Indian Standard GENERAL REQUIREMENTS FOR BUILDER S HOIST (First Revision )

Transcription

1 Indian Standard GENERAL REQUIREMENTS FOR BUILDER S HOIST (First Revision ) 1 SCOPE This standard lays down requirements for capacity, construction, safety, performance and testing of single and double platform hoists with or without tilting bucket for use in high rise structures and buildings. 2 REFERENCES The standards given below 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 these standards. IS No. IS 325: 1996 IS 2062: 2006 Title Three-phase induction motors (Fifth Revision) Hot Rolled Low, Medium and High Tensile Structural Steel (Sixth revision) IS 2266: 2002 Steel Wire Ropes for General Engineering Purposes Specification (Fourth Revision) IS 2932: 2003 Enamel, Synthetic, Exterior: (a) Undercoating (b) Finishing Specification (Third Revision) IS 3973: 1984 IS 7403: 1974 IS 10001: TERMINOLOGY Code of practice for the selection, installation and maintenance of wire ropes (First Revision) Code of practice for selection of standard worm and helical gear boxes Performance requirements for constant speed compression ignition (diesel) engines for general purposes (up to 20 kw) For the purpose of this standard, the following definitions shall apply. 3.1 Builder s Hoist

2 It shall mean platform hoists with or without tilting bucket and does not include any other type of hoists. 3.2 Unit It shall comprise of the following parts: a) A winch unit, b) A mast or masts, and c) A platform or platforms with or without bucket. 3.3 Safe Working Load The maximum external load excluding the weight of platform with bucket. 4 TYPES 4.1 Following are the two types of builder s hoist: a) Stationary (single or double platform), and b) Mobile (single or double platform). 5 CAPACITY 5.1 The capacity of the builder s hoist shall be expressed in terms of safe working loads and are given below: 0.25T, 0.5T, 0.75T and 1T at 0.3 to 0.5 m/s trolley speed. 5.2 Actual capacity of the hoists shall be 10 percent greater than the safe working load mentioned in 5.1 under normal conditions. 5.3 The portable hoist shall normally work up to a maximum height of 15 m. 6 MATERIALS 6.1 All materials and components of the hoists; unless otherwise specified, shall be in accordance with relevant Indian Standards. 6.2 All diesel engines shall conform to IS All electric motors shall conform to IS 325. Suitable starters/ ON-OFF switches shall be provided. 6.4 All gear boxes, couplings, etc, if used, shall conform to the relevant Indian Standards and the selection of gear boxes shall be in accordance with IS 7403.

3 6.5 The steel wire rope used shall be hemp cored, galvanized, of 6 19 or 6 37 construction and shall conform to IS The factor of safety shall not be less than 4. The selection, installation and maintenance of wire ropes shall be in accordance with IS All cast iron pulleys shall be suitably fitted with gun metal bushes. 6.7 Steel sections and plates shall conform to IS The winch shall be provided with a hand lever operated brake as well as with a foot operated brake. The brake shoes shall be adjustable and provision shall be made to lock the brakes in position. 6.9 Masts The masts shall be fabricated from structural steel plates and angle/channel sections conforming to IS They shall be fabricated in jigs so that each mast is an exact replica of the other. They shall be suitably braced. Ends of each mast shall have provision for socketing and bolting with another mast. Top mast shall have anchor provisions for bolting a head pulley and for anchoring wire ropes. The bottom section of the mast shall be provided with heavy duty helical springs for absorption of shock loads due to free fall of the platform/bucket All weld joints shall be in accordance with relevant Indian Standards. 7 CONSTRUCTION 7.1 Unit It consists of the following Prime Mover Prime mover may be either a diesel engine or an electric motor or both A Winch Unit In general, winch may be a friction type Winch unit commonly used is a friction winch. This consists of a rotating shaft fitted with two phenol fibre bushes running on gun metal bearings located on two side frames on either side. The frames also house two bearing blocks in which are fitted two cast iron cams through which runs a shaft bearing, a roped run with two Cl friction flanges. The drum pulley shall be made to mesh with the rotating fibre rol1ers and reversed back for braking with the help of hand lever.

4 Alternatively, it may consist of a rotating shaft fitted with V-groove Cl pinion supported on 2 or 3 bushes. The main V-groove pulley is bolted with the drum and rest on cam shaft bushes through a shaft. The drum V-groove pulley shall be made to mesh with the V-groove pulley and reversed back for braking with the help of hand lever A fabricated mast of convenient steel sections shall not be more than 3 m in height Platform The hoist may either be a single or a double platform type. Each platform shall have provision for sliding up and down in its respective mast through four steel (hardened) rollers suitably bushed. These rollers are carried by shafts. The upper shaft passes through two bearing blocks welded on to the platform. All bearing bushes are made of gunmetal (made from proportion of 85 : 5 : 5 : 5 ), that is, 85 percent copper, 5 percent lead, 5 percent zinc and 5 percent tin. The lower shaft carries a cast iron pulley on a pulley frame clamped on to the shaft through which the wire rope winds Emergency Brakes Emergency braking of platform shall be provided to cater wire rope failure Transmission of power from drive unit to winch, shall be through V-belts and pulleys. Hoisting shall be through a wire rope from the winch with minimum safety factor of The length, width and height of any section of the plant shall be such that it is transported easily Based on mutual agreement between the purchaser and the manufacturer, the builder s hoist may be equipped with a crane hook arrangement, fixed at the top of the mast for hoisting/lifting of materials All parts and components of the builder s hoists shall be provided with two coats of anti corrosive primer and one coat of synthetic enamel paint or PVC paint (each of 30 microns thickness) at the shop floor of the manufacturer. The components shall be thoroughly cleaned for removal of rust, oil, grease, dust etc. before application of primer coats. Second coat of synthetic enamel paint or PVC paint (30 microns thick) shall be applied on the hoist after its final assembly/erection at site. Synthetic enamel paints shall conform to IS SAFETY REQUIREMENTS Safety guards shall be provided for moving parts in accordance with the relevant safety regulations.

5 9 PROOF TESTING 9.1 The hoist shall normally be of 0.25 T/0.3T or 0.5 T/0.6T or 0.75 T/0.90 T or 1 T/1.25 T. The first number denotes the safe working load to be carried and the second number denotes the weight to which the hoists are to be tested. 9.2 To test the emergency brake, load the platform to the required testing load after jacking up the platform on knock-off pins. Allow the wire rope to go slack and let the serrated cam blocks jam on to the mast. Now knock-off the pins and see if platform slips. The platform should not slip more than 1 metre down with the load. 10 ERECTlON 10.1 The manufacturer shall provide drawings for foundation bolts and scaffolding with suitable anchorages, if so desired by the purchaser The manufacturer shall supply an operation and maintenance/ instruction manual and spare parts catalogue with each hoist The manufacturer shall supply a list of essential spare parts for two years normal operation. 11 MARKING 11.1 The hoist shall be marked with the following: a) Manufacturer s name; b) Machine Sr. No.; c) Engine/motor capacity; d) Capacity of the hoist with related trolley speed; e) Year of manufacture; f) Rope diameter; g) Engine/motor Sr. No.; and h) Weight of platform, bucket and structures.

6 Indian Standard CONCRETE DELIVERY PIPELINE Part I SPECIFICATION 1 SCOPE This standard covers construction features, technological requirements, dimensions and designations of straight pipes, reducer pipes and pipe bends used in Concrete Delivery Pipelines. 2. REFERENCES The standards given below 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 these standards. IS No. Title 1762 (Part1): 1974 Code for designation of steels - (Part 1) Based on letter symbols. (First Revision) 2004 : 1991 Carbon steel forgings for general engineering purposes - Specification (Third Revision) (Part1): 1993 General tolerances, part 1 (Tolerances for linear and angular dimensions without individual tolerance indication) (Third Revision) 2932 : 2003 Enamel, Synthetic, Exterior : (a) Undercoating (b) Finishing - Specification (Third Revision) : 2006 Steel Tubes for Mechanical and General Engineering Purposes Specification (Second Revision) : 1982 Recommendations for general pipeline welding 3. CONSTRUCTION FEATURES

7 3.1 Concrete Delivery Pipeline (i.e. straight pipes, reducer pipes and pipe bends) conforming to this standard shall be manufactured from abrasion resistant, seamless steel pipes duly welded with machined flanges manufactured from abrasion resistant steel The steel pipes of Concrete Delivery Pipeline shall conform to IS Pipes shall be hot finished seamless steel tubes complying with tube designation HFS 240. If required, the pipes may be cold-drawn to achieve the required diameter and thickness. The cold drawn seamless steel tubes shall comply with tube designation CDS 240. No heat treatment shall be required for hot finished pipes. But, cold-drawn pipes shall be normalized after the final cold draw pass at a temperature of o C. Tolerance limits of outside diameter and thickness of pipes shall be in accordance with section 26 of IS Carbon steel forgings of flanges shall conform to IS Chemical composition of the forgings shall comply with class 2 designation with carbon content not exceeding 0.22 percent. The steel forgings shall be normalized at a temperature of o C before machining. If required, the flanges may be fabricated from thick carbon steel plates of steel designation 20 C 8 (see IS 1762 part 1) At the discretion of the manufacturer, the flanges of concrete delivery pipeline may be sleeved and welded or butt-welded as shown in fig. 1. Butt joints for welding of pipes and flanges shall be prepared in conformity with IS Flanges of ground pipeline (also called fixed pipeline or stationery pipeline) for stationery concrete pumps shall be of type A (i.e. type A1 flange on one side and type A2 flange on the other side of the pipe / bend) whereas flanges of pipeline for placement booms shall be of type B as shown in fig. 2. FIG. 1 WELDING OF CONCRETE DELIVERY PIPELINE `A Type Flange `B Type Flange FIG. 2 FLANGES OF CONCRETE DELIVERY PIPELINE Standard engineering practices / recommendations for welding (see IS 10234) shall be followed for welding of the flanges with straight pipes / reducer pipes / pipe bends for proper fusion of weld material. Welding shall be uniform and smooth Suitable holding arrangements like jigs / fixtures shall be deployed during welding of flanges with straight pipes / reducer pipes / pipe bends to avoid twist / unequal shrinkage. 3.2 Reducer pipes shall be fabricated from the pipes of nominal size equal to the large end of the reducer by suitable profile cutting and welding.

8 3.3 The profile of pipe bends shall be uniform and without any visible kink Precautions shall be taken to minimize thinning of pipes during bending process for making pipe bends. Wall thickness at bent portion of the pipe bends shall be within the permissible limits Pipe bends shall be made by cold bending process. However, pipe bends of size beyond 125 mm nominal bore made by hot bending process, shall also be acceptable subject to fulfillment of conditions at 3.3 and above. 3.4 The outside surface of pipes, bends and reducer pipes shall be thoroughly cleaned to remove dirt / dust / grease etc. before application of two coats (each of minimum 20 microns thick) of anti-corrosive primer and two coats (each of minimum 20 microns thick) of synthetic enamel paint of light colour shade. The colour shade shall be as per agreement between the purchaser and the supplier. Synthetic enamel paints shall conform to IS TECHNOLOGICAL REQUIREMENTS 4.1 Manufacturer s test certificates of seamless steel pipes and flanges meeting requirements of IS 3601 and IS 2004 shall be furnished by the supplier of Concrete Delivery Pipeline to the purchaser. 4.2 A part of pipeline items shall be assembled with rubber sealing gaskets and pipe couplings at the works of the supplier of pipeline for pneumatic test at an air pressure of 10 kg / cm 2 in the presence of the purchaser. No leakage shall be permissible from the pipes and weld joints. However, for a test duration of fifteen minutes, maximum drop of pressure upto 0.05 kg / cm 2 per coupling joint of pipeline shall be permissible. 4.3 Percentage of pipeline items to be assembled for pneumatic test shall be as per specific agreement between the purchaser and the supplier. 5. DIMENSIONS 5.1 Nominal bore of pipeline shall be at least two and a half times the highest size of the coarse aggregates to be used in pumpable concrete Pipeline for placement booms shall be of nominal bore 100 or 125 mm Pipeline for stationery concrete pumps shall be of nominal bore 100 or 125 or 150 or 180 mm depending upon the rating of the concrete pump (i.e. pumping pressure and discharge rate) and the size of aggregates used in concrete.

9 Pipes with 4.5 mm wall thickness may be used for practically all normal operations of concreting through concrete delivery pipeline, subject to the following maximum pumping pressures of concrete: For 100 NB pipes, pumping pressure not to exceed 140 kg / cm 2. For 125 NB pipes, pumping pressure not to exceed 110 kg / cm 2. For 150 NB pipes, pumping pressure not to exceed 90 kg / cm For higher pumping pressures of concrete (see below), pipes with 8 mm wall thickness shall be used. For 100 NB pipes, pumping pressure not to exceed 230 kg / cm 2. For 125 NB pipes, pumping pressure not to exceed 190 kg / cm 2. For 150 NB pipes, pumping pressure not to exceed 160 kg / cm 2. NOTE : 1) Friction i.e. flow resistance and consequently pumping pressure being inversely proportional to the pipeline diameter, higher diameter pipes are to be preferred to reduce pumping pressure. But large diameter pipes being heavier and difficult to be handled manually, a compromise shall be made for selection of pipeline diameter. Pipeline of 125 mm nominal bore is a good compromise. Pipeline of 100 mm nominal bore shall be more suitable for short lengths where concrete distribution is done through end hose by manual labor. Pipeline of 150 mm nominal bore shall be preferred for tunnel concreting where large size aggregates (up to 60 mm) are used and concrete distribution is mechanized. 2) Small diameter pipelines (100 mm or 125 mm nominal bore) shall be preferred over large diameter pipeline (150 mm or 180 mm nominal bore) to avoid bleeding of concrete for descending pipelines. 3) Wall thickness of pipe bends shall be a little higher than the thickness of straight pipes to take care of more wear and tear due to heavy friction. 4) A few thick walled pipes shall be used immediately after the concrete pump to take care of high pumping pressure and more wear and tear due to heavy friction. Thick walled pipes shall also be used in the vertical section of pipeline or for the portion of pipeline, which is difficult to dismantle and reassemble. 5.2 Straight Pipes The straight pipes (fig. 3) shall be of standard lengths 500±4mm, 1000±4mm, 2000±6mm and 3000±8mm Straight Pipe with `B Type Flange Straight Pipe with `A Type Flange

10 5.3 Reducer Pipes FIG. 3 STRAIGHT PIPE The reducer pipes (fig. 4) to match with the size of concrete pump outlet and rest of the pipeline or to serve as transition from larger to smaller diameter pipes, shall be of standard lengths 500 ± 4 mm, 1000 ± 4 mm, 1500 ± 6 mm, 2000 ± 6 mm and 2500 ± 8 mm. Reducer Pipe with Eye for Tightening by clamping device FIG. 4 REDUCER PIPE NOTE : Intermediate lengths of straight pipes and reducer pipes (see 5.2 and 5.3 above) may also be manufactured suiting to the specific requirements of the purchaser. 5.4 Pipe Bends For Placement Booms (Fig. 5) Standard radius (R) of pipe bends for placement booms shall be 250 ± 2 mm or 275 ± 2 mm, suiting to the requirements of the purchaser. Radius (R) shall be 250 ± 2mm or 275 ± 2mm FIG. 5 PIPE BENDS FOR PLACEMENT BOOMS For Ground Pipelines (Fig. 6) Standard radius (r) of pipe bends of ground pipelines for stationery concrete pumps shall be 1000 mm or 2000 mm, suiting to the requirements of the purchaser. NOTE: Tolerance class m (i.e. medium) shall apply to the machined flanges (see and above) as per IS 2102 (Part 1). 6. DESIGNATION The designation for straight pipes, reducer pipes and pipe bends, as explained hereunder, shall briefly cover their relevant details. The dimensions indicated in the designations shall be in mm. Thickness of pipes shall be indicated upto one decimal place.

11 Pipe (or Reducer or Bend) IS (Code No.) Nominal Bore I x Nominal Bore II x Thickness Length of pipe (or degree and radius of bend) and Type of Flanges Example 1 : Designation of Straight Pipe of 125 mm nominal bore, 4.5 mm thick, 2000 mm long with A type flanges shall be: Pipe IS XXXX 125 x 125 x A Example 2 : Designation of Reducer Pipe of 150 mm x 125 mm nominal bore, 6.3 mm thick, 1500 mm long with A type flanges shall be: Reducer IS XXXX 150 x 125 x A Example 3 : Designation of 125 mm nominal bore, 5 mm thick, 90 o Pipe Bend of 275 mm radius for placement boom with B type flanges shall be: Bend IS XXXX 125 x 125 x o x 275 B XXXX : IS no. to be given after same is allotted for this document. Indian Standard CONCRETE BLOCK MAKING MACHINES - GENERAL REQUIREMENTS (First Revision) 1 SCOPE 1.1 This standard lays down requirements for concrete solid and cavity block making machines of stationary and travelling type, having electrical motor driven vibration and travel mechanism (for traveling type) for manufacturing concrete blocks according to IS 2185 (Part 1). 1.2 This standard does not cover completely manually operated hand moulding sets. 2 REFERENCES

12 The standards given below 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 these standards. IS No. Title IS 2185 : Part 1 : 2005 IS 2062 : 2006 IS 2932 : 2003 Concrete Masonry Units - Specification Part 1 Hollow and Solid Concrete Blocks (Third Revision) Hot Rolled Low, Medium and High Tensile Structural Steel (Sixth Revision) Enamel, Synthetic, Exterior : (a) Undercoating (b) Finishing Specification (Third Revision) 3 TERMINOLOGY 3.1 For the purpose of this standard, the following definitions shall apply. Nomenclature of the parts of the concrete block making machine is explained in Fig. 1. Fig Stationary Type A concrete block making machine with frame fixed on ground or on an elevated structure. The blocks are laid on wooden or metal pallets to be transported either manually or mechanically. 3.3 Travelling Type/Egg Laying Type A concrete block making mobile machine which lays blocks on a level platform on which it moves. The machine lays a particular number of blocks over the platform and moves further to lay another set of blocks, so as to cover the casting platform, in a continuous casting process. 3.4 Mould It is a structural steel (see IS 2062) fabricated member for moulding concrete blocks of required shapes and sizes. 3.5 Ram It is a structural steel (see IS 2062) fabricated member of complementary shape to the moulds with requisite tolerances for compaction of block concrete and for release of cast blocks from the moulds.

13 3.6 Machine Assembly Structural assembly of the machine consisting of: a) Main supporting frame to support the machine on platform and provide mobility mechanism for mobile machines; b) Ram fixing frame; and c) Mould fixing frame. Note: The material of above frames shall conform to IS Vibrator Assembly Electrically operated vibrating mechanism fixed to the mould frame to produce dense blocks. 3.8 Tamping Arrangement A form fitting arrangement to obtain compaction through ramming action and to provide required height to the concrete in the moulds after compaction. 4 DESIGNATION OF SIZES 4.1 The sizes of concrete block making machines shall be designated by the casting size of the machine in mm. Casting Size mm x mm The intermediate and other sizes shall not be considered as standard sizes, although these may be supplied by mutual agreement between the purchaser and the supplier. 5 OPERATION SPEEDS 5.1 The machine travelling speed shall not be less than 15 m/min along the casting platform. 5.2 Casting Speed Number of casting operations of the machine shall be between 40 to 55 numbers of casting of block operations per hour. The number of operations per hour shall be specified for each machine. The specifications for the motor shall be clearly identified.

14 6 GENERAL CONSTRUCTION 6.1 Besides vehicle chassis and the drive/ driven mechanism, other main components of the concrete block making machines are hydraulic pump and its accessories, frame structures for mounting the moulds and the mould assembly. All sub-assemblies, including the charging hopper and mould of concrete block making machines of the same size manufactured or supplied under a specific contract shall be physically and mechanically identical. 6.2 All parts and components shall be provided with two coats of anti corrosive primer and one coat of synthetic enamel paint or PVC paint (each of 30 microns thickness) before assembly of the concrete block making machine. The components shall be thoroughly cleaned for removal of rust, oil, grease, dust etc. before application of primer coats. Second coat of synthetic enamel paint or PVC paint (30 microns thick) shall be applied on the machine after its final assembly. Synthetic enamel paints shall conform to IS Ram frame shall be made from not less than 6 mm thick steel plates. The pockets for cavity shall be made from 3 to 4 mm steel plates. The edges and welds are dressed to remove burrs and irregularities so that the block contact surfaces are left cleaned and smooth. Steel plates shall correspond to IS Block machine shall have normal provision for fitment and use of different moulds. The machine shall have versatility for production of different types of concrete blocks and allied products. The removal of one ram mould pair and fitment of another ram mould pair shall be easy and require minimum time. 6.5 The machines shall have provision for making adjustment to the fitment of ram and mould assembly so as to have proper level and alignment. 6.6 The frame of machines shall be manufactured from suitable steel sections and plates corresponding to IS 2062 with normal cares for welding and cleaning. The machine shall be capable of incorporating ram and mould assembly for block sizes which shall be as specified in the relevant Indian Standards. 6.7 The vibrations shall be approximately vibrations per minute. Amplitude of vibrations shall be as required for proper compaction of the blocks as per the mix used. Vibration arrangement shall have scope for adjusting amplitude of vibration by adjusting the counter weights. The vibration spindles shall be rested on proper ball bearing to obtain smooth operation and belt vibrator with an electric motor as prime mover fixed to the main frame shall be used. 6.8 The travel of the ram shall be controlled so as to exert pressure on the concrete due to its travel till the correct height for the block is achieved. The height of the block shall be obtained by the ram assembly with the help of limit switches which shall cut off the power to the vibrator motor at appropriate time.

15 7 INSPECTION OF THE MACHINE 7.1 After assembly of the machine it should be checked for the following: a) Workmanship; b) Welding and cleaning of welds; c) Dry run of machine; and d) Sample moulding of blocks. 7.2 Sample Moulding of Blocks The test is done to ensure that the blocks are cast without damage and with correct size The mould and ram are fixed to the respective frames and by trying movements the alignment is checked and adjusted, if necessary Platform for Trial The trial is conducted on a concrete platform (or pallet) with good strength, surface finish and level The concrete is fed to the machine by spreader as in the actual use and one or two sets of blocks are cast to ascertain the concrete shape and dimensions. Any correction required is made immediately and more sets of blocks are cast till satisfactory results are obtained. 8 INSPECTION RECORD 8.1 A proper inspection record of the machine at the time of final testing is maintained as given in Annex A. 9. MAINTENANCE ACCESSIBILITY 9.1 Manufacturer shall provide operation and maintenance manual along with machine. 9.2 Ease of Maintenance All major assemblies and installed attachments shall be accessible for maintenance, repairs and replacements without the removal of other major assemblies and installed attachments. Covers and plates which shall be removed for component adjustments, replacements and maintenance shall be equipped with quick disconnect fasteners. 10 MARKING 10.1 Each concrete block making machine shall have firmly attached to it a plate giving the following particulars:

16 a) Name of manufacturer; b) Year of manufacture, c) Sr No. of machine, d) Size of machine, e) Details and Sr No. of electric motors, and f) Type of machine BIS Certification Marking - The Concrete block making machine may also be marked with the Standard Mark The use of the Standard Mark is governed by the provisions of Bureau of Indian Standards Act, 1986 and the Rules and Regulations made thereunder. The details of conditions under which the Iicence for the use of the Standard Mark may be granted to manufacturers or producers maybe obtained from the Bureau of Indian Standards.