h

( Clause 7.1.4)
Q=A/Ae

0.1

0.2

0.3

0.4

0.5

0.6

0.8

1,0

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

b/h = 0.5

0,75

0.4

0.32

0.21

0.15

0.05

0.05

0.05

blh = 1

0.92

0.75

0.59

0.43

0.25

0.1

0.1

0.1

blh = 2

0.95

0.8

0.63

0.5

0.33

0.2

!).2

0.2

blh = 4

0.88

0.76

0.66

0.55

0.45

0.45

0.45

b/h = 5

0.95

0.88

0.81

0.75

0.68

0.68

0.68

1.0

r\\mL

BEs

b/h=6

0.8

L\

0.6

T-1
0.4

1
\
\

0.2

b/h=3

b/i=2

I
blh=l

,,, ,

b/h=O. 5
[

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

FIG. 8 RELATIONDIAGRAM BETWEEN q ANDq

7.2.2

shall be designed to carry the following concentrated

loads:

Snow Load

Snow load shall be neglected in the design calculations

for over head traveling cranes, bridge cranes and jib
cranes.

7.2.3

Temperature

Variation

Stresses
due to temperature variation shall be
considered only in special cranes such as when members
are not free to expand.

300 kg for maintenance gang ways and

platform where materials may be placed.

b)

150 kg for gangways and platforms intended

only for access of personnel.

c)

30 kg as the horizontal force, which may be,

exerted on hand rails and toe-guards.

NOTE These loads are not used in the calculations

for girders.

In such cases, the maximum temperature fluctuation

shall be taken to be 20C to + 45C.
8 MISCELLANEOUS

a)

8.2 Seismic Load

LOADS

The horizontal load of 20 percent of the self-weight

shall be taken as seismic load irrespective to types,
such as traveling or fixed cranes. However, the
horizontal load of the hoisting load suspended by the

8.1 Loads Carried by Platforms

Access gangways, drivers cabins and platforms
12

IS 807:2006

rope may be neglected.

8.4.1

The seismic load coefficient in some important town

in India and map of India showing seismic load are
given in IS 1893.

The following shall be taken into consideration [ ( static

load due to deadweight)+ ( working load) x ( dynamic
coefficient, W )].

8.3 Amplification of-Load

8.4.2 Cranes Working with Wind

The impact Ioads caused in the hoisting operation

are different in value according to the hoisting speed,
deflection of the girder, rope length, and are given
by multiplying the impact factor specified in Table 12,
to the hoisting loads.

load ) ] + ( wind load in services ) + ( load due to

heat ), where M is the duty factor, Y is -the impact
factor.
8.4.3 Cranes Sutjected

the Ampljjication

Coefficient

(M)

to Exceptional

Loadings

Exceptional loading occurs in the following cases:

For a structural member, the stress caused from

the hoisting load is different in sign, from that of the
self-weight, a load multiplied by ( 1 V )/2 to the
hoisting load shall be taken into consideration of the
impact load caused by setting the load down on the
ground.
Choosing
or Duty Factors

Working Without Wind

M [ ( self weight ) + Y ( hoisting load ) + ( horizontal

8.3.1 Impact .Factors (Y)

8.3.2

Cranes

a)

Cranes out-of-service with maximum wind,

b)

Cranes undergoing static as well as dynamic

tests, and

c),

Cranes working and subjected to a buffer

effect.

The height of the following combination shall be

considered:

The value of the ampli~ing co-efficient M depends

upon the group classification of the cranes. The
main loads shall be multiplied by the duty factors
given in Table 13 considering the working conditions
and the importance of the duty.

a)

Loads due to the dead weight plus the load

due to the maximum wind;

b)

Loads due to dead weight and working load

due to the service load plus the greatest buffer
effect; and

c)

Loads S~ due to the dead weight plus the

highest of the-two loads YP,S~ and P&.

8.4 Case Loading ( Combination of Loads )

where
In the calculation of stresses, the most unfavorable
combination shall be applied. The three different cases
of loading are to be considered:

P, = coefficients by which the safe working load

is multiplied for the dynamic test;

P* = coefficients which the safe working load

a)

Working without wind;

b)

Working with limiting working wind; and

SL

c)

For exceptional loadings,

S~ = maximum permissible load,

is multiplied for the static test;

= safe working load; and

Table 12 Impact Factor, W

( Clause-8.3.1)
Group

of Cranes

Ml

M2

M3

M4

MS

M6

M7

M8

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

1.06

1.12

1.18

1.25

1.32

1.4

1.40

1.5

MS

M6

M7

M8

Table 13 Duty Factor

(Clause 8.3.2)
Group of

Ml

M2

M3

M4

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

1.05

1.06

1,1

1.12

1.2

Classification

IS 807:2006

NOTES
1 Alltheloads aretobe selected intbemostunfavourable
position
and magnitude
for the member under
consideration. For instance, if the value not multiplied
by Y is larger than multiplied by W, the value of Y should
be taken as 1.

b)

Exceeding the critical-tripping

iodd; and

or buckling

c)

Exceeding the limit of endurance to fatigue.

The fundamental allowable stress, o, shall be taken

as the value obtained by dividing either the yield point
(or yield strength at 0.2 percent strain) or the tensile
strength of the material by safety factor as per
Table 15, depending upon the respective loading
condition mentioned in the combination of loads,
whichever is the smaller.

2 The horizontal loads shall be considered over the worst

combination of loads which may happen simtdtaneously
of the loads. However if itis clear that the horizontal
motionsdo not occur at the same time with the hoisting
motions, the value of Y may be taken as 1.
3 When the crane is out of service, the trolley shall be
placed at a determined position with no load.

Table 15 Safety Factor

4 in case of the slewing crane, the jib shall be placed

at a designated position with no load when out of service.
5 The application of load due to temperature and seismic
load shall be referred to 7.2.3 and 8.2,

8.5 Transportation

and Erection

i)

1.5

1.8

Concentrated and uniformly distributed load imposed

by the dead weight, if crane structures in the course
of transportat ion and erection at the site. To take care
of the above condition the load factor as given in
Table 14 is to be considered. If this cannot be
determined, it shall be assumed that the trolley is placed
at the most unfavorable position.

ii)

11

1.3

1.5

iii)

111

1.15

1.4

1 Only tested quality materials ( plates, beam, channels,

angles and rails ) shall be used for the principal loading
members.
2 The quality of steels used shall be stated and the physical
properties, chemical composition and welding qualities
shall be guaranteed by the manufacturer of the material.

Table 14 Load Factor

,

I S1 No. 1

Type

(1)

1 Factor

(2)

i)

Erection loads

ii)

Transportation

[ , iii)

I Transportation

9.2 Structural Members and Welds

(3)
1.2

by road
by rail and ship

1.1

9.3 Rivets, Bolts and Pins

The allowable stresses for rivets, bolts and pins shall
conform to the specification as given in Table 17.

1 In the case of the slewing crane the jib shall be placed

at a designated position with no load when out of service.
If there is no designation. it shall be assumed that the
jib is located at the most unfavorable position.

9.4 Conventional
Spectrum

If it is clear that the job is unable to be slewed by the

wind, it shall be assumed that the jib is against the wind
in its most unfavorable
direction.

9.1 Fundamental

STRESS
Allowable

Number

of Cycles and Stress

The number of cycles of variation of loading and the

spectrum of stresses to be taken into consideration
for fatigue stresses. Suitable provision shall be made
in the design of the structural member to the protection
against cause of the following fatigue failure:

2 The application of load due to heat and seismic load

shall be applied respectively (see 7.2.3 and 8.2).

9 ALLOWABLE

.,.,

Allowable stresses for structural members and welds

are given in Table 16.

1.3

NOTES

Stress

The stresses set up in the various structural members

are determined for the case of loading ( the working
case without wind, the working case with limiting
working wind, the case of exceptional loading) and a
check is made to ensure that there is a sufficient safety
coefficient -y in respect of the critical stresses,
considering the following three possible causes of
failure:
a)

NOTES

E-xceeding the elastic limit;

14

a)

Failure due to maximum tensile stress of

sufficiently high value;

b)

A large enough variation or fluctuation in

the applied stress;

c)

A sufficiently large number of cycles of the

applied stress; and

d)

Protection against stress concentration,

temperature,
over
load,
corrosion,
metallurgical structure, residual stress and
combined stress.

1S 807:2006
Table 16 Allowable Stresses for Structural

Members and Welds

( CIause 9.2 )
Allowable

Kind of Stresses
Tension

Structural members

Compression

6,/1.15

Buckling

As given in 12

Butt weld

Oross
Gross

Gross

0,10

Bending

As given in 13.1

Tension

o,

Gross and net

0,

Compression
Shear
Fillet weld

Section for
Calculation

Ua

Shear

Welds

Stresses

Oalfi
oa

Tension in the direction

of-bead, compression
Shear

Throat

Is,lfi

NOTES
1 Net section shall be located at the position of minimum section excluding holes of rivets and bolts.
2 The welds shall conform to the
i)

followingconditions in the testing methods:

The weld shall be free from the defects for class M5 to M8.

ii) In case of presence of defects of class Ml to M4, the allowable value shall not be more than !4 of the allowable
value.

Table 17 Allowable

Stresses for Rivets, Bolts and Pins

.,

( Clause 9.3)
Kind of
Joint

Material

Rivet

IS 1363

Kind of Stresses
Shear

Shop

IS 1364

1.4 Oa

IS 2155

Shear 80% of the above

Bearing
pressure
Apparent shear
o.21aa

Diameterof bolt stem

IS 3138

Apparent shear

0.2IGl

Diameterof bolt stem

Reamed

Is 3737

Shear

CiaI J3

Diameter of bolt stem

bolt

1s 6610

Bearing pressure

1.40,,

Diameter of bolt stem

Pin joint

IS 6623

Shear

0,/ d3

IS 6639

Bearing pressure

1.40,

[S 6649

Bending

tra

1S 1929

High tensile
bolt
High tensile

-Fields

I
I

grip bolt

Diameter of pin when the pin slides

slightly only the allowable stress for

bearing -pressure shall be given as

50 percent of the left described

Anchor bolt

Tension

0.60,

Shear

9.4.1

Fatigue

Diameter of rivet hole

0,/43

Bearing
pressure

IS 1367

Remarks: Diameter
Used in Calculation,
etc

Allowable
Stresses

Diameter of bottom screw

0.35 Cra

against the number of cycles N.

Curve for Ferrous Metal

The basic method of presenting engineering fatigue

data is by means of S N curve, a plot of stress S

S N curve is ccmcerned chiefly in the fatigue failure

at high number of cycles ( N > 105cycles ).
15

..

:-...

IS 807:2006
S N curve becomes horizontal at a certain limiting
stress; below this limiting stress ( fatigue limit or
endurance limit ) the material can endure an infinite
number of cycles without failure. The failure is at high
stress in a short number of cycles.

the quality of the material used. The fatigue

ratio for steel shall be around 0.2 to 0.3. The
fatigue strength of the structural members depends
upon the shape and the method of making the
joints. The shapes of the parts joined and the
means of doing it have the effect of producing
stress concentration
( notch effect ) which
considerably reduces the fatigue strength of the
member. Representation
is given graphically
in Table 18 and Fig. 10. Classification of various
joints to their degree of stress concentration
(or notch effect ) is given in Annex A.

While designing the structural member, due

consideration shall be given to fatigue limit, high stress,
high number of cycles and load spectrum.
Representation is.given graphically in Fig. 9.
9.4.2

Material

Used and Notch Effect

The fatigue strength

of member depends upon

4/,,.
\
\

FATIGUELIMIT

,.6

,05

,.7

,.8

NUMBEROF CYCLESTO FAILUREN

FIG.

,09

.,. ,

9 FATIGUECYCLES

1400
1200

u)
(n
Lu
lx
1U-J

600

400

200

0
10

,02

,03

,04

,~5

NUMBER OF CYCLES ~
FIG. 10 NOTCH EFFECT
16

,.6

,.7

,.6

IS 807:2006
Table 18 Classification

by Notch Strength

( Clause 9.4.2)
S1 No.

(})

Explanation

Figure

(2)

Classification
by
Notch Strength

(3)

Butt joint at
right angles
to the force

As Welded

Bead Finished

(4)

(5)

(6)

Taken as d.
when a
backing
strip is used

Confirm
absence of
lamination

Parent metal

Remarks

Butt joint of fiat piates

~y~y
d
Butt joint of shapes
/

,/
d

Cruciform joint
.
---.~...

=.

.
,<.
= ..

&
d

*
0
ii)

Butt joint of
plates of
different
thickness at
right angles
to the force

Asymmetrical

Asymmetrical

slope

[_~-.-

, ,

joint

. ...

~-t-l

Symmetrical slope
*

:---=z~~
-------

Symmetrical joint

17

IS 807:2006

Table 18 ( Continued)
.
S1 No.

Explanation

Figure

Classification
by
Notch Strength

,
(1)
iii)

(2)

(3)

Fillet weld at
right angles to
the force

Remarks

As Welded

Bead Finished

(4)

(5)

(6)

Confirm
absence of
lamination

P
,..)

/
Q
d

@
/ /
iv)

Continuous butt
weld and fillet
weld parallel
to the force

Butt weld
/

Fillet weld
/
/ @

.,. ,
@

v)

Discontinuous

-R-L
-D-L
vi)

With necessary
member joint

Fillet weld, fillet weld ( spot)

/&
Butt

vii)

With necessary
member joint

Weld

Fillet weld,
~ R

[
1~i A*>
\.

=.
&
@

,K,x.,

_-_c__

IS 807:2006
Table 18 ( Continued)
S1 No.

Explanation

Figure

Classification
by
Notch Strength

.
(1)
viii)

As Welded

3ead Finishe[

(4)

(5)

Filletweld

Iillet weld (perfect)

(2)
loint of curved
flange and web

Fillet weld

A
-1

Remarks

(6)

-i

I
I

IA
Fillet weld (perfect)

I
!
!

1.,, ,

ix)

3eneath rail

u
h

/-

GY

x)

rruss

Fillet weld

19

IS 807:2006
Table 18 ( Concluded) .
S1 No.

Explanation

Figrme

(1)

(2)

(3)

xi)

Pipe

Classification
by
Notch Strength

Fillet weld

As Welded

Bead Finished

(4)

(5)

Remarks

(6)

. /
...
,.. ...
.. ..
..
,. ..
.. .. .. ..
. . . . . ...
. . .. . .
. . . . . . . . . ..
E. ..
%

---

Fillet weld E-groove

---

-.-..
JLD
xii)

--.

Perforated
member

---r:_t--

9.4.3 Determination

of the Maximum

Stress, O~aX

~~~~

This ratio, which varies from +1 to 1, is positive if

the extreme stresses are both of the same sense
( fluctuating stresses) and negative when the extreme
stresses are one of the opposite sense (alternating
stresses).

Maximum stress cr~ti is the highest stress in absolute

value that is, it maybe tension or compression which
occurs in the member in loading case, without the
application of amplifying coefficients, M.
9.4.4 Ratio (K) between the Extreme Stresses

9.4.5 Amplitude

This ratio is determined by calculating the extremes

values of the stresses to which the component is
subjected according to loading condition.

The amplitude of the variable Stresses ( o&fax~k~,,,)

shall not exceed the allowable stress and also shal I
satisfy the following three formulae:

The ratio may vary depending upon the operating

cycles but it depends on the safe side. To determine
this ratio K by taking two extreme values which can
occur during possible operation.

( ~~aX-~~i~ ) S J.F~. Cd-

( ~Ma.-rM,,)S ~J.~~. a~/ W with respect

to
the shear stress
for welds shall
be applied. FJ, ~~are
to be taken from
the
u
notch
(see 9.4.2 ).

K = ~~,n f o~o, or CT~d,,

I o~,. in case of shear
where
=

with respect to the

direct stress for
parent metals,

( ?w..-~lwn )< ~J.FL. 6d/ w

For welds,

If a~m and c~,n are the algebraic values of these extreme

stresses, o~aXbeing the extreme stress having higher
absolute valve, the ratio may be written:

Mm

Method

minimum direct stress, and

Max = maximum direct stress.

20

=1S807:2006
where
a A4U.K
= maximum
N/mmz;
~A{(n =

stress, in kgf/cm2 or

direct

minimum direct stress, in kgf/cm2 or

Nhnmz;

TMu.r =

maximum shear stress, in kgi7cm2 or

N/mm2;

Tli[lll =

minimum shear stress, in kgf/cm2 or

N/mmz;

F-,

joint factor given in Table 19;

FL,

= life factor given in Table 20; and

*d

allowable fatigue stress. This should be

taken as 1 000 kgf/cm2 or 100 N/mm2.
However, each stress shall not exceed
the al Iowable stress.
Table 19 Joint Factors (F,)

calculation, assuming the tipping point to have been

reached by increasing the working load and the
dynamic and weather effects by the factors
specified in Table 21, the rail track or the base of the
appliance being assumed to be horizontal
Typical diagram are shown in Fig. 12 to

and rigid.

16.

In case of floating cranes, due accounts shall be taken

of the inclination imparted to the crane as a whole.
10.1 Special Measures
Supplementary means of mooring may be provided
to ensure stability when out of service.
Further more, it is permissible to impose definite
positions of the cranes or of certain of its components
when out of services or alternatively to allow freedom
of movements of the latter ( crane jib for example ).
Such measures should only be adopted atler agreement
between the user and the manufacturer as they impose
conditions on operation.
10.2 Safety against Movement by the Wind

Table 20 Life Factors (F,)

(Clause 9.4.5)
Group of
Cranes

Ml

M2

M3

M4

M5

h46

M7 Mg

(2)

(3)

(4)

(s)

(6)

(7)

(8)

1,() lo
],()

Notches
(1)

9.4.6

a. b

1,3

1.2

1.2

1,1

].1

1.()

c.d

1.7

1,4

1.4

1.2

].2

I,o

Checking

the Members

Subjected

(9)

lo

to /atigue

The permissible stress for fatigue is derived from the

critical stress defined as being the stress which on
the basis of test made with test pieces, corresponds
to a 90 percent probability of survival to which a
coefficient of safety of 4/3 is applied thus: ad of
fatigue = 0.750, at 90 percent -survival. Graphical
representation is given in Fig. I I.
Practical indications based on the results of
research in this field is given in Annex A on the
determination of permissible stresses for steel
grade st-37, st-42, st-52 according to the various
group in which the components are classified and
notch effects of the main types of joints used.
10 STABILITY

AGAINST

OVERTURNING

Stability against overturning shall be checked by

Independently of the stability against overturning, a

check should be made that the cranes shall not be
set in motion if maximum wind increased by 10 percent.
This check shall be carried out assuming a coefficient
of friction equal to 0.14 for braked wheels and a
resistance to rolling of 10 kgf/t for unbraked wheels
mounted on anti-friction bearing or of 15 kgf/t for
bushed wheels.
Where there is danger of movement a mooring device
such as a chains, clamps, manual or automatic locking
pin, etc, shall be provided. For the design of clamps,
the coefficient of friction between the clamps and the
rail shall be taken as 0.25.
11 CALCULATION

OF TENSION

MEM-BERS

The tension stress shall be calculated by the net

sectional area excluding the holes of the bolts and
the rivets from the following formula:
Ut

=<qa
An

where
N=

tensile force in axial direction, in kgf or N:

An = net sectional area, in cm2 or mmz;
at = tensile stress, inkgf/cm2 or N/mmz; and
O,a = allowable tensile stress.

IS 807:2006

600
400

200

0
-1000

-500

(Tin=

1000

500

~m~x. + ~min.
2

1500

2000

( kgf/cm2) / ( N/mm*)

FIG. 11 ALLOWABLEFATIGUESTRENIGTH

STABILITY REACH
MEASURED FROM

STABILITY REACH
MEASURED FROM
BASE LINE TO

*
$)
\

1/

BASE LINE TO
GIB HEAD PIN

GtB HEAD PIN ,

BASE
NE ~

,
t

A
90

+++%

TABILITY
BASE

BASE LINE

~kLE4
l--STABILllY BASE 1

FIG. 12 ILLLJSTRATIONm STABILITYBASE STABILITYREACH AND REACHFORNON-SLEWING 3 OR 4 POINISUSPENSION CRANES

22

IS 807:2006

STABILITY
BASE
...

REACH

STABILITY

I----=Q

I I
1-

EACH-

FIG. 13 TYPEMOUNTED
MOBILECRANE

I-till

STABILITY
BASE

lrll/

FT

STABILITY
BASE

RADIUS

a)

b)
FIG. 14 TRAWLER
TYPEMOBILECRANE

.,

23

r
-

RADIUS

J
.

,,

/
///

FIG. 15

PORTAL
JIB CRANE

,... ._

,..
,A

.,

FIG. 1(j TOWER CRANE OR TOWER DERIRC CRANE

25

IS 807:2006
Table 21 Stability

Requirements

( C/ause

IO)

Loads to be Considered

Checks to .be Made

(3)

(2)

(1)
Static check

a) Safety working load

1.5

b) Horizontal effects

c) Wind

Dynamic

Cranes under

a) Safe working load

check

load

b) Twu horizontal effects

c) Limiting working wind

D}namic

Cranes uudcr

check

no-load

~ (hecking for m2i\inlunl tviud

I

Amplifying

Storm !vincl )

1.35

a) Safe working load

-0.1

b) Two horizontal effects

c) Limiting working wind

a) Safe working load

()

b) Horizontal effects

c) Maximum wind
~ Check for breakage of sling

1.1

a) Safe working load

b)

0.3

Two horizontal effect with no load

c) Limiting working wind

NOTES
I Limiting working wind ill the most unfavorable

direction.

2 Travel motion used for positioning only and shall bc made separately,
3 Unless calculation juslilj
12 CALCULATKIN

a lower value.

box girder subjected to bending and torsional

stresses shall be respectively calculated as follows.
However, in the case of the cranes when the ratio
( span/width ) of the girder is not more than 40, the
lateral buckling due to the bending is not considered.

OF COMPRESSION

MEMBERS

The compressive

stress shal I be calculated

sectional

area not excluding

the rivets

frolm

by the gross

the holes of the bolts or

the following formula:

13.1 Bending
6.

where
N=

compression force in axial direction, in kgf

orN;

cJ=
c

A = gross sectional area, in cm2 or mm2;

w=
buckling coefficient;
Oc = compressive stress, in kgf/cm2 or N/mm2;
and
rsca= allowable compressive stress.

T=

MM
I
M

<(3,2

An
< ~ca

!
F
.
An

<Ta

where
at = tensile stress along edge, in kg flcm~
or N/mm2;

The ratio of the effective length /to the least radius

of gyration for compression members shall not exceed
180 for main member and 240 for wind bracing and
subsidiary members.

a=c

compressive stress along edge, in kgf/cmz

or N/mm*;

q, = allowable tensile strkss;

T=

The actual values shall be taken from IS 800.

shear stress, in kgf/cm2 or N/mmz;

Ta = allowable shear stress;

A/f. bending moment, in kgfcm or Nmm:

13 CALCULATION OF BOX GIRDER SUBJECTED

TO BENDING AND TORSIONAL STRESSES
The bending stress and torsional

I=

stress for the

26

geometrical moment of inertia, in cm~

or mm4;

1S 807:2006
and

.1 = gross sectional area of tension flanges,

in cmz or mm2;

.4,, = net sectional area of tension flanges,

in cmz or mm2;

Moreover, open section such as 1section member shall

be checked about lateral buckling.

distance between the neutral axis to tension

edge, in cm or mm;
edge or compression

6=
,=

15 CALCULATION

shear force. in kgf or N; and

in cm? or mm2.

Stresses at the butt weld or the fillet weld shall be

calculated from the following formulae:

13-.2 Torsion

=_

M,

<~

2.A.I

P
X a.1

l~here
T,

OF WELD.ED JOINTS

15.1 Stresses on Joints under Tension, Compression

or Shearing Fcirce

A,, = net sectional area of web subjected to shear,

==distance between the neutral axis and the

edge of section, in cm or mm.

shear stress due to torsional moment in

kgf/cm~;

. P
X a.1

Ta =

allowable shear stress;

M, =

torsional moment around the shearing

centre in kgf cm or N mm;

G=

tensile or compressive stress at the weld.

in kgf/cm2 or N/mm2;

area surrounded with centre lines of webs

and flanges in cm? or mmz; and

r=

shear stress at the weld, in kgf/cmz or

N/mmz;

thickness of web or flange in cm or mm.

p.

force acting on the joint, in kgf or N;

a=

throat of the weld, in cm or mm; and

1=

effective length of the weld, in cm or mm..

t=

where

M CALCULATION OF MEMBERS SUBJECTED

TO BENDING BY FORCE IN THE DIRECTION
OF AXIS

15.2 Combined Stresses on Joints under Bending

and Shear Moment

Stress of the members subjected to bending by force

in the axial direction shall be calculated from the
following formulae or a precise buckling calculation
shall be carried out considering the deformation of
the members as required:

G=
c

M
.W+O.9

Composite stress shall be calculated from the following

formula for joints on which the bending moment and
the shear force act simultaneously, such as the
continuous weld connecting a web plate and flange,
vertical or horizontal butt weld of webplates and fiIlet
weld connecting l-shape girder to wall surface:
~s

.e < ~ta

where
6

where
0,

(3=
c

tensile stress along edge, in kgf/cm2

or N/mmz;

c = shearing stress.in kgf/cm2 or N/mmz.

compressive stress along edge, in kgf/cm2

or N/mmz;

15.2.1 Stress Due to Bending Moment

c

force in axial directicm, in kgf or N;

M = bending moment. in kgf-cm or N-mm;

geometrical moment of inertia, in cm4
1=
or mnd;
A=

= tensile or compressive stress at the weld,

in kgf/cm2 or N/mm2;

O. = bending stress in kgf/cm2 or N/mmz; and

crta = allowable tensile stress;

N.

6,

M
Y
[

where

gross sectional area of member, in cm2

0=

tensile or compressive stress at the weld,

in kgf/cm2 or N/mm2;

M=

bending moment acting at the joint, in kgfcm;

I=

moment of inertia of the throat around the

or mmz;

An = net section area of member, in cm2or mm2;

27

IS 807:2006
neutral

axis andinthe

case of

reduced accordingly

fillet weld,

the moment of inertia of expansion

effective

section as shown in Fig, 17 in which the

throat is expanded on the joining surface,
in cm4 or mm4; and
Y

==distance from the neutral axis to a point

under consideration, in cm or mm.

Iki

s
ki

where
value of the maximum
al = absolute
compressive stress in k-gf/cm2or N/cm~;

15.2.2 Shear ,Wress

T

o,

. P

A4fG
I.CI

where
-c=

shear stress, in ligf/cm2 or N/cmz;

p.

shear force at the joint, in kgf or N;

61k]=

local ideal buckling stress given from the

formula 6, = oC.k;

k] =

local ideal buckling given fi-omthe formula

~kl= OCk;

T=

shear stress in kgf/cm2 or N/mm*;

MG = geometrical moment of the area ofa section

outside of the weld line under consideration

about the neutral axis, in cms or mm3;

safety factor for local buckling

Table 22);

( see

I=

moment of inertia, in cm4 or mm4; and

fundamental buckling stress given from the

following formula:

a=

throat, in cm or mm.

CTc=

Isc =

16 CALCULATION OF LOCAL BUCKLING OF

PLATES
Local buckling strength of the plates shall be calculated
on both the buckling of a partial panel surrounded
by the stiffeners and the buckling of the whole panel
including stiffeners where the load acting on the plate
shall be multiplied by the impact factor (~) and the
duty factor, M.
Compressive
Independently

Stress

or Shear

Stress

t
b=
k=

Acts

16.1.1 In such case where OIL,,fit~i exceeds the elastic

limit of the material, the allowance stress shall be

al
t. /--

modulus of longitudinal
kgf/cm2 or N/mm2;
.

)2,kgf/cmz

elasticity,

poissons ratio;
width of the panel, in cm or mm;

.,,.,

local buckling coefficient and concerning

the partial panel it shall be in accordance
with Table 23. Concerning the whole surface
including stiffeners, it shall be obtained
according to the condition of each stress
from Table 23;
?1
r

a3
.
a4
~-

ll-f

R..

a5

a5

a = THROAT
FIG. 17 EXPANSIONOF TIiROKI
28

in

. thickness of the plate, in cm or mm;

I&f
1

=( 1378.:

or N/mm~
E.

16.1

n2.E.t2

12b2(l -p2)

IS 807:2006

a=

length of the panel, in cm or mm;

a=

ratio of length to width of the panel;

a

17 DESIGNS OF STRUCTURAL
SUBJECT TO AXIAL FORCES

The structural members and joints shall be of the

structure free from eccentricity and special stress
concentration, and in the inevitable case, these shal I
be designed taking into consideration the effect.

(1

h
stiffeners ratio of the stiffener;

Y=

J
Y-

17.1 Net Sectional Area of Tension Member

0.092 i5t3

In order to obtain the effective net sectional area of

the tension member, the areas of the rivet-or the bolt
holes shall be reduced adequately according to the
position of the rivets or the bolts. In Fig. 17, if the
section a-c-c-a is smaller than that of a-a, four rivets
or bolt holes shall be reduced from the sectional area
of the member.

hi

17.2 Slenderness

J=

geometrical moment of inertia about the

centre line of the plate to calculate the
local buckling for the gross section of the
stiffeners, in cm or mm4;

s=

ratio of area of the stiffener;

s

F=

gross sectional area of the stiffeners in cm2

or mm~.

Normal
Simultaneously

Stress

and

Shear

Stress

k= lklk
where

Acts

/k = buckling length, in cm or mm; and

k

The two local buckling stress. ol~,and ~,~iare separately

The buckling length f~shall be obtained as follows:

As to the buckling in aplane of a truss, the buckl,i~g
length is taken as lk, which is the distance between
the centre of gravity of the joining bolts ( including
rivets ) at the ends of the member. When a member
intersects the other members, the intersecting part may
be regarded as rigid in the plane of the truss.

3-4)
I+@ _ IS, +
4
4
(d
Ik!

,. a
Clki

*
)

-t (:)*
ki

where
$

The bend buckling vertical to the plane of the truss

shall be as follows:

= ratio of maximum to minimum stress acting

perpendicular to a plate.
In special case when ~ = O, ov~,= alk,

a)

The distance of nodal points may be taken

as /k, if the both ends of the member are
supported not to permit displacement.

b)

[n thecase where one end of the member is

joined rigidly to a lateral member having bend
rigidity not to displace laterally, f~ shall be
taken as 0.81.

c)

In the case where both ends are jointed rigidly

to the lateral members having bend rigidity
not to displace laterally, /k shall be taken as

when o = O, crVk,= i? ~ki

In case where ideal combined stress av~i
exceeds the elastic limit of the material the
allowable stress shall be determined by the
reduced combined stress Ovk
CT
vk

=drJ, ~+3#=

Cr

1,in kgflcm~or N/mm2

,s

where
al
s

0.71.

value of the maximum

= absolute
compressive stress in kgf/cmz or N/cm*,
safety factor for local buckling,

d)

(sVk = reduced combined stress,

ideal combined stress, and

a=vkl
ok

In Fig. 18, when the nodal of a and b of

both trusses do not displace perpendicularly
to the plane of truss and the forces of
members N,, Nl are different in magnitude
and N2< NI, it shall taken as
N2

all-owable reduced stress.

/k = (0.75+ 0.25 )
NI
29

= minimum radius of gyration relating to

buckling axis, in cm or mm.

calculated and the local combined stress, o,~i shall

be obtained from the following formula:
Ovkl =

Ratio

The slenderness ratio k of the member shall be

calculated from the following formula:

NOTE The values ot buckling coefficient shall be

taken from Tables 23 [o ?7.

16.2

M-EMBERS

IS 807:2006
Table 22 Safety Factors for Local Buckling
( Clause 16.1.1 )
S1 No.

Loading

Condition

(1)

(2)

.i)

Safety Factor for Buckling

of the Whole Plane

Safety Factor for Buckling of

a Partial Panel Surrounded
by Stiffness

(3)

(4)
1.5+0.075($1)

1.71 + 0.180($-1

ii)

11

1.50+0.125($-1)

1.35+0.05($-1)

iii)

111

1.35 +0.075

1.25+ 0.025 (@-l

Table 23(a) Buckling Coefficient

Loading

(($-1)

for the Partial Panel K ( without

( Clause
sl

Condition

stiffner

16.1.1 )
Range of Application

Bsrckling

Coefficient

No.
Uniformly distributed
compressive
stress
1#1=1
ii)

Linearly
distributed
compressive
stress
()< @<l

iii)

iv)

v)

Linearly
distributed
tensile and compressive
stresses,
where
compressive
stress is
larger -1<$<0

~
a

K=(l+@)K@K+
100
(l+@)
K= buckling coetlicient
.,,,,, Iijr
~= O ( refer-to No. ), )
K = buckling coefficient
for @= -1 ( refer to No. iv )

~Jm~

u >213

Linearly
distributed
tensile and compressive
stresses,
where
compressive stress are
equai and tensile stress
is larger @.S-1
Uniformly

distributed

shear stress

30

K=23.9

Table 23(b)

Buckling

Coefficient

for the Partial Panel h

( Clause 16.1.1 )
S1

Loading

No

i)

ii)

iii)

Condition

Uniformly distributed
compressive stress
o<l@l<l
One horizontal stiffener
at centre

and Arrangement

...-.
E-= ;

Buckling

Range of Application

,t
-1

HI
O-*

m.

=&x

of Stiffness

2
a<4dl+2y

0.95 ($$

o.95(@+l.1)

,.

a.ab

0.4 SCIS

Uniformly distributed
compressive stress. One
horizontal stiffener and
vertical
stiffeners
at
centre

0.9 SCX <1.1

i,o
B=(l+az

~=

0.5 s Cx<2.0

(9+ Lx:)~+3.3Lx2y

)z(9+az)~L2a:y

(l+a*)~+
d(l

+27

1+2(5

A = 1.5( I +a2)z+0.167

u-u

cx~(l +28)
I+ N1+27

Uniformly distributed
compressive stress
()<@<]
One vertical stiffener at
centre

Uniformly distributed
shear
stress.
One
horizontal stiffener at
centre

(l+cF)~
+1,1)

*U,

~=
iv)

Coefficient

[(l +a:)o +(9+&)2]

2(yL+yQ. a3)
+26L)

4.93 (l+cP)
a%
10.24 ( 1 + a2 )2 + 3.16 (1 +9c#)2 + 4.05y

(l+a2)2(
l+9az)2+ 2y(l+a2)z+2y(
I+9LY)Z
10.24( I +a2 )2+0.41 (9+a~)2+ 1~.lly
(l+a~)2(
9+a~)z+2ya;
(9+a3)z +162y(l+LZ2)~

r =

4.93 (1+az)
a~G
10.24( 1 +az )2+0,41 (l+9a~)z+ 13.11 yczz
1+9a2)z+ 162yu3( l+az)s+2yaz(
l+9aD)2
r ~l+a)2(
10.24 ( 1 + a2)z +3,16(9+ &)2+ 4.05yas

K=
v)

Uniformly distributed
shear stress. One vertical
stiffener at centre

vi)

Uniformly distributed
shear stress.
One
horizontal and one
vertical
centre

stiffener

(I+

Q?)2(9+cr2

)2+2@

(9+ry.2)2+

2y@(l+a2)2

0.5< a 52.0

at

NOTE Both stiffeners sl}all cross each other iiithout reduction of hknding stitTness or be combined at the same siiffness.

.l
..

N
z
m

IS 807:2006
Table 24
(Cluuse
Buckling

Coefficients

16.1.1)

@ for Steel Members of Yield not more than 24 kgf/mm2 ( 240 N/mm* )
2

20

1.04

1.04

1.04

1.05

1.05

1.06

1.06

I .07

1,07

1.08

20

30

1.08

1.09

I .09

1,10

1.10

1.11

[.11

1,12

1.13

1.13

:()

40

1.14

1.14

1.15

1,16

1.16

1,17

1.18

1.19

1.19

I .20

4(I

50

1.21

1.22

1.23

1.23

1.24

1.25

1.26

1.27

1.28

1.29

50

60

1.30

1.31

1.32

1.33

1.34

1.35

1.36

1.37

1.39

I .40

00

70

1.41

1.42

1.44

1.45

1.46

1.48

1.49

1.50

1.52

1.53

70

80

1.55

1.56

1.58

1,59

1.61

1.62

1.64

1.66

I .68

1.69

80

90

1.71

1.73

1.74

1.76

1.78

1.80

1.82

1.84

1,86

1,88

90

I 00

1.90

1.92

I .94

1.96

1.98

2.00

2.02

2.05

2,07

2.00

100

)10

2.11

2.14

2.16

2.18

2.21

2.23

2.27

2.3 I

2.35

2.39

110

120

2.43

2.47

2.51

2.55

2.60

2.64

2,63

2.72

2.77

2.81

1?()

130

2:85

2.90

2.94

2.99

3.03

3.08

3.12

3.17

3.22

3.26

I .30

140

3.31

3.36

3.41

3.45

3.50

3.55

3.60

3.65

3.70

3.75

I 40

150

3.80

3.85

3.90

3.95

4.00

4.06

4.11

4.16

4.22

4.27

150

160

4.32

4.38

4.43

4,49

4.54

4.60

4.65

4.71

4.77

4.82

160

170

4.88

4.94

5.00

5.05

5.11

5.17

5.23

5.29

5.35

5.41

170

180

-5.47

-5.53

5.59

5.66

5.72

5,78

5,84

5.91

5.97

6.03

180

I 90

6.10

6.16

6.23

6.29

6.36

6.42

6.49

6.55

6.62

6.69

I ()()

200

6.75

200

,,
Buckling Coefficients

01 for Cylindrical

Steel Members of Yield not more than 24 kgf/mm2 ( 240 N/mn12 )

.3

20

1.00

1.00

1.00

1.00

1.01

1.01

1.01

1,02

1.02

I .02

2()

30

1.03

1.03

1.04

1.04

1.04

1.05

1.05

1.05

1.06

1.06

3()

40

1.07

1.07

1.08

1,08

1.09

1.09

1.10

1,10

1.11

1.11

40

50

1.12

1.13

1.13

1.14

1.15

1.15

1.16

1,17

1.17

1.18

50

60

1.19

1.20

1.20

1.21

1.22

1.23

1.24

1.25

1.26

1.27

60

70

1,28

1.29

1.30

1.31

1.32

1.33

1,34

.1.35

1.36

1,37

70

80

1.39

1.40

1.41

1.42

1.44

1.46

1.47

1.48

1.50

1,51

X()

90

1.53

1.54

1.56

1.58

1.59

1.61

1.63

1,64

1.66

1.68

90

100

1.70

1.73

1.76

1.79

1.83

1.87

1.90

1.94

1.97

2.01

I 00

110

2.05

2.08

2,12

2.16

2.20

2.23

2.27

2.31

2.35

2.39

110

NOTE To cylindrical coefficients,

to 120 or more.

of which ratio of diameter to plate thickness is not more than 6 and k is

32

equal

1S 807:2006
Table 25

(Clause 16.1.1)
Buckling Coefficients

,
A

02 for Steel Members of Yield Point 30 kgf/mmz ( 300 N/mm* ) to32

( 320 N/mmz )

.5

kgf/mm2

20

1.o5

1.06

1.06

1.07

1.07

1,08

1.08

1,09

1.10

1.10

20

30

I.it

I.11

1.12

1.12

1.13

1.14

1.15

1.16

1.17

1.17

3()

40

1.18

1.19

1.20

1.21

1.22

1.23

1.23

1,24

1.25

1.27

40

50

1.28

1.28

1.29

1.31

1,32

1.33

1.35

1,36

1.37

1.38

50

60

1.39

1.41

1.42

1.44

1.45

1.46

1.48

1.50

1.51

1.52

60

70

1.54

1.56

1.58

1.60

1.61

1,63

1.65

1.67

1,69

1.71

70

80

1.73

1.74

1.76

1.79

1.81

1.83

1.85

1,88

1.90

1.93

80

90

1.95

1.98

2.01

2.03

!,

2.05

I 2.07

..,

2.11

.-,

2.15

2.20

2.24

()()

100

2.29

2.34

2.39

2.43

2.48

2.58

2.62

2.67

2.72

100

110

2.77

2.82

2.88

2.93

120

3.30

:.35

3.40

3.46

3,52

3.58

130

3.88

3.94

3.00

4.06

4.12

140

4.49

4.56

4,63

4.69

150

5.16

5.22

5.29

5.36

160

5.86

5.94

6.02

170

6.62

6.70

6.78

180

7.42

7.51

7.60

190

8.27

200

9.18

8.36

8.45

2.98

-,

2,53

3,09

3.14

3,19

3.63

3.69

3.75

4.18

4.24

4.30

4.75

4.81

4.88

5.43

5.50

5.57

6,09

6.17

6.25

6.86

6.94

7.68

7.76

8.54

3.03

8.62

-!

3.24

110

3.82

120

4.37

4.43

130

4.95

5.02

5.09

140

5.64

5.72

5,79

150

6.32

6.40

6.48

6.55

I 60

7.02

7.10

7.17

7.25

7.34

170

7.85

7,94

8.02

8.10

8.18

180

9.08

I ()()

8.70

8.79

8.88

8.98

2i)i)

Bucking Coefficients

for Cylindrical

Steel Nlembers to of Yield Point 30 kgf/mm2 ( 300 N/mmz ) to

32 kgf/mm2 ( 320 N/mmz )

()

20

1.02

1.02

1.02

30

1.05

1.06

1.06

40

1.10

1.11

50

1.17

1.18

60

1.26

70

1.38

80
90

1.03

1.03

1.03

1.04

1.04

1.04

1.05

?()

1,07

1.07

1.08

1.08

1.09

1.09

1,10

3()

1.11

1.12

1.13

1.13

1.14

1.15

1.15

1.16

40

1.19

1.19

1.20

1.21

1.22

1.23

1,24

1.25

5()

1.27

1.28

1,29

1.31

1.32

1.33

1.34

1.36

1.37

60

1.40

1.41

1 43

1.45

1.46

1,48

149

1.51

1.53

70

1.55

1.57

1.58

1.60

1.62

1.66

I .70

1.73

1.77

1.82

8()

1.86

1.90

1.94

1.98

2.03

2.07

2.11

2.15

2.20

2.24

90

NOTE To cylindrical
to I 00 or more,

coetTicients, Of which ratio Of diameter to

33

plate thickness is not more than 6 -and k is

eqLIal

IS

807:2006
Table26

(Cluuse 16.1.1)
Buckling Coefficients o) for Steel .Members of Yield Point 34 kgf/mm2 ( 340 N/mmz ) to 36 kgf/mm2
( 360 N/mmz )

1.07

1.08

1.13

1.14

1.14

1.19

1.20

121

1.22

1.23

40

1,18

1.10

1.11

20

1.16

1.17

1.18

30

1.24

1.25

1.26

1.27

40

1.36

1.37

1.38

1.40

50

1.55

60

1.09
1.15

I .07

1.12

Ill

.1.09

1.08

1,06

1,06

30

1.15

Z()

5()

1.28

1.29

1.31

1.32

1.33

1.34

60

1.41

I .43

i .44

1.46

1.47

I .49

1.51

1.52

1.54

70

1.58

1.60

1.62

1.64

1.66

1.68

1.74

1.76

70

I .79

1,81

1.83

1.86

1.88

1.91

1.70
],93

1.72

80

1.96

1.98

2.01

80

90

2.05

2.10

2.14

2.19

2.24

2.29

2.33

2.38

2.43

2.48

9()

10 ()

2.53

2,58

2.64

2.69

2.74

2.79

2.85

2,90

2.95

3,01

1()()

110

3.06

3.12

3.18

3.23

3.29

3.35

3.41

3.47

3.53

3.59

110

4.15

4.22

120

120

3.65

3.71

3.77

3.83

3.89

3.96

4.02

4,09

130

4,96

4,35

4.41

4.48

4.55

4.62

4.69

4.75

4.82

4.89

130

4.69

5.04

5.11

5.18

5.25

5.33

5.40

5.47

5.55

5.62

140

1-1o
+ 150

5.70

Buckling

[50

tocfficients

for Cylindrical

Steel Members w of Yield Point 34 kgf/mm2 ( 340 N/mmz ) to

36 kgf/mm2 ( 360 N/mmz )

()

k-

20

I .02

1.03

1.03

1,03

1.04

I .04

1.05

I .05

20

I,02

1.02

3()

1,05

1.06

1.06

1.07

1.07

1.08

1.08

1.09

1.10

1.10

30

40

1.11

1.11

1.12

1.13

1.13

1.14

1.15

1.16

1,16

1,17

40

5()

1.18

1.19

1.20

1.21

1.22

1.23

1.24

1.25

1.26

1.27

50

60

1.28

1,30

1.31

1.32

1.33

1.35

1.36

1.38

1.39

1.41

60

7()

1.42

1,44

1.46

1.47

1.49

1.51

1.53

1.55

1.57

1.59

70

80

I .62

1.66

1.71

1.75

1.79

1,83

1.88

1.92

1.97

2.01

80

Nol E To cylindrical
[0 90 or mm

ctwttlcients. of which ratio of diameter to plate thickness k not more than 6 and A.is equal

34

__

--

IS 807:2006
Table 27

(Clause 16.1.1)
Buckling

Coefficients

20
30

103
1.09

w for Steel Members of Yield Point 44 kgf/mmz ( 440 N/mm* ) to 46 kgf/mm2

( 460 N/mmz )

1.o4

II 1.04

1.10

1.11

1.o5
1.12

1.o6

1.06

1.13

1.13

1.07
1.14

I
1

1.07
1.15

1,09
1.16

1.09

?()

1.17

30

40

1.18

1.19

1.20

1.21

1.23

1.24

1.25

1.26

1.28

1.29

40

50

1.30

1.32

1,33

1.35

1.37

1.38

1.40

1.42

1.44

1.46

50

60

1.47

1.49

1.51

1.54

1.56

1.58

1.60

1.62

1.65

1.67

60

70

1.70

1.72

1.75

1,77

1.80

1.83

1.88

1.93

1.98

2.03

70

80

2.08

2.14

2.19

2.24

2.30

2..35

2.41

2.47

2.52

2.58

X()

90

2.64

2.70

2.76

2.82

2.88

2.94

3.00

3.06

3.13

3.19

90

100

3.26

3.32

3.39

3.46

3.52

3.59

3.66

3.73

3.80

3.87

I 00

Ilo

3.94

4.01

4,09

4.16

4,23

4,31

4.38

4.46

4.53

4.61

110

120

4.69

4.77

4.85

4.93

5.01

5.09

5.17

5.25

5.34

5.42

[Z()

130

5.50

5.59

5.67

5.76

5.85

5.94

6.02

6.11

6.20

6.29

130

140

6.32

6.47

6.57

6.66

6.75

6.85

6.94

7.04

7,13

7.23

140

150

7.33

Buckling

150

Coefficients

for Cylindrical

Steel Members (o of Yield Point 44 kgf/mm2 ( 440 N/mm2 ) to

46 kgf/mm2 ( 460 N/mmz )

?&

a.

20

loo

1.00

I .00

1.00

1.01

I.ol

1.01

1,02

1.02

1.03

30

1.03

1.04

1.05

1.05

1.06

1.06

I .07

1.08

1.08

1.09

3()

40

1.10

1.11

1.12

1,12

1.13

1.14

1.15

1.16

1.17

1.18

40

50

1.20

1.21

1.22

1.23

1.25

.1.26

1.27

1.29

1.30

1.32

50

60

1.34

1.35

1.37

1.39

1.41

1,43

I .45

1.47

1.51

1,55

60

70

!.60

1.64

1.67

1.74

2.03

-70

N(3TE To cylindrical
to 80 or more.

coefficients,

1.78

1.83

1.88

1.93

1.98

of which ratio of diameter to plate thickness is not more than 6 and k is equal

35

IS 807:2006

t-.

.+__Q-+-@---

1- A
FIG. 18 EFFECTIVENET SECTIONALAREA

l
I

where a and b are Nodal points ofTrusses and N, and N2and Forces of members
FIG. 19 BUCKLINGLENGTH OUT OF PLATE
Limit for Slenderness

17.3

Ratio

of the member shall have the equivalent

geometrical
moment of inertia obtained by
multiplying the maximum geometrical moment of inertia
by the reducing factor C, see Table 29.

The slenderness ratio of the members shall not exceed

the values given in Table 28,
Table 28 Limit of Slenderness
Sl
No. /

Ratio Members

Kinds of Members

(1)

(2)

i)

Main compressi},e member

ii)

Auxiliary compressive member

l=cxlMar
where

Slenderness
Ratio

~.

-JL-.-l
150

_ 10
IMUX

These shall be applied only to the bearing member

of hinged joint of

240

10>0.01 Ih,ur
17.4

Compressive

Members with Variable Height

c= 1 forll >0.8/

The compressive members having approximately

uniform sectional area but having variable height

c may be interpolated in linear proportion for

0.81~11 ~0.51
36

1S 807:2006
Table 29 Reducing Factor C
(C/ausc 17.4)
il Nu.

Reducing

Shape of Ibc Member

(1)

(3)

(~)
(r

i)

Factor

l,, ,=/.21.

1<0.51,0.l<r<l

(=(().17+

0.33r+().5~)+~

(0,62+~

1.52r)

s
ii)

I,)= rzll

/,<o.5/.

o.l<rs/

1[, =r~ll

II

:
c = (

0.08 + 0.92r ) +. ~

( ().32 +

4&4.32r

(,)
L

-Ea-

iii)

10=

II

r: [1

O.l<r<l

It,
I()=r:ll

~ =

().48 +

0.02r

+ o.~~

I)ilrabola
,.
i))

[o=r2[

O.l<r<l

1,
~=

13,18 + 0.32r+

0.5W

.,, ,

L
-la

I)mabola

where

compressive member;
= equivalent geometrical moment of inertia;

~=

1,AIm = maximum geometrical moment of inertia;

and

slenderness ratio of.all members to a

principal axis ( see Fig. 21 );

m=

number of single members built up into one

combined unit by means of horizontal joint
as shown in Fig. 21;

~=

slenderness ratio ofa single member;

10

= moment of inertia. in cm4 or mm4.

17.5 Combined Compressive

Members

The combined compressive members are divided into

lattice members shown in Fig. 20(a) and rigid frame
members shown in Fig. 20(11).

~l=nm2
~:%:i

k, = ~

The combined compressive members shall be dealt

same as single compressive member the equivalent
slenderness-ratio is given by the following formula:

e=
kl

for rigid frame member

distance between the neutral axis to tension

edge or compression edge, in cm or mm;

= radius of gyration of a single member in

cm or mm;
where
k, = equivalent slenderness ratio of a combined
37

d=

length ofa diagonal member in cm or mm:

A=

gross sectional area of a compound member

in cm2 or mm2;

.-

IS 807:2006
e

.
I

II
II
il
II
II
11
* e

II
!1
II
II
! 1
49 +

II

II

L_

61

I
I

I
I

r~
L

1:
I
I
I
I
I
1$
I

tl

II

:+

:1

II
II
II

II
t,

II

~0,
*

1+

b)

a)
F1~.20 COMBINW COMPRHSIVE MFMFERS
.4~ = sectional area of a lattice member cm2 or

where

mmz;

k,

b)

Z = number of horizontal joints arranged in a

parallel plane.
17.6 Shear Stress Acting on Combined Compressive
Members
where
a

80

18.1 Rivets or Bolts for Joining Girder

,4=

gross sectional
area of combined
compressive member in clmzor mm?; and

0=c<1

allowable comperssive stress in kgf/cml

or N/mm7.

The rivets or the bolts forjointing the combined member

in the relategirders shall be calculated from the formula:
FS

where

geometrical moment of inertia of a girder

to the neutral axis of the girder in cm4 or
mm~;

P=

1=

geometrical moment of inertia of a girder

to the neutral axis of the girder, in cmJ or
mtm4;

F=

shear force acting on the girder, in kgfor

N; and

II

5 [;-20)

,+

80

,
100

~
=/4%.

pitch of rivets or bolts, in cm or mm:

Ha = allowable load for rivet or bolt, in kgf or N:

For a rigid .frame member, in the case where

axial distance of single member exceeds
20 kl, the equivalent shear force shall be taken
as the value shown in the following formula:
.
~,=q

= angle between the main member and t]lc

diagonal member.

18 DETAILE-D DESIGN OF GIRDERS SUBJECTED

TO BENDING

w41ere
F, = equivalent stear force in kgf or N;

a)

t
Z sin a

with their ioints shall not exceed the allowable stresses

against the equivalent shear forces shown in the
following forlmula:

1=

In the case of a lattice member constituted

of two members, the force D acting on the
diagonal members due to F, is to be given
from the following formula:
D=

All of the batten plates and parting lathes together

= minimum radius of gyration of a sing,le

member.

II = buckling length ofa single member in cm

or mm; and

!1

= geometrical moment of area of the section

relating to the neutral axis of the girder. the

section of which is intended to be jointed
with rivets or bolts, in cm~ or mm;,

8020

38

1S 807:2006

YI

1,3 3

Y!

b) m=2

a) m=2

c) m=2

e
l----

YI

1P)
Jx

$iHF

+jJk

-\#

\4-

\
Y

YI
d) m=2

1]

.e) m=2

f) m=2

Y,

u
C=d
7 Fr
1,

31E

_.L--

.,,,
x

11

yl

g) m=2

,1

IY

*-IY
k) m=2

h) m=2

Y\
Y/

/Y
% \

FIG.

/Y

Y/

7\

21 MFTHOD OF SL~ND~RNESSRATIO ( Continued)

39

IS 807:2006

G!P-lik-.

T@

4+%,
_.

___

Xe

F1ci.21 METHOD OF SWNDERN~SSRATIO

18.2 Rivets, Bolts or Welded Directly Subjected

Iw
provided M,k= h4
[

to

Wheel Load

where

[he rivets, bolts or the welds directly subjected

to the wheel load shall be as given in Fig. 22. It

shall be assu[med that the wheel load is distributed

uniformly in the angular direction of 45 from just
under 50 mm of the wheel as shown in Fig. 22 where
the rail is just on the web and particularly the correct
calculation is impossible.

R=

resultant force acting on a bolt atJ, in kgf

orN;

n=

total number of jointing bolts on one side

of-the joining line;

~=

maximum shear force at thejoint, in kgfor N:

18.3 Web Joint of Plate Girder Receiving Bend

~w .

bending moment on the web, in kgf. cm or

N.mm;

~.

bending moment on the welded joint of the

girder, in kgf.cm or N mm;

I=

moment of inertia in cm4 or mm4;

The web joint ( see Fig. 23 ) of the plate girder

receiving bending moment shall be designed
considering both the shear force and the bending
moment. Then the maximum resultant force acting
on the joining bolts ( including rivets ) shall be
calculated from the following formula. In this case,
the allowable strength ot- -bolt shall be reduced
according to the fiatio ot- the distance from the
tlange of plate girder to the neutral axis relative toyn
in the formula:

Iw = geometric moment of inertia of the web

around the neutral axis of the gross section

of the girder, in cm4 or mm4;
Ey = total sum of square of distance from joint

bolts atone side of the joint line to the neutral

axis, in cmz or mm2; and
Y = distance

from the neutral axis to the

furthermost bolt, in cm or mm.

40

--1-

4--

t
A

.--1-

50

--1--

mm

.ITL

/
,
--Q--t%----e-t-o
---e-*
I

FIG.22 DISTRIBUTION
OFWHEELLOAD

,,
I

+---4

4+

-+-+

+--+-

+-+

+---+
NEUTRAL
-
AXIS

+--4

Y,
-J

+----i

Y, Y2 ----------Yn DISTANCES FROM NEUTRAL AXIS

FIG.23 WEBJOINT
41

(cmor mm)

IS 807:2006
19 WELDING
CRANES

OF IN.DIJSTRIAL

W = maximum trolley wheel load, in kg( without

AND M-ILL

impact ).

19.1 The following

consideration:

points shall be taken into

a) Weldability classification of qualified steel;

Short diaphragm shall be placed between the fulIdepth

diaphragm to support the bridge rail. All diaphragms
shall bear against the top cover plate and shall be welded
to the web plates.

b) Allowable stress in welds;

23 GIRDER

END -CONNECTION

c) Fatigue stress in welds; and

A substantial

end tie must be provided to give

horizontal tixed end for rigidity to girder. The girders
with the truck shall be provided by the large gusset
plate welded to the bottom of the truck and attached
to girders with bolts in reamed holes.

d) Classification of welded joints

1) Weld joint design.
2) Weld joint category.
19.2 Weld joint design. welding procedure and
inspection of welds given in Annex B.
20 LIMITING

24 BRIDGE TRUCKS
The cranes having bogie trucks, the wheel base is
measured from centre line to centre line of the two
wheels which are far apart on the runways.

DEFLECTiON

The deflection of members or the structure as a

whole ( without taking into consideration the impact
factor ) should not be such as would impair the strength
or efficiency of the structure or lead to damage to
tlnishing.

Cranes with fixed bogie trucks require a flexible end

connection to obtain the equalizing effec~. Cranes
with equalizing bogie trucks require a rigid end
connection.

The maximum vertical deflection of the girder

produced by the dead load. the weight of the trolley
and the rated load shall not exceed 1/750 of the span
of the crane ( if the span of the cranes is more than
12 m), and 1/600 of the span ( if the span of the crane
is less than 12 m ).

24.1 Ratio of Crane Span to End C-arriage Wheel

Base

Following condition to be considered:

21 CAMBERS
Girders
shall be cambered
to an amount
approximately equal to the dead load deflection
plus one-half the live load deflection.
22 DIAPHRAGMS

AND VERTICAL STIFFNESS

The spacing of vertical

exceed

web stiffness

shall not

24.2

where
v

= shear stress in web plate, in kg/cm2.

If the spacing exceeds 1.75 m or depth of the web (h),

whichever is greater, web plate shall be reinforced with
full depth diaphragms at major load points.
22.1 Diaphragms
The distance between the adjacent diaphragm ( longer/
short ) shall not exceed

For cranes over21 m span and up to 24.5 m,

not less than 3.5 m of the span; and

c)

For cranes over 24.5 m span not less than

one-seventh of the span.
Bridge and Gantry Rails

25 WELDED

BOX GIRDERS

Welded box girders ( Fig. 24 ) shall be fabricated of

structural steel with continuous ( full penetration butt
and fillet welds ) longitudinal welds running the full
length of the girders. All welds shall be designed for
maximum shear and bending.

7600 S
w
where
S

b)

depends upon the wheel load ( maximum) and wheel

diameter. The rails shall be selected based on the IRS
( Indian Rail Steel ), CR ( Crane Rail ) or equivalent
rails for both for bridge rails as well as gantry rails.
The bridge rail shall be attached to the bridge girders
by means of alternately spaced rail clips that are
welded to the girder or attached with welded studs.
The welding of clips are preferred. It is recommended
that the bridge rails shall be supported on wear plate
welded on top of the top cover plate and positioned
above each girder diaphragm, so that the bending
stress produced in the rail by trolley wheel load is
not transmitted into the top cover plate.

6
= thickness of one web plate, in mm; and

For cranes up to and including 20 m span

not less than one-sixth of the span;

The selection of bridge rails as well as gantry rails

800 [

a)

= section modules of rail, in mm3;and

42

TROLLEY WHEEL LOAD

[
.

n----n
II
II

II
II

di=d=l

.
,
,
l!!dl

Ii
++

TROLLEY STOPS :-A SOLID STOP SHALL BE WELDED TO

GIRDERS AS SHOWN IN THE FIGURE

FIG.24 GIRDERARRANGEMENT

43

II
II

II
11

1S 807:2006
25.1 Girder-Proportion

At reduced stress level, the maximum value M for

hlt maybe as follows:

The box girder shall be designed for suitable size taking

into account of the following proportions:
a)

//h shall not exceed 25,

a)

Maximum h/t for I 145 kg/cm2

compression stress

188

b)

Maximum h/tfor 845 kg/cm2

compression stress

220

c)

Maximum h/t for 700 kg/cm2

compression stress

240

b) I/b shall not exceed 60, and

c)

bfc shall not exceed 60.

where
[=

span of the crane. in mm;

h=

depth of the girder. in mm;

b=

width of the girder. in mm; and

c=

thickness of the top cover plates, in mm.

Height Thickness

25.2

25.3 Compression

( h/t ) Ratio of

Web

a)

Compression stress is less than I 235 kg/cmz

when the ratio of b/c ( see Table 30 ), is equal
to or less than 38.

b)

When the ratio of blc exceeds 38 ( see

Table 30 ), the allowable compression
stress shall be computed from the following
formula:

Plate
C(k+l)

1235

Stress

shall not exceed M

&
~=1235

where

38

J( )
blc

= thickness of top cover plates, in mm;

~c

= maximum compressive stress, in kgf or mm2;

= f~f,; and

= thickness of web. in mm
r

The coefficients C and M

For Longitudinal

Stiffness

Table 30 Values of Compression

None

81

188

One

162

376

Two

243

564

44

Shear Stress

S1 No.

b/c

f, ( kgf/cm2 )

i)

40

1 145

ii)

44

99()

iii)

48

x70

iv)

52

770

v)

56

690

vi)

60

625

IS 807:2006

ANNEX
(

9.4.2 and 9.4.6)

Clauses

CLASSIFICATION

A-1 DESIGN

OF BOLTED

A-1.l Coefficient

OF JOINTS

the torque to be applied to the bolt and given by the

formula:

JOINTS

of Friction ( p )
p,=l.lOc.

The coefficient of friction used for calculation of the

force transmitted by friction depends upon the joined
material and upon the preparation of the surfaces.

where
P, = torque to be applied, in m-kg;
d=
nominal diameter of the bolt, in mm;
F=
nominal tension to be induced in the bolt,

A minimum preparation before joining shall consist

of removing every trace of dust, rust, oil and paint
by energetic brushing with a clean metallic brush. Oil
stains must be removed by tlame cleaning orby the
application of suitable chemical products ( carbon tetrachloride for instance ).

in tonnes; and
c=

A more careful preparation may increase the coefficient

of friction. This could be sand blasting, shot blasting
or oxy-acetylene flame cleaning done not more than
five hours before tightening, brushing must be done
just prior to jointing.

SI
No.

Joined
Material

When determining the stress in the bolt, the tensile

area shall be calculated by taking the arithmetic
mean of the core ( minor ) diameter and the effective
thread diameter. These values are given in Table 32.

of Friction(p)

Normally Prepared
Surfaces
( DegreasesI and
Brushing )

A-1.4 Quality of the Bolts

-Bolts used for this type of joint have a high elastic
limit:

Special Prepared
Surfaces ( Flame
Cleaned Shot or
Sand Blasted )

(1)

(2)

(3)

(4)

i)

St 37

0.30

0.50

ii)

St 42

0.30

0.50

Iii)

St 52

0,30

0.55

coefficient depending on the thread

form, the friction co~fficient on the
threads and between the nut and the
washer, c = 0.18 ( metric bolts ).

A-1.3 Value of the-Tensile Stress Area of the Bolts

The coefficient of friction are given in Table31.

Table 31 Values of Coefficient

d.F

The ultimate tensile strength ORmust be greater than

the values given in Table 33.
where
E =

elastic limit.

The diameter of holes shall not exceed by more than

2 mm of bolt diameter.

It is necessary to insert two washers, one under the

bolt head, and the other above the nut. These washers
shall have a 45 bevel, at least on the internal rim and
turned towards the bolt head or the nut. They shall
be heat treated so that their hardness shall be at least
equal to that of metal constituting the bolt.

Effective friction surface shall be considered as:

A.1.2 Bolts Tightening

a)

m=l,

b)

m=2, and

c)

m=3

where m is the friction surface.

Value of the tension induced in the bolt shall be
pre-determined by calculation. The tension, resulting
from tightening, can be measured by calculation of

Property values of bolts are given in Table 34.

Schematic diagram is shown in Fig. 25.

Table 32 Values of Tensile Stress

( Clause A-1.3)
~ Nominal Diameter. in mm
L
i Tensile Stress Area, in inn):
[

8
36.6

10
58

14

12
84.3

115

45

16

18

20

22

24

157

192

245

303

353

.30

27
459
J

501

Table 33 Tensile Strength of Bolts

( Clause A- 1.4 )

o~ ( 0.2/. ), kg/mm2
(2)

SI No.
(1)

a~, kgf/mm2
(3)

i)

<70

~ 1.15tJE

ii)

70 to 85

> 1.12f3E

iii)

>85

> I. IOCTE

1 I

111

I I
ili
#1 1

1:1

Ill
Ill

I
I

I
I

FIG.25 EFFECTIVEFRICTIONSURFACE

I
1

Table 34 Property

Values

of Bolts

( Clause A-1.4)

SI

Bolt
Dia

No.

mm

Tensile
Stress
Area

Clamping
Force

Applied
Torque

A
+

p=o.3

kg.m

mmz

Specially

Normally Prepared
Surfaces
Steels A-37, A-42, A-52

Prepared

Surfaces
Steels A-52 p = 0.55

Steels A-37. A-42 p = 0.50

Case I

Case 11

Case 111

Case I

Case 11

Case 111

Case 1

Case 11

Case 111

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(lo)

(11)

(12)

(13)

(14)

i)

10

58

4.17

8.27

0.83

0.94

1.14

1.39

1.j7

1.89

[.52

1.72

2.08

ii)

12

84.3

6.06

14.4

1.21

1.36

1.55

2.02

2.28

2.75

2.22

2.50

3.03

iii)

14

115

8.27

22.9

1,55

1.86

2.25

2.75

3.10

3.76

3.02

3.42

4.14

iv)

16

157

11.30

35.8

2.26

2,55

3.08

3.79

4.25

5.14

4.15

4.68

j.65

v)

18

192

13.80

49.2

2.76

3.10

3.76

4.60

5.18

6.27

5.06

5.70

6.90

vi)

20

245

17.60

69.7

3.52

3.97

4.80

5.85

6.61

8.00

6.45

7.27

8.80

vii)

22

303

21.80

95.0

4.36

4.93

5.97

7.25

8.20

9.90

8,00

9.02

10.90

viii)

24

353

25.40

120

5.08

5.71

6.94

8.45

9.55

11.55

9.31

10.50

12.70

ix)

27

459

33.00

176

6.60

7.42

9.00

11.00

12.40

15.00

12.10

13.60

16,50

NOTE For bolt with elastic limit of CE, the values of the forces and of the torque indicated in this table are to be multiplied by the ratio oE/90. Where no special measures are taken
toavoid stripping of thethreads [O, =0.76E)
these values aretobe divided bY 1.14.

1S 807:2006

ANNEX B
( clause
WELD JOINT

DESIGN,

B-1 ALLOWABLE

19.2)

WELDING PROCEDURES
AND INSPECTION
INDUSTRIAL AND MILL CRANES

Base metal, and

b)

Weld metal.

FOR

is one that has been welded from both

sides or from one side, in which the weld
metal completely fill the groove and is fused
to the base metal throughout its total
thickness.

STRESSES

a)

OF WELDING

B-2 BASE METAL

B-5.3 Intermittent Groove Welds

The allowable tensile or compressive stress in the

base metal shall be 50 percent of the yield strength
and the allowable shear stress in the base metal shall
be 40 percent of the yield strength for members not
controlled by buckling.

Intermittent groove welds are prohibited, except in

secondary members.

B-3 WELD METAL

Types of fillet weld shown in Fig. 29.

B-5.4 Fillet Welds

Allowable stresses in the weld metal shall conform

m Table 35.
B-4

a)

The minimum
given in Table
size as shown
welds are used

b)

The maximum fillet weldsizepermitted along

the edges of members should be:

FATIGUE

The maximum stress in welded joints to repeated stress

fluctuation or reversals shall not exceed
a)

the basic allowable stress, or

b)

the allowable fatigue stress and the stress

range does not exceed the value given in Table
36, Table 37 and Fig. 26to 28.

1) Thickness of the base metal when the

metal is less than 6 mm thick.
2)

B-5 WELD JOINT DESIGN

Following

points
General

requirements,

b)

Groove

welds,

c)

Intermittent

d)

Fillet welds,

ej

Intermittent

f)

Staggered

g)

Plug and.slot welds.

groove

weld,

The effective weld area shallbe the effective

weld length multiplied by the effective
throat. The shear stress in a fillet weld
shall be considered as applied to this
effective area regardless of the direction of
applied load.

d)

Fillet welds shall not be used in skewed

T-joints that have an included angle of less
than 600.

e)

The edges of the abutting member shall be

beveled when necessary, to limit the root
opening to 3 mm maximum.

fi!let welds,
intermittent

fillet welds, and

B-5. I Genera} Requirements

B-5.5 Intermittent

Complete information regarding location type, size

and extent of all welds and welded joints shall be
shown on the drawing.

b)

The effective area of a full penetration

weld shall be the effective weld length
multiplied by the effective throat. The
dimensions for different metal thickness
are given in Table 37.
A complete-joint

penetration groove weld

48

Fillet Welds

a)

Length of any segment of intermittent

fillet weld shall not be less than 4 times the
weld size, with a minimum of 51 mm; at least
25 percent of the joint shall be welded.
Maximum spacing permitted between welds
shall be 300 mm.

b)

Intermittent fillet welds may be used to carry

calculated loads.

c)

Intermittent fillet -welds shall not be less than

51 mm in length at each end of the joint.

B-5.2 Groove Welds

a)

Thickness of the base metal 1.6 mm when

the metal is more than 6 mm thick.

c)

to be considered:

a)

fillet weld size -shallabe as

38 except where fillet weld
in Fig. 29 and where fillet
to reinforce groove welds.

IS 807:2006
Table 35 Allowable

Stresses in Weld

( Clause B-3)
II No.

Type of Weld

Allowable

Stress Weld

Stress

.
,(1)

(2)
i)

Complete
Penetration

(4)

(3)
Joint

Partial Joint

Matching weld metal shall be used

to

Same as base metal

Weld metal with a strength level

equal to or one classification less
than matching weld metal may be
used

Tension or compression
parallel to the axis of the
weld

Same as base metal

Weld metal with a strength level

equal to or less than matching weld
metal may be used

Shear on the effective area

0.27
nominal
tensile
strength of weld metal,
except
shear stress
on
base
metal
shall
not
exceed 0.36 yield strength
of base metal

Joint
not
designed to
bear

C.45
nominal
tensile
strength of weld metal,
except
stress
on base
meta[ sha!l not exceed
0.55 percent of base metal

to

Compression
normal
to
effective area

.loint designed to bear

Same as base metal

Tensile
parallel
weld

Same as base metal

or compression
to the axis of the

0.27
nominal
tensile
strength of weld metal,
except shear stress on
base
metal
shall
not
exceed 0.36 yield strength
of base metal

Partial Joint

Tension
nominal
effective area

iv)

Fillet Welds

Shear on effective area

0.27
nominal
tensile
strength of weld metal,
except shear stress on
base
metal
shall
not
exceed 0.36 yield strength
of base metal

Tension
parallel
weld

Same as base metal

Slot

Weld metal with a strength level

equal to or less than matching weld
metal may be used

..
to axis of

iii)

Plug and
Welds

(5)

Same as base metal

Shear parallel
weld

v)

Weld Strength
Level

the

Tension normal
effective area

normal
Compression
the effective area

ii)

Required

to

compression
to the axis of

Shear parallel to effective

area

nominal
0.27
tensile
strength of weld metal,
except tensile strength on
base
metal
shall
not
exceed 0.55 yield strength
of base metal

0.27
nominal
tensil e Weld metal with a strength level
strength of weld metal, equal to or less than matching weld
shear
stress
on metal metal may be used
shall
not exceed
0.3 6
yield
strength
of bas e
metal

49

IS 807:2006
Table 36 Fatigue Stress Provisions

Tension or Reversal

Stresses

( Clause B-4)
S1 No.

(1)

General

ii)

iii)

iv)

Base metal with rolled or cleaned surfaces.

with tine smoothness

Built-up Members

Base metal and weld met-al in members without attachment,

built-up plates or shapes connected by continuous complete or
partial joint penetration groove welds or by continuous fiIlet
welds parallel to the direction of applied stress

Calculated flexural stress at toe of transverse stiffener welds on

girder web or flanges

Base metal at end or partial length welded cover mates having

square or tapered endswith or without welds across the ends

Base metal and weld metal at complete joint penetration groove

welded splices of rolled and welded sections having similar
profiles when welds are ground and weld soundness established
by non destructive testing

Base metal and weld metal in or adjacent to complete joint

penetration groove welded splices at transitions in width or
thickness with welds ground to provide slopes no steeper than 1
to 2 % and weld soundness established by non-destructive testing

Groove Welds

Groove Welded

Oxygen cut edges

vi)

vii)

viii)

ix)
x)

Plain Material

Base metai at details of any length attached by groove welds

subjected to transverse or longitudinal loading or both when
weld soundness is transverse to the direction of stress is
established by non-destructive testing and the detail embodies
a transition radius, R with weld termination ground when

a) R>610mm
b)610mm>R>
152mm
c)152mm>R>51mm
d)51mm~R>0
v)

Category
(4)

(3)

(2)
O

Stress

Situation

Condition

Longitudinal
loading materials
having equal or
unequal thickness
welds
sloped
web
ground
connedion
BB
cc
DD
EE
c

Groove Welds

Base metal, and weld metal in or adjacent complete joint

penetration groove welded splices either not requiring transition
or when metal required with transition having slope not greater
is not
than I to 2 % and when in either case. reinforcement
removed and weld soundness is established by non-destructive
testing

Groove
or Fillet
Welded Connection

Base metal at details attached by groove or fillet welds subject

to longitudinal loading where the details embodied a transition
radius R, less than 51 mm and when the detail length L, parallel
to the line of stress is
a) <51 mm
b)51mm<L<102mm
c) L > 102 mm

c
D
E

Base metal at details attached by fillet welds parallel to the

direction of stress regardless of length when the details embodies
at transition radius R, 5 I mm or greater and with weld termination
ground
a) when R >610 mm
b)when610mm>R>
152mm
c)when152mm>R>51mm

B
c
D

Shear stress on throat of fillet welds

Base metal at intermittent welds attaching transverse stiffeners

and stud type shear connectors

Fillet
Welded
Connections

Fillet Welds

Base metal at intermittent fillet welds attaching longitudinal stiffeners

Stud Welds

Shear stress on nominal shear area of stud type shear connectors

Plug and Slot Welds

Base metal adjacent to or connected by plug or slot welds

50

..._

________

1S-807 :.2006

2000

200

1507)

150

1000

100

500

50

-1

500

-50

1000

-1oo

1500

-150

2000

-200

FIG. .26 ALLOWABLEFATIGUESTRESS FOR CRANES ( M 1 and M2 )

IS 807:2006

2000

200

1500

150

1000

100

50

-1=

-500

I WI

I
I -50

-1000

-1oo

-1500

-150

-2000

-200

I I
FIG.

1 I

27 ALLOWABLE
FATIGUE
STRESSFOR CRANES ( M3, M4 and M5 )

52

IS 807:2006

2000

200

1500

150

1000

100

500

50

-1

500

-50

,.
1000

-1oo

1500

-150

2000

-200

FIG. 28 ALLOWABLEFATIGUESTRESS FOR CRANES ( M6, M7 and M8 )

53

1S 807:2006

(- ?., ,
I
ROOT OF
WELD

29A

-WELDSIZE
--

WELD SIZE

--Jd

-;

; ~

i
ROOT CF
WELD

Weld deposit

29B

ikN\

ROOT OF
WELD
EFFECTIVE
THROGHOUT
REINFORCEMENT /

29C

Actual throat
reinforcement

of a bevel group
with a fillet weld

weld

FIG.29 FILLET WELD

54

Weld deposit by a deep

penetrating process

IS 807:2006

of the hole or slot m the plane of the faying

surface.

Table 37 Minimum Effective Throat for Partial

Joint Penetration Groove Welds

c)

( Clauses B-4 and B-5.2)

Minimum Effective
Throat
mm

SI
No.

Metal Thickness of
Thicker Part Joimt
mm

(1)

(2)

(3)

The minimum diameter of the hole for a plug

weld shall not be less than the thickness of
the part containing it, plus 8 mm. The maximum
diameter of the hole shall not be greater than
2 M times the thickness of the weld.

B-6 WELD JOINT -CATEGORIES

ii)

6to

iii)

13to19

Different types of weld joint categories are given in

Table 39.

iv)

19 to 38

B-6.1 Category I

v)

38.1 to 57.1

10

vi)

57,1 to 152

13

vii)

152

16

!3

Table 38 Minimum

Welded butt joints with complete joint penetration.

The root of the first weld is chipped, gouged or ground
to sound metal before making the second weld and
the weld faces are ground or machined flush with the
direction of metal removal parallel to the principal stress.
Finished joints shall be non-destructively tested.

Fillet Weld Size

( Clause B-5.4)

B-6.2 Category 11

~
in mm

(1)

(2)

Metal Arc

Process for Single

in mm

Horizontal
Position
in mm

(3)

(4)

Welded butt or T-joints with complete joint penetration.

The root of the first weld is chipped, gouged or ground
to sound metal before making the second weld.
Finished joints shall be non-destructively tested.
B-6.3 Category 111

Complete joint penetration butt, T-joints and corner

joint welded from both sides or from one side using a
backing strip that is not removed after welding.

EM!_U-l

B-6.4 Category IV

B-5.6 Staggered

a)

b)

Intermittent

Complete penetration butt, T-joints and corner joints,

partial penetration butt, T-joints and comer joint welded
on both sides, fillet welded lap, T-joints and corner
joints welded on both sides.

Fillet Welds

When staggered intermittent fillet welds are

used, the clean spacing shall be considered
the distance between two consecutive welds
even though they are on opposite sides of
the pIate.

B-6.5 -Category V

Partial joint penetration butt, T-joints and corner joints

and fillet, plug or slot welded up, T-joints and corner
joints welded on one side only.

When the total aggregate length of the

staggered intermittent fillet weld is 90 percent
or more of the joint length, any odd number
of weld segments may be used, provided:

B-6.6 Category VI

Joints with no special welded groove preparation such

as butt, T-joints corner, lap or edge joints, plug welds
in joints, welds of secondary importance in strength
and structural welded joints of secondary importance,

1) Welds are placed at each end of the joint

on one side, and
2)

Clear spacing does not exceed 152 mm.

B-7 WELDING-PROCESS

B-5.7 Plug and Slot Welds

a)

b)

a)

Plug or slot welds may be used to transmit

shear loading in a lap joint to prevent buckling
or separation of lapped parts, or to join
component parts of built up members except
with quenched and tempered steel.

b)
c)

Square-groove weld butt joint (B), comer joint

(Q;
Square - groove weld T-joint (7),corner joint
(q;
Single V-groove weld butt joint (B), corner
joint (C);

The effective area shall be the nominal area

d)
55

Double

V-groove weld butt joint (B);

Table 39 Classification
( Clause
Category

Configuratlon

of Welded Joinls

B-6)
of Welded Joints

.
r

I
I

11
&

EL

III

,-

56

IS 807:2006

Table 39 Continued

NOTES
1 Details of weld joint (groove design, root opening, etc) are those required for the welding process to be used.
2 The diameters of plug welds or the width of slot welds is indicated by dimension d.

e)

Single-bevel groove weld butt joint (B);

Single-bevel groove weld T-joint (7), comer

joint (C);

joint (C);

g) Double -bevel groove weld butt joint T-joint,

j)

Single J-groove weld butt joint (B), T-joint

(7),corner joint (C); and

k)

Double J-groove weld T-joint(7), corner joint

(C), butt joint (B).

comer joint (C);

h)

Single U-groove welds butt joint (B), corner

Some

57

of various joints are given in Table 40.

&
IS ?307:2006
Table 40 Square Grooved Butt Joints (B)
( Clause B-7)

MILD STEEL

Welding

Square-groove
weld
Butt joint (f?)
Process

Base Metal
Thickness
( U = Unlimited

Corner joint
(f)
Permitted
Welding
Positions

Groove Preparation
Tolerances in mm
)

Gas
Shielding
for
FCAW

T,

Tz

As tit Up

mm

Root
opening

As detailed

mm
$ub-merged Metal Arc
Welding ( SMAW )

6, Max

R=TI

+2, 0

+6, 2

All

Gas Metal Arc Welding

GMAW )

6, Max

R=T1

+2, (J

+6, 2

All

Flux Cored Arc Welding

: FCAW )

10, Max

R=TI

+2, (J

+6, 2

All

Not
required

Square Groove Butt Joint

Square-groove weld

Butt joint (B)

II

b&

MILD STEEL
Welding

Process

T]

Tz

mm

mm

Permitted
Welding
Positions

Groove Preparation

Base Metal
Thickness
( U = Unlimited )

Tolerances in mm

Root
opening

As detailed

As tit

Gas
Shielding
for
FCAW

Up

Sub-merged Metal Arc Welding

6, Max

+2,0

+2, -3,5

All

Gas Metal Arc Welding

Flux Cored Arc Welding

10, Max

R = 0-3.5

+2-0

+2, -3,5

All

Not
required

12.5, Max

R=O

+0

+2, -3,5

Fiat

Sub-merged Arc Welding (SAW)

R= T112

58

1S 807:2006
Square-Groove

T-Joint (7) Corner Joint (C)

Square-groove weld

T- joint (T)

Corner joint (C)

MILD STEEL
Welding

Process

Groove Preparation

Base Metal
Thickness
( U = Unlimited )

Permitted
Welding
Positions

Tolerances in mm

TI

Tz

As fit Up

mm

Root
opening

As detailed

mm

&tOX

Sub-merged Metal Arc Welding

6,

+2,0

+2, .3,5

All

IO,

Max

u
u

R= T,12

Gas Metal Arc Welding

Flux Cored Arc Welding

R= Oto 3.5

+2,0

+2, -3,5

All

Sub-merged Arc Welding

10,

Max

R=O

*O

+2, ()

Flat

Single V-Groove

Gas
Shielding
for
FCAW

Not
required

Butt Joint (B)

Tolerances

Single V-groove weld

Butt joint (B)

As detailed

AA

MILD STEEL

df%\.! J

As fit

!Q
-d&Welding

Process

Sub-merged Metal Arc Welding

Gas Metal Arc Welding

Base Metal
Thickness
( U=Unlimited

Groove Preparation
)

T,, mm

T2, mm

Root Opening

Flux Cored Arc Welding

R=6

Groove Angie
~ = 45o

R=1O

~ = 300

R= 12.5

~ = 200

R=5

~ = 300

R=5

~ = 300

R=6

~ = 300

Sub-merged Arc We[ding

2, Max

R=6

~ = 300

Sub-merged Arc Welding

R=8

(-J= 200

59

All

UP

IS 807:2006
Single V-Groove Corner Joint ( B )
$iogle V-groove weld
Corner joint (C)

MILD STEEL
I

Welding

Process

Base Metal
Thickaess
( U= Unlimited

;ub-merged Metal Arc Welding

Groove Preparation
)

Permitted
Welding
Positions

Gas
Shielding
for FCAW

T,, mm

T,, mm

Root Opening

R=6

a = 45

All

R=1O

a = 3130

F, OH

R= 12.5

a = 20

F, OH

R=5

a= 30

F, V, OH

las Metal Arc Welding

17-

Groove Angle

Required
Not required

Iux Cored Arc-Welding

Not recruired
;ub-merged Arc We!ding

12.5,

lub-merged Arc Welding

&fL7X

Double V-Groove Butt Joint (B)

Tolerances

Double V-groove weld

As detailed

Butt ioint (B)

MILD STEEL
fa

Note

.,

Welding Process

Base Metal Thickness

(f/= Unlimited)
T,, mm

I T,, mm

Sub-merged

U preferably

Metal Arc

16 or thicker

Weldirw

svacer = 3 x R

-~

Sub-merged Arc
Welding

U spacer = 6 x

Groove Preparation
Root
Opening

R=16

Root Face

f=

Oto6

f=io
a = +19 0

1.5. o

6.-0

+10, 5
+1.5, o

Permitted

Gas

Groove
Angle

a = 20

~Ip

= +0

lJ@

As fii

R=O

F,(3H

F. OH

Fl

IS 807:2006
Single-Bevel

Groove Butt Joint (B)

lingle-bevel groove weld

Tolerances

Butt joint (B)

R=+l.5,0
~ = +100 -00
IY

-.. ----.

+6, -1.5
+10, -5

(x

~,\M
~ n_p..

<.
MILD STEEL

Welding

9
Process

Base Metal
Thickness

T1
. .

Groove Preparation

I
Permitted
Welding

Gas
Shielding
for FCAW

7[, mm

Tz, mm

Root Opening

Groove Angle

R=6

~=450

All

Welding

R=IO

~ = 30.

F,OH

Gas Metal Arc Welding

R=5

a = 30.

All

Required

R=6

@= 45.

All

Requirwd

R=1O

~ = 30.

Flat

Not required

Sub-merged Metal Arc

Flux Cored Arc Welding

ositions

,,,

61

Single-Bevel

Groove

T-Joint

(T) and Corner

Joint (C)

( Clause B-7)

Single-bevel groove weld

Tolerances

..~x
. . .. .
~ ,,
#,!
v--t. -._ --.._ [
Note J

-..
f
-. .

T-joint (T)
Corner Joint (C)

T2
L![..

tilLD STEEL
Welding

Process

Sub-merged Metal Arc Welding

Base Metal
Thickness

Gas
Shielding
for FCAW

T,

Root
Opening
mm

R=6

cl=45

R=1O

~=loo

R=5

~=300

All

Required

R=1O

~=300

Flat

Not required

R=6

All

R=lfl

Ct=45
~= 30.

Not required

R=6

~=450

Arc Welding

Sub-merged Arc Welding

Groove
Angle

Permitted
Welding
Positions

T,

Gas Metal Arc Welding Flux Cored

Groove Preparation

All
* F, OH

Flat

* F = Flat. OH = Overhead
Double-Bevel

Groove Butt Joint (B)

B-7)

( Clause
louble-bevel

,.

TI

groove weld

Butt joint (B)

ma

c1
;

Note
*
Welding

Process

Base Metal
Thickness
T,

T,

Sub-merged Metal Arc

U Prefer-

Welding

ably 16 or
thicker

Gas Metal Arc Welding

Flux Cored Arc Welding

ilbiy 16
or thicker

f
Groove Preparation

Tolerances
Root
Opening
As fit LSp
Root Face As detailed
Groove
Angle

Permitted
Welding
Positions

Gas Shielding
for FCAW

R= Oto3

-o
-o

1.5,-3
not limited

p=oto
15

rx+p,
+ 1o,0

+1o,0

R= Oto3

-o
1.5, -o

1.5,
1.5,

j-=oto3
~= 450

( Prefer-

1.5,

f = o to.3
~=450

+10, 5

p= f).

+0

62

All

All

Not required

rx+p,
1,5. -0
Not limited

+10,5

IS 807:2006
Double-Bevel

Groove T-Joint (2) and Corner Joint (C)

( Clause B-7)

)ouble-bevel groove weld

, /-

,.
~1

J+.,

Note V
-..

T-joint (T)
Corner joint (C)

...

}J
~4

i?

Note J

Welding

T,

Sub-merged Metal
Arc Welding

Gas Metal Arc Welding

Flux Cored Arc Welding
Sub-merged Arc Welding

Gas Shielding
for FCAW

Base Metal
Thickness

Process

T,

Opening
Root Face As detailed
Groove
Angle

1T
u

R= Oto3
f=oto3
~=450

Preferably
16 or
thicker

As tit up

lJ

Preferably
16 or
thicker

R= Oto3

All

1.5, -3
not limited
+10, 5

1.5, o
1.5, -o
+10. .00

+(j, -(l

*O

f= 5, Max +0, -5

*1.5

~ = fjoo

+10, 5

+10, 0

All

Not required

All

Not required
.,, ,

Single U-Groove Butt Joint (B) and Corner Joint (C)

( Clause B-7)
Single U-groove weld

Tolerances

Butt joint (B)

As detailed

As fit

Corner joint (C)

R = +1.5, O

+6, 1 .5

a = +10, 0

+10, 5

ly~~~l

-:qg{:,
R.

-.,
h

Welding

Process

Base Metal
Tlrickness
( U=Unlimited
T,

T,

Sub-merged Metal Arc

Flux Cored Arc Welding

u
u

f =*1.5

Not limited

R = +6, -0

+1.5

Permitted
Welding
Positions

Gas Shielding
for FCAW

Root
Opening

Root
Face

Groove
Angle

Groove
Radius

R= Oto3

f= 3

~ = 450

~=(j

All

j=

~ = 200

~=6

* F, OH

f= 3
f= 3

~ = 450
a = 20

~=6
~=6

All

F,OH

R= Oto3

f= 3

a = 20

~=6

All

Not required

R= Oto3

f= 3

u = 200

~=6

All

Not required

R= Oto3

u
u

,{..

R= Oto3
Gas Metal Arc Welding

,.

Groove Preparation

R= Oto3

Welding

NOTE J

Up

* F = Flat, OH = Overhead

63

.
.

IS 807:2006
Single J-Groove Butt Joint (B)
(Clause B-7 )
Tolerances

jingle J-groove weld

Butt joint (B)

~ = +100, 00

I +10,-50

f = 1.5,0

I Not limited

r = +fj,

Welding

Process

Base Metal
Thickness
( U=Unlimited

()

*1.5

Permitted
Welding
Positions

Groove Preparation
)

Gas Shielding
for FCAW

Sub-merged Metal Arc

Welding
Gas Metal Arc Welding
Flux Cored Arc Welding

Single J-Groove T-joint (T) and Corner Joint (C)

( Clause B-7)
Tolerar

;ingle J-groove weld

.
-. . ;~--+
if
~fp1!?
.,.

T-joint (T)
Corner joint (C)

ru
-\

-F

..... Nolo V

*..I

I ___
---

es

As detailed

As fit

R = +1.5, -O

+1.5, -3

a = +1 O, -0

+10, -5

Up

f = 1.5, -0

Not limited

r=

*1.5

+6,-O

Ldk
Welding

Process

Base Metal

Permitted
Welding
Positions

Groove Preparation

Thickness
( U=Unlimited )

Sub-merged Metal Arc

Welding
Gas Metal Arc Welding
Flux Cored Arc Welding

-=-bu

All
R= Oto3

f= 3

a = 30

r=10

* F, OH

R= Oto3

f= 3

a = 30

r=10

All

* F = Flat, OH = Overhead

64

Gas Shielding
for FCAW

Not required

. . ..

..

IS 807:2006

Double J-Groove Butt Joint (B)

( Clause B-7)

\[I/

Double J-groove weld

Butt joint (B)

.K-.

<-;>

,,1,
... p

Toleral
As detailed

As fit UP

R = +1.5, -O

+1.5, -3

a = +10, -00

+10, 5

Not limited

= 1.5, -o

r = +6. -O

*1.5

-Welding Process

Sub-merged Metal Arc

Welding

Gas-Metal Arc Welding

Flux Cored Arc Welding

Base Metal
Thickness
( U= Unlimited

..

T,

T,

Root
Opening

Root
Face

u
Preferably
160r
thicker

R= Oto3

j-= 3

R= Oto3

f= 3

11

Permitted
Welding
Positiona

Groove Preparation

Preferably
16 or
thicker

65

Groove
Angle

a = 30

Gas Shielding
for FCAW

troove
Radius
r=10

All

r=10

All

Not required

IS 807:2006
Double J-Groove T-Joint (.2)and Corner Joint (C)
( Clause B-7)
Tolera

Double J-groove weld

es

T-joint (T)

As detailed

As tit Up

Corner joint (C)

R = +1,5, -O

+1.5, -3

..

.
.+
R~
Note

r:%

d
l--

Process

Sub-merged Metal Arc

Welding

Gas Metal Arc Welding

Flux Cored Arc Welding

T,

Root
Opening

Root
Face

Groove
Angle

Groove
Radius

R= Oto3

f= 3

~ = 45

r=10

R= Oto3

j=

a = 30

r=10

R= Oto3

f= 3

~ = 3rJo

r=10

u
Preferably
160r
thicker

+1.5

Permitted
Welding
Positions

w
T,

Not limited

r = +6, o

Nole, J

Groove Preparation

+10, -5

f = 1.5, -0

..

..

Welding

~ = +100 -00

Gas Shielding
for FCAW

All

Not required

Preferably
16 or
thicker
I

F = Flat, OH = overhead.

applied heat while welding progresses.

B-7.1 Tolerances for Groove Weld Joint Preparations

for Arc Welding

c)

A programme for welding sequence and

distortion control shall be provided where
shrinkage stresses or distortions are Iikely
to affect the adequacy of the structure.

d)

Joints that are expected to produce large

shrinkage should &ually be welded with as
little restraint as possible before other joints
that are expected to cause less shrinkage are
welded.

Some joint preparations

are shown in Fig. 30 and
tolerances given in Table41.
B-8 CONT-ROL OF DISTORTION
SHRINKAGE STRESSES
a)

b)

AND

Procedure
and welding sequence for
assembling and joining parts of a structure
or of built-up members or for welding
reinforced parts to members shall be designed
to minimize distortion and shrinkage.

B9 NOMINAL NUMBER OF MM.DING CYCLES

For different type of stress category, the loading cycles
are given in Table 42.

All welds, in so far as practicable, shall be

deposited in a sequence that will balance the

66

IS 807:2006

24

24
1

REMOVE

AFTER

2;

I
24
1
Transition

by slopingweldsurface chamfering
1

CHAMFER
BEFORE

24

CHAMFER
BEFORE
WELDING

24

24

BEFORE
WELDING

OFFSET ALIGNMENT

CENTRE LINE ALIGNMENT

FIG.

30 TRANSITIONBY CHAMFERINGTHICKNESSPART

Table 41 Tolerances

for Groove Weld Joint Preparation

for Arc Welding

( Clause B-7.1)
Root not Gouged
mm

Weld Preparations

S1 No.

(2)

(1)

Root Gouged

mm

(3)

(4)

i)

Root face

*1.5

Not limited

ii)

Root opening with other than steel backing

+1.5

+1.5

iii)

Root opening with steel backing

+6

Not applicable

Groove angle

+ 5

iv)

67

+ 10
-5

IS 807:2006
Table 42 Allowable

Range of Stress (MPa)

( Clause B-9)

SI No.
(1)

Stress Category

10000 to 20000

(2)

i)

(3)
276

221

166

166

ii)

228

172

117

103

96

83

iii)

100000 to .500.000 500000 to 2000000

(4)
(5)

Over 2000000
(6)

193

145

166

117

69

62

v)

117

83

48

41

vi)

117

96

76

62

iv)

...

_ ..-.

IS 807:2006

ANNEX

( Foreword)
COMMIITEE COMPOSITION

Cranes, Lifting Chains and Its Related Equipment Sectional Committee, ME 14

Representative(s)

Organization

Bharat Heavy Electrical

SHRIK. MANICKAM
(Chairman)

Ltd, Tiruchirappalli

Armsel MHE Pvt Ltd, Bangalore

SHRIA. C. HERI
SH~IN. VASUOEVA
( A/lernate )

Anupam Ltd, Anand

SHRIK. K. PATHAK

Bharat Heavy Electrical

SHRI GIRISH SHRIVASTAVA

Ltd, Hyderabad

SHRI H. BHARANI (

A1/ernate )

SHRIR. L. GUPTA
SHRID. K. GAUTAM

Central Building Research Institute, Roorkee

Alternate )

Directorate General Factory Advice Service and Labour

Institute. Mumbai

SHRID. K. DAS
SHRI K. C. S. RAO ( A1/ernute )

Furnance and Foundry Equipment Co, Mumbai

SHRI SHYAM M. GURNANI

Hercules Hoists Ltd, Mumbai

SHRI P. B. KUCHERIA

Indian Chain Pvt Ltd, Kolkata

SHRI P. CHITLANGIA
SHR~ LALITMOHA~ (

Indian Link Chain Manufacturers

SHRIP. K.

Ltd, Mumbai

.lessop and Co Ltd. Kolkata

Alternate )

NEVATIA

SHRI BIMAL CHANDRAPAL

SHRI TAPAN DATTA ( Alternate
SHRI M. S. CHAKRABORTHY

Larsen and Toubro Limited, Kolkata

SHRIL. N.

MISHRA (

Alternate )

SHRI D. MAJUMDAR

Mega Drives Pvt Ltd, Thane

SHRI N. B. BHUJLE (

Metallurgical

Alternafe )

SHRIT. K. ROY
SHRIH. S. SINGH( Alternate )

and Engineering Consultants (1) Ltd, Ranchi

M.N. Dastur and Co Ltd, Kolkata

SHRI D. GHOSH
SHRIG.

Ministry of Defence ( DGI ), New Delhi

C. t3ANERJF.E( Alternate)

SHRI K. PARTHI~AN
SHRI RAJJNDER SJNGH (

Alternate )

T. K. DATTA

Ministry of Surface Transport. New Delhi

SHRI

Mukand Ltd. Thane

SHRI D. CHAKRABORTHY
SHRJ D. S. SENTHILVEL (

National Thermal Power Corporation

SHRIB. K.

Ltd, New Delhi

Alternate )

BHATTACHARYA

SHRI R. S: YADAV ( Alternate

SHRI
SHRI

and Locomotive Co Ltd, Pune

R.K.

GANDHI ( A/ferns/e

SHRID. P.

Jamshedpur

SHRI

Pvt Ltd, New Delhi

RATHORE

SHRI J. P. SINGH (

Unicon Technology lntcrnationol

R. K. JOSHI
SHRI S. MISHRA ( A/[ernate

Tata iron and Steel Company limited,

SHRI BALRAJ GOEL

Reva Engineering industrial (P) Ltd. New Delhi

Tata Engineering

.,

Allernate )

R. S. N AI-WA
SHRI MANISH NALWA ( A/ternate

69

IS 807:2006
WMI Cranes Ltd, Mumbai

SHRI S. M. MALANI
SHRI D. CHATTERJEE ( Alfernate

BIS Directorate General

SHRIA. S. BASU,Director and Head ( MED )

[ Representing Director General, BIS ( flx-oficio ) ]

Member Secretary
SHRJS. B. ROY
Director ( MED ), BIS

70

Bureau of Indian Standards

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Amend No.

Issued Since Publication

Text Affected

Date of Issue

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