AA SPEC 254001 Stacker Reclaimer Spec PDF

AA SPECIFICATION
SPEC 254001
STACKING AND RECLAIMING EQUIPMENT:

MECHANICAL & STRUCTURAL
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This document supersedes AAC_SPEC_254001
CONTENTS
PAGE
SCOPE
TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER
DEFINITIONS
REQUIREMENTS
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
GENERAL
MATERIAL TO BE HANDLED
ENVIRONMENT
DESIGN
MATERIALS
MECHANICAL
STRUCTURAL
CASTINGS
FORGINGS
CORROSION PROTECTION
SAFETY
3
3
3
4
4
5
16
18
19
20
20
QUALITY ASSURANCE PROVISIONS
21
TEST AND INSPECTION METHODS
21
6.1
6.2
6.3
6.4
GENERAL
LOAD AND OPERATING TESTS
STRUCTURAL TESTS
GEAR REDUCERS
21
21
22
23
PACKING AND MARKING
23
7.1
7.2
PACKING
MARKING
23
24
APPENDIX A : RELATED DOCUMENTS
25
APPENDIX B : RECORD OF AMENDMENTS
28
AA_SPEC_25400100.DOC
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For information or comments on this document please contact ATD QA

Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or
the information contained therein, irrespective of the cause and quantum thereof.
AA SPECIFICATION
SPEC 254001

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SCOPE
This specification details the structural and mechanical requirements for stacking and
reclaiming equipment.
TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER

The following shall be specified on every invitation to tender.
Title, number, issue and date of this specification
The equipment requirements. For other requirements refer to the enquiry or contract
document.
DEFINITIONS
For the purpose of this specification the following definitions shall apply:
AGMA
American Gear Manufacturers Association
APPROVED
Approved by the Engineer in writing
ASTM
American Society for Testing and Materials.
BSI
British Standards Institute
CONTRACTOR
The company, partnership or person contractually obliged to

supply products or services to the purchaser.
CRITICAL
A component or permanent assembly the failure of which, by

analysis, judgement and experience, is likely to result in
hazardous or unsafe conditions for individuals using, maintaining
or depending upon the equipment or structure of which it is a part:
OR
A component or permanent assembly which the failure of which is
likely to very significantly affect the performance of important
equipment and structures of which it is a part:
OR
A component or permanent assembly which requires 24 hours or
more to replace.
DEFECTIVE
A part or parts of the equipment that fails in one or more respects

to comply with the requirements of the specification
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SPEC 254001

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ENGINEER
Consulting Engineer, Consulting Mechanical and

Engineer of AA or their appointed representatives
ISO
International Standards Organisation
MAJOR
A component or permanent assembly, other than Critical, the

failure of which is likely to materially reduce the ability to use the
equipment or structure of which it is a part.
MINOR
A component or permanent assembly the failure of which is not

likely to materially reduce the ability to use the equipment of which
it is a part
PURCHASER
The company designated as the recipient of finished products or

services
PURCHASERS
REPRESENTATIVE
A company, partnership or person authorised by the Engineer to

act on the purchaser's behalf
QUALITY
SURVEILLANCE
AUTHORITY
An approved inspection agency appointed by the contractor
SANS
South Africa National Standard
SAE
Society of Automotive Engineers (American)
SAIW
South African Institute of Welding
REQUIREMENTS
4.1
GENERAL
Electrical
This specification deals with specific requirements for stacking and reclaiming handling
equipment.
4.2
MATERIAL TO BE HANDLED
The equipment shall be designed to handle the material and at the rate specified in the
contract.
4.3
ENVIRONMENT
The equipment shall be capable of the duty specified in the contract when exposed to the
operating environment.
The Contractors shall ascertain any further details not covered in the enquiry from the
Engineer.
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4.3.1
Noise levels: noise level of the equipment when operating at full rated capacity shall not
exceed 80dBA measured at a point one metre above ground and one metre from any
bogie. The noise level inside the cab(s) with doors and windows closed shall not exceed
70dBA.
4.3.2
Wind speed: the maximum regional basic wind speed in the area of deployment for a
50-year mean return period shall be obtained from SANS 10160, unless otherwise stated
in the contract. In countries other than South Africa the applicable local data shall apply.
4.4
DESIGN
4.4.1
General design: equipment shall be designed in accordance with current technology and
engineering practice. The design shall comply with requirements of this specification and
relevant company, national and international standards (see Appendix A).
The requirements of the South African Minerals Act and the Inspector of Machinery shall
be complied with where applicable.
4.4.2
Design audit: the mechanical and structural integrity of the major items of plant shall be
subject to an independent review/audit by an auditor approved by the purchaser. The
Contractor shall make available to the auditor all necessary design information as required
in the contract document.
4.5
MATERIALS
4.5.1
Plate: all steel plate materials shall be to SANS 1431 Gr. 350WC, or as agreed by the
Engineer in countries other than South Africa.
4.5.2
Forgings: forging shall be within the limiting ruling section for the material and conditions
specified with a minimum 3:1 forging ratio.
4.5.3
Castings: shall comply with EN 10293 unless the design requires better. Castings shall
only be repaired in accordance with repair procedures submitted for approval by the
Engineer at the time of tender.
4.5.4
Slew roller and rings: the material shall have a maximum grain size of 5 or finer. It shall
be vacuum degassed to a maximum of 2.5 parts per million hydrogen.
The following properties shall be stated at time of tender by the contractor for the
bearings:
Case depth
Case hardness
Core minimum yield strength
Case/core transition thickness.
Steel cleanliness shall be to ASTM E45 plate II to be obtained by electroslag re-melting,

consumable electrode vacuum arc re-melting or equivalent.
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Average of the 10 worst field ratings in any specimen shall not be in excess of:
A - 0 maximum
B - 0 maximum
C - 0 maximum
D - 1.5 maximum
for both the fine and thick series.
4.6
MECHANICAL
4.6.1
General: mechanical components of the stacker/reclaimer shall be designed generally in

accordance with the procedures of FEM 2.131/2.132.
4.6.2
Design loads: shall comply with the requirements of FEM 2.131/2.132 with the following
amendments.
Mechanism loads shall include all of the structural load cases specified by ISO 5049-1.
Case I and II loads in ISO 5049-1 shall be modified to be consistent with corresponding
amendments to structural loadings as detailed in Clause 4.7.1 of this specification.
Loads considered in fatigue life calculations shall include bucket wheel stalls which shall
be assumed to occur at a frequency of 2 per hour over the operating life of the machine.
Stall torque during these stall events shall be assumed to reach 1.1 times the torque
setting of the torque limiting clutch/coupling.
Case II loads for the bucket wheel shall include the rapid rotational deceleration of the
wheel, decelerating uniformly to rest from full rotational speed over a distance of 300 mm at
the bucket lip.
4.6.3
Design life: mechanism components shall be designed to achieve a life equivalent to

100,000 hours of continuous operation of the stacker/reclaimer system.
The corresponding design lives (continuous operation) for the major drives shall be
assumed as follows:
Bucket Wheel Drive
100,000 hours
Conveyors (Boom, transfer, movable)
70,000 hours
Luff Mechanisms
30,000 hours
Slew Mechanisms
70,000 hours
Travel drives
30,000 hours
Other drives
20,000 hours
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4.6.4
Bucket wheel and drive: the bucket wheel shall be of the cell-less type. The bucket
wheel drive shall if necessary be provided with suitable mechanical and/or electrical
devices to limit the torque in the gearbox and drive shafts so that no damage is caused
when the wheel stalls from full speed.
4.6.5
Ball and roller bearings: rolling element bearings shall have a minimum modified L10 life
commensurate with a total operating life for the stacker/reclaimer of 100,000 hours,
operating continuously at the worst combination of load and speed. The modified L10 life
shall be calculated using the rating method of ISO 281.
4.6.6
Slew bearings: The slew bearing shall be designed to have the factors of safety for the
failure modes listed below under the calculated load conditions.
Classical Fatigue Spalling. The modified L10 life shall not be less than 15 years under
load case I load combinations. The modified L10 life shall be calculated using the rating
method of ISO 281. The experience and recommendation of the bearing manufacturer
shall also be sought.
Static Capacity or Brinelling. The maximum allowable static load that a raceway can carry
shall be 1.5 times the static capacity (Co). The maximum allowable static load shall be
greater than 2 times the maximum calculated static load under load case III load
combinations. The experience and recommendation of the bearing manufacturer shall
also be sought.
Core Crushing. The static shear yield at certified strength shall be greater than 2 times
the calculated sub-surface yield stress under load case III load combinations.
Certification of hardness profile and core tensile and yield strengths shall be submitted to
the engineer within 10 days of heat treating the raceways. Data for the certificate shall be
obtained by processing a test bar of the same cross section from the same heat of steel
along with the raceways and using the bar to determine hardening patterns and core
properties.
4.6.7
Plummer blocks: shall have self aligning bearings. Housings shall be cast steel or
malleable iron. Four holding down bolts shall be employed unless otherwise approved.
Pulley shaft bearings shall have one fixed and one floating bearing.
4.6.8
Plain bearings: shall be bushed with an approved SAE or British Standard leaded bronze
in accordance with the requirements of BS 4480.
4.6.9
Lubrication system: Grease passage shall be available to all the lubricating areas.
4.6.10
Sealing devices: shall be designed for outdoor service in the presence of fine abrasive
dust. Particular attention shall be given to bearing seals to prevent ingress of moisture
and foreign material. Rolling element bearings and plain journal bearings shall have
primary labyrinth and Neoprene line contact seals. Plummer blocks shall be supplied with
multiple labyrinth seals designed to receive adequate lubrication grease. Lubricated
bearings shall have pressure relief holes to avoid seal damage and over lubrication.
Felt or fibre packing shall not be used for dynamic seals.
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Propriety equipment shall have sealing devices as recommended by the manufacturer for
the duty and specified environment.
4.6.11
Shafts: less than 100mm diameter for non critical duty shall be ductile shafting to
SANS 1431 Grade 300WA or 350WA.
Shafts over 100mm diameter and shafts in critical areas shall be to BS 970 Part 2 Grade
826M40 with mechanical properties to BS 2772 Part 2 Grade 826M31 and comply with
the following requirements:
The shaft shall be designed to minimise the possibility of failure through corrosion fatigue,
the maximum stress in the shaft during operation shall be below the fatigue regime for the
material.
Shaft flanges shall be forged integral with the shaft, unless otherwise approved in writing
by the engineer.
Section changes shall have large fillets, with a radius of at least 10% of the shaft
diameter. Fillets shall be polished.
Shafts shall have a surface texture of Ra 0,8mm on bearing surfaces and shall be
measured in accordance with the requirements of BS 1134.
4.6.12
Couplings: shall be rated for more than the peak motor torque or motor fault torque,
which ever is the greater. Couplings shall provide for parallel, angular and axial
misalignment of the shaft.
Fluid couplings shall be used for drives over 7.5 kW and be fitted with a thermal, fusible
plug.
4.6.13
Power transmission: sprocket drives are not permitted except with the approval of the
Engineer.
Pulleys (and sprockets if permitted) shall be attached to shafts using 'Ringfeder',
'Taperlock' or other approved locking devices selected with due regard to starting, stalling
and pulsating torques.
Pulleys (and sprockets if permitted) shall run true and be statically balanced, but not by
the addition of masses by welding or the removal of parent material by drilling.
4.6.14
Gearboxes and gears: all gearing shall be rated for capacity in accordance with the
appropriate standards of the American Gear Manufacturers Association (AGMA) using
conservative interpretations of the Standards.
For design checking purposes it shall be assumed that full load rated output power of the
drive motor is applied to each gear wheel for the whole of the operational life. In the case
of multiple or variable speed drives, the most unfavourable combination of load and speed
shall be assumed to apply for the whole of the operating life.
Spur and helical involute gearing shall be rated in accordance with AGMA.908-B89 and
2001-D04. In determining gear capacity using this standard, the following procedures shall
be adopted.
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The effects of torsional vibration shall be considered in rating the gearing. In no case
however shall the level of torsional oscillation (p-p) exceed 40% of the average torque.
In the case of epicyclic (or planetary) gearing stages where the load sharing principle is
limited to a simple floating sun pinion, then an appropriate allowance shall be made for
mal-distribution of torque between the planet pinions. This mal-distribution factor shall be
appropriate to the geometry adopted but not less than a multiplier of 1.15 applied to the
forces and torques calculated from a perfect load distribution within the planet system.
Gearboxes shall be designed for outdoor mounting and resistant to the environmental
conditions, i.e. rainwater, abrasive dusts, and shall operate without the addition of external
cooling systems up to a bulk oil temperature of 70C. A metal plate shall be fixed to the
casing and indicate rating and lubricant required. The gear casing shall allow access for
inspection and maintenance particularly sludge removal and shall be approved by the
Engineer.
Gear casings shall be tolerant of operating overload and erection forces without distortion.
Casings shall be steel or malleable cast iron. Gear boxes shall be free of weld splatter,
metal debris and coated inside with an approved heat and oil resistant paint.
Where natural convection is insufficient to remove heat from the gearbox, fans shall be
provided. Fans shall be mounted on the reduction box arranged to be cleanable and not
collect dust or rainwater. Fans shall operate efficiently for both directions of rotation of the
gearbox. Means shall be provided to maintain the oil temperature at the optimum
especially at partial load.
Oil seals shall be suitable for the lubricant, operating temperature, dust conditions,
ambient conditions and environment specified. Labyrinth seals shall be re-greasable. Oil
seals shall withstand all pressure fluctuations within the gearbox due to blocked vents or
temperature fluctuations.
Vents shall have replaceable filters, unless otherwise approved. Dessicant pots shall be
used to prevent condensation in the gearbox where operating temperature is low or oil
has a moisture affinity.
Gearboxes shall have fill plugs, in line filters with pressure bypass (where applicable),
drain plugs and a graduated oil level indicator, all accessible after installation. No sight
glassware allowed.
Where applicable, magnetic plugs shall be included in the filter system or the drain plugs.
The drain plugs shall be at the lowest possible position of the gearbox.
Only input and output shafts shall pass through the casing. External shafts shall be
protected against corrosion and spillage. Gears shall be totally enclosed and splash or
pressure lubricated.
Load tests shall be conducted during commissioning
(see Clause 6.0) at which time noise levels shall be measured and results approved by
the Engineer.
4.6.15
Gear accuracy/quality: the manufacture of the gears and gearboxes shall conform to the
accuracy requirements of the relevant AGMA standards.
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The assumption used in the rating procedures for such matters as alignment, lead
variations, profile error, shall be attained or surpassed in practice. The Engineer shall
approve the method of verification of gear rating, quality and accuracy within the approved
drawing tolerances.
4.6.16
Gearbox bearing: where a gearbox is split across a bearing, the bearing shall be housed
in a separate ring or cartridge. Gearbox bearings shall be of the ball or roller type and
shall have a modified L10 life commensurate with a life of 100,000 operating hours for the
stacker/reclaimer equipment. The modified L10 life shall be calculated using the rating
method of ISO 281.
For this life rating it shall be assumed that input to the gearbox is the most arduous
combination of torque and speed when the drive motor is operating at full output.
4.6.17
Gearbox lubrication: gearbox oil circulation pumps shall be a type and configuration
suitable for handling viscous fluids and provided with adequate net positive suction head
to avoid cavitations and related noise. The design viscosity for this purpose shall be the
viscosity of the bulk oil at start-up of the machine under the coolest operating conditions.
The pump suction shall be designed for a low oil velocity, and be free of elbows and other
restrictions to smooth flow.
For the bucket wheel drive and other gearboxes mounted on luffing booms, the above
requirement shall apply over the whole of the luffing range to the maximum and minimum
angle limits.
4.6.18
Shaft mounted gearboxes: shaft mounted gearbox/motor units of more than 250 kW
rated power shall be flange and spigot mounted.
4.6.19
Drive base plates: motors gearboxes and couplings shall be mounted on a common
fabricated or cast baseplate rigid in all directions to withstand the static and dynamic
loading of motor/gearbox and transport/erection forces without excessive deflection about
the mountings or connected shafting.
Drive base plates shall be machined, unless otherwise agreed at the time of tender by the
Engineer, shop set-up and delivered assembled where practicable. Cast iron shall be
allowed to age for four weeks before machining. Stress relieving shall be carried out after
welding of fabricated baseplates.
The number and size of fixing bolts for the baseplates shall be capable of withstanding all
normal operating peak surge loads, be specified by the Contractor and approved by the
Engineer.
4.6.20
Crawlers: shall be designed to permit ready inspection and replacement to wearing

surfaces. They shall also be designed with jacking steps at each end of the crawler for
ready installation of jack footing for removal of major components, including main
equalisers, without having to excavate below the track pads.
Lifting beams shall be provided for lifting the crawler frame in two stages. Support pads at
each side of the crawlers shall also be provided adjacent to the jacking point at each end
of the crawler frame.
APPROVED
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4.6.21
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Bogie wheel(s): loads including operating wind loads and impact factors, but excluding
lateral and vertical inertial forces from boom luffing shall be specified by the Contractor in
tons/wheel together with the maximum rail loading in kg/m and be approved by the
Engineer. The following shall also be specified by the Contractor and approved by the
Engineer.
Sleeper centres
Laying tolerance
Maintenance tolerance
Structural stops shall be provided on each bogie such that in the event of a shaft failure
the bogie cannot drop more than 45mm. Indication of failure shall be provided at the
control cabin (see Clause 4.11) to indicate wheel and shaft failure. Rail scrapers which
embrace the rail crown shall be provided on both sides of each rail bogie.
Balance beam pivots shall be provided with grading points to the high pressure sides.
Buffers shall be provided to contact machine stops and shall be capable of bringing the
machine to rest without exceeding the specified machine long travel deceleration rates
with all the travel drives operating.
Power required at each bogie shall be related to the most unfavourable distribution of
bogie loads, including wind effects. Reduction gearboxes shall not be used without the
approval of the Engineer.
Wheels of multiple wheel systems shall be carried in fabricated steel pivoted frames with
all shafts equidistant and parallel to ensure equal load distribution to each wheel. Driving
wheels shall be sufficiently numerous to allow acceleration, travel and braking without
skidding under all specified operating conditions and configuration of the machine.
The geometry and drive configuration shall be arranged to prevent crabbing on both high
speed and low speed operation. Maximum lateral wheel loads due to skewing shall be
submitted at time of tender for approval.
4.6.22
Wheels: shall be steel, double flange parallel tread type conforming to the requirements
of BS 3037. Tread hardness shall be 320 Brinell minimum.
Coefficient of friction to be used in calculations shall not be less than the following:
Static friction between drive wheel and rail 0.2
Sliding friction between locked wheel and rail 0.12
Rolling friction between idler wheel and rail 0.02 (including the effects of bearings and
seals).
APPROVED
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4.6.23
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Brakes: all travelling equipment shall be equipped with service brakes capable of
operating in both directions, designed to stop and hold the machine on an incline of 1 : 10
in all climatic conditions with the wind blowing down the incline in the direction of travel at
the specified velocity and with the machine slewed (where applicable) to present the
maximum profile to the wind.
The specified velocity shall be the maximum regional basic wind speed in the area of
deployment for a 50-year mean return period (See Clause 4.3.2).
The brake system shall be capable of stopping the machine in the event of failure of the
traverse drive, i.e. the brake system shall be designed as a stopping brake system without
any electrical retardation via the drive unit.
Brakes shall be of the drum or disc type and shall be rated at a minimum of 200% of full
load motor torque. Brake actuation shall be by spring or counterweight compression and
hydraulic or electromagnetic release such that the brake fails 'on'. Brake shoes shall be
self-aligning, non binding and easily replaceable.
Crawler mounted equipment shall be provided with holding brakes and all rail mounted
machines shall be provided with rail clamps.
Rail clamps shall be activated automatically by the cup anemometer when the wind speed
exceeds that for the local 50-year mean return period. Clamps shall apply a balanced,
horizontal pressure to the rail head.
4.6.24
Conveyor drives: shall consist of an electric motor driving through a fluid coupling and
totally enclosed reduction gear boxes mounted horizontally and directly coupled to the
conveyor pulley by a flexible coupling. The whole assembly shall be mounted on a
common base plate. Bevel helical type gearboxes shall be used. Hold-backs shall be
installed on all inclined conveyors and rated 150% of full load motor torque. Electric
motors shall be capable of starting at 125% of fully loaded belt capacity and six starts per
hour. Speed reducer service factor shall be not less than 1.25.
4.6.25
Conveyor pulleys: shall be fabricated in accordance with AA Specification 371001.

Eccentricity of the pulleys shall not exceed 4mm TIR. Pulleys shall not be welded or
thermally shrunk onto the shaft. Pulley surface shall have a crowned profile. Pulley
diameter shall be compatible with the belt construction, thickness and shall be approved
by the Engineer. Drive pulleys shall be lagged with an approved lagging.
4.6.26
Conveyor belting: shall be either textile reinforced in accordance with the requirements
of SANS 1173 or steelcord in accordance with the requirements of SANS 1366. The belt
width, rating, construction, cover material and top and bottom cover thickness shall be
suitable for the application and environment, specified by the Contractor and approved by
the Engineer.
Belt stretch under full load condition shall be guaranteed at not more than 2% of belt
length for textile reinforced belt. Belt stretch for steelcord belt shall be guaranteed at not
more than 0.25%.
APPROVED
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4.6.27
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Conveyor troughing idlers: shall be one or both of the following:

Rigid type: shall conform to SANS 1313-1 and to AA Specification 373001.
Idler rolls shall be mounted on metric series deep grove ball bearings sealed with labyrinth
type seals applicable to the working environment. Bearings shall be grease packed
'lubricated for life' assemblies. The same type of bearing shall be fitted to all rolls.
Suspended type: the rolls shall be in accordance with requirements of SANS 1313-2 and
AA Specification 373001. The type of suspension arrangement shall be submitted by the
Contractor for approval at time of tender.
4.6.28
Conveyor belt take-ups: take-up devices shall be gravity, hydraulic type or electric winch
with load cells.
Gravity take-ups shall be provided with a means to restrict travel in order to arrest the
assembly in the event of belt breakage.
Hydraulic take-ups shall be provided with load measuring devices to ensure a constant
tension in the belt.
The minimum take-up distance provided shall be 2.5% of the conveyor belt length
between head and tail pulley centres plus 500mm.
4.6.29
Conveyor belt training: tilted carrying idlers may be fitted on belts which run in one
direction only. On short reversible belts crowned head take-up pulleys shall be used.
Belt training may be aided by special training idlers, swivel idlers are not permitted.
Acceptable idlers are 'V' form, negatively troughed idlers on return side of belt sited
immediately prior to the tail pulley.
4.6.30
Conveyor belt cleaners: belt cleaners of an approved design shall be provided at the
head pulley.
Ploughs shall be provided on the return belt to prevent material entering pulley nip points.
4.6.31
Conveyor wind boards: shall be provided on both sides of the conveyor belt where
required.
4.6.32
Transfer chutes and skirts: chutes shall be designed to accommodate material

trajectory and build up. The transfer points shall have a material flow at the receiving belt
in the same direction as that of the belt travel and fed at a low angle of trajectory. Chutes
shall incorporate an easily replaceable impact plate in the position dictated by the material
trajectory. Chute liner plates shall be secured by bolting the chute structure, securing
bolts shall be counter-sunk to a depth equal to the maximum permissible wear. Chute
volume shall be adequate to accommodate run-down capacity. Skirt length shall allow
material to settle on the belt without spillage, be specified by the Contractor and approved
by the Engineer. Chutes and skirt plates shall be of 8mm thick mild steel plate suitably
reinforced and lined with a minimum of 10mm thick abrasion resistant steel plate
(500 HBN) or approved equivalent at points in direct contact with the main stream of
materials and with 4mm thick polished Grade 314 stainless steel for dribble chutes from
pulley scrapers. Details of wear plates shall be included in the tender.
APPROVED
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4.6.33
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Winch and wire rope systems: where a control cab is supported by wire ropes the
equipment and wire ropes shall conform to the requirements of the South African Mines
and Works Act.
Wire ropes shall be 'over lay', fibre core and galvanised with provision for external
lubrication and cleaning. Ropes shall not be ultra-high tensile and shall not have reverse
bends. Thimbles for wire ropes shall conform to the requirements of EN 13411-1.
Rope termination design shall be submitted by the Contractor at time of tender for
approval.
Winch drums shall be spiral grooved and have capacity to spool the maximum required
rope length in one layer, have a wrapper plate and a minimum of six dead turns. Where
two ropes are wound on one winch drum it shall have right and left hand spiral grooving
and ropes layed to suit. Winch drum bearing details shall be submitted by the Contractor
at time of tender for approval.
Wire rope sockets shall be in accordance with the requirements of AA Specification
288002.
Brakes shall have the required thermal capacity. Brakes shall be capable of stopping in
overspeed conditions and 150% maximum torque (including plugged chute) and be
capable of halting the associated movement to a smooth stop from all loads and speeds.
Safety circuits shall be provided to achieve fail safe conditions and stop the machine in
the event of brake or rope failure.
The emergency brake operations shall be interlocked through an adjustable timer such
that the emergency brake shall be applied after a given time from application of the
service brake. When an overspeed condition is detected in excess of 125% of normal
speed, both operating and emergency brakes shall apply simultaneously. Brakes shall
operate to ensure that there are never less than six full turns of rope on the winch drum.
Safety circuits shall be provided to achieve fail safe conditions and stop the machine in
the event of brake or rope failure.
Winches shall be mounted on rigid steel frames capable of withstanding all forces which
may occur. Each winch shall be provided with a dual braking system as follows:
Emergency brake operating on the low torque side of the reducing gear.
Normal service brake operating directly on the winch drum. It shall be capable of being
manually applied and released at the winch.
Winches shall have drum anchorages suitable for reverse winding.
Sheave wheels shall be generally in accordance with the requirements of
AA Specification 281011. Sheaves shall be standard sizes to facilitate replacement and
shall have adequately sealed rolling element bearings. The sheave design and bearing
data shall be submitted for approval.
APPROVED
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4.6.34
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Hydraulic system: pressures shall be a maximum of 13.7MPa and be fitted with trip
control pressure gauges. The use of flexible lines shall be kept to a minimum and shall
conform to the requirements of EN 853 or EN 856. Adequate safety provisions shall be
provided for the event of component or reticulation element failure. Components which
carry a sustained load shall be of zero leak design. Hydraulic piston motor systems on
hoists shall be arranged so that the motor cannot be starved of oil even with the electrical
power cut off for prolonged periods. A mechanical brake shall be included in this type of
system. Cylinders shall be designed to hold or release under control for all loads which
may occur in either direction. Hydraulic systems for hoisting or luffing shall be equipped
with lock valves.
Overhung loads carried on shafts of hydraulic motors or pumps shall be included when
computing the allowable working pressure difference. Motor and pump units shall be
mounted on a common bedplate, in turn be mounted on anti-vibration mounts and have
drainable drip trays.
The hydraulic reservoir, electric motor and pump shall be housed in a separate, ventilated
room or enclosure. Oil reservoirs shall be protected from the effects of moisture
condensation and corrosion within the tank. Reservoirs shall be positioned to provide a
positive head feed to hydraulic pumps. Fluid level switches, over temperature switches,
heaters or desiccants and a means for completely draining the reservoir and the system
shall be provided. Reservoir breathers shall either be closed circuit or shall be equipped
with replaceable desiccant type filters of adequate capacity. Means of air bleeding of the
system shall be provided where necessary. Bleeding points shall be readily accessible.
Bleeding sequences shall be fully specified in instruction documents and approved by the
Engineer.
Oil filters shall be of the 'tell tale' type, accessible and readily replaceable. Oil shall be
filtered in accordance with the component manufacturers' requirements and all make up
oil shall be filtered into the reservoir. Oil temperature measured at the hottest area in the
oil reservoir shall not exceed 50C.
The oil type and viscosity to Anglo American code shall be clearly and permanently
marked on a plate and secured to the reservoir. Valves shall be fitted to manifold blocks.
Pipe connections shall be welded. The use of breakable fittings shall be compatible with
the hydraulic fluid specified.
4.6.35
Flexible hose assemblies: shall have swaged end fittings with female running nuts at
each end and shall be in accordance with accepted international standards and installed
in accordance with manufacturer's recommendations giving particular attention to the
following:
Motion shall be in one plane and torsional stresses avoided. Rubbing against other
hoses, machinery or structures shall be avoided. Minimum recommended radii shall be
used. Support in thrust and compression shall be provided and flexing distance shall be
considered.
Pipework shall be as specified by the Contractor at time of tender for approval. Pipework
shall be adequately supported and securely fixed immediately before and after a bend or
off set. Pipework shall conform to the requirements of the following standards:
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BS 778
Steel pipes and joint for hydraulic purposes
EN 10220
Seamless and welded steel tubes. Dimensions and masses per unit
length
BS 1710
Identification of pipelines
BS 4368-1
Metallic tube connectors for fluid power and general use. Split collet
compression fittings.
Pipe supports shall incorporate suitable vibration damping material and the support
assembly shall not damage the pipe. Accumulators shall have provision to: positively
isolate the hydraulic system from banks of accumulators, automatically vent on system
shutdown except where power conservation or standby supply is required. Ready access
to filling points and for component maintenance and replacement shall be provided.
4.6.36
Lubricants: shall conform to the applicable Anglo American Specifications. Oil

lubricated machinery shall be delivered to site without oil and the interior surface of all oil
containers painted with approved oil corrosion and heat resistance coatings. These units
shall be cleaned with an initial charge of the correct grade of lubricating oil, drained and
refilled with the correct grade of lubricating oil by the Contractor on site.
Oil pumps shall incorporate a replaceable oil filter and oil pressure gauge to measure the
pressure drop across the filter and shall include a fill plug and oil level indicator. Vents to
atmosphere shall be covered by a replaceable filter of adequate capacity.
Hand lubrication shall be restricted to those points which require infrequent greasing. All
points where frequent lubrication is required shall be connected to an automatic system.
Lubrication pumps, control equipment and lubricant reservoirs for this system shall be
housed in dust proof enclosures and equipped with adjustable timing devices and
malfunction alarm systems.
Distributors shall be standardised, in a visible position and replaceable without removing
other components.
The number of points to be lubricated automatically or by hand shall be nominated by the
Contractor.
Attention shall be given to minimising the number of different types and brands of
lubricants to be used.
4.6.37
Maintenance: Moving parts of the machine shall be readily accessible for inspection,
maintenance and replacement. Heavy items (motors, gearboxes, winches, sheaves etc.)
shall have adequate lifting equipment and winches, or monorails suitable for use with
manual hoists.
The reach of monorails or fixed lifting equipment shall enable components to be lowered
on to platforms or ground in a position accessible to mobile cranes operating at ground
level. For small, elevated items cantilever frames shall be provided.
Jacking points shall be provided where appropriate. Attention shall be paid to the lateral
access to equipment for dismantling and re-assembly.
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Special service tools required shall be provided and clipped into a lock-up tool store
located on the machine.
Switched power outlets for welding and hand equipment shall be provided at rail track
bogie and at machinery levels.
Maintenance schedule recommendations shall be provided by the Contractor at the time
of tender for approval.
4.6.38
Spares: recommended spares and material lists covering the following categories shall be
provided by the Contractor.
Commissioning: spares and engineering materials required or consumed during
commissioning of each machine.
Consumables: spares and engineering materials which it is predicted will be required or
consumed in the first two years of operation of the machine(s) assuming a production rate
equal to the full specified production capacity of each machine. This data shall be based
on experience of the Contractor of similar equipment in similar environments.
Insurance: spares which it is recommended should be held (in addition to above) in order
to minimise long delivery of spares. Manufacturers or suppliers shall be identified by the
Contractor for each insured spare.
Local suppliers shall be identified at time of tender for approval.
4.7
STRUCTURAL
4.7.1
Structure design: the structure and components shall be designed in accordance with
the requirements of ISO 5049-1 Part 1.
The following clauses of ISO 5049-1 Part 1 shall be amended as follows:
Section 3.1.2.1.1b) second paragraph to read the cross-sectional area shall be
determined assuming the belt loaded to overflowing with material at maximum surcharge
angle.
Section 3.1.6.2 the third paragraph to be deleted (i.e. the inertia forces always to be
taken into account, irrespective of the number of cycles).
Section 3.1.8 first paragraph to read Metal flooring, stairways, ladders, platforms and
hand railing shall be designed according to the SA Steel Construction Handbook. In
countries other than South Africa the applicable local standards shall apply.
Section 3.2.1 the following shall be added The in-service (operating) design wind speed
shall be as agreed with the client. The out-of-service design wind speed shall be the
regional basic wind speed V in Figure 3, under Section 5.5.2.2 of SANS 10160. Figure 3
in SANS 10160 gives values of V for a 50-year mean return period, and the minimum
value is 40 m/s. In countries other than South Africa the applicable local data shall apply.
Section 9.1 - for the purposes of structural and stability calculations the calculated inertia
forces shall be scaled by a factor 1.5, and the out of service wind speed shall be used.
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Special Loads as specified in Section 3.3 of ISO 5049-1 Part 1 shall include the following
additional cases.
End-on collision of boom.
Loss of bucket wheel. Consider loads 3.1.1 (excluding the bucket wheel), 3.1.2
(excluding the material load normally in the bucket wheel), 3.1.3, 3.1.5, 3.1.6 (relevant
components) 3.1.7 and 3.2.1.
Loads during maintenance. Loads to be considered are those imposed on the

machine during maintenance when parts of the structure or machinery might be
removed or their support might be altered.
The overall design and that of all critical or sensitive structural areas shall be submitted to
the Engineer for review. The Contractor shall give every assistance but any survey shall
not relieve the Contractor of responsibility for the design.
Structural details in the areas of fluctuating stresses shall be designed to minimise stress
concentrations. Structural connections shall, wherever practical, be positioned away from
highly stressed area.
All main and critical components of the structure shall be assessed for their loaded and
unloaded natural frequency to ensure no resonance problems occur. This data shall be
supplied by the Contractor and approved by the Engineer.
Access shall be provided for maintenance on major components and jacking points
provided to assist in the maintenance of components subject to frequent replacement.
The structure shall be designed to minimise dirt and water collection points.
Equipment loads shall be transferred to the track through a number of three point support
systems.
4.7.2
Structural fabrication: welder qualification, fabrication, inspection and acceptance

criteria shall be in accordance with the requirements of AWS D1.1.
Structural steel shall not be located closer to the edge of a conveyor belt than 150mm with
the belt in the central position.
Welding procedures shall be supplied by the Contractor at time of tender for approval.
The welder qualifying authority shall be the SAIW or approved organisation and shall be
included in the tender.
Welds between the circular diaphragm and the rail pad of a slew bearing shall consist of
full penetration butt welds with large fillets and ground to a smooth profile. These welds
shall be 100% ultrasonically tested and test results shall be submitted for approval. Weld
spatter shall be cleaned off the platework and welds dressed to obtain a clean finish.
Where joints occur or where liner plates are bolted on the welds shall be dressed level
with the platework. A weld strikeplate shall be provided on the equipment.
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Welds, joining components of thickness 75mm and greater, or of complex configuration,

shall be the subject of large scale diagrams on the working drawings showing fit up and
clearances. References shall be given from such diagrams to approved weld procedures
in each case.
The Contractor shall ensure that items being welded are earthed directly to avoid possible
damage to equipment that is adversely affected by the passage of current, e.g. bearings.
Where possible bearings and electrical equipment shall be installed after welding is
complete.
Site welding shall only be carried out with the approval of the Engineer and shall be done
under supervision of a qualified welding supervisor provided by the Contractor.
The Engineer may elect to take radiographs of up to 10% of the length of site welds. If
such radiographs show defects, the weld shall be ground out and the components rewelded and re-radiographed by the Contractor free of charge. The Contractor shall bear
the cost of radiographs. Grinding, re-welding and radiography shall continue until a set of
radiographs shows satisfactory welds throughout the test lengths. Only two repairs shall
be allowed in any defective area. The Engineer may, if deemed necessary, call for up to
100% radiography.
Connection of monorail and crane runway beams to the machine structure shall be made
with High Strength Friction Grip Bolts. Where bolted joints are required the bolt spacing
shall be a maximum of 16 times the thickness of the thinnest flange. If mounting holes are
not in alignment they shall be reamed out. Flame cutting is not permitted.
The angle between the bolt axis and the surface under the rotating component (i.e. bolt
head or nut) shall be 90+ or - 3. For angles outside these limits a tapered washer shall
be correctly positioned.
Handling of fabricated platework shall ensure that distortion or damage is avoided. Use
shall be made of lifting eyes or hooks where these are provided on the platework.
Damaged surfaces shall be treated as per the corrosion protection section of this
specification (see Clause 4.10).
Alignment of all mechanical and structural components will be subject to the Engineer's
inspection. At least seven days prior notification that inspection is required shall be given
in writing to the Engineer.
Platework shall be tested for dust tightness to the satisfaction of the Engineer.
4.8
CASTINGS
4.8.1
Carbon equivalent: castings to which connections are welded shall have a carbon
equivalent (C.E.) not greater than 0.44%. When calculated as follows:
C.E. = C + Mn + Cr + Mo + V + NiCu
6
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4.8.2
Non-destructive examination: all critical areas of castings, including abrupt changes in

section and areas to be machined shall be magnetic particle tested using the procedures
of EN 1369. In addition, the complete surface of each casting shall be examined visually
to EN 12454, and shall be free from cracks, hot treats, gross porosity, shrinkage and sand
inclusions. Machined areas shall be retested after rough machining. Magnetic particle
inspection shall be carried out in accordance with the requirements of
AAC Specification 999000 on all Critical and Major castings.
4.8.3
Defect repair: shallow defects shall be ground out and blended into sound metal to a
maximum depth of 10mm or 25% of section thickness, whichever is the smaller.
Confirmation that the defect has been fully removed shall be made using magnetic particle
or dye penetrant testing.
Weld repairs of larger defects shall be made using an approved welding procedure and
welders qualified to ASTM A488. All weld repairs shall be subjected to a stress relief heat
treatment. Defects with depth greater than 15% of the section thickness shall be cause of
rejection. No repair welding or stress relief shall be conducted after final machining.
The weld repair procedure shall be submitted for approval at time of tender.
All weld repairs shall be surface crack tested in accordance with AA Specification 999000.
All indications greater than 5mm in length shall be ground out and blended into sound
metal. Larger defects shall be re-welded subject to approval.
4.8.4
Dimensions and tolerances: all dimensions of cast components after final machining
shall be in accordance with the Contractor's drawing tolerances.
4.8.5
Local hardening: where wearing surfaces of sheaves and rope drums are locally
hardened, limited surface crazing shall be permitted. The hardened surfaces shall attain
the values specified by the Contractor.
4.9
FORGINGS
4.9.1
Non destructive examination

Critical items
UT to be in accordance with the requirements of EN 10228-3 for volumetric examination,
M.P.T. to be in accordance with the requirements of EN 10228-1 for surface examination.
Acceptance criteria to AA Spec 999000.
Major items
As critical items.
Minor items
M.P.T. to be in accordance with the requirements of EN 10228-2 and acceptance criteria
to AA Specification 999000.
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Defect repair: No repair welding shall be permitted on forgings.

Minor surface defects shall be dressed out by careful grinding and blending into sound
metal. Repair welding of surface defects is generally not permitted.
Details of all defect repairs to be undertaken by the Contractor shall be submitted to the
Engineer for prior approval.
4.9.3
Dimensions and tolerances: all forgings shall be visually and dimensionally inspected
before machining.
4.10
CORROSION PROTECTION
4.10.1
General: surface preparation and corrosion protection of steelwork and equipment shall
be in accordance with the requirements of AA Specification 164000 and AA Specification
164050.
Galvanising shall be in accordance with the requirements of SANS 121.
The finish coat colour schedules for the equipment shall be specified by the Engineer.
4.11
SAFETY
4.11.1
Controls: all controls shall be fail safe and in the event of a power interruption brakes and
rail clamps shall set, all motions arrested and positions prior to power failure shall be
retained. Hydraulically controlled equipment shall maintain position in the event of
pressure failure. Manual restart of the system shall be required on restoration of the
supply.
4.11.2
Guarding: guards capable of supporting 100kg mass shall be provided for all couplings,
gears, pulleys, conveyor nip points, tensioning equipment and moving machinery.
Guards shall be securely fixed in position. Fixing shall be such that the use of a hand tool
is required for their removal. Removal and replacement of individual sections of guards
shall not require disturbance of other guards.
Guards shall be either perforated or solid construction. If perforated it shall not be possible
for a persons to pass a hand through the openings.
Guards shall conform to EN 593. Conveyors shall be equipped with guards that also comply
with AAC Specification 375001.
4.11.3
Rail clamps: shall be kept released during normal operations. They shall set immediately
in the event of a power failure or the operation of the emergency stop system. Rail clamp
interlocks shall prevent power being supplied to the traverse drive while the rail clamps
are engaged.
4.11.4
Access: to and from the ground to the operators position or cab shall be possible with the
machine in all operational positions. The maximum angle to horizontal of any stairway
shall be 40 and ladders shall be provided with back protection.
Walkways shall be provided on both sides of conveyors and be accessible from ground
level on both sides.
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Access shall conform to the following:

Access to points that are essential for operation and maintenance shall be safely and
conveniently reached
4.11.5
Audible alarms: an audible alarm shall be mounted in the machine and be operable from
a push button on the control panel as well as being automatically actuated 10 seconds
prior to start-up of the conveyors. Each device that controls a conveyor shall operate into
the warning system circuit in such a manner that the warning alarm shall actuate each
time the conveyor starts. The alarm shall sound until cancelled by the operator.
4.11.6
Emergency pull-cords: an emergency stop pull-cord shall extend the full length of each
conveyor on the accessible side or sides. The associated switches shall latch in the off
position, have indicating flags and be mounted so as to be readily accessible for resetting.
These shall stop the associated conveyors. A similar emergency stop pull-cord, readily
accessible from ground level, shall extend the full length of each motorized rail bogie
system. All emergency pull cords shall switch on the alarm.
4.11.7
Belt tear: a belt tear device shall be fitted to all conveyors with a means of indication in
the control position.
4.11.8
Fire detection and protection: a fire extinguisher shall be provided in the control cab
and near the door of each electrical equipment room. The extinguisher shall be 9kg, dry
powder type and conform to the requirement of SANS 1910 and AAC Specification
762005. A fire detection and alarm system shall be installed that conforms to
SANS 50054.
4.11.9
Wheel and shaft failure: means of indication shall be provided in the control position to
indicate wheel and shaft failure.
QUALITY ASSURANCE PROVISIONS

Shall be in accordance with the requirements of AA STD 100.
TEST AND INSPECTION METHODS
6.1
GENERAL
All materials, structural, mechanical and electrical, shall be tested and inspected but not
limited to the requirements of the applicable standards and specifications.
6.2
LOAD AND OPERATING TESTS

The Contractor shall conduct the following load and operating tests and shall notify the
Engineer when the equipment is ready for such test. The Contractor shall submit the
results of all tests to the Engineer. The cost of these tests shall be for the Contractors
account.
If the equipment fails any of the tests specified, the test shall be repeated at the
Contractors expense until the equipment meets the requirements of this specification and
the requirements of the contract document.
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The Contractors work shall be considered acceptable upon demonstration of the following,
as applicable to the equipment.
6.2.1
Inspect: and adjust the movements of all mechanical and electrical parts and equipment.
6.2.2
Test: all protective devices.
6.2.3
Balance: the equipment to determine the centre of gravity and the ballast weight.
6.2.4
Position and operate: the material handling system for at least three consecutive shifts
and establish, to the satisfaction of the Engineer, that the material handling system is
capable of operating under load.
6.3
STRUCTURAL TESTS
6.3.1
Static test: load the boom with the following:

Conveyor load: equivalent to belt filled to overflowing with material.
Encrustation load at the boom tip equal to the weight of a 120 mm thick layer of material
on the boom and if applicable the centre of the bucket wheel, considered as a solid disc
up to the cutting circle.
If applicable, live loads in 80% of the total number of buckets being 100% full with
material.
If applicable, encrustation load on the drum equal to a weight of a 12 mm thick layer of
material.
If applicable, live load in the reclaim discharge chute equivalent to the chute being filled to
the brim with material.
If applicable, simulated vertical digging force equal to the maximum digging force
(theoretical) obtained from the rating of the bucket wheel or drum drive motor, the
efficiency of the transmitting gear and the speed of the cutting edge.
6.3.2
Dynamic test: with the static test loads acting carry out the following:
Lower and raise the boom through the full luffing range.
Increase and decrease the shuttle conveyor run to its full limits.
Slew the boom through the full slewing range.
If applicable rotate the drum through more than 360.
Assess the equipments ability to travel at creep speed.
6.3.3
Wheel load measurement: during the dynamic test (see Clause 6.3.2) the wheel loads
shall be measured and recorded. The boom(s) shall be in positions that cause maximum
and minimum wheel loads.
The Engineer shall supply material for the execution of these tests. The Contractor shall
supply sandbags for the additional loads.
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6.3.4
Jacking to determine the mass and balance of the structure supported by the slew ring
shall be carried out in one operation under dead load only after erection is complete.
6.4
GEAR REDUCERS
Test runs for the gear reducers shall be conducted under no load conditions for a period
of 24 hours, using recommended oil and supplied by the Contractor for in-service running.
During the test runs, the Contractor shall record the ambient temperature, bulk oil
temperature and high speed shaft bearing temperature.
The Engineer may at his discretion require that the high speed bearing temperatures be
measured by transducers in direct contact with the side of the stationary races of the
rolling bearings.
The costs of any tests shall be borne by the Contractor. The Contractor shall also bear
the costs of any dismantling required to establish that permissible contact patterns and
backlash have been obtained.
Noise levels shall be measured (and the results approved by the Engineer) with
gearboxes operating under load.
PACKING AND MARKING
7.1
PACKING
The method of packing shall protect all the equipment against damage and the effects of
climatic conditions during transportation and storage.
All parts shall be transported in as large a unit as practicable but within the limits specified
by Provincial Road regulations.
Components shall be adequately labelled and boxed in crates of closed wooden
construction, lined with waterproof material. The crates shall be reinforced and bound on
all sides.
Machined surfaces shall be protected from corrosion and damage during transportation
and storage.
Spare parts shall be packed separately in containers for long term storage. They shall be
boxed individually or in kits to be used in one single renewal or overhaul operation. Other
spare parts or kits shall not be disturbed when using one set or kit. For the convenience
of export shipping more than one set of spare parts may be packed in one single crate or
case.
Prior to the first shipment the Contractor shall send to the Engineer a complete packing
list for the equipment to be shipped. This packing list shall contain but not be limited to
the part or equipment reference, drawing number and quantity.
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MARKING
Spare parts shall be plainly marked Spare Parts Only and clearly identified by stamped
markings on screwed on metal plates. Each part of the equipment shall be legibly marked
to show the unit of which it is part and match marked to show its relative position in the
unit for easy assembly.
Specific lifting points shall be clearly marked on the crates.
All wording on labels and crate markings shall be in English.
A packing list indicating the contents of each container shall be furnished in a moisture
proof envelope securely fastened to the outside of the container. A copy of this packing
list shall be included in the operation and maintenance instructions.
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APPENDIX A : RELATED DOCUMENTS

Unless otherwise specified the latest issue of the following documents are deemed to form part of this
specification.
AA STD 100
Quality Management Systems.
AA Specification 64000
Users guide for corrosion prevention: System selection.
AA Specification 371001
Conveyor pulleys and shafts.
AAC Specification 164050
Corrosion protection of steelwork with coatings
Elevator equipment: Cast steel sheave wheels
Wire rope sockets for draglines.
Belt conveyor idlers and rolls.
Guarding of belt conveyors
Fire extinguishers
Non-destructive testing.
AGMA 908-B89
Geometry Factors for Determining the Pitting Resistance and

Bending Strength of Spur, Helical and Herringbone Gear Teeth
AGMA 2001-D04
Fundamental Rating Factors and Calculation Methods for Involute

Spur and Helical Gear Teeth
ASTM E45
Standard test methods for the determining of the inclusion content

of steel.
ASTM A275M-06
Standard Test Method for Magnetic Particle Examination of Steel

Forgings
ASTM A488
Standard Practice for Steel Castings, Welding, Qualifications of

Procedures and Personnel
AWS D1.1
Structural welding code Steel.
BS 778
Steel pipes and joints for hydraulic purposes.
BS 970 Part 2: 1970
Wrought steels in the form of booms, billets bars and forgings.
BS 1134
Assessment of surface texture.
BS 1710
Identification of pipelines.
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BS 2772 Part 2:1989
Colliery haulage and winding equipment. Specification for wrought

steel
BS 3037
Double-flanged parallel tread tyres.
BS 4368-1:1998
Metallic tube connectors for fluid power and general use. Split collet
compression fittings.
BS 4480 Part 1:1992
Plain bearings, metric series.
EN 593:1998
Safety of machines. Guards. General requirements for the design

and construction of fixed and movable guards.
EN 853:1996
Rubber hoses and hose assemblies. Wire braid reinforced hydraulic

type. Specification
EN 856:1996
Rubber hoses and hose assemblies. Rubber-covered spiral wire

reinforced hydraulic type. Specification
EN 1369:1996
Founding. Magnetic particle inspection
EN 1371-1:1997
Founding. Liquid penetrant inspection. Sand, gravity die and low

pressure die castings
EN 10220:2002
Seamless and welded steel tubes. Dimensions and masses per unit
length
EN 10228-1:1999
Non-destructive
inspection
EN 10228-2:1998
Non-destructive testing of steel forgings. Penetrant testing
EN 10228-3:1998
Non-destructive testing of steel forgings. Ultrasonic testing of ferritic

or martensitic steel forgings
EN 12454:1998
Founding. Visual examination of surface discontinuities. Steel sand

castings
EN 12680-1:2003
Founding. Ultrasonic examination. Steel castings for general

purposes
EN 12680-2:2003
Founding. Ultrasonic examination. Steel castings for highly stressed

components
EN 12680-3:2003
Founding. Ultrasonic examination. Spheroidal graphite cast iron

castings
EN 12681:2003
Founding. Radiographic examination
APPROVED
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of
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forgings.
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EN 1559-2:2000
Founding. Technical conditions of delivery. Additional requirements

for steel castings
ISO 4992-2:2006
Steel castings. Ultrasonic examination. Steel castings for highly

stressed components
EN 1011-8:2004
Welding. Recommendations for welding of metallic materials.

Welding of cast irons
EN 10293:2005
Steel castings for general engineering uses
EN 13411-1:2002
Terminations for steel wire ropes. Safety. Thimbles for steel wire
rope slings
FEM 2.131/2.132
Rules of the design of mobile equipment for continuous handling of

bulk materials
ISO 281:2007
Rolling bearings Dynamic load ratings and rating life.
ISO 5049-1-1994
Mobile equipment for continuous bulk materials Part 1 : Rules for

the design of steel structures.
SANS 121
Hot dip galvanized coatings on fabricated iron and steel articles

Specifications and test methods
SANS 1173
General purpose textile-reinforced conveyor belting.
SANS 1366
Steel cord reinforced conveyor belting
SANS 1313-1
Conveyor belt idlers Part 1: Troughed belt conveyor idlers (metallic

and non-metallic) for belt speeds of up to 5,0 m/s
SANS 1313-2
Conveyor belt idlers Part 2: Link suspended idlers and fixed-form

suspended idlers
SANS 1431:2007
Weldable structural steels
SANS 1910:2006
Portable refillable fire extinguishers
SANS 10160
General procedures and loadings to be adopted for the design of

buildings.
SANS 50054
Fire detection and alarm systems.
Mine Health and Safety Act and Regulations of the Republic of South Africa.
Occupational Health and Safety Act and Regulations of the Republic of South Africa.
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APPENDIX B : RECORD OF AMENDMENTS

Issue 0
Based upon AAC Specification 254001 (Issue 4) with the following amendments:
Para 4.11.2 updated to include EN 593 and AAC Specification 375001;

Para 4.11.8 updated to include AAC Specification 762005 and SANS 50054;
Appendix A updated.
Allan Lill (February 2008)
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12 February 2008
Page 28 of 28


AA SPEC 254001 Stacker Reclaimer Spec PDF

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AA SPEC 254001 Stacker Reclaimer Spec PDF

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AA SPECIFICATION

STACKING AND RECLAIMING EQUIPMENT:

This document supersedes AAC_SPEC_254001

TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER

QUALITY ASSURANCE PROVISIONS

TEST AND INSPECTION METHODS

PACKING AND MARKING

APPENDIX A : RELATED DOCUMENTS

APPENDIX B : RECORD OF AMENDMENTS

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER

Title, number, issue and date of this specification

American Gear Manufacturers Association

Approved by the Engineer in writing

American Society for Testing and Materials.

British Standards Institute

The company, partnership or person contractually obliged to

A component or permanent assembly the failure of which, by

A part or parts of the equipment that fails in one or more respects

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

Consulting Engineer, Consulting Mechanical and

International Standards Organisation

A component or permanent assembly, other than Critical, the

A component or permanent assembly the failure of which is not

The company designated as the recipient of finished products or

A company, partnership or person authorised by the Engineer to

An approved inspection agency appointed by the contractor

South Africa National Standard

Society of Automotive Engineers (American)

South African Institute of Welding

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

Core minimum yield strength

Case/core transition thickness.

Steel cleanliness shall be to ASTM E45 plate II to be obtained by electroslag re-melting,

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

General: mechanical components of the stacker/reclaimer shall be designed generally in

Design life: mechanism components shall be designed to achieve a life equivalent to

Bucket Wheel Drive

Conveyors (Boom, transfer, movable)

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

Crawlers: shall be designed to permit ready inspection and replacement to wearing

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

Static friction between drive wheel and rail 0.2

Sliding friction between locked wheel and rail 0.12

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

Conveyor pulleys: shall be fabricated in accordance with AA Specification 371001.

For information or comments on this document please contact ATD QA

STACKING AND RECLAIMING EQUIPMENT:

Conveyor troughing idlers: shall be one or both of the following:

Transfer chutes and skirts: chutes shall be designed to accommodate material