DR AS 4324.

1:2024

Draft
Australian Standard

Public Comment is invited for:

DR AS 4324.1:2024, Mobile equipment for continuous handling of bulk

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materials, Part 1: General requirements for the design of steel structures

During their development process, Australian Standards are available in draft form during the
public consultation period to allow any interests concerned with the application of the proposed

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Standard to review the draft and submit their comments.
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This draft is liable to alteration. It is not to be regarded as an Australian Standard until finally
issued as such by Standards Australia.

Upon successful conclusion of the Public Comment period it is proposed to publish this Standard
as AS 4324.1:202X.
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 DR AS 4324.1:2024

© Standards Australia Limited 2024

ii

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 iii DR AS 4324.1:2024

Preface
This Standard was prepared by the Standards Australia Committee ME-043, Bulk Handling Equipment,
to supersede AS 4324.1:2017.
The objective of this document is to provide requirements for the design of steel structure for bulk
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handling equipment.
The major changes in this edition are as follows:
(a) Section 2 Materials has been simplified to allow greater automatic acceptance of steel
procured in conformance to AS 4100 or AS/NZS 5100.6. Testing requirements for when this is
not the case have been provided.
(b) Introduction of a new load case at Clause 3.4.2, Ws, termed “stranded from tiedown”. This

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load case addresses several instances experienced by industry where uncontrolled motion
and damage of machines has been caused by rapidly approaching local storm events.
(c) Introduction of a new load case at Clause 3.5.14, Ws, termed “loss of chutes/telescopic
chutes”. This load case addresses several instances experienced by industry where chutes on
shiploaders have has been lost from their booms.

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(d)
(e)
(f)
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Additional clarification and minor improvements to loading requirements in Section 3.
Further clarification and modifications of resistance to drifting requirements in Clause 4.2.
Variation of the modified yield the value to be used for structural design in Clause 5.3.
(g) Additional clarification and minor improvements to the use of the structural design rules
in Section 5.
(h) Modification and simplification of the tensile safety factors required for ropes, as straps, stays
and hydraulic cylinders intention in Clause 5.7.5.
(i) Introduction of minimum buckling factors for hydraulic cylinders in compression in
Clause 5.7.7.
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Explanatory notes on the drafting of this document are given in Appendix A.
The terms “normative” and “informative” have been used in this Standard to define the application of
the appendix to which they apply. A “normative” appendix is an integral part of a Standard, whereas an
“informative” appendix is only for information and guidance.

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 DR AS 4324.1:2024 iv

Contents
Preface.............................................................................................................................................................................................................................................. iii
Introduction............................................................................................................................................................................................................................... vii
Section 1 Scope and general................................................................................................................................................................................... 1
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1.1 Scope..................................................................................................................................................................................................................... 1
1.2 Application....................................................................................................................................................................................................... 1
1.3 Normative references............................................................................................................................................................................. 1
1.4 Terms and definitions............................................................................................................................................................................. 2
1.5 Symbols and abbreviated terms.................................................................................................................................................... 6
1.6 New designs and innovations.......................................................................................................................................................... 9
1.7 Basis of design............................................................................................................................................................................................... 9
1.8 Technical specification........................................................................................................................................................................... 9

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1.9 Basic digging parameters for bucket wheel machines............................................................................................... 9
1.10 Corrosion protection and machine condition.............................................................................................................. 10
1.11 Mechanisms, electrical, controls, commissioning, operation and asset management ............ 10
1.11.1 Mechanisms....................................................................................................................................................................... 10
1.11.2 Electrical and controls (including computer/programmable controls)........................ 10
1.11.3 Commissioning, operation and asset management......................................................................... 10

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Section 2
2.1
2.2

2.3
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Materials.......................................................................................................................................................................................................11
General.............................................................................................................................................................................................................. 11
Limitation on use of brittle materials.................................................................................................................................... 11
2.2.1 General....................................................................................................................................................................................... 11
2.2.2 Fracture and failure critical applications..................................................................................................... 11
Alternative materials and fabrication Standards......................................................................................................... 12
2.3.1 General....................................................................................................................................................................................... 12
2.3.2 Basis of design..................................................................................................................................................................... 13
2.3.3 Material substitution..................................................................................................................................................... 13
2.3.4 Fabrication practices and Standards............................................................................................................... 13
2.3.5 Demonstration of adequacy of alternative Standards used......................................................... 13
Section 3 Load assumptions................................................................................................................................................................................14
3.1 General.............................................................................................................................................................................................................. 14
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3.1.1 Technical specification and design loading................................................................................................ 14
3.1.2 Loads and load limiting devices........................................................................................................................... 14
3.1.3 Bulk density (γ).................................................................................................................................................................. 14
3.2 Load groups.................................................................................................................................................................................................. 15
3.3 Main loads...................................................................................................................................................................................................... 15
3.3.1 Grouping................................................................................................................................................................................... 15
3.3.2 Dead loads (E)..................................................................................................................................................................... 15
3.3.3 Encrustation (V)................................................................................................................................................................ 15
3.3.4 Inclination (N)..................................................................................................................................................................... 16
3.3.5 Live loads (F)........................................................................................................................................................................ 16
3.3.6 Basis for normal digging and lateral resistance determination............................................... 17
3.3.7 Normal digging resistance (U).............................................................................................................................. 17
3.3.8 Normal lateral digging resistance (S)............................................................................................................. 18
3.3.9 Permanent dynamic effects (D)............................................................................................................................ 19
3.3.10 Forces associated with conveyor elements (G)................................................................................... 20
3.3.11 Friction (R)......................................................................................................................................................................... 20
3.3.12 Travel (L).............................................................................................................................................................................. 20
3.4 Additional loads........................................................................................................................................................................................ 21
3.4.1 Grouping................................................................................................................................................................................... 21
3.4.2 Wind during operation (Wo, Wr, Ws).............................................................................................................. 21
3.4.3 Temperature (T)................................................................................................................................................................ 22
3.4.4 Abnormal digging resistance (UU).................................................................................................................... 22
3.4.5 Abnormal lateral digging resistance (SS).................................................................................................... 22

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3.4.6 Travel skew forces (LS)............................................................................................................................................... 23

3.4.7 Non-permanent dynamic effects (DD)........................................................................................................... 27
3.4.8 Snow, ice and hail loads (K)..................................................................................................................................... 27
3.4.9 Access ways (P).................................................................................................................................................................. 28
3.4.10 Erection, dismantling and weighing (Y).................................................................................................... 28
3.4.11 Maintenance loads (X).............................................................................................................................................. 28
3.4.12 Abnormal inclination (NN)................................................................................................................................... 28
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3.5 Special loads................................................................................................................................................................................................ 29

3.5.1 Grouping................................................................................................................................................................................... 29
3.5.2 Grounding of a bucket wheel, ladder or discharge boom.............................................................. 29
3.5.3 Uneven support where rail-mounted (QQ)................................................................................................ 30
3.5.4 Uneven support where crawler-mounted (QQ)..................................................................................... 30
3.5.5 Blocked chutes and hoppers (VV)...................................................................................................................... 31
3.5.6 Excess material on conveyors (FF).................................................................................................................... 32
3.5.7 Travelling device obstructed (LL)...................................................................................................................... 32

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3.5.8 Lateral collision of boom (FS)................................................................................................................................ 33
3.5.9 End-on collision of boom (FT).............................................................................................................................. 34
3.5.10 Wind while idle (WWp and WWu).................................................................................................................. 35
3.5.11 Buffers (OO)....................................................................................................................................................................... 36
3.5.12 Earthquakes (EQp and EQu)................................................................................................................................. 36
3.5.13 Burying (ZZ)...................................................................................................................................................................... 37

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3.6
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3.5.14 Bucket wheel and gearbox loss or loss of Boom Equipment (BL)...................................... 37
3.5.15 Abnormal friction (RR)............................................................................................................................................ 38
3.5.16 Extra loads (EL).............................................................................................................................................................. 38
Fatigue loads................................................................................................................................................................................................ 39
3.6.1 General....................................................................................................................................................................................... 39
3.6.2 Dead loads and encrustation (+/+E and +/+V)...................................................................................... 39
3.6.3 Inclination (+/−N)........................................................................................................................................................... 39
3.6.4 Live loads on conveyors (+/0CF.F).................................................................................................................... 40
3.6.5 Normal digging resistance (+/0CU.U)............................................................................................................. 40
3.6.6 Lateral digging resistance (+/−CS.S)................................................................................................................ 40
3.6.7 Permanent dynamic effects (+/−D).................................................................................................................. 40
3.6.8 Conveyor elements (+/+G)....................................................................................................................................... 40
3.6.9 Friction (+/−R)................................................................................................................................................................... 40
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3.6.10 Travel (+/−L)..................................................................................................................................................................... 40

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3.7 Load cases...................................................................................................................................................................................................... 41
Section 4 Overturning and drifting..............................................................................................................................................................51
4.1 Stability against overturning......................................................................................................................................................... 51
4.2 Resistance against drifting.............................................................................................................................................................. 51
Section 5 Design of structures..........................................................................................................................................................................53
5.1 Loads and load cases............................................................................................................................................................................ 53
5.2 Fatigue design life................................................................................................................................................................................... 53
5.3 Steels having a high yield to ultimate tensile strength ratio.............................................................................. 53
5.4 Design methods to allow for strength and serviceability..................................................................................... 53
5.4.1 General....................................................................................................................................................................................... 53
5.4.2 Permissible stress design method..................................................................................................................... 54
5.4.3 Limit-state-design method....................................................................................................................................... 57
5.4.4 Serviceability........................................................................................................................................................................ 59
5.5 Fatigue strength of structural components and joints............................................................................................ 59
5.5.1 General....................................................................................................................................................................................... 59
5.5.2 The required Standard and relevant parameters for fatigue design shall
be as defined in the technical specification in accordance with Appendix
B.Permissible stress ranges.................................................................................................................................. 59
5.5.3 Compressive stress ranges....................................................................................................................................... 60
5.6 Bolting and riveting............................................................................................................................................................................... 60
5.6.1 Fitted bolts............................................................................................................................................................................. 60
5.6.2 Low strength non-fitted bolts (e.g. forged black bolts)................................................................... 60

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5.6.3 Rivets........................................................................................................................................................................................... 60
5.6.4 Joints using high tensile bolts................................................................................................................................ 60
5.6.5 Serrated bearing bolts.................................................................................................................................................. 60
5.7 Steel wire ropes, straps and stays in tension, and hydraulic cylinders..................................................... 60
5.7.1 General....................................................................................................................................................................................... 60
5.7.2 Factors to be included.................................................................................................................................................. 61
5.7.3 Duplication for operator’s cabin.......................................................................................................................... 61
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5.7.4 Duplication of ropes, straps and stays............................................................................................................ 62

5.7.5 Safety factor........................................................................................................................................................................... 62
5.7.6 Chains and racks................................................................................................................................................................ 62
5.7.7 Hydraulic cylinders......................................................................................................................................................... 63
5.8 Slewing race safety hooks to prevent separation at the slew race............................................................... 63
5.9 Mass and centre of gravity of machine................................................................................................................................. 64
5.10 Lifting beams and lugs..................................................................................................................................................................... 64
Section 6 Ancillary structures...........................................................................................................................................................................65

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6.1 Loads and load cases............................................................................................................................................................................ 65
6.2 Supporting structures and rails.................................................................................................................................................. 65
6.3 Tie-down and restraints.................................................................................................................................................................... 65
6.4 Major maintenance works............................................................................................................................................................... 65
Appendix A (informative) Explanatory notes............................................................................................................................................66

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Appendix B (normative) Information to be supplied within the technical specification........................ 100
Appendix C (informative) .......................................................................................................................................................................................... 108
Appendix D (informative) ......................................................................................................................................................................................... 109
Appendix E (informative) Typical types of mobile continuous bulk handling equipment.................... 110
Appendix F (informative) Basic digging parameters for bucket wheel machines.......................................... 118
Appendix G (normative) Loose measure volumetric capacity of digging elements...................................... 126
Appendix H (informative) Typical bulk densities of handled material...................................................................... 129
Appendix I (normative) Live loads on conveyors.............................................................................................................................. 130
Appendix J (informative) Plate buckling.................................................................................................................................................... 139
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Appendix K (informative) Functions for a design audit engineer during audit of a structure.......... 140

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Bibliography.......................................................................................................................................................................................................................... 143

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 vii DR AS 4324.1:2024

Introduction
This document is the third revision of AS 4324.1.
The development of the first edition of this Standard in 1995 was based largely on the German Code
for structural design, BG—1986 Regulations, Calculations and dimensioning of large machines in open
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cuts, and the International Standard ISO 5049-1:1994, Mobile equipment for continuous handling of bulk
materials, Part 1: Rules for the design of steel structures, but included a number of variations to provide
coverage of a more comprehensive range of machinery and loading conditions.
The 2017 edition provided greater clarity in loading requirements and greater simplicity in the
prescription of structural design requirements. More emphasis was placed on specifying design
requirements that are specific to the machine, and the recognition that effective controls, protective
devices systems and load limiting devices play an integral part in the operation and limitation of applied
loading to structures of this type. Duplication of requirements for structural materials and design rules

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was avoided where possible by direct reference to established Australian or International Standards.
Following structural reliability analyses, the strength limit state approach was also modified to
accommodate the load factor (per primary load case) and resistance design/partial safety factor
approach. The preferred method of structural design is a subject for agreement between the purchaser
and the supplier or prescription via the technical specification.

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This edition continues the development of the Standard to recognize and refine the requirements to
contemporary circumstances.
Committee ME-043 recognizes that some load cases are based on general industry knowledge and
other international precedents. For future revisions of specific values in certain clauses, coordinated
field-testing or a significant level of research across a wide variety of machines and materials is likely
to be required.
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 NOTES

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 1 DR AS 4324.1:2024

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

Section 1 Scope and general

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1.1 Scope
This document specifies general requirements, design loads and specific requirements for the design
of structures of mobile equipment for continuous handling of bulk materials, including appliances and
machines that are intended to carry out similar functions (e.g. excavators, stackers, reclaimers, ship
loaders, ship unloaders, belt wagons, sizing rigs and spreaders).

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This document may be applied to the design of stationary equipment that is similar to mobile equipment
in this document.
It is not intended that this document be applied to the following equipment, but it may be applied to
parts of such equipment:

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(a)

(b)
of materials.
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Feeders, fixed conveyors, bucket elevators and storage structures with through flow

Intermittent operation bulk handling equipment (i.e. equipment that handles or excavates
material on a cyclic basis, such as draglines and power shovels).
NOTE Explanatory notes on the drafting of this Standard are given in Appendix A.

1.2 Application
This document shall be used for the design of new structures of mobile equipment for continuous
handling of bulk materials. This document should be used as part of a risk assessment process for
evaluation of existing machine structures for continued use, upgrade or modification, including
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machines designed to this document.

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The application, omission, or variation of the requirements of specific clauses of this document shall
be documented in a technical specification (see Clauses 1.4.38 and 1.8), subject to the requirements of
this document.
Specified omission or reduction of the requirements of this document shall only occur following
assessment of the risk of that load case occurring. The risk assessment shall include the assessment
and documentation of the effectiveness of the controls and protections that will be implemented to
prevent the situation occurring and the consequences if the event occurs. This risk assessment
shall be documented with justifications provided as technically and practicably valid. Refer to
AS/NZS ISO 31000.
Appendix B provides the information that shall be established within a technical specification for
supply of a machine.

1.3 Normative references

The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document.
NOTE Documents referenced for informative purposes are listed in the Bibliography.

AS 1170.4, Structural design actions, Part 4: Earthquake actions in Australia

AS 1418.1:2002, Cranes, hoists and winches, Part 1: General requirements

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AS 1657, Fixed platforms, walkways, stairways and ladders—Design, construction and installation
AS 3569, Steel wire ropes—Product specification
AS 3990, Mechanical equipment—Steelwork
AS 4100, Steel structures
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AS/NZS 1170.0:2002, Structural design actions, Part 0: General principles

AS/NZS 1170.2, Structural design actions, Part 2: Wind actions
AS/NZS 1170.3, Structural design actions, Part 3: Snow and ice actions
AS/NZS 5100.6, Bridge Design, Part 6: Steel and composite construction

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1.4 Terms and definitions
For the purpose of this document, the following terms and definitions apply.
1.4.1
alternative Standard

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alternative (Standard) to that specified by this documentor the Standards referenced by this Standard
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that are prescribed in the technical specification (see Appendix B)
1.4.2
appropriate recognized Standard
Standard that is recognized by the global industry and is conventionally used for the application so
defined
1.4.3
approved
approved, in writing
1.4.4
balance
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state of the machine masses, both dead load and operating loads in relation to the load’s locations

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generally with reference to a pivoting point
Note 1 to entry: This is generally assessed by review of luff system forces and slew bearing moments.

1.4.5
bulk density
weight of a unit volume of loose material, including moisture
1.4.6
constructor
erector
party that conducts the site construction or erection of the machine
Note 1 to entry: This party may not necessarily be the supplier (1.4.37) or the designer (1.4.9).

1.4.7
crowding board
board placed near the edge of a conveyor belt either to increase the carrying capacity or to prevent
spillage
Note 1 to entry: Crowding boards are sometimes referred to as skirt plates. Other devices (e.g. including closely
spaced wire ropes, pipes or tube sections) that achieve the same effect are treated as though they are crowding
boards.

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1.4.8
design audit engineer
suitably qualified engineer who undertakes independent checks of the design
Note 1 to entry: to entry: Design audit engingeer is also known as a “proof engineer” or a “design verifier”.

1.4.9
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designer
design engineer
designer of the machine, including preparation of the necessary design calculations, drawings and
fabrication/construction specifications
1.4.10
effective torque limiting coupling
torque limiting coupling that, upon activation, in any foreseeable operation scenario, ceases operation
or reduces the transmitted torque and power across the coupling

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1.4.11
excavator
machine that digs in virgin ground, and sometimes in blasted material
1.4.12

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fatigue

1.4.13
fatigue strength
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damage caused by repeated fluctuations of stress leading to gradual cracking of a structural element

stress range defined in AS 4100 for each detail category varying with the number of cycles, or similar
results from the use of an alternative fatigue design Standard
1.4.14
full load torque
output torque generated at 100 % of the rated power of the relevant drive
1.4.15
limit state
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limiting condition beyond which the structure ceases to fulfil its intended function

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Note 1 to entry: Includes strength, stability, serviceability and fatigue strength.

1.4.16
load limiting device
protective device
device or control that prevents a specific load or a combination of loads from exceeding a defined value
1.4.17
material in transit
material that is in motion on a conveyor belt or within a reclaiming device or chute
1.4.18
mobile equipment for continuous handling of bulk materials
equipment such as those illustrated in Appendix E as follows:
(a) Bucket wheel excavators and bucket chain excavators in Figure E.1.
(b) Reclaimers in Figure E.2.
(c) Stacker-reclaimers in Figure E.3.
(d) Tripper-stackers in Figure E.4.
(e) Scraper-reclaimers in Figure E.5.

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(f) Stackers in Figure E.6.

(g) Belt wagons in Figure E.7.
(h) Ship continuous loaders in Figure E.8.
(i) Ship unloaders in Figure E.9.
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(j) Conveyor drive units in Figure E.10.

Note 1 to entry: These machine types that are diagrammatically illustrated are typical and are not intended to
prevent the use of other types. Mobile equipment for continuous handling of bulk materials are referred to in this
document also as “equipment”, “machine” and “plant”.

1.4.19
normal operation

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operation of the machine that does not cause any loads to exceed —
(a) their main load/Type I limiting value(s);
(b) the initiation of any controls or limits; or
(c) the loads in additional (excepting wind, W) or special load types being experienced

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1.4.20
operating and maintenance manual(s)
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instructions and information to enable safe operation and maintenance of the machine
1.4.21
owner
ultimate possessor/owner of the equipment
1.4.22
purchaser
party (e.g. person, company) who ordinarily manages procurement actions for a machine that is to be
supplied
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Note 1 to entry: The purchaser may be the owner or may be a party responsible to the owner.

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1.4.23
reclaimer
machine that recovers material from a stockpile
1.4.24
regulatory authority
authority having regulatory powers to control the design, manufacture, erection and operation of
continuous operation bulk handling equipment within the relevant state or territory of Australia
1.4.25
safety device
device, that through its operation, is a load limiting or protective device
1.4.26
shall
indicates that a statement is mandatory
1.4.27
should
indicates a recommendation

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1.4.28
spreader
machine for delivering material onto a stockpile or waste dump
Note 1 to entry: Similar to a stacker.

1.4.29
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stacker
machine for delivering material onto a stockpile
1.4.30
stockpile
quantity of the material in storage
Note 1 to entry: Either in the open (i.e. exposed to weather) or covered (i.e. located in a shed or building).

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1.4.31
storm park position
location where equipment can be secured against winds exceeding safe operating limits
1.4.32
strap

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stay AF
components in suspension/tension supporting booms and counterweight booms, generally comprising
a steel plate or rod member/component, which may be segmented
Note 1 to entry: The design actions experienced by straps/stays are primarily tensile, with minimal bending
stresses.

1.4.33
strength
capacity of a member, component or assembly to resist failure, except where the context dictates
otherwise, by mechanisms such as yielding, cleavage or buckling
1.4.34
stress range
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algebraic difference between two extremes of stress of a particular stress cycle

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1.4.35
stress spectrum
<design> histogram of stress cycles produced for the nominal loading events expected during the
design life, relevant to the design fatigue assessment
1.4.36
structural calculations
compilation of documented evidence that illustrates the loading used, the methods of analysis
undertaken, the results obtained from the analyses and design verifications (to demonstrate
conformance) of the design of the structure
1.4.37
supplier
party (e.g. person, company) who supplies the machine design
Note 1 to entry: The supplier may or may not be the constructor or erector.

1.4.38
technical specification
document that details the application, omission, or variation of requirements within specific clauses of
this document
Note 1 to entry: See Clause 1.8.

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 DR AS 4324.1:2024 6

1.4.39
tripper
machine,typically coupled to a stacker, used to elevate the material and deliver it into the receiving
chute

1.5 Symbols and abbreviated terms

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The quantity symbols listed below are used in this document with the exception of Appendix F, where
different quantity symbols are used.

Clause
Quantity Unit
Quantity reference to
symbol symbol
the first use
A1 Force from a slight grounding of a bucket 3.5.2.2​
wheel, bucket ladder or boom

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A2 Force from a partial grounding of a bucket 3.5.2.3
wheel, bucket ladder or boom
AA Force from a full grounding of a bucket wheel, 3.5.2.4
bucket ladder or boom
a

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Centre distance between track wheels, track m 3.4.6.3

B
BL
Total width of belt
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wheel groups or bogies; where horizontal
guide rollers are used, a is taken as the centre
distance between rollers

Loads due to loss of bucket wheel and gearbox

m I.2
3.5.14
bu Usable width of belt m I.2
CB Chord length of surcharge portion above main I.3
belt width
CF Fatigue modifying factor for live loads (F) 3.6.4
Ch Height of belt conveyor crowding board I.3
CS Fatigue modifying factor for lateral digging 3.6.6
resistance (S)
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CU

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Fatigue modifying factor for normal digging 3.6.5
resistance (U)
Cw Chord length of surcharge portion above I.3
crowding boards
c Design clearance between wheel flange or mm 3.4.6.3
guide roller and side of rail
c1 Top chord length of belt cross-section I.2
c2 Lower chord length of belt cross-section I.2
D Permanent dynamic loads 3.3.9
DD Non-permanent dynamic force effects 3.4.7
E Dead loads 3.3.2
EL Extra loads 3.5.16
EQ Loads arising from the effects of earthquakes 3.5.12
F Main live loads due to handled material 3.3.5
F(I)B/W Statically equivalent force representing inertia Figure 3.5.8
of bucket wheel
F(I)Boom1 Statically equivalent force representing inertia Figure 3.5.8
of main boom
F(I)Boom2 Statically equivalent force representing inertia Figure 3.5.8
of counterweight boom

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 7 DR AS 4324.1:2024

Clause
Quantity Unit
Quantity reference to
symbol symbol
the first use
F(I)C/W Statically equivalent force representing inertia Figure 3.5.8
of counterweight
F Lat Lateral collision force at bucket wheel Figure 3.5.8
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F Long Force at outermost extremity of the boom 3.5.9

in direction of boom axis during an end-on
collision
Fo Main load on the lowest carrying capacity t/m I.1.1
upstream conveyor
FF Special live loads from excess material on 3.5.6
conveyor
FS Loads due to lateral collision of a boom 3.5.8

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FT Loads due to end-on collision of a boom 3.5.9
G Loads from conveyor elements 3.3.10
Hx Maximum total travel force available from the 3.4.6.4
drives

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Hy Skew reaction due to forward travel
AF 3.4.6.4
Hyij Skew force acting horizontally transverse to 3.4.6.3
the rail (i) on the wheel or bogie (j)
I1 Struck volume of the bucket m3 G.2
I2 Bucket wheel ring space m3 G.2
K Loads due to snow, ice and hail 3.4.8
KF Reduction factor that allows for the flexibility 3.4.6.3
of the rail-mounted structure as a function of
the lowest horizontal natural frequency (or
torsional natural frequency about a vertical
axis) for the whole structure
KG Ko × KF 3.4.6.3
DR
KGmin Minimum permissible value of KG 3.4.6.3

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Ko Skew reaction coefficient 3.4.6.3
L Loads resulting from resistance to travel 3.3.12, 3.6.10
LL Loads due to obstruction of travelling device 3.5.7
LS Travel skew force 3.4.6
lm Effective lengths of rollers m I.2
ls Distance between line of action of driving force m 3.4.6.4
Hx and the centre of mass
l1, l2 Effective length of rollers m I.2
Md Dynamic factor used in skew force calculation 3.4.6.4
Mo Overturning moment 4.1
Ms Stabilizing moment 4.1
N Loads due to inclination during normal 3.3.4
operation
NN Loads due to abnormal inclination (e.g. during 3.4.12
travelling or in transit)
O Overfill volume G.2
OO Loads due to operation of buffers 3.5.11
P Loads on access ways 3.4.9
p Rail gauge m 3.4.6.3

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 DR AS 4324.1:2024 8

Clause
Quantity Unit
Quantity reference to
symbol symbol
the first use
Qth Theoretical output at minimum bucket wheel t/h I.1.2
speed
Qths Theoretical output at maximum bucket wheel t/h I.1.2
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speed
QQ Loads due to uneven support 3.5.3
R Resistance forces due to friction 3.3.11
RR Load due to abnormal friction at a pivot 3.5.15
S Normal lateral digging resistance 3.3.8
Sm Maximum cross-sectional area of material on m2 3.5.6
conveyor with or without crowding boards

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Sx Cross-sectional area of material on belt m2 I.1.1
S1, S2, S3 Cross-sectional areas of portions of material m2 I.2
on belt for normal design belt loading
S1Bm, S2Bm, Cross-sectional areas of portions of material I.3
S3Bm on belt for maximum belt loading with

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crowding boards AF
S1m, S2m, S3m Cross-sectional areas of portions of material m2 I.3
on belt for maximum belt loading without
crowding boards
SS Abnormal lateral digging resistance 3.4.5
smax Maximum bucket wheel speed, in buckets per min−1 I.1.2
minute
smin Minimum bucket wheel speed, in buckets per min−1 I.1.2
minute
T Loads due to temperature effects 3.4.3
Tdesign LODMAT °C 2.2.2
T(I)Str Statically equivalent torque representing Figure 3.5.8
DR
inertia of superstructure

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TSlew Slew drive torque as limited by slew clutch or Figure 3.5.8
safety coupling
U Normal digging resistance 3.3.7
UU Abnormal digging resistance 3.4.4
V Encrustation load 3.3.3
Vc Belt speed of conveyor m/s I.1.1
Vc Bucket wheel cutting speed F.1
Vijmax Maximum vertical load on each rail (i) or 3.4.6.3
on each wheel or bogie (j), computed for
the machine centre of gravity S in its most
unfavourable position
Vo Belt speed of yard conveyor or of the upstream m/s I.1.1
conveyor with the lowest carrying capacity
Vp Basic wind speed 3.5.10
Vt Travel speed of the unit m/min I.1.3
VV Loads due to blocked chutes and hoppers 3.5.5
W Wind load during operation 3.4.2
WW Wind load while idle 3.5.10
X Maintenance loads 3.4.11
Y Erection and weighing loads 3.4.10

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 9 DR AS 4324.1:2024

Clause
Quantity Unit
Quantity reference to
symbol symbol
the first use
ZZ Forces from the effects of burying 3.5.13
α Swell factor Table H1
α Oblique travel gradient mm/m 3.4.6.3
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γ Bulk density of material as handled t/m3 3.1.3

λ, λ1, λ2 Troughing angles for rollers degree I.2
μ Friction coefficient 3.3.12
ρ Surcharge angle degree I.2
Ψ Angle of repose of material as dug G.2

NOTE Quantity symbols used in this document are generally similar, but not identical, to those in AS 4100 and

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AS 3990.

1.6 New designs and innovations

This document does not prevent the use of materials, methods of assembly, procedures and the like that

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do not conform with the specific requirements of this document, or are not mentioned in it, provided
AF
the minimum dimensional and performance requirements specified herein are met.

1.7 Basis of design

The design of equipment shall conform to the following principles:
(a) Due care and skill, experience, supervision and quality control is provided during the
design and execution of the work (during design, fabrication, construction, assembly, and
commissioning).
(b) The construction materials and products used are in accordance with the relevant standards
and are consistent with the design requirements.
DR
(c) The structure will be maintained such that the condition of the structure, mechanisms and

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load limiting devices meets the requirements of the design throughout the machine life.
(d) The structure will be used in accordance with the design requirements.

1.8 Technical specification

A technical specification for equipment to be procured conforming to this document shall be prepared.
Information that shall be supplied with a technical specification is given in Appendix B.

1.9 Basic digging parameters for bucket wheel machines

For bucket wheel machines, forces determined in accordance with this document are based on the
actual torque/power ratings of drive equipment (i.e. motors and couplings). These ratings shall be
determined for the equipment so that it is possible to dig the material at the specified rates.
However, this document does not provide performance characteristics for materials handling rates.
NOTE In Appendices F and G, guidance is given on how to confirm that the equipment design can reasonably
meet the long-term output goals when the geometry of the machine and the nature of the excavating process are
taken into account. This may be found particularly useful for determining the numbers of slew and travel cycles
for the overall design life.

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 DR AS 4324.1:2024 10

1.10 Corrosion protection and machine condition

Steel structures shall be protected against corrosion in the working environment. Corrosion protection
requirements are specified in AS 4100.
Corrosion allowances in defined regions of structure should be as prescribed within the technical
specification.
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1.11 Mechanisms, electrical, controls, commissioning, operation and asset

management

1.11.1 Mechanisms

Standards for the design of mechanisms shall be as defined in the technical specification, as indicated
in Appendix B.

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For loading conditions that are reliant upon a mechanism, electrical or controls protection being in
place, the required setting of the device/control should be clearly defined in the structural calculations
and the operating and maintenance manuals.
The design criteria for mechanism design may vary from the design criteria for structures.

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1.11.2
AF
Electrical and controls (including computer/programmable controls)

Standards for the design of electrical and controls shall be as defined in the technical specification as
indicated in Appendix B.
For loading conditions that are reliant upon an electrical or controls protection being in place, the
required setting of the device/control should be clearly defined in the structural calculations and
relevant manuals.

1.11.3 Commissioning, operation and asset management

The commissioning, operation and asset management requirements affecting the design of the
DR
equipment should be implemented in accordance with the Standards as defined by the technical

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
specification, as indicated in Appendix B. Where no Standards are defined in the technical specification,
the Standards used for, or referred to by, the design shall be used.
Commissioning requirements shall be as defined by the technical specification, as indicated in
Appendix B.
NOTE Operation and asset management (post-supply) should be carried out in accordance with the operating
and maintenance manuals, as a minimum.

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 11 DR AS 4324.1:2024

Section 2 Materials

2.1 General
Unless otherwise nominated in the technical specification, structural materials, material properties
and testing requirements for structural materials shall conform to any relevant Australian Standards
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or an alternative Standard (see Clause 2.3.5).

Materials should be selected from AS 4100:2020 Section 2 (Materials) and Section 10 (Brittle fracture)
or AS/NZS 5100.6:2017 Section 2 (Materials) and Section 14 (Brittle fracture and lamellar tearing).
Materials in conformance to AS 4100 or AS/NZS 5100.6 do not require additional testing described in
this section. Mill certificates, test reports or test certificates that conform to the requirements of the
appropriate Standard listed in AS 4100:2020 Clause 2.2.1 or AS/NZS 5100.6:2017 Clause 2.2.1 shall
constitute sufficient evidence of conformance of the steel to the Standards listed in those clauses.

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NOTE 1 Requirements for mill certificates, test reports or test certificates are provided in the relevant
Standards listed in AS 4100 and AS/NZS 5100.6.

Materials selected should be impact tested at a temperature of not greater than 0 °C or a lower
temperature where required by AS 4100 or AS/NZS 5100.6.

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The requirements of AS 4100 or AS/NZS 5100.6 in respect of brittle fracture shall apply to all structural
steel.
Where structural materials cannot be shown to conform, e.g. by certification, to the relevant Standard,
their mechanical properties, chemical composition and, where applicable, weldability shall be
established by testing.
NOTE 2 The use of a modified yield value for design purposes is described in Clause 5.3.

2.2 Limitation on use of brittle materials

2.2.1 General
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All materials should be assessed for brittle fracture.

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Steels used shall meet the following minimum ductility requirements:
(a) fu/fy ≥ 1.2, where fu is the specified minimum ultimate tensile strength and fy is the specified
minimum yield strength.
(b) Elongation at failure not less than 15 % on a gauge length of 5.65 √S0, where S0 is the cross-
sectional area of the test piece before testing.
(c) The ultimate strain εu ≥ 6εy, where εu corresponds to the ultimate strength fu and εy is the
yield strain (εy = fy/E).
Steel conforming to one of the steel grades listed in AS/NZS 5100.6:2017 Table 2.1 shall be accepted as
satisfying these requirements.
NOTE Steels meeting the requirements of AS 3597 and AS/NZS 1163 Grade C450 do not meet the requirement
of Item (a) above, but are deemed to have satisfactory ductility. For use of these materials, see Clauses 5.3 and
5.7.5 where applicable.

2.2.2 Fracture and failure critical applications

The technical specification shall define the regions of structure where this clause (2.2.2) shall apply.
Where a failure of a structural element could influence the safety of the machine as a whole or the safety
of personnel, or where reliability is important, the properties of materials having an ultimate tensile

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 DR AS 4324.1:2024 12

strength in excess of 550 MPa or an actual yield strength in excess of 450 MPa shall be established by
tests conducted on samples from the material actually to be used in manufacturing the element. These
tests shall conform to relevant Australian Standards and shall include tests that are able to establish
the following properties:
(a) Charpy impact energy, at a temperature that conforms to the requirements of AS 4100 or
AS/NZS 5100.6, but not less than 0 °C.
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(b) Percentage of ductile fracture area on Charpy test specimens, at a temperature that conforms
to the requirements of AS 4100 or AS/NZS 5100.6, but not less than 0 °C.
(c) Ultimate tensile strength at 20 °C.
(d) Yield strength at 20 °C.
(e) Percentage elongation at 20 °C.

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(f) Percentage reduction of area at 20 °C for through thickness properties.
Tdesign is the lowest one day mean ambient temperature (LODMAT) determined for the area where the
equipment will operate, based on appropriate Australian Bureau of Meteorology records or LODMAT
isotherms in AS 4100.

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AF
Used test specimens shall be kept for the duration of the construction and commissioning periods, or
such longer period as may be nominated in the technical specification. Used test specimens shall be
traceable to their respective components by means of a marking system.
Where a brittle fracture could cause a failure and influence the safety of the machine as a whole or the
safety of personnel, brittle materials shall not be used. For such critical applications, materials shall be
deemed to be brittle if the following properties are not achieved, with the orientation of test specimens
selected so as to result in the least favourable test results:
(i) The average of three Charpy impact test specimens, at a temperature that is the lesser
of (Tdesign – 15) °C and 0 °C, shall be greater than 1.4 × (ultimate tensile strength, in
megapascals)0.5, in joules.
(ii) The minimum individual value of the three Charpy impact test specimens, at a temperature
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
that is the lesser of (Tdesign – 15) °C and 0 °C, shall be greater than (ultimate tensile strength,
in megapascals)0.5, in joules.
(iii) The minimum ductile fracture area on any Charpy test specimen, at a temperature that is the
lesser of (Tdesign – 15) °C and 0 °C, shall be more than 75 %.
(iv) The minimum elongation at 20 °C is more than 10 % and the minimum reduction in area is
greater than 40 %.
Materials that satisfy the brittle fracture requirements of AS 4100 or AS/NZS 5100.6 and the materials
testing requirements of the Standards referred to in those Standards do not require further testing
provided the steel type selected conforms to AS 4100:2020 Clause 10.2 or of AS/NZS 5100.6:2017
Clause 14.5.

2.3 Alternative materials and fabrication Standards

2.3.1 General

The use of alternative materials and fabrication Standards shall be as defined in the technical
specification. See Clause 2.3.5.
NOTE This should be the subject of agreement by the owner/purchaser and the supplier.

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 13 DR AS 4324.1:2024

2.3.2 Basis of design

The design shall reflect the structural size, material (including strength grade and ductility sub-
grade where appropriate) and other necessary properties as are required by the relevant structural
design Standard, chosen in accordance with Section 5. Where possible, the designer should take into
consideration the likely materials of fabrication and construction.
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2.3.3 Material substitution

Where the use of a material specified in the design is not possible, a process of material substitution
shall be carried out to select material with at least equivalent properties to the specified design material
is supplied for the fabrication.
Substitution shall assess, which may include by testing, all material characteristics pertinent to the use
of that material including, but not necessarily limited to, mechanical properties, chemical composition

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and, where applicable, weldability.. Statistical testing methods shall be used. The permission to use and
the testing of substitute materials shall be documented in the technical specification as indicated in
Appendix B.

2.3.4 Fabrication practices and Standards

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minimum.

2.3.5
AF
Use of fabrication practices and Standards other than Australian Standards may be permitted by the
technical specification where structural performance requirements of this document are achieved as a

Demonstration of adequacy of alternative Standards used

Where Standards other than Australian Standards are used, a documented evaluation and justification
shall be prepared and included in the technical specification. Where materials not manufactured to
specifications listed in AS 4100 or AS/NZS 5100.6 are used, the material properties (including chemical,
mechanical, ductility, weldability properties, etc.) deemed necessary as described by the relevant
manufacturing Australia Standard shall be obtained either by factory testing or by independent testing.
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 DR AS 4324.1:2024 14

Section 3 Load assumptions

3.1 General

3.1.1 Technical specification and design loading

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The application of the requirements of specific clauses of this section shall be documented in a technical
specification in accordance with Appendix B.
The technical specification shall define whether a load case is required to be included, is permitted to
be omitted, and/or where deviations to the values specified by this document are to be incorporated in
the design.
Specified omission or reduction of requirements within this document shall only occur following formal
assessment of the risk of that load case occurring. The risk assessment shall include the assessment

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and documentation of the effectiveness of the controls, protections and load limiting devices that will
be implemented to prevent the load occurring. The risk assessment should follow the principles and
guidance set out in AS/NZS ISO 31000.

3.1.2 Loads and load limiting devices

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AF
Many loads applied to this type of equipment can be controlled and excess loading prevented by the use
of controls, electrical protective devices and mechanical protective devices.
Where the limit of loading is reliant upon a protective device or function, their use shall be as defined in
the technical specification in accordance with Appendix B. The provided protection and its setting shall
be defined in the structural calculations and be included in the operating and maintenance manual. The
protective device should be able to be tested to the setting so defined.
Where there is the possibility of significant damage to the machine due to an upper bound load being
exceeded, protection should be provided prior to the upper bound load being reached.
An appropriate and recognized Standard for the design and installation of controls and devices to an
adequate level of integrity and reliability should be used. The design of protective devices and systems
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should incorporate progressive limits [e.g. operational (primary), secondary (alarm), final cutout].

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3.1.3 Bulk density (γ)

Calculations of the strength and the stability of a machine shall be based on the maximum specified
bulk density of the material to be handled, γ. Calculations of volumetric capacity shall be based on
the minimum specified bulk density of the material to be handled. The specified bulk density for
encrustation shall be used for encrustation loads.
Bulk density values for design shall be nominated in the technical specification in accordance with
Appendix B. These values should include —
(a) a bulk density value to be used for “structural” load;
(b) a bulk density value to be used for “encrustation” load calculations, which may be the same or
higher than the “structural” bulk density;
(c) a bulk density value to be used for “power” calculations;
(d) a bulk density value to be used for “volumetric” calculations; and
(e) a bulk density value to be used for “fatigue” calculations.

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 15 DR AS 4324.1:2024

3.2 Load groups

The equipment shall be designed to withstand all relevant loads, including the following loads, which
have been grouped according to their frequency of occurrence:
(a) Main loads, that are listed in Tables 3.7(A) and 3.7(B) and described in Clause 3.3.
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(b) Additional loads, that are listed in Tables 3.7(A) and 3.7(B) and described in Clause 3.4.
(c) Special loads, that are listed in Tables 3.7(A) and 3.7(B) and described in Clause 3.5.
Where it is intended to use the equipment to handle different materials at different speeds, in varying
machine configurations or under other varying design parameters, the design for strength and stability
shall allow for the most adverse combinations of loadings and configurations.

3.3 Main loads

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3.3.1 Grouping

Main loads is a grouping that comprises permanent (i.e. steady) loads and variable loads that occur
whenever the equipment is used under normal operating conditions.

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3.3.2 Dead loads (E)
AF
This load case shall apply to all machine types. The method of design dead load estimation and
calculation shall be as defined in the technical specification in accordance with Appendix B.
Dead loads shall comprise the sum of the masses (that are always present in operation) of the fixed
and moving parts of the machine as built, clean and ready for service, and in the finished condition,
including ballast, liquid fillings, protective coatings, and auxiliary and spare components permanently
installed on the machine.

3.3.3 Encrustation (V)

This load case shall apply to all machine types.

DR

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The following requirements apply to loads due to encrustation, such as accumulation of spillage or
material that is sticking to digging devices:
(a) On conveying devices, allowances shall be not less than 10 % of the theoretical design material
loading uniformly distributed along the conveyor, as calculated according to Clause 3.3.5 for
live loads carried on a conveyor.
(b) For bucket wheels, allowances shall be not less than the weight of a 50 mm thick layer of
material acting at the centre of the bucket wheel, as a solid disc up to the cutting circle and at
“Encrustation” density. For sticky materials, the thickness of the layer shall be increased to
not less than 100 mm.
(c) For bucket chains, allowances shall be not less than 10 % of the theoretical live load uniformly
distributed over the total length of the ladder, as calculated according to Clause 3.3.5 for mass
of material in digging devices.
(d) For scrapers, allowances shall be not less than 10 % of the theoretical live load uniformly
distributed over the total length of the scraper supporting structure, as calculated according
to Clause 3.3.5 for mass of material in digging devices.
(e) At specific locations where additional spillage occurs (e.g. near hoppers, near loading points,
along walkways, in washdown launders, around bucket-wheel areas, chutes, etc.), the
encrustation load to account for the actual degree of buildup possible should be included,

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 DR AS 4324.1:2024 16

unless the structural integrity and stability of the machine is protected by installation of
appropriate load limiting devices.
Where load-limiting devices are used to control this load, their use shall be as defined in the
technical specification in accordance with Appendix B. The device/control, its setting and the
action upon activation of the device/control shall be defined in the structural calculations
and be included in the operating and maintenance manual.
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(f) Where spillage and material build-up or abnormal encrustation could occur during a loading
event attributable to a special load (e.g. a wear hole in a transfer chute), the portion of
encrustation above that defined as “normal” encrustation shall be included in the special load
combination.
(g) Encrustation that may occur within chutes shall be taken into account.
Special allowances for encrustation shall be as defined in the technical specification in accordance with

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Appendix B.
NOTE For “sticky” material, or structures with large flat areas or chutes, consideration should be given to
increasing these allowances.

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3.3.4 Inclination (N) AF
This load case shall apply to all machine types.
Design loads due to inclination of the working level shall be based on the maximum inclination for
normal operation (i.e. excluding ramps or while in transit), as nominated in the technical specification
in accordance with Appendix B.

3.3.5 Live loads (F)

This load case shall apply to all machine types.

Live loads are due to the weight of handled material and caused by the material flow.
Live loads carried on a conveyor shall be determined in accordance with the principles contained in
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Appendix I and as defined in the technical specification in accordance with Appendix B. For structural

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
design purposes, live loads on conveyors shall be based on a minimum surcharge angle for the carried
material of 20°.
For bucket chains and scrapers, the mass of material in digging devices shall be included and shall be
based on not less than the following:
(a) For bucket chains —
(i) the lower one-third of all the buckets in contact with the face being one-third full;
(ii) the middle one-third of all the buckets in contact with the face being two-thirds full;
and
(iii) the top one-third of buckets up to the tumbler being full.
(b) For scrapers (all types) — the scraper flights on the material carrying length of the scraper
chain being two-thirds full.
Where applicable, live loads arising from material in transit through chutes and spouts shall be included
(either globally, locally or both), including impact, inertia and change of velocity.
The calculation of dynamic resonance/excitation due to material flow may also be required.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon

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 17 DR AS 4324.1:2024

activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.

3.3.6 Basis for normal digging and lateral resistance determination

This load case shall apply to reclaiming and excavating machines.

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Calculations of forces due to normal digging (see Clause 3.3.7) and to normal lateral movement (see
Clause 3.3.8) of the digging element shall be based on concentrated loads acting at the following points
—
(a) for bucket wheels, the most unfavourable point of the cutting circle for each load case;
(b) for bucket chains, a point one-third along the ladder length in contact with the face, measured
from the outboard end of the ladder; and

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(c) for scrapers, the most unfavourable point for each load case.
Drives for bucket wheels, bucket chains and lateral motions of bucket wheels and bucket chains (i.e. slew
and travel) shall each be provided with two or more levels of protection to prevent overloading. The
nature of such levels of protection should be as nominated in the technical specification in accordance

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with Appendix B; provided that at least two levels of protection are achieved by independent means. At
AF
least two levels of protection shall be provided to control the loads due to the operation of the digging
and slewing devices.
It is intended that the protection/load limiting device that is set to the lowest value will govern the
calculation of normal digging resistances U and S, as further described by Clauses 3.3.7 and 3.3.8.
The load limiting/protection device that is set to the highest value, or the value of the maximum load
expected to be experienced, shall govern the calculation of abnormal digging resistances UU and SS, as
further described by Clauses 3.4.4 and 3.4.5.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in
the operating and maintenance manual. The first level of protection may restrict or control loading,
whereas the second level shall cease operation to prevent further loading being experienced.
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3.3.7 Normal digging resistance (U)

This load case shall apply to reclaiming and excavating machines.

The calculated force due to normal digging of the digging element, as determined in accordance with
Clause 3.3.6, shall be determined as a force tangential to the wheel cutting circle or parallel to the bucket
or scraper chain. The calculated force shall be based on the rating of the drive motor, while taking into
account the cut-off torque of any torque limiting coupling, the setting of any load limiting/protection
device and the efficiency of the drive gear reducer and the speed at the bucket lips.
The minimum design torque/digging force shall be based on 1.1 times the lesser of —
(a) the load limiting/protection device setting; and
(b) the nominal coupling limit; and
(c) the hydraulic drive limit;
subject to a minimum of 1.1 times the motor rated torque for reclaimers and a minimum of 1.3 times
the motor rated torque for excavators.
Where a load limiting/protection device is present but does not cease the operation, or reduce the
transmitted torque or force, of the digging element, this device shall not be used for calculation of the
digging force U.

© Standards Australia Limited 2024

 DR AS 4324.1:2024 18

For bucket wheels, the full drive torque shall be used, without deducting contributions associated with
lifting material in the buckets.
For bucket chains, the torque needed to lift material in the buckets (see Clause 3.3.5) shall be deducted
for the purpose of calculating the digging force.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
PUBLIC COMMENTING DRAFT

specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.

3.3.8 Normal lateral digging resistance (S)

3.3.8.1 General

T
This load case shall apply to reclaiming and excavating machines that experience lateral loading due to
digging.

3.3.8.2 Bucket wheel machines

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Unless otherwise specified, the calculated force due to lateral movement of the digging element, as
AF
determined in accordance with Clause 3.3.6, shall be —
(a) where a torque limiting coupling or clutch is used as the first level of protection of lateral
digging force, not less than the greatest of the following:
(i) 0.3 times the normal digging force (U) calculated as if all of the drive power was
available for digging (i.e. without deducting the power needed to lift the material in
the buckets).
(ii) The force derived from 1.1 times the lesser of the cut-off torque of the torque
limiting coupling or clutch and the lowest overload protection device limit on the
relevant lateral drive (e.g. travel or slew); minus the frictional losses in the slewing
or travel drive system between coupling and digging element.
DR
(b) where a torque limiting coupling or clutch is not fitted to the slew or travel drive, a lateral

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
digging force not less that the greatest of the following:
(i) 0.3 times the normal digging force (U) calculated as if all of the drive power was
available for digging (i.e. without deducting the power needed to lift the material in
the buckets).
(ii) 1.3 times the force derived from the rated torque of the relevant lateral drive (e.g.
travel or slew); minus the frictional losses in the relevant drive system (e.g. travel or
slew) between drive motor and digging element.
Fatigue loading shall use a value for S of 0.3 times the normal digging force (U) unless a greater value is
specified in the technical specification in accordance with Appendix B. Load reversal shall be included
where applicable.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.

3.3.8.3 Other reclaiming machines/fixed boom type machine

The same principles and requirements as defined in Clause 3.3.8.2 shall be applied to other reclaiming
machines, unless varied by the technical specification in accordance with Appendix B.

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 19 DR AS 4324.1:2024

3.3.9 Permanent dynamic effects (D)

This load case shall apply to all machine types.

Permanent dynamic load effects, such as inertia forces due to acceleration and deceleration of
components and overall machine movements, shall be allowed for as main loads. In general, dynamic
effects from impact of falling material at the transfer points, rotating mechanical parts, vibrating
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feeders, etc. need only be included as acting locally. However, variations in digging resistance at bucket
passing frequency shall be included as a particular fatigue loading for the design of buckets, bucket
wheels and bucket wheel shafts and for assessing possible resonant excitation of the overall machine
structure.
Permanent dynamic loads shall be taken as the greater of the following:
(a) Loads calculated from linear and angular acceleration or deceleration of the structure,
resulting from operation (including braking) of the main drives (e.g. travel, slew, luff,

T
steering).
(b) Vertical and horizontal loads as calculated by applying the dynamic effects factors given in
Table 3.3.9 to the relevant structural sub-assemblies.
Permanent dynamic effects shall be applied to the relevant sub-assembly dead weights and live loads.

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AF
Permanent dynamic effects should be applied to E, V and F loads as a minimum.
Equipment whose motion varies in linear acceleration/deceleration/velocity (i.e. due to slewing) along
its length, dynamic effects can be included as a triangular distribution, with the values in Table 3.3.9
used at the extremity of the equipment.
For assessment of fatigue [load case F/I, see Table 3.7(A) or Table 3.7(B)], stress cycles determined due
to dynamic effects shall be included at a frequency that takes into account operational circumstances
and the possibility of a number of oscillations at a relevant structural natural frequency, each time
a motion is initiated or stopped. In general, the effects of inclination as defined in Clause 3.3.4 will
need to be accounted for separately within any Miner’s Rule calculation at a lesser frequency than for
permanent dynamic effects.
For strength load combinations, the simultaneous occurrence of dynamic effects and the effects of
DR
inclination as prescribed by Clause 3.3.4 shall be included.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
The dynamic factors for cabins for operators are only required to be applied to the cabin itself and the
localized structural design of its immediate supporting structure back to the supporting main sub-
assembly. These factors need not be applied for the global structural assessment.
Where load-limiting devices are used to control these loads, their use shall be as defined in the
technical specification in accordance with Appendix B. The device/control, its setting and the action
upon activation of the device/control shall be defined in the structural calculations and be included in
the operating and maintenance manual. This includes maximum speeds, “ramp times” and associated
accelerations and decelerations for normal operating motions.
For the purposes of stability and wheel load calculations, the design shall use one of the following
methods:
(i) Permanent dynamic effects are included as loads calculated from linear and/or angular
acceleration or deceleration of the structure, resulting from operation (including braking) of
the main drives (travel, slew, luff or other as appropriate) multiplied by a factor of 1.2 (to
account for dynamic amplification effects).
(ii) Addition of the applicable dynamics effects factor from Table 3.3.9 to the (overall) overturning
moment.

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 DR AS 4324.1:2024 20

Table 3.3.9 — Dynamic effects factors

Dynamic effects factors
Machine Machine part Horizontal
Vertical
Transverse Longitudinal
All rail mounted Without digging element 1/10 1/30 1/30
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machines With digging element 1/8 1/30 1/30

Crawler mounted Bucket wheel boom 1/5 1/30 1/30
machines and Discharge boom 1/5 1/10 1/30
equipment with
mechanical or Counterweight boom 1/5 1/15 1/30
hydraulic lifting Tower or central structure 1/5 1/30 1/30
feet
Connecting bridges 1/5 1/10 1/15

T
All machines Cabins for operators 1/2 1/2 1/2

3.3.10 Forces associated with conveyor elements (G)

This load case shall apply to machines with conveying elements.

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Structures shall be designed to withstand the effects of forces associated with conveyor elements
AF
arising from belt tension, chain tension, etc. The maximum load resulting from belt tensions occurring
during starting, stopping or normal running with live loads as specified in Clause 3.3.5 for a conveyor
shall be used. The de-tensioned belt case shall also be included in the design.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and the operating and
maintenance manual.

3.3.11 Friction (R)

This load case shall apply to all machine types.

DR
For structural design purposes, calculations of resistance force due to friction shall use coefficients (μ)

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
of not less than —
(a) for pivots and ball shaped socket bearings: 0.15; and
(b) for structural parts with sliding friction: 0.25.

3.3.12 Travel (L)

This load case shall apply to all machine types.

This clause is subject to the requirements of Clauses 4.1 and 4.2.
Calculations of resistance force due to travel, for structural design purposes (strength and stability),
shall use friction coefficients (µ) of not less than the following:
(a) For rail-mounted machines, due to —
(i) rolling resistance of wheels: 0.03; and
(ii) traction forces between driven wheels and rails: 0.25.
(b) For crawler-mounted machines, due to —
(i) track wheels: 0.10; and

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 21 DR AS 4324.1:2024

(ii) traction forces between crawler pads and operating surfaces during travelling,
steering and slewing of the machine —
(A) during normal and abnormal operation: 0.6; and
(B) while crawlers are bogged: 0.9.
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There exists a special case for crawler-mounted machines when required to relocate down a slope or
drive. In this case, the regenerative power or mechanical braking requirements shall be included in
sizing load banks, dynamic braking resistors, or other such braking mechanisms used to restrain the
forward motion of the machine. The technical specification, in accordance with Appendix B, should
nominate the appropriate friction factor for the purposes of design of the travel components in this
instance as this value will vary dependent on site specific parameters and conditions; however, this
value should not be more than 0.3.

T
3.4 Additional loads

3.4.1 Grouping

Additional loads are a grouping that comprises loads that occur infrequently. They may occur during
operation of the equipment or while the equipment is not working. These loads may either replace

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3.4.2
AF
certain main loads or add to the main loads.

Wind during operation (Wo, Wr, Ws)

This load case shall apply to all machine types.

Where a machine is not completely shielded from the wind, calculations of the wind load on the
machine in operation, Wo, shall be in accordance with AS/NZS 1170.2 using a wind speed (based on
the permissible stress design method, see Clause 5.4.2) in the most adverse direction of not less than
20 m/s.
A wind speed for relocation, Wr, (generally greater than 20 m/s) shall also be included in the design as
an additional load. The relocation (e.g. travelling but not handling material) wind speed shall be defined
in the technical specification in accordance with Appendix B.
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
A wind speed, Ws, for a circumstance where a machine is not located within its storm tie-down
restraint system, is not subject to travelling motion, but is subjected to storm winds, should be included
in the design. The design shall use the Region A design windspeed in conformance to AS 1170.2, or,
alternatively a site specific statistical wind loading analysis. The requirement for the inclusion of Ws in
the design shall be defined in the technical specification. For machines with a nominal 25-year design
life, a V250 design wind speed in conformance to AS 1170.2 should be used.
The most adverse wind direction shall be taken into account for determining wind loads. It is normally
sufficient to consider wind directions along the main axis of the structure, at right angles to the main
axis of the structure and at 45° to the main axis of the structure, in each possible configuration.
In addition to uniform wind loading, non-uniform wind loading (e.g. due to partial shielding of the
machine, variability of gust behaviour over the entire machine) or other possible effects shall be
included in the design. The wind direction and machine configuration shall be varied to determine the
worst case of wind loading for stability and design of structures and mechanisms.
Where a variability of gust behaviour across the extent of a machine is the only apparent reason for
wind loading on the machine being non-uniform, any resultant torque that is exerted on any rotatable
or slewable portion of the machine shall be calculated, assuming the wind loading on one side of the
rotating or slewing axis to be reduced to 50 % of the full load on that side. The wind direction and the
side of the axis that is reduced by 50 % shall be chosen to give the maximum possible torque.
Alternatively, wind tunnel testing and/or computational fluid dynamics are permitted for the
determination of wind loading.

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 DR AS 4324.1:2024 22

Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.

3.4.3 Temperature (T)

PUBLIC COMMENTING DRAFT

This load case shall apply to all machine types.

Temperature effects on loads need to be included in certain cases (e.g. where materials with very
different expansion coefficients are used within the same component; where a significant temperature
difference can exist throughout a structure).

3.4.4 Abnormal digging resistance (UU)

T
This load case shall apply to reclaiming and excavating machines.
The calculated abnormal digging force shall be determined as the force tangential to the wheel cutting
circle or parallel to the bucket or scraper chain that results from the maximum torque of the motor
(e.g. during stalling or starting, including breakdown torque under no power), taking into account
the second or final cut-off torque of any effective torque limiting coupling, the setting of any load

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AF
limiting/protection device, the efficiency of the drive gear reducer and the speed at the bucket lips.
Where an effective torque limiting coupling or hydraulic drive or load limiting device is not fitted, the
design torque before consideration of frictional and efficiency losses shall be not less than the maximum
torque of the drive motor (i.e. during starting or stalling, including breakdown torque under no power),
subject to a minimum of 2.0 times the motor full load torque.
Where an effective torque limiting coupling or hydraulic drive is fitted, the limiting design torque at the
output of the coupling or hydraulic drive shall be based on the greatest of —
(a) 1.1 times the greatest load limiting/protection device limit setting; and
(b) a minimum of 1.5 times the motor full load torque for an electric motor drive.
DR
For design purposes, the maximum abnormal digging force on a bucket wheel shall be an equivalent

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
force acting at the bucket lips, without deduction for the force needed to lift material in the buckets.
Thus the force needed to lift material in the buckets is included as part of the digging force. The effect
of friction and efficiency losses in the drive system shall be included so as to increase (i.e. rather than to
decrease) the design torque, since during an abnormal digging event, the bucket wheel or bucket chain
friction can decelerate the drive system. The friction and efficiency factor shall be not more than 0.95.
Therefore, the maximum torque shall be increased by a factor of not less than 1.05.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.

3.4.5 Abnormal lateral digging resistance (SS)

3.4.5.1 General

This load case shall apply to reclaiming and excavating type-machines that experience lateral loading
due to digging.

3.4.5.2 Slewing or bucket wheel machines

A load limiting/protection coupling or clutch on slewing machines shall be provided.

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 23 DR AS 4324.1:2024

The abnormal lateral digging resistance shall be taken as —

(a) where a safety coupling or clutch is fitted to the slew or travel drive, the force derived from
the sum of —
(i) 1.1 times the highest value of the cut-off torque of the load limiting/protection
coupling or clutch and the load limiting/protection device limit on the relevant
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drive (i.e. slew or travel); plus

(ii) the frictional losses in the relevant drive system (i.e. slew or travel) between
coupling and digging element (that shall be added to increase the design resistance).
(b) where a safety coupling or clutch is not fitted to the slew or travel drive, the force derived
from the sum of —
(i) the maximum torque (i.e. during starting or stalling) of the relevant lateral drive

T
motor (i.e. slew or travel); plus
(ii) the frictional losses in the relevant drive system (i.e. slew or travel) between drive
motor and digging element (that shall be added to increase the design resistance).
Where a torque limiting device (e.g. a slew clutch) is fitted, the design cut-off torque shall be not less

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than 1.1 times the sum of the torques due to inclination of the machine (see Clause 3.3.4) plus the design
AF
wind load for the machine during operation or relocation (see Clause 3.4.2).
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.

3.4.5.3 Other reclaiming machines/fixed boom type machines

The same principles and requirements as defined in Clause 3.4.5.2 shall be applied to other reclaiming
machines, unless varied by the technical specification in accordance with Appendix B.

3.4.6 Travel skew forces (LS)

DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
3.4.6.1 Crawler-mounted machines

This load case may be limited or controlled by a skew control system (with at least two levels of
protection achieved by independent means).
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.
For crawler-mounted machines, the travel skew force to be taken into account for the structural design
of the machine shall be as determined from the friction coefficients as specified in Clause 3.3.12(b).

3.4.6.2 Rail-mounted machines — General

This load case may be limited or controlled by a skew control system (with at least two levels of
protection achieved by independent means).
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.

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 DR AS 4324.1:2024 24

For rail-mounted machines, the total travel skew force at a wheel to rail contact shall be the sum of the
skew reaction determined for oblique travel (see Clause 3.4.6.3) plus the skew reaction determined for
forward travel with the driving force not coincident with the centre of mass (see Clause 3.4.6.4).

3.4.6.3 Rail-mounted machines — Skew reactions due to oblique travel

For rail-mounted machines, such as travelling conveyor gantries, skew reactions transverse to the rail
PUBLIC COMMENTING DRAFT

due to oblique travel can occur due to skewing or unintended deviation from the direction of travel
[see Figure 3.4.6(a)]. These reactions are in addition to those due to wind and forces of inertia. Skew
reactions due to oblique travel shall be calculated from the following equation:

H yij  Vijmax  K G

where

T
Hyij = skew force acting horizontally transverse to the rail (i) on the wheel or bogie (j)

Vijmax = maximum vertical load on each rail (i) or on each wheel or bogie (j), computed for the
machine centre of mass in its most unfavourable position

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KG = Ko × KF AF
KF = reduction factor that allows for the flexibility of the rail mounted structure as a function
of the lowest horizontal natural frequency (or torsional natural frequency about a
vertical axis) for the whole structure

= 1.0, if natural frequency ( f n) > 5.0 Hz

= 0.83, if natural frequency ( f n) > 3.2 Hz and ≤ 5.0 Hz

= 0.66, if natural frequency ( f n) > 2.4 Hz and ≤ 3.2 Hz

=
 
0.5
0.426  fn , if natural frequency ( f n) ≤ 2.4 Hz
DR
with fn to be not less than 1.0 Hz for calculation purposes

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
KO = skew reaction coefficient, whose value is given in Table 3.4.6 as a function of the oblique
travel gradient   
KGmin = minimum permissible value of KG

= 0.025 (p/a)

p = rail gauge, in metres

α = oblique travel gradient, in millimetres per metre = c/a

c = design clearance between wheel flange or guide roller and side of rail, in millimetres [see
Figure 3.4.6(c)]

≥ the sum of 10 % of the rail head width (to allow for wear) plus the greater of 10 mm and
75 % of actual maximum initial clearance

a = centre distance between track wheels, track wheel groups or bogies, in metres

= centre distance between rollers, in metres, where horizontal guide rollers are used

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 25 DR AS 4324.1:2024

Table 3.4.6 — Skew reaction coefficient

α KOa
mm/m
≤ 1.5 0.094
2 0.118
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3 0.158
4 0.196
5 0.214
6 0.233
7 0.248
8 0.259
9 0.268

T
10 0.275
12.5 0.287
15 0.293
> 15 0.300

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a Where KO < KGmin/KF, the value for KG to be used in the calculations shall be set equal to KGmin.​
AF
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024

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 DR AS 4324.1:2024 26

H y11 y H y11 y

Rail 1 Rail 1 Rail 1 Rail 1

a a a a
2 2 H 2 2 H y12
y12
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s (c entre of m a s s) s (c entre of m a s s)
p x p x

H y 21

Rail 2 Rail 2 Rail 2 Rail 2

T
Hy22
(i) S e p a r ate b o g i e s o n eac h s i d e (ii) A c o m b i n e d b o g i e o n o n e s i d e
(a) S kew reac t i o n s d u e to o b l i q u e trave l m o t i o n

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Hy y Hy y

Rail 1

a
2
a
2 Hy
AFRail 1 Rail 1

a
2
a
2 Hy
Rail 1

s (c entre of m a s s) s (c entre of m a s s)
p Is x p Is x
H x (resultant H x (re s u l t a n t
Hy driving forc e) driving forc e)

Rail 2 Rail 2 Rail 2 Rail 2

DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Hy
(i) S e p a r ate b o g i e s o n eac h s i d e (ii) A c o m b i n e d b o g i e o n o n e s i d e
(b) S kew reac t i o n s d u e to for war d trave l m o t i o n

W h e el

Rail

c (w h e e l /r a i l c l e a r a n ce)

(c) Geometr y of w h e el o n r a i l

Figure 3.4.6 — Lateral skew reactions for machines on rails

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 27 DR AS 4324.1:2024

3.4.6.4 Rail-mounted machines — Skew reactions due to forward travel

Where the driving force Hx is not coincident with the centre of mass of the machine, the calculations
of skew reactions due to forward travel motion shall assume, where appropriate, that all Hyij are equal
and that they resist an inertial moment equivalent to Md × Hx × ls [see Figure 3.4.6(b)]. The calculation
for Hy shall include where the driving force, Hx, is affected by drives being out-of-service as defined
by the technical specification. The values so calculated may be reduced if a skew control system is
PUBLIC COMMENTING DRAFT

incorporated but not below 30 % of the calculated values,

where

Md = dynamic factor

≥ 1.5

Hx

T
= maximum total travel force available from the drives

= sum of the drive forces associated with individual driver wheels

≤ μ × (sum of all the vertical reactions on the driver wheels)

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μ = limiting coefficient of friction between the driver wheels and the rails
AF
≥ 0.25 for steel wheels on steel rails

ls = distance between line of action of driving force H x and the centre of mass,
in metres
Thus, for the example shown in Figure 3.4.6(b)(i) —

Md  H x  ls
Hy 
2a
and for the example shown in Figure 3.4.6(b)(ii) —

Md  H x  ls
DR
Hy 

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
a

3.4.7 Non-permanent dynamic effects (DD)

This load case shall apply for all machine types.

Inertia forces due to non-permanent dynamic load effects, such as abnormal acceleration and braking
of moving parts of the machine (e.g. emergency braking), shall be classified as additional loads. They
may be disregarded where their effect is in the same direction and less than that of the wind force
during operation, as calculated in accordance with Clause 3.4.2. Where these non-permanent dynamic
effects are in the same direction and exceed the wind force, the wind effect may be disregarded.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual. This includes maximum velocities and calculation of associated
accelerations/decelerations under activation of controls/devices.

3.4.8 Snow, ice and hail loads (K)

Where applicable, or where prescribed by the technical specification in accordance with Appendix B,
the design shall include the effects of loads due to snow, ice and hail. The amount of additional loading
that needs to be taken into account will depend on the area where such material can collect to a degree

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 DR AS 4324.1:2024 28

in excess of the encrustation loading already taken into consideration (see Clause 3.3.3). The amount
of additional loading shall conform to AS/NZS 1170.3. The annual probability of exceedance for these
loads shall be as nominated in the technical specification and in accordance with AS/NZS 1170.0:2002
Appendix F, when they are required to be included.
Snow, ice and hail loads that may be present at the location of fabrication and during construction
and/or delivery should be included.
PUBLIC COMMENTING DRAFT

3.4.9 Access ways (P)

This load case shall apply for all machine types.

Access ways, such as stairs, platforms, walkways and guardrails, shall be designed in accordance with
AS 1657 and, in addition, shall be able to support a concentrated load of 3 kN at any point. The local area
of the main structure of the machine that supports stairs, platforms, walkways, guardrails, access ways

T
and the like shall be designed to withstand the concentrated and distributed loads as required above, as
if these loads are applied locally. These loads need not be included for the purposes of assessing overall
machine strength and stability unless indicated otherwise in the technical specification in accordance
with Appendix B.
Where stairs, platforms, walkways, access ways or the like may temporarily support an additional

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load that may be in excess of the loads required in the foregoing paragraph (e.g. material build-up,
AF
maintenance personnel, equipment), they shall be designed and sized accordingly.

3.4.10 Erection, dismantling and weighing (Y)

This load case shall apply to all machine types.

Loads that can be applied as a result of erection, dismantling or weighing shall be included. During
erection, machines shall be secured against movement caused by winds having a strength as set out in
AS/NZS 1170.2.
Wind loading shall be in accordance with Clause 3.5.10 (i.e. WW) unless varied by the technical
specification in accordance with Appendix B.
DR
The technical specification should define the extent to which these loads and associated structural

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
configurations are subject to design audit.

3.4.11 Maintenance loads (X)

This load case shall apply to all machine types.

Loads that can arise during any special maintenance operations (e.g. replacement of slew bearing,
replacement of bogie) shall be taken into account. During maintenance, machines shall be secured
against movement caused by wind speeds as set out in AS/NZS 1170.2.
Where wind loading less than that defined for load WW is to be used, this shall be defined by the
technical specification in accordance with Appendix B.

3.4.12 Abnormal inclination (NN)

This load case shall apply to all machine types.

Abnormal loads due to extreme inclination of the working level shall be based on the following:
(a) For machines in operation:

NN1 = 1.2 × (maximum slope for normal operation as specified in the technical
specification in accordance with Appendix B)

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 29 DR AS 4324.1:2024

(b) For crawler mounted machines in transit:

NN2 = 1.2 × (maximum in transit slope as specified in the technical specification in

accordance with Appendix B)

3.5 Special loads

PUBLIC COMMENTING DRAFT

3.5.1 Grouping

Special loads are a grouping that comprises loads that do not normally occur while the machine is
operating or idle, but may occur in exceptional circumstances and shall be included in the design.

3.5.2 Grounding of a bucket wheel, ladder or discharge boom

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3.5.2.1 General

This load shall apply to machine types with a bucket wheel, ladder or discharge boom.
Machines that have only one level of protection against grounding shall include loading for both

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Clauses 3.5.2.3 and 3.5.2.4. AF
This load shall be included for both operational (i.e. live loads present) and non-operational (i.e. dead
load only present) conditions.
While this clause (3.5.2.1) generally requires calculation of the effects of physical grounding at the
boom tip, the design may need to consider the possibility of grounding at locations along the boom.
The inclusion of grounding of counterweight booms shall only be required if defined by the technical
specification in accordance with Appendix B.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the required action
upon activation of the device/control shall be defined in the structural calculations and be included in
the operating and maintenance manual.
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
3.5.2.2 Slight (A1)

To allow for grounding of a bucket ladder, bucket wheel or boom that would cause the force in its
support or actuating/monitoring system (i.e. suspensions, ropes or hydraulic cylinders) to fall to 10 %
below the lowest nominal support load in normal operation, allowance shall be made for 1.1 times the
resultant force acting at a bucket ladder or up through the centre of a bucket wheel in the case of an
excavator or reclaimer, or through the centre of the conveyor end pulley on the boom of a machine such
as a stacker. This corresponds to a first level setting of the support load limiting/protection device that
shall be set at 1.0 times the resultant force defined above and prevent load applied above that value.

3.5.2.3 Partial (A2)

To allow for grounding of a bucket ladder, bucket wheel or boom that would cause the force in its
support or actuating/monitoring system to fall to 20 % below the lowest nominal support load in
normal operation, allowance shall be made for 1.1 times the resultant force acting at a bucket ladder,
or up through the centre of a bucket wheel in the case of an excavator or reclaimer, or through the
centre of the conveyor end pulley on the boom of a machine such as a stacker. This corresponds to a
second level setting of the support load limiting/protection safety device that shall be set at 1.0 times
the resultant force defined above and prevent load applied above that value.

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 DR AS 4324.1:2024 30

3.5.2.4 Full (AA)

Where safety devices required by Clauses 3.5.2.2 and 3.5.2.3 are not installed, or do not limit applied
loads to below the defined values, the machine shall be designed to permit full grounding of the bucket
wheel, bucket ladder or boom.
For machines with safety load limiting/protection devices as required in Clauses 3.5.2.2 and 3.5.2.3,
PUBLIC COMMENTING DRAFT

the technical specification may prescribe a failure of the safety device leading to full grounding.
A possible full-grounding situation for a reclaimer rehandling stockpiled material, where a slip of the
face would create an uplift of the wheel, is illustrated in Figure 3.5.2.4.

T
S t o c k p i le sur face before slide
S l i p c ir c l e
S t o c k p i le sur face af ter s l i de

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M ain uplif t for c e
AF
Figure 3.5.2.4 — Typical up-lift of a bucket wheel

3.5.3 Uneven support where rail-mounted (QQ)

This load case shall apply to all machine types that are rail mounted.
DR
Strength and stability calculations for rail-mounted machines shall allow for the machine orientation

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
that represents the most adverse case of tipping. Where uneven support, such as variations in flatness
of travel rails, could cause unloading of a group of travel wheels, loading of remaining wheels shall not
exceed that needed to maintain a stability ratio for the overall machine of not less than 1.2, for the most
adverse configuration of the machine in relation to the loaded wheels. Maximum wheel loads shall be
less than the limits contained in the technical specification in accordance with Appendix B.

3.5.4 Uneven support where crawler-mounted (QQ)

This load case shall apply to all machine types that are crawler mounted.
Strength and stability calculations for crawler-mounted machines shall allow for the most adverse case
of tipping or travel over uneven ground that may occur. Dimensions and geometry of crawler systems
shall be such as to prevent the crawler ground pressure from exceeding the maximum specified.
Unless stated otherwise in the technical specification in accordance with Appendix B, the factor of
safety between actual crawler ground pressures and permissible ground pressures shall be calculated
on the basis that the maximum supporting area of a crawler is the plan area of the crawler, calculated
from the distance between the first and the last track wheels × crawler track width.
However, for crawlers that are effectively rigidly connected to the undercarriage, the pressure
distribution over the length of a crawler due to the effect of the machine centre of mass not coinciding
with the centroid of the supporting crawler area shall be calculated on the basis that at the limiting

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 31 DR AS 4324.1:2024

condition, the pressure distribution would be uniform, but the crawler would be loaded over a length of
less than the full distance between first and last track wheels.
Load cases to be evaluated shall include the following loading arrangements:
(a) For fully equalized crawlers having the maximum load supported as two concentrated loads,
one at each end tumbler and with a take-up tumbler in its outer position.
PUBLIC COMMENTING DRAFT

(b) For two-crawler machines having the crawler main frames rigidly connected to the
underframe, a loading situation that allows for the entire machine weight and the applied loads
to be supported on two points, one point being on each crawler at a position corresponding
to a tumbler or an equalized wheel group. The support points shall be determined from
consideration of overall equilibrium of the machine under the loads applicable to the load
case being assessed.
(c) For two-crawler machines having the crawler main frames rigidly connected to the

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underframe that is a loading situation that allows for the entire machine weight and the
applied loads to be supported on three points, one point being a tumbler or equalized wheel
group on one crawler and the other two points corresponding to either a tumbler or an
equalized wheel group on the other crawler. The support points shall be determined from
consideration of overall equilibrium of the machine under the loads applicable to the load

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case being assessed. AF
NOTE The maximum load to be supported at one of the points for the most adverse loading situation
corresponding to Item (b) or (c) above may typically be found to be two-thirds to three-quarters of the
total load to be supported.

(d) For two-crawler machines having each of their crawler main frames pivoted to the underframe,
a loading situation that allows for the entire machine weight and the applied loads to be
supported on four points, two points being on each crawler and being either a tumbler or an
equalized wheel group. The support points shall be determined from consideration of overall
equilibrium of the machine under the loads applicable to the load case being assessed.
(e) For steered crawlers that are shearing material that has built-up against the side of the pads,
the resistance shall be the greater of that derived from the shear strength of the ground
material or that based on a coefficient of friction of 0.9.
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
(f) Loads arising from cross-sliding of the crawlers when loads on the underframe are the
most unfavourable under Cases I and II loads (see Clause 3.7), without steering, and with a
coefficient of friction of 0.6 between the crawler pads and the operating surface.
Crawler mounted machines shall be designed to be able to traverse the nominated range of terrain and
gradients, under relocation conditions, during the course of their operational life.
During abnormal load combinations in these configurations, where the potential for a two-crawler
configuration machine to rock forward onto the crawler tumblers, the strength and stability of the
relevant components and structures of the machine shall ensure the machine is able to safely recover
from this position.
If such a possibility exists, the forward rocking motion and in particular, the severity of the return
oscillation should be limited, or eliminated as far as is practicable within the constraints of the design.
Where it is not practicable to stipulate a specific machine relocation configuration to alleviate this
load case, strength and stability requirements shall be as prescribed in the technical specification, in
accordance with Appendix B.

3.5.5 Blocked chutes and hoppers (VV)

This load case shall apply to all machine types.

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 DR AS 4324.1:2024 32

Calculations of the mass of material in blocked chutes, ship loader spouts, hoppers, etc. shall be based
on the bulk density of the material (see Clause 3.1) multiplied by the sum of the following:
(a) The volume of the chute or hopper.
(b) The volume of any possible surcharge on the chute or hopper, taking into account the angle of
repose of the material.
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(c) The volume of any possible overflow material resting on secondary structures or surfaces,
taking into account the angle of repose of the material.
The mass of material in the chute or hopper during normal operation may be deducted from the total
mass of material in the chute or hopper for the purposes of determining the additional mass present
during a blockage, but only where it has been included as part of the live load (see Clause 3.3.5).
The calculations shall use an angle of repose of the material of not less than 35°.

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Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the required action
upon activation of the device/control shall be defined in the structural calculations and be included in
the operating and maintenance manual.

Licensed to Paul Yakimoff of ME-043 at 09:12 (AEST) on Wed Oct 30 2024 for Committee and Standards Australia use only.
3.5.6 Excess material on conveyors (FF)
AF
This load case shall apply to all machine types.
Where a failure of load-limiting devices, blocking of chutes or anything else may cause material loads in
excess of those specified in Clause 3.3.5, such excess loads shall be calculated as special loads.
Excess material loads (FF) carried on a conveyor shall be determined in accordance with the principles
contained in Appendix I. Unless varied by the technical specification in accordance with Appendix B,
for structural design purposes, the live load shall be based on the maximum possible cross-section
of material (Sm) as defined in Clause I.3 of Appendix I (i.e. corresponding to zero edge distance and
surcharge angle of at least 35°, subject to a minimum of the angle of repose of the material, and including
allowance for any crowding boards).
DR
Unless required by the technical specification, the maximum load derived for FF is that limited by

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
the physical geometrical properties of the conveyor and the material conveyed (i.e. if a theoretical
bucketwheel output is greater than the conveyor geometrical FF capacity, the conveyor cross sectional
capacity governs). Where the bucketwheel output is greater than the conveyor cross sectional capacity,
the excess spillage should be included for this loading in accordance with Clause 3.5.5.
Where load limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the required action
upon activation of the device/control shall be defined in the structural calculations and be included in
the operating and maintenance manual.

3.5.7 Travelling device obstructed (LL)

This load case may be limited or controlled by a skew control system (with a minimum of at least two
levels of protection achieved by independent means) for machines with large rail gauge distances.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the required action
upon activation of the device/control shall be defined in the structural calculations and be included in
the operating and maintenance manual.
The method of application or omission of this clause (3.5.7) in relation to equipment with a large rail
gauge distance shall be defined in the technical specification in accordance with Appendix B.

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 33 DR AS 4324.1:2024

To allow for the obstruction of travelling devices, such as bogies of rail-mounted equipment becoming
locked (e.g. by derailment or rail fracture), calculations of loads occurring under such conditions shall
be based on the sum of the stall torque of the drive motors plus the inertial loading associated with
decelerating the machine at the rail from maximum velocity at a constant rate of deceleration over
a distance of 300 mm (this distance may be varied by the technical specification in accordance with
Appendix B), except that loads imposed by driven wheels need not be taken as greater than would occur
for a coefficient of friction (μ) between driven wheels and rails of 0.33.
PUBLIC COMMENTING DRAFT

The case where driven wheels on one rail are blocked completely but driven wheels on the other rail are
free to drive the machine into skew shall be included. The most adverse combinations of loading from
obstructed bogies shall be included in the design. Pairs of travel wheels on a crawler-mounted machine
shall be treated similarly with a coefficient of friction (μ) of not less than 0.33. It shall be assumed
that the machine is both slewing and travelling at the maximum velocity for each drive motion, unless
interlocks prevent both motions occurring simultaneously, in which case the worst loading situation for
either slewing or travelling at the maximum velocity for that drive alone shall apply.

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3.5.8 Lateral collision of boom (FS)

This load case shall apply to equipment with slewing and/or long travel motion capability. This load
case shall also be applied to the counterweight boom as specified by the technical specification in

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accordance with Appendix B. AF
The application or omission of this clause (3.5.8) in relation to equipment that has non-slewing or fixed
boom type arrangements shall be defined in the technical specification in accordance with Appendix B.
Calculations of the maximum lateral resistance of a boom colliding against an obstruction while slewing
or travelling shall be based on the sum of —
(a) the maximum slew torque or travel drive torque for the motors during starting or at stall (or
as limited by the safety load limiting/protection coupling, slip clutch or brake but factored by
1.1) divided by the efficiency of the slewing or travel drive; and
(b) the inertial loading associated with decelerating the outermost extremity of the boom from
maximum velocity at a constant rate of deceleration over a distance of 300 mm.
DR
It shall be assumed that the machine is both slewing and travelling at the maximum velocity for each

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
drive motion, unless interlocks prevent both motions occurring simultaneously, in which case the
worst loading situation for either slewing or travelling at the maximum velocity for that drive alone
shall apply. The efficiency factor shall be not greater than 0.95. Therefore, the maximum torque shall be
increased by a factor of not less than 1.05.
The force calculations should be based on a simulation of the deceleration of the machine while
travelling and slewing, taking account of the distributed inertia of the machine superstructure. It
should be noted that the machine may still be travelling forward after the forward motion of the boom
tip has been arrested. For non-slewable machines, it may be necessary to account for the flexibility of
the structure, to obtain a realistic estimate of the inertial loading during a collision.
Stresses in the boom and superstructure resulting from such a collision may be calculated using a
statically equivalent set of forces and moments, in which case the inertial loading should be represented
by a number of distributed forces and lumped forces having the same effect as the mass items that they
represent at their respective distances from the centre of rotation and travelling at the constant rate
of angular deceleration. By way of example, Figure 3.5.8 illustrates an acceptable representation for a
stacker-reclaimer that is slewing but not travelling.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.

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 DR AS 4324.1:2024 34

Where this load case is omitted, or a lower value is used in the design, the protection system should
consider the level of deflection of the boom that would cause structural nonconformance and/or
damage.
The calculation of this load case for collisions at locations other than at the end of the boom shall be as
specified by the technical specification in accordance with Appendix B.
PUBLIC COMMENTING DRAFT

T (I)S t r
F (I) C / W Rail Rail

F (I) B o o m 2 F Lat
D ire c t i on of trave l

F (I) B o o m1

T
F (I) B / W
TS l e w

Key
FLat collision force at bucket wheel
F(I)B/W statically equivalent force representing inertia of bucket wheel

Licensed to Paul Yakimoff of ME-043 at 09:12 (AEST) on Wed Oct 30 2024 for Committee and Standards Australia use only.
F(I)Boom1
F(I)Boom2
F(I)C/W
T(I)Str
TSlew
AF
statically equivalent force representing inertia of main boom
statically equivalent force representing inertia of counterweight boom
statically equivalent force representing inertia of counterweight
statically equivalent torque representing inertia of superstructure
slew drive torque as limited by slew clutch or safety coupling

Figure 3.5.8 — Reactions from a lateral collision of a stacker-reclaimer boom

3.5.9 End-on collision of boom (FT)

This load case shall apply to equipment with slewing and/or long travel motion capability. This load case
DR
is not required to be included for equipment that does not have a motion capability (nearing) parallel

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
to the boom, unless so defined by the technical specification in accordance with Appendix B. This load
case shall be applied to the counterweight boom only as specified by the technical specification in
accordance with Appendix B.
The application or omission of this clause (3.5.9) in relation to equipment that has fixed boom type
arrangement shall be defined in the technical specification in accordance with Appendix B.
A loading situation that allows for an end-on collision of the boom of a slewable machine while the
machine is travelling shall be included in the design. For the purpose of determining the resulting
loads, the boom shall be taken to be slewed at an angle of 20° to the direction of travel at the moment
of collision. The forces so induced shall include a lateral force (F Lat) normal to the boom axis and a
longitudinal force (F Long) along the boom axis. These forces shall be calculated as follows:
F Lat = the sum of —
(a) the force at outermost extremity of the boom, normal to the axis of the boom so as to just
cause slippage of the slew clutch or slew brake, whichever is appropriate for the manner in
which the machine operates;
(b) the efficiency losses in the drive system due to the deceleration of the drive by the collision
force where the efficiency factor shall be not greater than 0.95. Therefore, the maximum
torque shall be increased by a factor of not less than 1.05; and

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 35 DR AS 4324.1:2024

(c) the inertial loading associated with bringing the end of the boom to rest in the direction of
travel over a distance of 300 mm in the direction of travel.
In determining when slippage might reasonably be expected to occur for a clutch or brake, a minimum
factor of 1.1 shall be applied to the rated slew clutch torque, and a minimum factor of 1.35 shall be
applied to the nominal torque capacity of the brake to allow for setting inaccuracies and variability in
performance.
PUBLIC COMMENTING DRAFT

F Long = force at outermost extremity of the boom, aligned in the direction of the boom axis and
equal to F Lat cot 20°

The force calculations should be based on a simulation of the deceleration of the machine in travel and
slew, taking account of the distributed inertia of the machine superstructure. It should be noted that
the machine may still be travelling forward after the forward motion of the boom tip has been arrested.

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Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.
Figure 3.5.9 illustrates this loading situation for a rail-mounted stacker-reclaimer by way of example.

Licensed to Paul Yakimoff of ME-043 at 09:12 (AEST) on Wed Oct 30 2024 for Committee and Standards Australia use only.
AF Rail

Rail 20 °

D ire c t i on of trave l
F L at

L
DR
F L at F Long F TOT

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
20 ° F Long

F TOT

F L o n g = F L at c ot 20°
F TOT = F L a t c o s e c 20°

Figure 3.5.9 — Reactions from an end-on collision of a stacker-reclaimer boom during

travelling

3.5.10 Wind while idle (WWp and WWu)

This load case shall apply to all machine types.

Wind loads calculated according to the permissible stress design method shall be designated WWp.
Wind loads calculated according to the ultimate limit state design method shall be designated WWu.
Where machines are not completely shielded from the wind, the wind load on an idle machine shall be
calculated in accordance with AS/NZS 1170.2, based on the basic wind speed (Vp) for the permissible
stress design method. Determination of the basic wind speed (Vp) for the permissible stress design
method shall be based upon the (ultimate limit state) V500 (or greater) regional wind speed divided by
the square root of 1.5.

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 DR AS 4324.1:2024 36

The most adverse wind direction shall be taken into account for determining wind loads; although it is
normally sufficient to consider wind directions along the main axis of the structure, at right angles to
the main axis of the structure and at 45° to the main axis of the structure.
Where a machine is parked only in the one configuration, wind loads for only that configuration need
be included.
PUBLIC COMMENTING DRAFT

In addition to uniform wind loading, non-uniform wind loading (such as may arise due to partial
shielding of the machine or variability of gust behaviour over the entire machine) or from other possible
effects shall be included in the design. The wind direction and machine configuration shall be varied to
determine the worst case of wind loading for stability and design of structures and mechanisms.
Where the only apparent reason that wind loading on a machine would be non-uniform is due to
a variability of gust behaviour across the extent of the machine, any resultant torque that would be
exerted on any rotatable or slewable portion of the machine shall be based on a 50 % reduction of the
full wind loading on that side of the rotating or slewing axis. The wind direction and the side of the axis

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that is reduced by 50 % shall be chosen to give the maximum possible torque.
Wind tunnel testing and/or computational fluid dynamics are permitted for the determination of wind
loading.

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3.5.11 Buffers (OO) AF
This load case shall apply to relevant motions for all machine types.
For rail-mounted machines, buffers shall be capable of absorbing the total energy of the moving masses
(including the rotational energy of the drive system) under full power at rated travelling velocity, and
at uniform deceleration to zero speed from the point of contact to the full combined compression of the
buffers. The energy to be absorbed by the buffers shall include not only the kinetic energy of the moving
masses, but also the work done by the travel drive motors acting over the distance of combined buffer
compression (the actual travel drive torques determined from the motor torque-speed characteristic
should be used).
The resulting loads imparted to the structure shall be based on the retardation imparted by the buffers
and the linear and rotational inertias of the moving parts.
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Special cases should be as set out in the technical specification in accordance with Appendix B (e.g. a
tripper locked onto a belt while it is travelling at rated speed).
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in
the operating and maintenance manual. These principles shall also be applied to other moving sub-
assemblies where buffers are installed.

3.5.12 Earthquakes (EQp and EQu)

This load case shall apply to all machine types.

Earthquake loads calculated according to the permissible stress design method shall be designated
EQp.
Earthquake loads calculated according to the ultimate limit state design method shall be designated
EQu.
Loads arising from the effects of earthquakes shall be calculated in accordance with AS 1170.4. The
ultimate limit state design loading, EQu, shall be calculated using an annual probability of exceedance
of 1/500 (i.e. a probability factor, kp, of not less than 1.0), or a more onerous value as defined by the
technical specification in accordance with Appendix B.
The permissible stress design earthquake loading EQp shall be calculated as EQu/1.4.

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 37 DR AS 4324.1:2024

3.5.13 Burying (ZZ)

This load case shall apply where the load, burying, is explicitly specified in the technical specification
in accordance with Appendix B.
Where collapse of a stockpile or slippage of the bank could cause the reclaiming or excavating component
of an operating machine to become partially or fully buried, it may be appropriate to consider this as a
PUBLIC COMMENTING DRAFT

special load case.

Figure 3.5.13 illustrates a typical burying situation. A possible load description for a burying that could
be included in a technical specification is given in Table B.1 of Appendix B.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the action upon
activation of the device/control shall be defined in the structural calculations and be included in the
operating and maintenance manual.

T
S l i p c ir c l e

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S l i p c ir c l e

ψ
AF ψ
B

(a) S t o c k p i le sur face before slide (b) S t o c k p i le sur face af ter s l i d e

S t o c k p i le

B ur y ing vo lume B l o c ke d c hute vo l u m e

DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Sl
ip cle
cir

VIE W B

Figure 3.5.13 — Typical burying of a bucket wheel

3.5.14 Bucket wheel and gearbox loss or loss of Boom Equipment (BL)

3.5.14.1 General

This clause applies to situations where rapid loss of equipment from a machine can cause significant
effects to the strength and stability of the machine. The two cases prescribed are for possible loss of a
bucketwheel and/or gearbox and a boom mounted discharge chute.

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 DR AS 4324.1:2024 38

3.5.14.2 Bucket wheel and gearbox loss (BL)

This clause (3.5.14.2) shall apply to bucket wheels and/or drive assemblies that are not contained or
captured by the structure upon failure of the shaft (i.e. such as cantilever bucket wheel shafts) or as
defined in the technical specification in accordance with Appendix B.
This applies to bucket wheel machines, where the bucket wheel is mounted at the end of a boom. The
PUBLIC COMMENTING DRAFT

load case involves the bucket wheel, bucket wheel shaft assembly and bucket wheel drive unit separating
and falling from the end of the boom.
On machines where the bucket wheel is contained in such a case, but the drive unit is not, a loss of the
drive unit shall be included in the design unless the drive unit is similarly contained by means of a
catchment structure or system.
For this situation, the design shall be such that either the slew bearing or slew race safety hooks will
hold the superstructure, preventing separation at the slew race. Dynamic effects associated with the

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bending oscillation of the boom following release of the bucket wheel, bucket wheel shaft and bucket
wheel drive gearbox shall be included in the design.

3.5.14.3 Loss of Chutes/Telescopic Chutes

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This clause (3.5.14.3) shall be included for boom mounted chute assemblies that are not contained or
AF
captured by the structure upon failure of the supporting components, or as defined in the technical
specification in accordance with Appendix B.
This applies to booms of machines with discharge or telescopic chutes mounted at the end, or within
the length, of a boom (for example, shiploaders with a telescopic chute). The load case involves the chute
assembly separating and falling from the boom.
On machines where the parts of the chute may be contained, the loss of the part able to be lost shall
be included unless all of the chute system is similarly contained by means of a catchment structure
or system. Dynamic effects (including recoil) associated with the bending oscillation of the boom
following rapid release of the chute shall be included in the design.
For this situation, the design shall be such that either the slew bearing or slew race safety hooks hold
DR
the superstructure (where applicable), preventing separation at the slew race. Stability shall also be

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
checked for the loss of the mass and the dynamic effects.

3.5.14.4 Loss of Other Significant Masses

Where the loss of other significant masses is prescribed in the technical specification in accordance
with Appendix B, the effects of that loss shall be included in the design.

3.5.15 Abnormal friction (RR)

This load case shall apply when specified by the technical specification in accordance with Appendix B.
A load case should be included for each pivot (e.g. pinned joint or spherical seat) where it is assumed
to be seized to such an extent that the abnormal friction coefficient is as much as 0.85, while all other
pivots exhibit normal friction as specified by Clause 3.3.11. Allowance need not be made for more than
one pivot seizing at the one time.

3.5.16 Extra loads (EL)

Other special loading situations may occur due to the particular or peculiar circumstances associated
with a machine design or operating environment. A particular example is a failure of safety devices that
are provided specifically to limit the loads on the machine. The technical specification, in accordance
with Appendix B, shall identify any such further special loads required to be included in the design. The
appropriate load case combinations, stability ratios, and factors of safety (or load combination type I, II

© Standards Australia Limited 2024

 39 DR AS 4324.1:2024

or III) shall be as defined in the technical specification in accordance with Appendix B, so as to provide
an acceptable level of risk under the circumstances.
Where load-limiting devices are used to control this load, their use shall be as defined in the technical
specification in accordance with Appendix B. The device/control, its setting and the required action
upon activation of the device/control shall be defined in the structural calculations and be included in
the operating and maintenance manual.
PUBLIC COMMENTING DRAFT

3.6 Fatigue loads

3.6.1 General

The load cases in this clause (3.6) shall apply toall machine types.
Fatigue loading shall be determined by considering variations of the main loads as discussed in

T
Clauses 3.6.2 to 3.6.10.
For any given machine, this will generally result in one or more cyclical loadings that will occur
repetitively throughout the operational life of the machine. For each such cyclical load component,
a load range (i.e. maximum to minimum) and a corresponding number of load cycles that will occur
during the design life of the machine shall be determined. Where there are two or more cyclical loading

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AF
components, the combined effect shall be assessed using a Miner’s Rule summation.
For assessing the capability of a structure or parts thereof (e.g. welded joints) to resist fatigue based
on the fatigue load cases defined in Table 3.7(A) or Table 3.7(B), the loads used shall be based on
representative working loads (i.e. without inclusion of limit state load multiplying factors or factors
of safety) so that calculated stress ranges may be compared directly with the fatigue strength for the
appropriate joint configuration. Fatigue load modifying factors are specified in Table 3.6 for certain
loading components that allow for these loads being unlikely to reach their maximum value on every
cycle.
Unless otherwise nominated in the technical specification in accordance with Appendix B, Clauses 3.6.2
to 3.6.10 shall be used to calculate fatigue load components. The symbols used for fatigue loads have
the following meanings:
DR
(a) +/− indicates a change in load from one extreme to the other where the direction of load

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
changes.
(b) +/0 indicates a change in load from zero to some maximum value.
(c) +/+ indicates a change in load due to geometry or load variation.
Load combinations for the fatigue load case (F/I) should include those fluctuating loads that can occur
together at a similar frequency of fluctuation.

3.6.2 Dead loads and encrustation (+/+E and +/+V)

Changes in machine configuration that occur during the machine’s operational cycle (e.g. geometry
changes that occur as a result of slew, luff, travel or boom shuttling motions), and how these geometry
changes alter loads on the machine or loads on the components of the machine, shall be included in the
design. Variation in loads and cycle numbers shall be determined from consideration of motion limits
and frequencies occurring during normal operation of the machine.

3.6.3 Inclination (+/−N)

Loads due to inclination apply to machines that slew during operation. They shall be calculated in
accordance with Clause 3.3.4, but taking account of the slew angle and the combined longitudinal and
cross slopes on which the machine operates.
Load cycles shall be taken to be the same as those used for normal digging (see Clause 3.6.5).

© Standards Australia Limited 2024

 DR AS 4324.1:2024 40

3.6.4 Live loads on conveyors (+/0CF.F)

For conveyors on machines having a digging element, the variation in live load shall be the difference
from zero to the maximum as calculated in Clause 3.3.5 multiplied by the factor CF. The values of CF
for different machines are listed in Table 3.6. In the case of bucket wheel excavators or reclaimers, this
variation will occur once every slew pass.
PUBLIC COMMENTING DRAFT

Where a fatigue bulk density is used for the calculation of live loads in accordance with Clause 3.1.3, CF
shall be taken as 1.0.
For machines without digging elements, the same load variation shall be included, but the number of
cycles shall be based on operational factors that control the loading and unloading of conveyors.

3.6.5 Normal digging resistance (+/0CU.U)

T
Digging resistance load cycle components apply only to machines with digging elements. Variation of
this loading shall be from zero to C U.U, where C is calculated as in Clause 3.3.7. The values of C U for
different machines are listed in Table 3.6. For bucket wheel excavators and reclaimers, this variation
will occur at least every digging pass of the machine (slew or travel).

3.6.6 Lateral digging resistance (+/−CS.S)

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For machines with digging elements, lateral digging resistance load components shall be CS.S where S
is as calculated in Clause 3.3.8 with allowances for the fact that the direction of application reverses
on each digging pass. The values of CS for different machines are listed in Table 3.6. Cycle numbers will
generally be one-half the number calculated for normal digging resistance.

3.6.7 Permanent dynamic effects (+/−D)

Variation of permanent dynamic cyclical components shall assume these loads are applied at a value D,
as calculated in Clause 3.3.9 in either direction. Cycle numbers shall be determined from a consideration
of operational circumstances. For machines with a luffable boom or a slewable boom, cycle numbers
shall be taken at least as frequently as in Clauses 3.6.5 and 3.6.6. However, the number of cycles of
oscillation that may occur at a natural frequency, for a relevant structural component each time a
DR
motion is initiated or stopped, shall be factored into the design.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
3.6.8 Conveyor elements (+/+G)

Forces on conveyor elements shall be assumed to vary from the loading on the belt being zero to the
conveyor element loads G for a conveyor loaded at the F load magnitude, as calculated in accordance
with Clause 3.3.5. The number of load cycles shall be the same as specified in Clause 3.6.4.

3.6.9 Friction (+/−R)

Cyclical loads resulting from changes in magnitude and direction of friction at pivots of booms and
similar shall be included, with magnitude calculated in accordance with Clause 3.3.11. Cycle numbers
shall be determined from operational considerations.
The extent that resistance due to travel or for friction effects at pivots are to be included in the fatigue
design of a machine should be defined in the technical specification in accordance with Appendix B.

3.6.10 Travel (+/−L)

For rail-mounted machines, the extent the resistance to travel (+/−L) shall be treated as a fatigue load
and shall be as defined in the technical specification in accordance with Appendix B.

© Standards Australia Limited 2024

 41 DR AS 4324.1:2024

Table 3.6 — Fatigue load modifying factors

Machine type CF CU CS
Rail-mounted
Stackers 0.9 — —
Ship loaders 0.9 — —
PUBLIC COMMENTING DRAFT

Reclaimers 0.8a 0.7a 0.7a

Crawler-mounted (e.g. BWEs, spreaders, beltwagons) 0.7 0.7 0.7
a These values are minimum values for design and may be altered by the technical specification.

3.7 Load cases

For the purpose of fatigue, strength or stability design, the total effect from the simultaneous

T
application of various possible combinations of loads shall be included in the design, including those set
out in Tables 3.7(A) or 3.7(B). These combinations are grouped into four classes, as follows:
(a) Load Case F/I are combinations of the fatigue loads.
(b) Load Case I are combinations of the main loads.

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(c)
(d)
AF
Load Case II are combinations of the main and additional loads.
Load Case III are combinations of the main, additional and special loads.
Changes in the point of application of each of the loads arising from each of the possible equipment
configurations shall be included for the various load case combinations nominated in Tables 3.7(A) or
3.7(B). For each strength or stability assessment, the worst case of these alternatives shall be adopted.
Assessments of each particular part of the structure shall take account of non-permanent loads that
increase stresses in the part, but not non-permanent loads that decrease stresses in the part. The same
method shall be used for determinations of load combinations for stability assessments.
In particular, the determination of design loads for all of the load case combinations for strength and
stability shall be based on the worst possible arrangement for the support of the machine due to uneven
ground conditions in the case of crawler-mounted equipment and, due to deviations of the rail top
DR
surfaces from a true plane, for rail-mounted equipment. This may be particularly important for crawler-

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
mounted machines with a rigid connection between the undercarriage and the crawler beams. In such
cases, it is possible for the entire weight of the machine to be carried on as few as three or sometimes
two effective support points, each support point being an equalized crawler group or tumbler [see
especially Clause 3.5.4 Items (a), (b), (c) and (d), which shall be deemed to also apply to load cases I, II
and III in respect of support assumptions].
For some specific machines, it might not be possible for some of the load combinations nominated in
Tables 3.7(A) or 3.7(B) to occur simultaneously in practice. In these cases, only those load components
that can occur simultaneously shall be included. In determining design loads for fatigue and the
corresponding cycle numbers, the worst case arrangement for support of the machine shall be taken
into account for such a period of operation as is likely under such support conditions.

© Standards Australia Limited 2024

 PUBLIC COMMENTING DRAFT
Table 3.7(A) — )Load combinations for design of machine structures — Permissible stress design method
Fatigue Main
Load combination Main and additional loads Main, additional and special loadsb
loadsa loads
Load case F/I I II III
Factor of safety,
DR AS 4324.1:2024

υa, for permissible

— 1.5 1.33 1.33 1.33 1.33 1.33 1.2 1.1* 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.0 1.1 1.2 1.1*
stress design
method Mini-
Clause mum
reference Stability ratio (to require-
be based only on ment i

© Standards Australia Limited 2024

loads determined
1.2/
in accordance with — 1.5 1.33 1.33 1.33 1.33 1.33 1.2 1.1 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.1 1.1 1.2 1.1*
1.5
the permissible
stress design
method)
Load combination III/ III/ III/ III/ III/ III/ III/
F/I I II/1 II/2 II/3 II/4 III/1 III/2 III/3 III/4 III/5 III/6 III/7 III/8 III/9

Main loads
numberc 10 11 12 13 14 15 16

3.3.2, E Dead loads All +/+E E E E E E E E E E E E E E E E E E E E E E

V V V V V V V V V V V V V V V V V V V V V
3.6.2
3.3.3, Encrustation All +/+V

N N N N N N N N N N N N N N N N N N N
3.6.2
42

3.3.4, Inclination All +/−N

F F F F F F F F F F F F F F F F
3.6.3
DR
3.3.5, Live loads All +/0C F. F F

U U U U U U U U U U U U U
3.6.4
3.3.7, Normal RC +/0C U.U U

S S S S S S S S S S S S
3.6.5 digging
3.3.8, Normal RC +/−CsS
3.6.6 lateral

D D D D D D D D D D D D D D D D D D
digging
3.3.9, Permanent All +/−D
3.6.7 dynamic
AF
G G G G G G G G G G G G G G G G G G G G G G
effectsh
3.3.10, Conveyor All +/+G

R R R R R R R R R R R R R R R R R R R R R
3.6.8 elements
3.3.11, Friction All +/−R

L L L L L L L L L L L L L L
3.6.9
3.3.12,
3.6.10
Travel

Additional loads
All +/−L
T
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Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
 PUBLIC COMMENTING DRAFT Table 3.7(A) (continued)
Fatigue Main
Load combination Main and additional loads Main, additional and special loadsb
loadsa loads
Load case F/I I II III
Factor of safety,
υa, for permissible
— 1.5 1.33 1.33 1.33 1.33 1.33 1.2 1.1* 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.0 1.1 1.2 1.1*
stress design
method Mini-
Clause mum
reference Stability ratio (to require-
be based only on ment i
loads determined
1.2/
in accordance with — 1.5 1.33 1.33 1.33 1.33 1.33 1.2 1.1 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.1 1.1 1.2 1.1*
1.5
the permissible
stress design
method)
Load combination III/ III/ III/ III/ III/ III/ III/
F/I I II/1 II/2 II/3 II/4 III/1 III/2 III/3 III/4 III/5 III/6 III/7 III/8 III/9
numberc 10 11 12 13 14 15 16
3.4.2 Wo, Wind during All Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s Wo,r,s
Wr operation or
relocationd
43

T T T T T T T T T T T T T T T T T T T T T
Ws or storm
DR
UU UU UU
3.4.3 Temperature All
3.4.4 Abnormal RC

SS SS SS
digging
3.4.5 Abnormal RC
lateral

LS LS LS LS LS LS LS LS LS LS
digging

DD DD DD
3.4.6 Travel skew TR
3.4.7 Non- All
permanent
dynamic
AF
K K K K K K K K K K K K K K K K K K K K K
effectsd
3.4.8 Snow, ice TS
and hail

P P P P P P P P P P P P P P P P P P P P P
loads
3.4.9

3.4.10 Y
Access
wayse
Erection
and
TS

All Y
T
X X
weighing f

NN
3.4.11 Maintenancef TS
3.4.12 Abnormal TS NN1 NNmax

Special loads
inclinationg

© Standards Australia Limited 2024

DR AS 4324.1:2024

Licensed to Paul Yakimoff of ME-043 at 09:12 (AEST) on Wed Oct 30 2024 for Committee and Standards Australia use only.
Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
 PUBLIC COMMENTING DRAFT Table 3.7(A) (continued)
Fatigue Main
Load combination Main and additional loads Main, additional and special loadsb
loadsa loads
Load case F/I I II III
Factor of safety,
DR AS 4324.1:2024

υa, for permissible

— 1.5 1.33 1.33 1.33 1.33 1.33 1.2 1.1* 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.0 1.1 1.2 1.1*
stress design
method Mini-
Clause mum
reference Stability ratio (to require-
be based only on ment i

© Standards Australia Limited 2024

loads determined
1.2/
in accordance with — 1.5 1.33 1.33 1.33 1.33 1.33 1.2 1.1 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.1 1.1 1.2 1.1*
1.5
the permissible
stress design
method)
Load combination III/ III/ III/ III/ III/ III/ III/
F/I I II/1 II/2 II/3 II/4 III/1 III/2 III/3 III/4 III/5 III/6 III/7 III/8 III/9
numberc 10 11 12 13 14 15 16
3.5.2 Grounding of a
bucket wheel,
ladder or discharge

A1 A1
boom

A2 A2
3.5.2.2 Slight All

AA AA
44

3.5.2.3 Partial All

QQ QQ
3.5.2.4 Full TS
DR
3.5.3 Uneven TR
support
where rail

QQ QQ
mounted
3.5.4 Uneven TR
support
where
crawler

VV VV
mounted
3.5.5 Blocked All
chutes and
AF
FF FF
hoppers
3.5.6 Excess All
material on

LL LL
3.5.7

3.5.8 FS
conveyors
Travelling
device
obstructed
Lateral
collision of
TR

SL, TS
T FS

boom

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 PUBLIC COMMENTING DRAFT Table 3.7(A) (continued)
Fatigue Main
Load combination Main and additional loads Main, additional and special loadsb
loadsa loads
Load case F/I I II III
Factor of safety,
υa, for permissible
— 1.5 1.33 1.33 1.33 1.33 1.33 1.2 1.1* 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.0 1.1 1.2 1.1*
stress design
method Mini-
Clause mum
reference Stability ratio (to require-
be based only on ment i
loads determined
1.2/
in accordance with — 1.5 1.33 1.33 1.33 1.33 1.33 1.2 1.1 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.1 1.1 1.2 1.1*
1.5
the permissible
stress design
method)
Load combination III/ III/ III/ III/ III/ III/ III/
F/I I II/1 II/2 II/3 II/4 III/1 III/2 III/3 III/4 III/5 III/6 III/7 III/8 III/9

FT FT
numberc 10 11 12 13 14 15 16
3.5.9 End-on SL, TR
collision of
boom
45

3.5.10 WWp Wind while All WWp WWp WWp

DR
OO OO
idled, f
3.5.11 Buffers SL, TR

ZZ ZZ
3.5.12 EQp Earthquakes All EQp

BL BL
3.5.13 Burying RC, TS
3.5.14 Bucket RC, TS
wheel and

RR RR
gearbox loss
3.5.15 Abnormal All, TS

EL EL
friction
AF
3.5.16 Extra loads TS
a Load combinations for the fatigue load case (F/I) shall include those fluctuating loads that can occur together at a similar frequency of fluctuation. Several such load combinations shall be
analysed and the resulting stress ranges used in a Miner’s Rule calculation to determine acceptability. By way of example, the effect of inclination is likely to be accounted for in a load combination that
does not include permanent dynamic effects, because these loads will generally occur at different frequencies. The symbols used for fatigue loads have the following meanings:
      (a)
      (b)
      (c)
b
+/− indicates a change in load from one extreme to the other where the direction of load changes.
+/0 indicates a change in load from zero to some maximum value.
+/+ indicates a change in load due to geometry variation or load variation.
T
For values marked with an asterisk (*) refer to relevant descriptions of load cases to determine circumstances where lower factors may be permitted.
c For the purposes of categorizing other load combinations that may be identified as being relevant, where occurrence is continuous the load case is I, where occurrence is infrequent the load case
is II and where occurrence is rare the load case is III.
d

© Standards Australia Limited 2024

DR AS 4324.1:2024

Non-permanent dynamic effects are to be included in lieu of wind forces where they are greater. Wo or Wr shall be selected for the relevant load combination.

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Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
 PUBLIC COMMENTING DRAFT Table 3.7(A) (continued)
Fatigue Main
Load combination Main and additional loads Main, additional and special loadsb
loadsa loads
Load case F/I I II III
Factor of safety,
DR AS 4324.1:2024

υa, for permissible

— 1.5 1.33 1.33 1.33 1.33 1.33 1.2 1.1* 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.0 1.1 1.2 1.1*
stress design
method Mini-
Clause mum
reference Stability ratio (to require-
be based only on ment i

© Standards Australia Limited 2024

loads determined
1.2/
in accordance with — 1.5 1.33 1.33 1.33 1.33 1.33 1.2 1.1 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.1 1.1 1.2 1.1*
1.5
the permissible
stress design
method)
Load combination III/ III/ III/ III/ III/ III/ III/
F/I I II/1 II/2 II/3 II/4 III/1 III/2 III/3 III/4 III/5 III/6 III/7 III/8 III/9
numberc 10 11 12 13 14 15 16
e When considering overall stressing of the machine structure, loads (P) on walkways, accessways, platforms, stairs and the like need only be applied locally and need not be included in the
machine stability assessment, unless otherwise required by the technical specification (see Clause 3.4.9).
f Wind loads less than WW may be applicable for load cases incorporating loads from Clause 3.4.10 and 3.4.11, i.e. II/3 and II/4. The winds speeds to be used for design purposes for these load cases
should be as defined in the technical specification.
g NNmax is the maximum of NN1 or NN2, as appropriate.
46

h For load combinations involving inertia load cases, there is no requirement to duplicate the inertia or dynamic effects in a single direction via separate loads.
DR
i Requirements designations are as follows:
      (a) All — the load is applicable to all machine types.
      (b) TR — the load is applicable for machines with a travel motion (both long travel and travel within sub-assemblies such as a shuttle).
      (c) RC — the load is applicable for machines with a reclaiming device.
      (d) SL — the load is applicable for machines with slewing capability.
      (e) TS — the requirements for the load require explicit direction in the technical specification as to their required applicability and consideration.
NOTE Load cases defined in Table 3.7(A) may comprise of variations due to the possibility of some loads being at their maximum value or their minimum value (i.e. zero) for the load case and
configuration under consideration.
AF
T
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 PUBLIC COMMENTING DRAFT
Table 3.7(B) — Load combinations for design of machine structures — Ultimate limit state design method
Fatigue Main Main and additional
Load combination Main, additional and special loadsb
loadsa loads loads
Clause
Load case Requirementi F/I I II III
reference
Load combination
F/I I II/1 II/2 II/3 II/4 III/1 III/2 III/3 III/4 III/5 III/6 III/7 III/8 III/9 III/10 III/11 III/12 III/13 III/14 III/15 III/16

Main loads
numberc

3.3.2, E Dead loads All +/+E 1.35 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

V
3.6.2
3.3.3, Encrustation All +/+V 1.35 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

N
3.6.2
3.3.4, Inclination All +/−N 1.35 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

F
3.6.3
3.3.5, Live loads All +/0C F. F 1.35 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

U
3.6.4

U
3.3.7, Normal RC +/0C U. 1.35 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

S
3.6.5 digging
3.3.8, Normal RC +/−Cs. S 1.35 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
47

3.6.6 lateral

D
digging
DR
3.3.9, Permanent All +/−D 1.35 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
3.6.7 dynamic

G
effectsh
3.3.10, Conveyor All +/+G 1.35 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

R
3.6.8 elements
3.3.11, Friction All +/−R 1.35 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

L
3.6.9
3.3.12, Travel All +/−L 1.35 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

Additional loads
3.6.10
AF
3.4.2 Wo,r, s Wind during All 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
operation or
relocationd

T
or storm
3.4.3
3.4.4

3.4.5
UU

SS
Temperature All
Abnormal
digging
Abnormal
lateral
RC

RC
1.2
1.2

1.2
1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
T 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
1.2

1.2
1.2

LS
digging
3.4.6 Travel skew TR 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2

© Standards Australia Limited 2024

DR AS 4324.1:2024

Licensed to Paul Yakimoff of ME-043 at 09:12 (AEST) on Wed Oct 30 2024 for Committee and Standards Australia use only.
Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
 PUBLIC COMMENTING DRAFT Table 3.7(B) (continued)
Fatigue Main Main and additional
Load combination Main, additional and special loadsb
loadsa loads loads
Clause
Load case Requirementi F/I I II III
reference
Load combination
F/I I II/1 II/2 II/3 II/4 III/1 III/2 III/3 III/4 III/5 III/6 III/7 III/8 III/9 III/10 III/11 III/12 III/13 III/14 III/15 III/16

DD
numberc
DR AS 4324.1:2024

3.4.7 Non- All 1.2 1.2

permanent
dynamic

K
effectsd

© Standards Australia Limited 2024

3.4.8 Snow, ice TS 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
and hail

P
loads
3.4.9 Access TS 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
wayse

Y
Erection
3.4.10 and All 1.2

X
weighing f

NN
3.4.11 Maintenancef TS 1.2
3.4.12 Abnormal TS 1.2 1.2

Special loads
inclinationg
48

3.5.2 Grounding of a
bucket wheel,
DR
ladder or discharge

A1
boom:

A2
3.5.2.2 Slight All 1.2

AA
3.5.2.3 Partial All 1.1

QQ
3.5.2.4 Full TS 1
3.5.3 Uneven TR 1
support
where rail

QQ
mounted
3.5.4 Uneven TR
AF 1
support
where
crawler

VV
mounted

3.5.5

3.5.6 FF
Blocked
chutes and
hoppers
Excess
material on
conveyors
All

All
1

1
T
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 PUBLIC COMMENTING DRAFT Table 3.7(B) (continued)
Fatigue Main Main and additional
Load combination Main, additional and special loadsb
loadsa loads loads
Clause
Load case Requirementi F/I I II III
reference
Load combination
F/I I II/1 II/2 II/3 II/4 III/1 III/2 III/3 III/4 III/5 III/6 III/7 III/8 III/9 III/10 III/11 III/12 III/13 III/14 III/15 III/16

LL
numberc
3.5.7 Travelling TR 1
device

FS
obstructed
3.5.8 Lateral SL, TS 1
collision of

FT
boom
3.5.9 End-on SL, TR 1
collision of

1 1
boom
3.5.10 WWu Wind while All 1

OO
idled, f
3.5.11 Buffers SL, TR 1

ZZ
3.5.12 EQ u Earthquakes All 1
49

BL
3.5.13 Burying RC, TS 1
DR
3.5.14 Bucket RC, TS 1
wheel and

RR
gearbox loss
3.5.15 Abnormal All, TS 1

EL
friction
3.5.16 Extra loads TS 1.2-
1.5
a Load combinations for the fatigue load case (F/I) shall include those fluctuating loads that can occur together at a similar frequency of fluctuation. Several such load combinations shall be analysed and
the resulting stress ranges used in a Miner’s Rule calculation to determine acceptability. By way of example, the effect of inclination is likely to be accounted for in a load combination that does not include
permanent dynamic effects, because these loads will generally occur at different frequencies. The symbols used for fatigue loads have the following meanings:
AF
      (a) +/− indicates a change in load from one extreme to the other where the direction of load changes.
      (b) +/0 indicates a change in load from zero to some maximum value.
      (c) +/+ indicates a change in load due to geometry variation or load variation.
b

c
where occurrence is rare the load case is III.
d

e
T
For values marked with an asterisk (*) refer to relevant descriptions of load cases to determine circumstances where lower factors may be permitted.
For the purposes of categorizing other load combinations that may be identified as being relevant, where occurrence is continuous the load case is I, where occurrence is infrequent the load case is II and

Non-permanent dynamic effects are to be included in lieu of wind forces where they are greater. Wo or Wr shall be selected for the relevant load combination.
When considering overall stressing of the machine structure, loads (P) on walkways, accessways, platforms, stairs and the like need only be applied locally and need not be included in the machine stability
assessment, unless otherwise required by the technical specification (see Clause 3.4.9).
f Wind loads less than WW may be applicable for load cases incorporating loads from Clause 3.4.10 and 3.4.11, i.e. II/3 and II/4. The winds speeds to be used for design purposes for these load cases should be

© Standards Australia Limited 2024

DR AS 4324.1:2024

as defined in the technical specification.

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 PUBLIC COMMENTING DRAFT Table 3.7(B) (continued)
Fatigue Main Main and additional
Load combination Main, additional and special loadsb
loadsa loads loads
Clause
Load case Requirementi F/I I II III
reference
Load combination
F/I I II/1 II/2 II/3 II/4 III/1 III/2 III/3 III/4 III/5 III/6 III/7 III/8 III/9 III/10 III/11 III/12 III/13 III/14 III/15 III/16
numberc
DR AS 4324.1:2024

g NNmax is the maximum of NN1 or NN2, as appropriate.

h For load combinations involving inertia load cases, there is no requirement to duplicate the inertia or dynamic effects in a single direction via separate loads.
i Requirements designations are as follows:

© Standards Australia Limited 2024

      (a) All — the load is applicable to all machine types.
      (b) TR — the load is applicable for machines with a travel motion (both long travel and travel within sub-assemblies such as a shuttle).
      (c) RC — the load is applicable for machines with a reclaiming device.
      (d) SL — the load is applicable for machines with slewing capability.
      (e) TS — the requirements for the load require explicit direction in the technical specification as to their required applicability and consideration.
NOTE Load cases defined in Table 3.7(B) may comprise of variations due to the possibility of some loads being at their maximum value or their minimum value (i.e. zero) for the load case and configuration
under consideration.
50

DR
AF
T
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 51 DR AS 4324.1:2024

Section 4 Overturning and drifting

4.1 Stability against overturning

In order to check safety against overturning, the stability ratio shall be calculated for the various load
case combinations nominated in Table 3.7(A), as follows:
PUBLIC COMMENTING DRAFT

Ms
Stability ratio =
Mo
where

Ms = the minimum stabilizing moment due to the total permanent load referred to a
possible axis of tipping

T
Mo = the maximum overturning moment due to the sum of the various non-permanent
horizontal and vertical overturning forces referred to the same axis of tipping.
Non-permanent forces shall be applied only to the extent that they increase the
overturning moment

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Stability against overturning shall be based on loads and forces assumed for the permissible (working)
AF
stress design method.
The stability ratio values so calculated shall be not less than the relevant values set out in Table 3.7(A).
The stability ratio shall be not less than 1.33 for additional loads arising from erection, maintenance or
weighing operations. For load combination III/10, the required stability ratio of either 1.2 or 1.5 shall
be nominated in the technical specification in accordance with Appendix B.
This ratio shall apply to each of the possible axes of tipping, including the tipping axis with the least
degree of stability (i.e. the smallest stability ratio). The movable parts of the dead load for each tipping
axis shall be in the most unfavourable position. Non-permanent loads that increase the tipping moment
shall be included and those that decrease the tipping moment shall not be included.

4.2 Resistance against drifting

DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
The ratio of the sum of the drag forces (i.e. resistance against drifting) to the sum of the drift forces
due to the wind and the inclination of the support surface, based on 1.2 times the greatest inclination
specified for the machine, shall be not less than —
(a) 1.33 during operation, while only the automatic brakes of the drive motor act, under an
operating wind-induced load, Wo, in accordance with Clause 3.4.2;
(b) 1.20 while not operating under a wind-induced load, WW, in accordance with Clause 3.5.10.
The machine may be located in a specified configuration/position for this circumstance;
(c) 1.10 while operating, or under relocation and under drive power (of slew or travel), or while
only the automatic brakes of the drive motor act, under a relocation wind-induced load, Wr, in
accordance with Clause 3.4.2.
(d) 1.10 while only static braking mechanisms act and the machine is not in motion or under
drive power (of slew or travel) for a wind-induced load, Ws, in accordance with Clause 3.4.2.
The machine may be located in a specified configuration/position for this circumstance.
Resting of the digging device on the face or ground shall not be taken into consideration. Friction
coefficients (μ) used in calculating drag forces shall be taken as not greater than the following relevant
value:

(i) For driven wheels on rails 0.14.

© Standards Australia Limited 2024

 DR AS 4324.1:2024 52

(ii) For non-driven wheels with ball or roller bearings 0.01.

(iii) For non-driven wheels with bushes 0.015.

(iv) For rail clamps (in a static circumstance only), if no larger values are 0.25.
measured by testing
PUBLIC COMMENTING DRAFT

Any specific considerations and values that vary from the above shall be as defined in the technical
specification in accordance with Appendix B.

T
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AF
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024

© Standards Australia Limited 2024

 53 DR AS 4324.1:2024

Section 5 Design of structures

5.1 Loads and load cases

The loads and load cases that are set out in Clause 3.7 shall be included in the design of structural
components, except as varied by the technical specification in accordance with Appendix B. The design
PUBLIC COMMENTING DRAFT

shall be based upon the possibility that forces will act at the most unfavourable location under the most
unfavourable combinations for each of the various configurations for the machine.
Load cases defined in Clause 3.7 may comprise of various variations due to the possibility of some loads
being at their maximum value or their minimum value (i.e. zero) for the load case defined.

5.2 Fatigue design life

Structural components shall be designed for a fatigue life of at least the design life as prescribed in the

T
technical specification of normal operation, subject to a minimum of 100 000 operating hours, taking
into account cyclical loadings defined by load combination F/I in Tables 3.7(A) or 3.7(B). Where load
combinations II and III can occur sufficiently frequently and cause cyclical stresses large enough to
significantly affect life, they shall also be taken into consideration.

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The required design life shall be as defined in the technical specification in accordance with Appendix
AF
B.

5.3 Steels having a high yield to ultimate tensile strength ratio

For steels where the ratio of yield strength to ultimate tensile strength exceeds 0.8, the following
modified value of yield strength shall be used in design calculations:

 Y  0.8  R
 Ym 
2
where

σYm
DR
= modified yield strength

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
σY = yield strength

σR = ultimate tensile strength

5.4 Design methods to allow for strength and serviceability

5.4.1 General

Strength and serviceability shall be assessed using either the permissible/working stress design
method in accordance with AS 3990 and Table 3.7(A) or the ultimate limit state method in accordance
with AS 4100 and Table 3.7(B), and the requirements of this document.
Fatigue design shall be in accordance with Clause 5.5.
The method used for strength assessment shall be as defined in the technical specification in accordance
with Appendix B. Any specific design provisions from alternative Standards that may be used shall be
documented in the technical specification in accordance with Appendix B.
Irrespective of the design method selected, member loads and stresses shall be determined by a reliable
means of engineering analysis.

© Standards Australia Limited 2024

 DR AS 4324.1:2024 54

For the purposes of analysis (i.e. determination of stresses/stress ranges), members shall be assumed
to remain elastic for both permissible stress design, for the strength limit state design and for the
serviceability limit state design.
For Type I and Type II load combinations, the structure shall remain in the elastic region under
permissible stress design loading (and serviceability loading for limit state design).
PUBLIC COMMENTING DRAFT

For Type III load combinations assessed using finite element analysis (FEA), localized regions may
exceed the allowable stress levels, but yielding should be avoided under permissible stress design
loading (and serviceability loading for limit state design). If localized yielding is present, both short-
term and long term structural performance shall not be affected.
Plastic (hinge) design shall not be used in any circumstances.
For complex fabrications where high-localized stresses or deformations can be expected and where
fluctuating stresses may lead to fatigue cracking of critical regions, FEA should be undertaken.

T
The use of FEA should follow established methods of modelling, assumptions and assessment (e.g.
AS/NZS 5100.6:2017 Clause 4.10 or EN 1993‑1‑5:2006 Annex C).
The minimum extent of FEA shall be as defined in the technical specification in accordance with
Appendix B.

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5.4.2

5.4.2.1
Permissible stress design method

Application
AF
Where a permissible stress design method of assessment is specified, Clauses 5.4.2.2 to 5.4.2.6 shall
apply.

5.4.2.2 General

Structural components shall be designed for the relevant load combinations specified in Clause 3.7, and
a check shall be made to ensure that an adequate safety margin exists in respect of the critical stresses,
including the following:
DR
(a) Yield strength (see Clauses 5.4.2.3 and 5.4.2.4).

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
(b) Crippling or buckling strength (see Clauses 5.4.2.3, 5.4.2.5 and 5.4.2.6).
(c) Fatigue strength (see Clause 5.5).
Stresses in the structural components shall be determined by application of accepted calculation
procedures for strength of materials, including use of simple mathematical representations of the
relationships between load and stress for situations that are well understood, and use of finite element
analysis for analysis of complex sections of the structure where no simple generally accepted calculation
procedure exists.

5.4.2.3 General design approach

In assessing applied loads/stresses against maximum permissible stresses, the use of either of the
following two methods is acceptable:
(a) Applying a reduction factor of υa/1.5 to the relevant load combination, whereby υa is the
factor of safety for permissible stress design method defined in Table 3.7(A).
(b) Applying the loads in accordance with the relevant load combination and assessing all
required design checks with consideration of an increase in the maximum permissible stress
or stress ratio (via the design check equation as defined in AS 3990) via a factor of 1.5/υa,
whereby υa is the factor of safety for permissible stress design method defined in Table 3.7(A).

© Standards Australia Limited 2024

 55 DR AS 4324.1:2024

5.4.2.4 Determination of permissible stresses with respect to yield strength

For structural components subject to loads and combined stresses that are to be assessed with respect
to yield strength, the permissible stresses shall be determined in accordance with the principles
outlined in AS 3990, as varied by Clause 5.4.2.3. For complex structures assessed by FEA, the von Mises
equivalent stress shall be determined and be less than the allowable stress.
PUBLIC COMMENTING DRAFT

The von Mises equivalent is defined as follows:

For combined loads, where a normal stress ( σ x ), a normal stress perpendicular to ( σ y ) and a shear
stress ( τ ) occur simultaneously in a flat plate —

 eq   2
x   y2   x y  3 2 
 a

T
where

σ eq = Resultant combined equivalent stress

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NOTE Care must be taken to use the correct signs for σ x and σ y .
AF
5.4.2.5 Permissible stresses and loads causing buckling

For structural components subject to loads and combined stresses that may cause buckling, the
permissible stresses shall be determined in accordance with the principles outlined in AS 3990, as
varied by Clause 5.4.2.3.

5.4.2.6 Plates and shells

Permissible stresses for plates and shells subject to yielding criterion shall be determined according to
Clause 5.4.2.4.
Assessment of plate or shell buckling resistance shall be carried out according to a relevant recognized
DR
Standard, e.g.EN 1993-1-5, EN 1993-1-6 and EN 1993-1-7, or by FEA/FEM forms of structural analysis. If

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
the permissible stress design method has been selected for load combinations and general design, but
an ultimate limit state standard is necessary for plate/shell buckling criteria, a load factor of 1.5 shall
be used for all load combinations.
Plate and fabrication imperfections shall be included in the determination of a safety margin for
buckling.
Requirements for minimum buckling factor values shall be as defined in the technical specification in
accordance with Appendix B.
NOTE Further guidance on plate buckling is provided in Appendix J.

5.4.2.7 Connections

For structural connections, the permissible stresses shall be determined in accordance with the
principles outlined in AS 3990, as varied by Clause 5.4.2.3.
Non-friction grip bolting shall conform to the design procedures of AS 3990, with allowable tensions
and shear loads being determined from the proof load of the bolt by application of the factors of safety
given in Table 3.7(A). For strength considerations, the permissible stresses used for fitted bolts, non-

© Standards Australia Limited 2024

 DR AS 4324.1:2024 56

fitted bolts and rivets, except high tensile bolts that are used in high strength friction-grip applications,
shall not exceed the values determined from the following equation:

 Ym
 ab   s
a
PUBLIC COMMENTING DRAFT

where

σab = permissible stress in bolt or rivet

σYm = modified yield strength of bolt or rivet; except that if this is greater than the modified
yield bearing strength of the plate material that is being bolted, the value for the plate
material is used for bearing stress assessments

υa = factor of safety for bolted joints [see Table 3.7(A)]

T
υs = stress factor for bolts and rivets [see Table 5.4.2.7(A) corresponding to type of stress
being assessed]
NOTE 1 Where bolted joints are not fully preloaded to a value that is greater than the maximum load to which
the joint may be subjected in tension, the permissible tensile stress would need to be derated to avoid a fatigue

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failure. For such applications, high strength friction-grip bolted joints should be used.
AF
Table 5.4.2.7(A) — Stress factors for bolts and rivets
Stress factor (υs)
Type of fastener Type of shear
Shear stress Bearing pressurea Tensile stress
Fitted bolts Single 0.6 1.3 0.625
Multiple 0.8 1.75
Non-fitted bolts Single or multiple 0.5 1.0 0.625
Rivets Single 0.6 1.3 —
Multiple 0.8 1.75
a Based on the projected bearing area of the bolt or rivet.
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Friction grip bolted joints shall conform to the design procedures of AS 3990, except for the following
variations:
(a) Friction coefficients to be used in the design of friction grip joints shall be taken from
Table 5.4.2.7(B). A coefficient greater than 0.35 shall not be used for design. Painting a plate
before it is assembled is only permitted if the paint is inorganic zinc silicate over a Class 2 1/2
surface preparation.
(b) The load factor to be used shall be that defined in AS 3990:1993 Appendix F.
(c) The minimum bolt tension to be used in calculations of joint capacity and allow able loading of
bolts shall be based on 0.7 times the proof load of the bolt, rather than 1.0 times the proof load
of the bolt as used in AS 3990.
NOTE 2 This derating is in line with ISO 5049-1. It allows for this type of machinery being generally subjected
to more severe dynamics than other equipment, as well as some relaxation of the preload.

© Standards Australia Limited 2024

 57 DR AS 4324.1:2024

Table 5.4.2.7(B) — Friction coefficients

Friction
Surface treatment
coefficient
Clean rolled surface that is free of paint, lacquer, galvanizing or other 0.35
applied finish
PUBLIC COMMENTING DRAFT

Hot-zinc sprayed and sand blasted 0.28

Hot-dip galvanized and grit blasted or wire brushed 0.20
Hot-dip galvanized and slightly weathered 0.15
Inorganic zinc silicate paint over Class 2 1/2 surface preparation (see 0.35
Note)
NOTE Higher friction coefficients are possible; however, the design friction coefficient has
been limited to that for clean plate. Painting with other than zinc silicate paint at the joint is
not permitted, since friction coefficients for such other joint treatments are unpredictable.

T
5.4.3 Limit-state-design method

5.4.3.1 Application

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The limit-state-design method may be used as a method of structural design.
AF
Where a limit-state-design method of assessment is specified, Clauses 5.4.3.2 to 5.4.3.6 shall apply.
Any special requirements shall be as defined in the technical specification in accordance with
Appendix B.

5.4.3.2 General

Structural components shall be designed for the relevant design load combinations specified in
Clause 3.7 with the relevant load factors defined in Table 3.7(B) applied, and a check shall be made to
ensure that an adequate safety margin exists, including the following:
(a) Yield strength (see Clauses 5.4.3.3 and 5.4.3.4).
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
(b) Crippling or buckling strength (see Clauses 5.4.3.3, 5.4.3.5 and 5.4.3.6).
(c) Fatigue strength (see Clause 5.5).
Design internal action effects in the structural components shall be determined by application of
accepted calculation procedures for strength of materials, including use of simple mathematical
representations of the relationships between design loads and design action effects for situations that
are well understood, and use of finite element analysis for analysis of complex sections of the structure
where no simple, generally accepted calculation procedure exists.

5.4.3.3 General design approach

The general design approach shall follow AS 4100:1998 Clause 3, as modified by this document:
(a) The loads and actions shall be determined in accordance with Section 3 and the strength limit
state design loads shall be determined in accordance with Clause 3.7 and Table 3.7(B).
(b) The design action effects S* [an asterisk (*) shall be used to represent the ultimate limit state
method load] resulting from the strength limit state design loads shall be determined by a
reliable means of analysis.
(c) The ultimate limit state design capacity (φRu) shall be determined from the nominal capacity
(Ru) determined from the relevant section of AS 4100, as appropriate, where the capacity
factor (φ) shall not exceed the appropriate value given in AS 4100.

© Standards Australia Limited 2024

 DR AS 4324.1:2024 58

(d) All members and connections shall be proportioned so that the design capacity (φRu) is not
less than the design action effect (S*), i.e. —

S *   Ru

5.4.3.4 Determination of minimum design capacity with respect to yield strength

PUBLIC COMMENTING DRAFT

For structural components subject to loads and combined stresses that are to be assessed with respect
to yield strength, the minimum design capacities shall be determined in accordance with the principles
outlined in AS 4100, as varied by Clause 5.4.3.3.
For complex structures assessed by FEA, the von Mises equivalent stress shall be determined using
the limit state design action effects and shall be less than the (modified) yield stress multiplied by the
relevant material capacity factor of 0.9 as follows:

T
 d    Ym

where

σd = von Mises equivalent stress due to applied loads, which incorporate the strength limit state

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load multiplying factors given in Tables 3.7(A) and (B)
AF
σYM = modified yield stress (see Clause 5.2)
ϕ = capacity factor = 0.9
The following equation may be used for determining the von Mises equivalent stress for biaxial stress
states where a normal stress (σx) a normal stress (σy) perpendicular to (σx), and a shear stress (τ) occur
simultaneously in a flat plate:

 eq   2
x   y2   x y  3 2 
NOTE 1 Care needs to be taken to use the correct signs for (σx) and (σy).
DR
For combined loads producing a fully three-dimensional stress state, the von Mises equivalent stress

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
(σeq ) can be calculated from the principal stresses σ1, σ2, and σ3 using the following equation:

 2 
    2   3    3   1 
2 2
 eq    1   2  / 2
  
NOTE 2 Care needs to be taken to use the correct signs for σ1, σ2, and σ3.

5.4.3.5 Determination of minimum design capacity with respect to buckling strength

For structural components subject to loads and combined stresses that are to be assessed with respect
to buckling strength, the minimum design capacities shall be determined in accordance with the
principles outlined in AS 4100, as varied by Clause 5.4.3.3.

5.4.3.6 Plates and shells

Assessment of plate or shell buckling resistance shall be carried out according to a relevant recognized
Standard, e.g. EN 1993-1-5, EN 1993-1-6 and EN 1993-1-7, or by FEA/FEM forms of structural analysis.
Plate/shell buckling criteria using an ultimate limit state method shall use a load factor of 1.5 for all
load combinations.

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 59 DR AS 4324.1:2024

Plate and fabrication imperfections shall be included in the determination of a safety margin for
buckling.
NOTE Further guidance on plate buckling is provided in Appendix J.

5.4.3.7 Connections
PUBLIC COMMENTING DRAFT

For structural connections, the minimum design capacities shall be determined in accordance with the
principles outlined in AS 4100, as varied by Clause 5.4.3.3.
The strength and serviceability limit states of bolted, riveted and welded connections shall conform to
the requirements of AS 4100 and the additional requirements of this clause.
For high strength bolting, the design check procedure for friction grip joints set out in AS 4100 for
serviceability limit state shall be applied with the loads used for strength limit state to ensure that
no slippage of a friction grip joint will occur even under extreme loading conditions. For all checks on

T
friction grip joints, the capacity factor (ϕ) shall be taken as 0.63. Friction coefficients to be used in the
design of friction grip joints shall be taken from Table 5.4.2.7(B). A coefficient greater than 0.35 shall
not be used for design. Painting of plate before assembly is only permitted for inorganic zinc silicate
paint over Class 2 1/2 surface preparation.

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For rivets and bolting other than high strength bolting, the capacity factor (ϕ) shall be 0.6 for fitted
AF
bolts and rivets and 0.5 for non-fitted bolts. Rivets shall be checked for conformance to AS 4100 for
bolting with a 0.6 capacity factor.
The use of lower capacity factors than are normally required by AS 4100 takes into account the fact
that this type of machinery is generally subjected to more severe dynamics than other equipment, as
well as some relaxation of the preload. Where a bolted joint is subjected to fluctuating loads and is not
fully preloaded to a value that is greater than the maximum load to which the joint may be subjected
in tension, failure of the bolts in fatigue is more likely than a failure in strength. For such applications,
high strength friction grip bolted joints should be used.

5.4.4 Serviceability

Serviceability shall be included in the design. This includes deflection behaviour, dynamic behaviour
DR
(including vibration), connection serviceability and corrosion/erosion protection.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
5.5 Fatigue strength of structural components and joints

5.5.1 General

Structural components and joints shall conform to the fatigue strength requirements given in AS 4100.
More rigorous fatigue assessments may be carried out against established practices such as those
from the International Institute of Welding, EN 1993-1-9 and BS 7608. The Miner’s Rule summation in
BS 7608:2014 Clause 16.7 should be used for damage estimation.

5.5.2 The required Standard and relevant parameters for fatigue design shall be as defined in
the technical specification in accordance with Appendix B.Permissible stress ranges

The assessment of the structure for fatigue endurance, with particular reference to life expectancy in
the vicinity of welds, shall be based on assessing the maximum stress ranges (for various fatigue load
cases) at each point in the structure and comparing these stress ranges with the fatigue strength for
the particular weld joint configuration as obtained from AS 4100 (or other relevant Standard for joint
configurations or unusual circumstances not covered by AS 4100) for at least a 95 % probability of
survival.

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Load combinations that produce the maximum and minimum stresses shall be included, and the stress
ranges shall be obtained by subtraction. Tables 3.7(A) and 3.7(B) contain the minimum required load
combinations that shall be included in the design.
Permissible stress ranges shall include the requirements of AS 4100:1998, Clauses 11.1.5 and 11.1.6.

5.5.3 Compressive stress ranges

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Fatigue assessments shall treat apparent fully compressive stress ranges as being equally damaging
as are fully tensile or fully reversed stress ranges. This requirement acknowledges the existence of
residual tensile stresses in the vicinity of welds, even after stress relieving.

5.6 Bolting and riveting

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5.6.1 Fitted bolts

Holes for fitted bolts shall be drilled and reamed (punching is not acceptable). The fit as specified by
AS 1654 for fitted bolts shall be as follows:

(a) For variable loading always in the same direction H11/h11.

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(b)

5.6.2
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For alternating loading involving a reversal of the loading direction

Low strength non-fitted bolts (e.g. forged black bolts)

H11/k6.

Low strength non-fitted bolts may only be used for secondary joints of members subjected to minor
loads. They shall not be used for joints subjected to fatigue.

5.6.3 Rivets

Rivets shall not be subjected to tensile load. Rivet holes shall be drilled and reamed (punching is not
acceptable).
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5.6.4 Joints using high tensile bolts

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
High strength friction-grip bolts should be used for joining members subjected to dynamic loads. The
mating nuts shall be supported by washers having a hardness of not less than that of the nut material.
Intermediate spring washers shall not be used. High tensile bolts shall be tensioned in accordance with
AS 4100 or AS 3990 using the part-turn method of tensioning, a direct tension method of indication or
another method that can reliably result in a minimum bolt load that is equal to the proof load.
Use of torque-control tensioning is not recommended but may be acceptable under some circumstances
where bolts and nuts have a good surface finish, are protected from the weather or other contamination
prior to assembly, have threads lubricated before tensioning, and have the relationship between torque
and bolt load established by measurement.

5.6.5 Serrated bearing bolts

Serrated bearing bolts shall not be used.

5.7 Steel wire ropes, straps and stays in tension, and hydraulic cylinders

5.7.1 General

Steel wire ropes shall be selected to conform to the requirements of AS 1418.1:2002 and the additional
requirements of this clause (5.7), using loads determined in accordance with the permissible stress
design method. For the purpose of this clause, a cable is to be assessed as a rope.

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The maximum design tensile load applied to a rope, strap or stay resulting from consideration of the
loadings specified in Section 3 as appropriate, shall be not more than the following relevant values:
(a) For ropes, the minimum breaking force of the rope, as defined in AS 3569, divided by the
safety factor Ψc given in Table 5.7 and multiplied by the lowest efficiency factor corresponding
to any joint or end termination.
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(b) For straps and stays, the lesser of —

(i) the ultimate capacity of the strap or stay based on the net cross-sectional area of the
strap or stay multiplied by the ultimate tensile strength of the material and divided
by the safety factor Ψc given in Table 5.7; and
(ii) the yield capacity of the strap or stay based on the net cross-sectional area of the
strap or stay multiplied by the modified yield strength of the material and divided
by 1.6 (this factor applies under all load case situations, including the case of a

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double-guy system with one strap failed).

5.7.2 Factors to be included

The maximum design tension for ropes, straps and stays shall include, where applicable, the effects

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of — AF
(a) maximum load from Load Case I, Load Case II or Load Case III/6;
(b) mass of suspended rope and reeving;
(c) loads resulting from rolling and friction on sheaves for reeved systems;
(d) acceleration forces and dynamic effects, including the hoisting factor defined in
AS 1418.1:2002; and
(e) inclination effect of ropes where appropriate.
For reeved ropes, a breaking rope load case shall be included. For the case of a breaking/broken reeved
rope, a minimum dynamic amplification factor of 1.5 shall be applied to the static loads calculated.
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The dynamic amplification factor of 1.5 shall only be varied (lower or higher) if an alternative value is

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determined by a detailed dynamic analysis. In no case shall a dynamic amplification factor of less than
1.25 be used.
A dynamic amplification factor is not required to be applied for the design case of fixed ropes, straps or
stays if the amplification is less than 1.5.
All of the above factors and effects shall be included prior to application of the safety factors defined in
Table 5.7.
The case of a breaking/broken rope, strap, stay case shall be included as an Extra Load and the required
load combinations for this circumstance shall be defined by the technical specification in accordance
with Appendix B.
Changes to the support of booms and other structure due to the failure of a rope, strap or stay should
be assessed.

5.7.3 Duplication for operator’s cabin

Where an operator’s cabin is on a boom, and the cabin or boom is supported by a wire rope, strap or
stay system, two totally independent rope, strap or stay systems shall be provided, each one capable of
supporting the cabin and boom. Such double rope, strap or stay systems shall be designed so that the
load can be equalized between ropes, straps or stays.

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 DR AS 4324.1:2024 62

For the situation where one rope, strap or stay fails, the required safety factor for the remaining
independent system shall be met during the course of failure of the other rope, strap or stay, taking into
account any dynamic loading that may occur during the failure and any eccentricities of loading that
may result from failure of the one rope, strap or stay and consequent rotation and bottoming of any
equalizing arrangement on the remaining system.
Rope, strap and stay anchorages and areas of the structure to which they are attached, as well as
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connecting pins shall satisfy the same minimum safety factor requirements identified in Clause 5.7.1(b).
The machine shall be designed so that in the event of failure of a single rope strap or stay in a double
rope, strap or stay system, the machine will remain stable and the main structural members will not
be overstressed by virtue of the remaining independent support carrying the full load. The factors of
safety and stability ratios that apply to the structure shall be those corresponding to Load Case I, II or
III, as appropriate, as given in Tables 3.7(A) and 3.7(B).
Similar requirements shall apply if failure of boom support ropes, straps, stays or hydraulic cylinders in

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tension could result in damage to an operator’s cabin, mounted in some other location on the machine.

5.7.4 Duplication of ropes, straps and stays

For machines where boom and/or counterweight structures are supported by static ropes, straps or

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stays, the rope, strap or stay support system should be duplicated on each side.
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If a single static rope, strap or stay system (per side) is provided, the factor of safety for a single element
defined in Table 5.7 shall be satisfied.
For machines where boom and/or counterweight structures are supported by winched or reeved ropes,
a dual rope system shall be provided, including equalizing geometry to prevent eccentric support in the
event of one rope failing, i.e. a crossed rope system.

5.7.5 Safety factor

The minimum safety factor (Ψc) for wire ropes, straps or stays and hydraulic cylinders in tension
relative to ultimate capacity/minimum breaking force shall be as given in Table 5.7.
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Table 5.7 — Minimum safety factor (Ψc) for steel wire ropes, straps, stays and hydraulic

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cylinders in tension
Minimum safety factor,
Type of cable/rope
Ψc
Single rope, strap, stay in the normal case 5
Guy, stay ropes/cables,
Double system in the normal case 4
straps, hydraulic
cylinders Double system after failure of one guy, stay
2
rope, cable, strap, or hydraulic cylinder
Single rope/cable in the normal case 6
Winch or reeving ropes/ Double system in the normal case 6
cables Double system after failure of one rope or
3
cable

5.7.6 Chains and racks

Where the integrity and security of a sub-assembly (such as a shuttle) relies on the integrity of a chain
or rack system, the provisions of Clause 5.7.1 to 5.7.5 apply.
The requirements for the application of Clause 5.7.1 to 5.7.5 to chains or racks shall be defined in the
technical specification in accordance with Appendix B.

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5.7.7 Hydraulic cylinders

Single hydraulic cylinder support systems shall not be used (for tension or compression).
Hydraulic cylinders used in tension shall satisfy the same requirements as ropes, straps and stays. The
maximum design tensile load applied to hydraulic cylinders in tension shall be the ultimate capacity of
the hydraulic cylinder in tension, as provided by the hydraulic cylinder supplier, divided by the safety
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factor Ψc given in Table 5.7.

Where hydraulic cylinders are used, the structure and the cylinders shall be designed considering one
cylinder has failed (in both tension and compression). The case of a failed luff cylinder shall be included
as an Extra Load and the required load combinations for this circumstance shall be defined by the
technical specification in accordance with Appendix B.
The minimum safety factor against buckling (Ψc) for hydraulic cylinders in compression relative to the
ultimate buckling capacity force shall be as given in Table 5.7.7.

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Table 5.7.7 — Minimum buckling safety factor (Ψc) for hydraulic cylinders in compression
Type of Support Minimum buckling safety factor, Ψc
Double hydraulic cylinder system in the normal case 4

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Double system after failure of one hydraulic cylinder 2

The buckling factor is calculated by dividing the applied load by the hydraulic cylinder buckling load.
The hydraulic cylinder buckling load shall be calculated by an established method.

5.8 Slewing race safety hooks to prevent separation at the slew race
Where an open ball path is used for the slew race on a machine, safety hooks shall be provided. The
safety hooks shall be capable of preventing separation of the slewable structure from the main support
structure at the slew race under extreme loading conditions. The safety hooks shall be designed to
withstand the maximum hook load calculated on the basis of one of the following:
(a) Assume the structure is in static equilibrium but taking into account a dynamic factor of
at least 2.5 and a load sharing factor equal to (number of hooks)0.8, to allow for uneven load
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Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
sharing between the hooks provided to support the total hook load. Where the design is
undertaken in accordance with the permissible stress design method, a safety factor of not
less than 1.5 shall apply.
(b) For rapidly applied loads (e.g. in the event of the loss of a bucket wheel), adopt a rational
elastic-plastic failure analysis that takes account of —
(i) the energy acquired by the superstructure as it rotates, in the event that it separates
at the slew bearing, allowing for hook clearances and the displacement as the hooks
extend; plus
(ii) for a machine with a bucket wheel, the elastic energy initially stored in the boom
and its suspension system that is released when the bucket wheel and gearbox
weight is removed from the end of the boom; and
(iii) using this approach, the total amount of energy to be dissipated shall be less than
one quarter of the total failure energy of the available hooks.
Regardless of the design approach adopted, it shall be assumed that the hooks may deform plastically
and the design shall ensure that the hooks do not disengage due to excessive deflection before absorbing
the assumed failure energy.
For all machines, a design load case involving grounding of a boom shall be included. For a machine
with a bucket wheel, when specified in the technical specification in accordance with Appendix B, the
design load cases shall also include a situation involving accidental loss of the bucket wheel, bucket

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wheel shaft, bucket wheel drive gearbox (and drive motor/platform if integral with the gearbox) during
working.
The design shall include provision for reacting tangential forces at the contact interface of the safety
hooks in the event that the machine is slewing at the time the safety hooks come into play. The design
force in the tangential direction shall be calculated from the normal reaction force using a friction
coefficient of at least 0.9.
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To avoid accidental damage to the hooks due to contact while slewing, it is not recommended that a
machine be designed that requires safety hooks to prevent separation at the slew race for load cases
less severe than the rarest Case III loading situation.
The structure to which the safety hooks are attached shall be designed to withstand the same dynamic
design loads used for the safety hooks as if the load were applied to the structure locally.
Catch hooks should not be used for regular restraint unless they have been designed under the

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conventional design rules of Clauses 5.4 and 5.5 accordingly.

5.9 Mass and centre of gravity of machine

After a machine has been constructed, the mass and centre of gravity of the as built machine shall be

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accurately determined. AF
Weighing of the whole machine or at least of its superstructure is the preferred method. Weighing
equipment and technique shall ensure an accuracy of ±1 %.
The method of weighing to be used and the extent of verification of the actual as-constructed mass and
mass distribution of the machine shall be as nominated in the technical specification in accordance
with Appendix B.
If the final as-constructed mass exceeds the mass used in the design calculations of dead load by more
than 5 %, the stresses shall be re-checked. Where the technical specification applies this 5 % limit to a
superstructure only, the stresses shall be re-checked for both the superstructure and its effect on the
substructure of a machine.
NOTE If the final as-constructed mass is less than 95 % of the mass used in the design calculations, the stresses
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and stability should be re-checked dependent on the mass distribution.

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The stability and balance shall be re-checked based on the measured masses. If the stability
requirements are not met, the machine shall be re-ballasted. Re-ballasting may necessitate further
design checks.
If the as-constructed balance status is misaligned with the design parameters (such as luff cylinder
forces and/or slew bearing moments), the balance shall be corrected by re-ballasting or the acceptability
of the as-built balance state shall be determined by re-calculation. Re-balancing requirements may
necessitate additional design checks.
Where a machine is modified in a manner that significantly affects the mass, centre of gravity, stability
or balance, then the requirements of this clause (5.9) shall apply.

5.10 Lifting beams and lugs

Any special requirements shall be as defined in the technical specification in accordance with
Appendix B.
Each lifting beam and each lug shall be labelled with its working load limit (WLL) or maximum rated
capacity (MRC), in a location clearly visible and legible to the user of the machine, as follows:
(a) WLL xxx kg (or tonne as applicable); or
(b) MRC xxx kg (or tonne as applicable).

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Section 6 Ancillary structures

6.1 Loads and load cases

The loads and load cases that are set out in Clause 3.7 shall be included in the design of ancillary
structural components, except as varied by the technical specification in accordance with Appendix B.
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The design shall be based upon the possibility that forces will act at the most unfavourable location
under the most unfavourable combinations for each of the various configurations for the machine.
Load cases defined in Clause 3.7 may comprise of various variations due to the possibility of some loads
being at their maximum value or their minimum value (i.e. zero) for the load case defined.

6.2 Supporting structures and rails

The extent of loads and load cases as set out in Clause 3.7 to be included in the design of supporting

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structures and rails shall be defined by the technical specification in accordance with Appendix B.

6.3 Tie-down and restraints

The extent of loads and load cases as set out in Clause 3.7 to be included in the design of tie-down and

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restraints shall be defined by the technical specification in accordance with Appendix B.
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6.4 Major maintenance works
The extent of loads and load cases as set out in Clause 3.7 to be included in the design of major
maintenance works, and their associated equipment, shall be defined by the technical specification in
accordance with Appendix B.
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Appendix A
(informative)

Explanatory notes
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A.1 Introduction
This appendix gives background information that was used to draft some of the clauses in the original
1995 edition and describes changes incorporated in subsequent editions of the Standard. For the
purpose of this appendix, the second edition Standard is called the “2017 edition”, and the third edition

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is called the “2024 edition”.
Since the 2017 edition, an Appendix A clause has been provided for each clause.
Changes since original publication of the 1995 edition have been conducted on the basis that changes
have been made where sufficient justification has been established by the Committee. Where no such

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justification could be established, no change has generally been made.
AF
A.2 Section 1 Scope and general
Section 1 was expanded in the 2017 edition on the basis of industry knowledge and feedback gained
over almost 20 years of use. The additions provide consideration of the contemporary and global
procurement environment whereby to achieve a satisfactory outcome, detailed specification of the
requirements is generally necessary.
Additional prescription of generic requirements for the future parts of the AS 4324 suite of Standards
was provided in 2017. The reference to these future parts was removed in 2024 due to the unlikely
production of these documents in the foreseeable future.
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A.3 Clause 1.1 Scope

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The document covers the design of structures. The scope has expanded to include belt wagons, sizing
rigs and spreaders, even though these items were referenced in the appendices of the 1995 edition.

A.4 Clause 1.2 Application

Clause 1.2 describes the intended method of application of this document. Clause 1.2 was expanded
in the 2017 edition to address the issues affecting industry regarding the inclusion or exclusion
of load cases.
The preparation of a technical specification is now a requirement in Clause 1.2. In the case of situations
where certain load cases are to be reduced or omitted, the clause requires that the risk of reduction
or omission be formally assessed. Inclusion of controls and protections is required and documented
justifications prepared.
This document should be used as part of a risk assessment process for older machines designed before
the introduction of AS 4324.1:1995, as well as for machines designed to this document. The use in this
manner will allow the assessment of risk and consequences of load conditions occurring on the machine,
irrespective of the original basis of design. This form of assessment may be used in combination with
AS ISO 13822 and AS 5104/ISO 2394.
Reference to asset management Standards (e.g. AS ISO 55000) and to related machinery safe use
Standards (e.g. AS 2550) may also be beneficial for the assessment of continued use.

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The approach of Clause 1.2 is intended to assist in satisfying the statutory requirements associated
with safety in design and in operation.

A.5 Clause 1.3 Normative references

Clause 1.3 was updated in the 2024 edition to become the “Normative references” clause. Previously,
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in the 1995 and 2017 editions, Clause 1.3 was the “Innovation” clause. That clause has been moved to
Clause 1.6 with the new heading “New designs and innovations”.
Normative references in Appendix C were updated in the 2017 edition and have moved to the main
body in the 2024 edition. Informative references have been relocated to the Bibliography.

A.6 Clause 1.4 Terms and definitions

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Clause 1.4 was previously the location of the “Normative references” clause. It is now the location of the
“Terms and definitions” clause.
Additional definitions were added in the 2017 edition and futher updates have been made in the 2024
edition.

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A.7
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Clause 1.5 Symbols and abbreviated terms
Clause 1.5 is unchanged from the 1995 edition, with the exception that the heading has been changed
from “Notation” to “Symbols and abbreviated terms” in the 2024 edition.

A.8 Clause 1.6 New designs and innovations

Previously the location of the “Terms and definitions” clause, Clause 1.6 is now the location of the “New
designs and innovations” clause, which features updated text.

A.9 Clause 1.7 Basis of design

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This new clause was introduced in the 2017 edition (as Assumptions) to outline the basis of design
under this document. It includes statements of expectation that the design, fabrication, construction,
assembly and commissioning will be executed in a quality control environment. It also specifies that
the condition of a machine (including its load limiting devices) will be maintained such that the original
design basis assumptions are valid and achieved. The approach described in Clause 1.2 should be
referred to.
Additional guidance on assessment for continued use may be obtained from relevant Standards such as
asset management Standards (e.g.AS ISO 55000) and to related machinery safe use Standards (e.g. AS
2550).

A.10 Clause 1.8 Technical specification

This clause was introduced in the 2017 edition to mandate a requirement for a technical specification
to be prepared. This should be prepared by the owner/purchaser, as a basis for technical agreement
with the supplier. This specification enables agreed variations or additional requirements as well as
approval of relevant requirements within this document. Load cases identified as requirements are
subject to additional requirements to account for any variation in the technical specification.
Guidance on the requirements for content within the technical specification is provided in Appendix B.

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A.11 Clause 1.9 Basic digging parameters for bucket wheel machines
Clause 1.9 is unchanged from the 1995 edition, except “must” has been changed to “shall” for consistency.

A.12 Clause 1.10 Corrosion protection and machine condition

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Additional wording was included in the 2017 edition, alerting to the possible need to specify corrosion
allowances in some regions of structure, plus the design assumption that structure is to be inspected,
repaired and maintained throughout the life of operation.
Where some corrosion may be expected to occur, despite the provision of corrosion protection,
inclusion of a corrosion allowance when selecting member sizes and plate thicknesses may be advisable
in some regions of structure.

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A.13 Clause 1.11 Mechanisms, electrical, controls, commissioning, operation
and asset management
Clause 1.11 was added in the 2017 edition.

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Clause 1.11 in the 2017 edition referred to Parts 2, 3 and 4 of the Standard. At the time of publication of
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the 2017 edition, there was no defined timeline to produce and publish Parts 2, 3 and 4.
As no progress has been made in development of the previously proposed Parts 2, 3, and 4, the 2024
edition has removed references to them, and replaced the wording with generic requirements.
The 2017 edition provided generic provisions to coordinate the structural design with the necessary
mechanism and electrical/controls design.
Of prime importance to the structural design is the reliability and setting of mechanisms, devices
and controls which limit loading applied to the machine. These mechanisms, devices and controls and
their settings should be clearly defined in the calculations and manuals, such that their importance is
recognized and maintenance systems can be used to achieve the necessary level of reliability.
1.11.1— Mechanisms
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While AS 4324.1 defines loads to be considered for structural design, it is recognized that the design
criteria for mechanism design may vary from the structural design criteria.
The industry Standards generally referenced for mechanism design have been Section II De La
Federation Europeenne De La Manutention FEM Document 2.131/2.132 (1997) Rules for the design of
mobile equipment for continuous handling of bulk materials and AS 1418, the Australian Standard for
crane design.
The relevant Standards for mechanism design should be included in the technical specification.
1.11.2— Electrical and controls (including computer/programmable controls)
The design of electrical and controls to a relevant Standard is to be as defined in the technical
specification. There is considered a need in some circumstances to assess the reliability and integrity of
electrical devices that control or limit loads.
The relevant Standards for electrical and controls design should be included in the technical
specification.
This may include the need to consider the requirements of Standards such as the AS 61508 or AS 4024
(series).
1.11.3— Commissioning, operation and asset management

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This clause (1.11) identifies the need for definition of the Standards to which the machine is to be
managed throughout its life.
The supply of effective design drawings and instructions for manufacture/construction/erection is
required.
With regards to commissioning, operation and inspection, instructions and manuals should be available
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that contain information to a sufficient degree that demonstrates compliance with the necessary
regulations in relation to safe use and maintenance of the machine.
The relevant Standards for commissioning, operation and asset management should be included in the
technical specification.
This may include the need to consider the requirements of Standards such as the AS ISO 55000 (series)
or DIN 22261 (series) as well as guidance provided by standards such as AS 2550 (series).

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A.14 Section 2 Materials
The 2017 edition added Clause 2.3 to address the issues encountered by industry in a global procurement
environment. In general, the same properties as required by materials allowed by AS 4100:2020
Sections 2 and 10 should be obtained and assessed.

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The 2024 edition has simplified testing and certification requirements for materials procured to
AS 4100 and AS/NZS 5100.6 accepted materials. There is a general recommendation to procure
materials with impact properties tested at 0 °C, to mitigate risk with brittle fracture.

A.15 Clauses 2.1 and 2.2

The 1995 edition was developed on the basis that AS 4100 and AS 3990 do not permit the use of steels
having a yield strength of more than 450 MPa. However, martensitic steels with yield strengths of more
than 450 MPa are being used in some machines (for stays,pins, and some connecting elements).
The current AS 4100 and AS/NZS 5100.6 has now incorporated the ability to use quenched and tempered
steels in accordance with AS 3597.
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Materials with yield strengths of more than 450 MPa are permitted, provided the material has
properties shown to be satisfactory on an individual basis (i.e. the actual material to be used for a
component is required to be tested in its final heat-treated form).
Particular attention is focused on achieving adequate ductility and impact toughness for the material.
This has been nominated in terms of requirements for percentage elongation, percentage reduction of
area, Charpy impact test values and percentage ductile fracture area.
The 2017 and 2024 editions provide clarification around the acceptance of materials that are acceptable
to AS 4100 or AS/NZS 5100.6, provided that sufficient test certifications or other tests are carried out in
determination of conformance to the relevant material Standard.
The 2024 edition has expanded on minimum ductility requirements for steels used, and where testing
is required due to materials procurement that is not in accordance with AS 4100 and AS/NZS 5100.6
accepted materials.
Minimum Charpy values are based on meeting typical minimum specification values for 250 Grade
structural plate (i.e. 410 = 20 joules ) at the low strength end, and values considered typical for
martensitic steel specified in BS 970-1 at the high strength end. The choice of Charpy test temperature
is intended to ensure the values so determined are likely to be relevant as upper plateau values at the
actual operating temperature.
The requirement for more than 75 % ductile fracture area on Charpy test specimens is to further ensure
the Charpy values apply to the upper plateau and can be used to estimate the plane strain fracture

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toughness from upper plateau correlations, if necessary, to determine the size of defects permitted
during inspection.
The location of fabrication and the temperatures that may be present during construction,
commissioning and/or delivery should be considered.
Thorough thickness testing may be required in some circumstances.
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Additional caution is recommended with the use of C450 materials, particularly where welding may be
undertaken in the cold formed radius regions. This guidance includes the following:
(a) Where failure could result in a catastrophic collapse of the machine, consider avoiding
SHS/RHS with wall thickness exceeding 12.5 mm (for r/t ratio of 1.5).
(b) When using cold formed SHS/RHS apply a reduction factor to the design yield strength based
on Clause 5.3. When using grade C450 SHS/RHS, at critical locations where failure could lead

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to the catastrophic collapse of the machine, consider limiting the design yield strength to
350 MPa.
(c) For design details that rely on the transfer of load through a welded connection to the radius
corner of the SHS/RHS, consider limiting the design thickness of the SHS/RHS to 12.5 mm
(preferably 10 mm). For thicknesses exceeding this, undertake additional charpy impact tests

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(d)
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for the steel at the radius corner to Clause 2.2. If the requirements of Clause 2.2 are met, there
are no restrictions on welding in the corners.
For grade C450 SHS/RHS used in critical applications (Clause 2.2) undertake additional
charpy impact tests. Test samples should be taken from both the flat sides and radius sections.

A.16 Clause 2.3 Alternative materials and fabrication Standards

The 2017 edition introduced the recognition that materials other than those manufactured to
Australian Standards, and fabrication Standards that may not be Australian Standards, may be used in
both the design and manufacture/fabrication of machine structures.
Clause 2.3 describes the general requirements/general procedures for allowing these actions. As this
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topic is extraordinarily extensive with regards to alternative Standards and materials, the guidance

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
provided is generic in nature only.
Therefore, there is a requirement to evaluate and justify whether alternative materials or fabrication
Standards will produce acceptable structural performance.
The technical specification is required to provide the procedure for acceptance/approval of alternative
Standards and/or material substitutions and may also provide the Standards/materials upon which the
design is carried out (as opposed to the construction).
Relevant regulations in regards to duties associated with importing equipment need to be considered.

A.17 Section 3 Load assumptions

The 2017 and 2024 editions sought to make changes that remove ambiguity, and simplify or clarify
loading assumptions for design purposes. Where there has been insufficient justification for change,
clauses have generally not been altered.
Increased emphasis has been placed upon the clear definition of requirements in a technical specification
and the role of load limiting devices in the restriction of applied loads to below their design values.
Care has been taken in the 2017 and 2024 editions to ensure that the clause numbering for individual
loads in Clauses 3.3, 3.4 and 3.5 have not been altered, such that misinterpretation between different
editions of this Standard does not occur.

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A.18 Clause 3.1 General

The 2017 edition substantially revised Clause 3.1, to be more comprehensive in how the prescription
of load cases are required to be carried out, including use of the technical specification and the
relationships with protective/load limiting devices and systems.
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A.19 Clause 3.1.1 Technical specification and design loading

This clause, introduced in the 2017 edition, emphasizes the detailed application of load cases contained
in this Standard with additional information as prescribed by a technical specification. Clause 3.1.1
stipulates when deviation from this Standard is permitted.
This Standard requires that load cases not be considered for reduction or omission without an explicit
and documented formal risk assessment process being carried out.

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This has been introduced to address the occurrences of unsubstantiated claims of conformance to this
document that have occurred in the past.

A.20 Clause 3.1.2 Loads and load limiting devices

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This clause, introduced in the 2017 edition, specifies the requirement to clearly define where
protective/load limiting devices and controls are used to limit loads and to define and clearly document
their respective settings in the structural calculations and operating and maintenance manuals. The
load calculations should also consider the effects of the accuracy of the device, the accuracy of the
setting, and the actions/sequence of events following activation of the device/protection.
This prescription is to avoid the outcome of a structural design being reliant upon a load limiting device,
but that device either not being provided, being at an incorrect setting or being removed from service
during operation.
The use of Standards to establish suitable levels of integrity of protective/load limiting devices is also
recommended. Examples of such Standards include the AS 61508 series and AS 4024 series.
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A.21 Clause 3.1.3 Bulk density

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
The 2017 edition has modified Clause 3.1.3 to provide for the ability to specify bulk densities for
different design purposes.
It is not uncommon for a design to consider —
(a) a structural “density” for the purposes of structural strength design (normally at the upper
bound of expectations of the material to be handled) relating to the maximum bulk density of
the most dense material specified for the foreseeable service life of the machine;
(b) a higher density of material for encrustation purposes, due to its finer particle size, lower
void-age fraction and therefore more dense nature to material in transit;
(c) a lower density for (mechanical/electrical) power calculations relating to partial compaction
of material in transit;
(d) a lower bound density for volumetric calculations to ensure the sizing of reclaiming, conveyor
and chute components is sufficient to handle the lightest material specified for the foreseeable
service life; or
(e) a lower density for fatigue design, on the understanding that actual materials handled over
the service life of the machine will not be at the maximum bulk density for the majority of the
operating life. Where a lower density for fatigue design is used, the applied CF factors may not
be applicable and a CF factor of 1.0 should be used.

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A.22 Clause 3.2 Load groups

Clause 3.2 is unchanged from the 1995 edition, except for reference to the two load combination tables,
Table 3.7(A) and Table 3.7(B).

A.23 Clause 3.3 Main loads

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The main load grouping of loads is the group of loads that the machine is expected to experience under
steady-state, “normal” operating conditions.
Care should be taken such that there is not an underestimation of the loads likely to be encountered in
service, due to this group of loads direct use in both strength and fatigue design.

A.24 Clause 3.3.1 Grouping

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Clause 3.3.1 is unchanged from the 1995 edition.

A.25 Clause 3.3.2 Dead loads (E)

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Clause 3.3.2 is unchanged from the 1995 edition, except for the addition that this load is a requirement.
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The method and level of detail used during the design process can have a significant effect on the
conformance of the mass to the requirements of Clause 5.9. Variations in design mass during the process
of the design should be constantly monitored and updated as modifications are made.
There should also be focus on the basis and establishment of the design mass (to be used for assessment
against Clause 5.9) such that the mass used is representative, traceable and applicable to the values
used for structural design.
Purchasers may consider the need for suppliers to regularly monitor and submit dead load design
estimates and build measured loads, both overall and for major components, where dead load is critical
to supporting structures (i.e. rails, berms, wharf infrastructure etc.).
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A.26 Clause 3.3.3 Encrustation (V)

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Encrustation (V), is similar to that specified in ISO 5049-1 with additional detail provided.
Clause 3.3.3 is substantially unchanged from the 1995 edition, with the following exceptions:
(a) The addition of the statement that this load is a requirement.
(b) Loads are to be considered based on the bulk density specified for encrustation.
(c) The addition of the requirement to define the setting and action upon activation of a load
limiting device/control.
(d) The addition of the requirement for design to account for spillage and material build-up
potentially caused by “special” loading conditions and the ability for those encrustation loads
to also be considered “special” loads.
(e) The addition of the requirement that encrustation that may occur within chutes is to be taken
into account.

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A.27 Clause 3.3.3(a) Encrustation (V)

There are occasions where an encrustation load may exceed 10 % of the conveyor load, such as where
machine booms are fabricated as a large pipe section that allows substantial build-up of material to
occur. Loads in excess of 10 % may require consideration.
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A.28 Clause 3.3.3(b) Encrustation (V)

The use of the nominal 50 mm thick layer on a bucket wheel may not necessarily account for all the
encrustation that can occur on bucket wheels and their surrounding components.
Industry experience with some sticky materials has identified that 100 mm is closer to being an
adequate and more applicable value.
The requirement to consider build-up and encrustation around the bucket wheel area has been added

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due to the commonly observed significant levels of build-up in these areas, particularly in the iron ore
industry. The designer should make allowance for the encrustation that would be expected to occur in
these regions.

A.29 Clause 3.3.3(e) Encrustation (V)

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Designers should carefully consider the load implications of spillage collection systems installed under
conveyors. On several occasions, these systems have been observed to be full of encrusted material to
the stage where it meets the underside of a return conveyor belt. These loads are significant and have
resulted in localized structural failure and belt fires.

A.30 Clause 3.3.3(f) Encrustation (V)

The reference to a hole in a transfer chute is intended to provide specific guidance in highlighting the
potential for an extreme load case associated with this event. Particular attention should be paid to the
ability for material from a holed chute to completely fill walkways and maintenance platforms. These
loads have previously resulted in localized structural failure.
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Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
A.31 Clause 3.3.4 Inclination (N)
Clause 3.3.4 is unchanged from the 1995 edition, except for the addition of the statement that this load
is a requirement.
On rail-mounted machinery, the effects of (rail) inclination is generally so small as to be able to be
neglected for structural design purposes.
Consideration for mechanical design is required.

A.32 Clause 3.3.5 Live loads (F)

Live loads (F) are similar to those specified in ISO 5049-1, except that additional detail is given in
Appendix I for calculation of live loads. The dynamic factor of 1.1 required by ISO 5049-1 to be applied
to live loads on a conveyor has been deleted and replaced by a requirement to apply the dynamic effects
factors contained in Table 3.3.9 to sub-assembly dead weights and live loads.
Clause 3.3.5 is substantially unchanged from the 1995 edition, with the following exceptions:
(a) The addition of the statement that this load is a requirement.
(b) The addition of the requirement to define the setting and action upon activation of a load
limiting device/control.

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The surcharge angle to be used for load calculation is set out in the technical specification. Test work on
some materials has identified angles well above the 20 degree minimum.
The load determined by cross-sectional area is the design requirement, unless approved otherwise (i.e.
by reliance on upstream controls) is as nominated in the technical specification.
It is not uncommon for machines whose design has been based upon their defined throughput to
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experience loading above those values. That is, it is normal for short-term peak throughput to be
significantly higher than nominal or average throughput.
The higher value of the bucket-wheel output values and the cross-sectional calculation should be used.
Appendix I details the requirements.
AS 4324.1 does not address the detail design requirements of conveyor design. The relevant Australian
Standards for conveyor design should be consulted in this respect.

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A.33 Clause 3.3.6 Basis for normal digging and lateral resistance determination
For bucket wheel machines, two levels of protection on the wheel drive motion are required and two
levels of protection on the lateral drive motion are required. The first level settings influence the
calculation of U and S, while the second level settings influence the calculation of UU and SS.

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(b)
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Clause 3.3.6 is substantially unchanged from the 1995 edition, with the following exceptions:
(a) The addition of the statement that this load is a requirement.
The reference to the requirement to define the setting and action upon activation of a load
limiting device/control.
A technical specification may also include the detailed requirements or the type of protection/load
limiting devices to be provided.

A.34 Clause 3.3.7 Normal digging resistance (U)

Clause 3.3.7 is substantially unchanged from the 1995 edition, with the following exceptions:
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Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
(a) The addition of the statement that this load is a requirement.
(b) The reference to the requirement to define the setting and action upon activation of a load
limiting device/control.
The technical specification may also include the detailed requirements or the type of protection/load
limiting devices to be provided.
Some reclaiming machines have been observed to be set-up operationally such that ceasing of the bucket
wheel operation occurs at much higher levels than the nominal 100 % FLT of the motor. Therefore,
provision of a design allowance at the likely real setting of where the drive will be tripped is required.
The digging loads that are specified are based on a compromise between the philosophies of ISO 5049-1
and the German Code, BG—1986 Regulations. Whereas ISO 5049-1 permits use of rated motor torque,
this document requires use of a torque corresponding to the lowest protection limit, subject to minimum
levels. An accuracy of ±10 % is assumed for setting protection limits, and the design loads need to be
increased by 10 % to account for this uncertainty.
For bucket wheels, the approach of the German Code, BG—1986 Regulations, of calculating an equivalent
tangential cutting force based on the full amount of available torque, while ignoring the torque needed
to lift the material in the buckets, has been adopted.

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A.35 Clause 3.3.8 Normal lateral digging resistance (S)

Clause 3.3.8 is substantially unchanged from the 1995 edition, with the following exceptions:
(a) The addition of the statement that this load is a requirement.
(b) The reference to the requirement to define the setting and action upon activation of a load
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limiting device/control.
(c) Format of the wording.
The technical specification may also include the detailed requirements or the type of protection/load
limiting devices to be provided.
The lateral digging forces are required to be determined from several considerations; however, it is to
be expected that the value determined from consideration of the slew or travel drive limiting torque will

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prevail. This is in accordance with the approach of the German Code BG—1986 Regulations (compared
to the ISO 5049-1 approach, which utilizes 0.3 × tangential digging force). The requirement to adopt
a force of not less than 0.3 × tangential digging force is included, to avoid the likelihood of producing
a structure that can only survive with an underpowered slew drive. The magnitude of S = 0.3 × U for
fatigue design purposes has been seen to adequately cover the slew drive force requirements for bucket
wheel machines in most circumstances.

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The magnitude of frictional losses should not be overestimated and rolling resistances used in the
calculation of this load case need to be maintained throughout the machine design calculation, for
example in the sizing of slew drive power requirements.

A.36 Clause 3.3.9 Permanent dynamic effects (D)

The 1995 edition stated that permanent dynamic effects (see Table 3.3.9) are based on a similar table
in German Code BG—1986 Regulations, but with modification to the vertical values to be more in
conformity to measured responses on machines of typically 500 t to 1 000 t total mass. In the German
Code, BG—1986 Regulations, values were developed for very large machines operating in German coal
mines. Table 3.3.9 is intended to be sufficiently general for application to a wider range of equipment
and be generally consistent with the dynamic factors used in AS 1418.1. The dynamic effects factors are
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to be applied to the sub-assembly dead weights and live loads.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
The frequency of occurrence of permanent dynamic effects at the levels nominated in Table 3.3.9 is
not fully specified and the designer is given flexibility to undertake the fatigue assessment using an
appropriate number of equivalent cycles. By way of guidance, three to five significant cycles of dynamic
loading may typically occur each time a motion is initiated or stopped.
The 2017 edition has made some additions to Clause 3.3.9 to provide increased clarity in respect to the
practical application of Clause 3.3.9, particularly considering that some international clauses allow a
magnitude of zero for accelerations below a certain threshold.
Clause 3.3.9 has included modifications from the 1995 edition in that permanent dynamic effects due to
angular acceleration may be considered as a triangular distribution and permanent dynamic effects for
stability calculations have been modified to be based on calculated accelerations with a safety margin
of 20 %. The dynamic effects on operator’s cabins are to be considered locally, not globally.
Through the process of developing the 2017 edition, while submissions were made for both lowering
and increasing the current values, insufficient evidence was provided to justify a change. If the current
values are considered for change in the future, a comprehensive study would be required.

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A.37 Clause 3.3.10 Forces associated with conveyor elements (G)

Clause 3.3.10 is substantially unchanged from the 1995 edition, with the following exceptions:
(a) The addition of the statement that this load is a requirement.
(b) The reference to the requirement to define the setting and action upon activation of a load
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limiting device/control.
Designers need to be aware that the inclusion of the belt tension in a design assessment of a boom
may make certain members appear less highly stressed and others more highly stressed. To avoid
undersizing some members, it is important to consider the case of a de-tensioned belt.
Designers may need to consider the possibility of a maximum possible tension cases that can be applied
by the conveyor drive systems due to protection failures.

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A.38 Clause 3.3.11 Friction (R)
Clause 3.3.11 is substantially unchanged from the 1995 edition.
The pins/pivots to which application of Clause 3.3.11 is required to be defined in a technical

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specification, including the extent. As a minimum, the friction co-efficient should be considered for all
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rotating pins, unless otherwise omitted by the requirements of the technical specification.

A.39 Clause 3.3.12 Travel (L)

Clause 3.3.12 is substantially unchanged from the 1995 edition, with the exception of the addition of a
special case for crawler mounted machines.
It is not uncommon for reduction of the rolling resistance of wheels friction coefficient to be reduced
from 0.03 to 0.01 due to the use of low friction roller bearings.

A.40 Clause 3.4 Additional loads

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The additional load grouping is the group of loads that the machine is expected to experience

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
infrequently.

A.41 Clause 3.4.1 Grouping

Clause 3.4.1 is unchanged from the 1995 edition.

A.42 Clause 3.4.2 Wind during operation (W)

Clause 3.4.2 modifications in the 2017 edition included the following:
(a) The addition of the statement that this load is a requirement.
(b) The reference to the requirement to define the setting and action upon activation of a load
limiting device/control.
(c) The specification of the 85 % rule has been relocated to Appendix A (see below) as guidance.
(d) The need for the technical specification to nominate operating and relocation wind speeds.
(e) Allowing the use of wind tunnel testing and computational fluid dynamics to be used for the
calculation of wind loading as an alternative to AS/NZS 1170.2.
Wind loading has been specified in accordance with AS/NZS 1170.2.

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Consideration is required of wind directions other than along the main axis of the structure and at
right angles to the main axis. To assess wind loads at 45° to the main axis of the structure, it is sufficient
to simultaneously apply 85 % of the wind loads calculated individually for the directions along the
main axis of the structure and at right angles to the main axis of the structure. The 85 % rule for a 45°
direction is based on consideration of drag coefficients on some typical sections at different angles, as
well as the results of studies on trussed structures.
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Sizing of slew drives and brakes needs to take into account the torque due to wind loading on the slewable
structure, particularly where this is not uniform. The load on one side of the slew axis is required to
be arbitrarily reduced by 50 % of the normal calculated value, to account for non-uniformity of gust
loading. Designers are alerted to the potential hazard that can be created should a clutch, without a
self-reset function, release under wind loading.
The defined wind speed for design is taken as at the conventional 10 m reference height (above ground
or water surfaces) per AS/NZS 1170.2.

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Clause 3.4.2 modfications in the 2024 edition include the following:
(i) The addition of a “stranded from tie-down” wind speed, Ws, to address several occurrences
of uncontrolled motion of machines resulting from the rapid approach of a storm event. The
inclusion recognizes that rapidly approaching, short-duration storms have the potential to

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impact machines of this type due to insufficient time to enable relocation and tie-down. The
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upper bound of short-duration storms tend to have an intensity similar to Region A limit state
wind speeds.
(ii) For machines with a 25-year design life, a V250 windspeed in conformance to AS 1170.2 is
recommended.
The design may need to consider the inclusion of operating loads (i.e. U, S, F, etc.) in combination with
either Wr or Ws, due to the rapid onset of storm conditions.
As guidance for the application of operational, relocation, and stranded from tie-down wind speeds, the
following matters may form part of an owner/purchaser’s Technical Specification:
(A) Normal operation wind speed, Wo
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The inclusion of other operating loads is required in combination with Wo.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Reclaiming machines can generally terminate operation and remove operational loads quickly
with the onset of higher wind speeds.
Stackers, spreaders and ship loaders often require the material being handled be purged
from the machine and associated upstream conveyor to enable the machine to travel to its
tie-down position. In the case of long conveyors, the time required to purge the system may
exceed 20 min. Therefore, it may be necessary to account for higher operational windspeeds
in the design for machines of this type. Alternatively, the requirement to relocate to the storm
park position may be triggered at a lower wind speed than the nominated operational limit to
allow adequate time to purge material from the system.
(B) Relocating wind speed, Wr
For reclaiming machines, the termination of operation and the removal of operational loading
can generally occur quickly by stopping the reclaiming device(s) (i.e. bucketwheel and slew
movement) and run off of material from the machine’s conveyors. The machine may then
relocate without restriction due to material on the associated downstream conveyor.
As described above, stacker, spreaders and ship loaders may need to accommodate at least
some operational loading during relocation. This should be defined in the owner/purchaser’s
technical specification.

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Securing the machine relies on both structural and mechanical restraint to resist wind
actions. For the relocating case, the machine requires sufficient drive power to accelerate
and overcome wind-induced loads, and other travel resistances, with the machine in its most
adverse orientation. Where motors are operated at over-synchronous for normal operation,
their speed may be reduced to synchronous speed to enable full load torque (FLT) to be
utilized to travel against relocating wind loads.
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Similarly, brakes shall have sufficient torque to bring the machine movement to rest against
wind-induced loading and other travel resistances, with the machine in its most adverse
orientation. Rail clamps or other secondary (static) brake systems are ordinarily excluded
from the assessment.
(C) Stranded from tie-down wind speed, Ws
In some cases, relocation to the storm park or tie-down position is not possible for a rapidly
approaching, short duration wind event due to the time required to relocate the machine to

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the storm tie-down position and coordination of the tie-down parking sequence.
In this situation, the machine should be capable of maintaining a static position at any
location along its travel range. There is no requirement to travel in this circumstance. The
requirements of Clause 4.2(d) apply. The machine may be orientated in a specific operational

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park position, e.g. reclaimer with boom horizontal and slew position over runway to maximize
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stability.
The use of secondary brake systems, such as long travel rail clamps or additional braking is
foreseen in these circumstances. A secondary brake system or locking device for slew systems
should be considered.
During normal operation, secondary braking systems should only be applied once the machine
movement has come to rest. It is critical that such secondary brake systems have a suitable
delay to application of braking force to ensure that the secondary brake force is not applied
during abnormal deceleration of the machine under emergency braking. Indequate delays
could impose higher loading on the machine, exceeding the values defined in Clause 3.4.7
Non-permanent dynamics effects (DD).
In the circumstance that the actual wind speed exceeds the nominated “stranded from tie-
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down” wind speed, Ws, there is a risk of an uncontrolled movement of the machine. While

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
the long travel systems using rail clamps typically have a resistance ratio well above the
requirements of Clause 4.2(d), slew systems typically have limitations associated with both
brakes and clutches as part of the slew drive assembly. If the wind speed exceeds the limit
of the brakes and/or clutch, the slewable superstructure of the machine may rotate. The
purchaser should assess this risk when defining the requirement for Ws in the technical
specification.

A.43 Clause 3.4.3 Temperature (T)

Clause 3.4.3 is unchanged from the 1995 edition.

A.44 Clause 3.4.4 Abnormal digging resistance (UU)

Abnormal digging forces are to be considered as the maximum digging force due to starting or stalling
of the drive, taking into account settings of any torque limiting devices. The calculation method is
generally in accordance with the method of the German Code, BG—1986 Regulations, which permits
the peak torque to be limited by the upper level protection limit. Accounting for efficiency losses as an
increase in abnormal digging force during stalling of the drive is also in accordance with the method of
calculation used in the German Code, BG—1986 Regulations.

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Clause 3.4.4 is substantially unchanged from the 1995 edition, with the following exceptions/changes:
(a) The addition of the statement that this load is a requirement.
(b) The reference to the requirement to define the setting and action upon activation of a load
limiting device/control.
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(c) Various clarifications on the derivation of loading.

(d) Specifying the minimum allowance for addition of the efficiency factor.
(e) Introducing a minimum 200 % Full Load Torque should there be no effective torque limiting
coupling.
The technical specification may also include the detail requirements or the type of protection/load-
limiting devices to be provided. Where a fluid coupling is provided as a load-limiting device, the viscosity

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of the fluid to be used in the coupling also needs to be included in the device setting information.
Some reclaiming machines have been observed to be able to transmit far more than the nominal 150 %
FLT of the bucket wheel drive motor. Many of these issues have been due to the ability of the supposed
“torque limiting” coupling, such as high inertia couplings and fluid couplings having the ability to
transmit much higher torques, particularly if torque transmission is sensitive to set-up such as the fluid

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fill level. AF
A.45 Clause 3.4.5 Abnormal lateral digging resistance (SS)
Clause 3.4.5 is substantially unchanged from the 1995 edition, with the following exceptions/changes:
(a) The addition of the statement that this load is a requirement.
(b) The reference to the requirement to define the setting and action upon activation of a load
limiting device/control.
(c) That provision of a load limiting/protection coupling or clutch is mandatory on a slewing
machine.
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(d) The note from the 1995 edition has been relocated to this Appendix A as follows:

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“NOTE: A bucket wheel boom can decelerate the slew or travel drive system under extreme
digging conditions such that gearbox losses act so as to increase the lateral resistance load,
which would have otherwise been determined from the limiting torque of the drive clutch.”
Designers are also alerted to the general need to have a load limiting coupling or clutch on the output
side of the brake. Situations of placement of the brake on the output side of the clutch has resulted in
the clutch being inoperable without the drive being energized and severe damage to a machine under a
collision case and the clutch not being able to slip and control the lateral load to the machine.
The technical specification may also include the detail requirements or the type of protection/load
limiting devices to be provided.

A.46 Clause 3.4.6 Travel skew forces (LS)

Travel skew forces are calculated in accordance with AS 1418.1, for relevant natural frequencies above
2.4 Hz. However, for many rail-mounted machines, the relevant natural frequency for determining
oblique travel skew forces will be approximately 0.5 Hz and the specified procedure will produce values
similar to those determined in accordance with ISO 5049-1.
For simplicity, a nominal 1 Hz minimum has been included for calculation purposes.

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 p
The minimum permissible value of KG (KGmin) has been set at  0.025   , which is the sloping section
 a
of the line given in the relevant figure of ISO 5049-1 for determining skew reactions.
Whereas ISO 5049-1 apparently ignores skew forces due to forward travel motion, these are required
to be calculated. Once again, this is consistent with AS 1418.1. However, credit for inclusion of a skew
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control system is allowed.

Clause 3.4.6 is substantially unchanged from the 1995 edition, with the following exceptions/changes:
(a) The addition of the statement that this load is a requirement.
(b) The ability to use a skewing control system, provided that two levels of protection are
provided. Two levels are considered necessary of machines that require a skew control
system, as they are generally large span machines which can experience significant skew

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forces if uncontrolled, which will consequently impart large forces into support structure.
(c) The reference to the requirement to define the setting and action upon activation of a load
limiting device/control.
The 2024 edition has introduced a requirement to consider a case where some drives may be out of

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A.47
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service, creating a torque due to unequal drive forces between the rails.

Clause 3.4.7 Non-permanent dynamic effects (DD)

Clause 3.4.7 is substantially unchanged from the 1995 edition, with the following exceptions/changes:
(a) The addition of the statement that this load is a requirement.
(b) The addition of the requirement to define the setting and action upon activation of a load
limiting device/control.
In addition to structural loads resulting from non-permanent dynamic effects, an assessment should
be conducted of machine acceleration or deceleration generated on walkways and platforms to ensure
that a safe working environment is provided for personnel. Guidance on acceptable accelerations can be
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Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
sought from AS 1735.5 on lifts, escalators and moving walks. Handrail system design should consider
the potential for personnel to be “thrown off balance” during emergency stop events. Alternatively,
operational procedures can be developed to prevent personnel from being exposed to the potential risk.
Non-permanent dynamic load effects (i.e. emergency braking events) should be at a frequency that
results in less than 20 000 events in a machine lifetime (not more than approximately 2 events per day
for 25 years). If the frequency of dynamic effects due to these events is expected at a greater frequency,
then they should be treated as permanent dynamic effects (D). The proximity of normal operations to
limiting motion speeds, accelerations and decelerations may require review.

A.48 Clause 3.4.8 Snow, ice and hail loads (K)

Clause 3.4.8 is substantially unchanged from the 1995 edition, except consideration of environmental
conditions that may occur in the location of manufacture or erection (as opposed to final siting) may be
required.

A.49 Clause 3.4.9 Access ways (P)

Clause 3.4.9 is unchanged from the 1995 edition, except the addition of the statement that the load is a
requirement of this document.

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A.50 Clause 3.4.10 Erection, dismantling and weighing (Y)

Clause 3.4.10 is unchanged from the 1995 edition, except noting dismantling of a machine at the
location of manufacture or erection may be required to transport to the final site and that the technical
specification is to state the details to be considered.
Designers and suppliers need to incorporate the temporary configurations experienced by the structure
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during erection, dismantling and weighing. Transport, sea-fastening and global lifting configurations
may also require consideration.
Clause 3.4.10 allows for winds less than WW to be considered for erection and weighing when defined
by the technical specification.

A.51 Clause 3.4.11 Maintenance loads (X)

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Clause 3.4.11 is unchanged from the 1995 edition, except the addition of the statement that the load
case is a requirement of this document and that the technical specification is to state the requirements
to be met.
Designers and suppliers need to incorporate the temporary configurations experienced by the structure

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during maintenance activities. AF
This may include long travel equipment change-outs, conveyor belt change-outs, slew bearing change-
outs, bucket wheel change-outs, luff cylinder change-outs or any other major maintenance activity that
is expected to be carried out during the operational life of the machine.

A.52 Clause 3.4.12 Abnormal inclination (NN)

Clause 3.4.12 is unchanged from the 1995 edition, except for the addition that this load is a requirement
statement.
On rail-mounted machinery, the effects of (rail) inclination is generally so small as to be able to be
neglected for structural design purposes.
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The clause sets a mechanical design requirement.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
A.53 Clause 3.5 Special loads
The special load grouping is the group of loads that would not normally occur while the machine is
operating or idle.

A.54 Clause 3.5.1 Grouping

Clause 3.5.1 is unchanged from the 1995 edition.

A.55 Clause 3.5.2 Grounding of bucket wheel, ladder or boom

The situation of boom grounding can occur on most machines (if proximity type protections
malfunction). The magnitude of grounding is controlled by effective protection systems.
It should be noted that some pressure relief valves/systems are unreliable.

A.56 Clause 3.5.2.1 General

Clause 3.5.2.1 is substantially unchanged from the 1995 edition, except clarification has been provided
that identifies that both machine loaded and unloaded conditions need to be included, that grounding

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may also occur along the length of a boom (e.g. on stockpiles, cyclone tie-down frames, etc.), and that
protection/load limiting devices and settings are required.
The application of Clause 3.5.2.1 may also need to address the occurrence of grounding of counterweight
booms, or where contact with the boom may not necessarily be at the boom tip, but rather along the
length of a boom.The designer should check for this type of condition, particularly if the stockpile peak
or other structures are in regions other than at the boom tip.
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Structural analysis and design methods may utilize a support in lieu of an applied force, provided that
realistic outcomes are achieved.
The designer needs to account for how grounding loads will be measured (i.e. what devices will be
used and their location) and how the protection systems will prevent the grounding load exceeding the
design allowances.
The use of two separate load limiting devices and levels aims to prevent full grounding, which in many

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circumstances will place the structural integrity of a machine at risk. Industry protection systems
often include both monitoring and (pressure) relief systems.
Applied grounding loads are calculated upon the practical settings of a load protection device and/or
system. That is, the physical limits and settings that are provided, and the load conditions to which

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they intend to limit being applied to the structural system, are required to be directly included in the
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structural calculations.
Circumstances for design may need to include both active (i.e. a machine being driven into a grounding
situation by a luffing motion) and passive (i.e. a machine undergoing grounding say on a stockpile due
to long travel) circumstances and how the relevant protection systems will operate. Where pressure
relief is intended as a protective function, the assessment of the flow-rate and the rate of change of the
geometrical position of the impact point will require assessment.

A.57 Clause 3.5.2.2 Slight (A1)

Clause 3.5.2.2 is substantially unchanged from the 1995 edition, except for the reference to load
limiting/protection device requirements and the actuating/monitoring system.
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The value of 10 % change is required to be aligned with the relevant assumptions in the protection

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
system. Some designs have used 10 % of the maximum value, and some have used 10 % of a working
range. What is essential is that the relevant protections align with the load assumptions made.

A.58 Clause 3.5.2.3 Partial (A2)

Clause 3.5.2.3 is substantially unchanged from the 1995 edition, except for the reference to load
limiting/protection device requirements and the actuating/monitoring system.

A.59 Clause 3.5.2.4 Full (AA)

Clause 3.5.2.4 is substantially unchanged from the 1995 edition, except for the reference to load
limiting/protection device requirements.
The technical specification defines whether full grounding is required to be considered, or whether it
can be omitted from the design and the necessary protections to be provided.
It should also be noted that for articulated booms, the effect of grounding can be limited to the loss of
the portion of the boom mass outward from the articulation point.

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A.60 Clause 3.5.3 Uneven support where rail-mounted (QQ)

Clause 3.5.3 is unchanged from the 1995 edition, except for the addition of the statement that the load
is a requirement.

A.61 Clause 3.5.4 Uneven support where crawler-mounted (QQ)

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Clause 3.5.4 is unchanged from the 1995 edition, except for the addition of the statement that the load is
a requirement of this document.

A.62 Clause 3.5.5 Blocked chutes and hoppers (VV)

Clause 3.5.5 is substantially unchanged from the 1995 edition, with the following exceptions/changes:

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(a) The addition of the statement that this load is a requirement.
(b) The reference to the requirement to define the setting and action upon activation of a load
limiting device/control.
Some blocked chutes may provide stabilizing mass and this is required to be neglected when considering

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stability. AF
The design of the chute or hopper and the point at which the blockage or bridging event is triggered
should be such that this additional material delivered by the upstream conveyor run on is contained
within the chute or hopper.
It is accepted that in some high speed, high rate and significant length conveyors, retention of the entire
volume delivered by the upstream conveyor may not be practicable. In this case, the designer should
make allowance for the overflow volume to be retained on the structure immediately adjacent to, and
at the same level of, the chute or hopper overflow point, in accordance with Clause 3.5.5(c).
Consideration may need to be given to the dynamic effects of the loss of a blocked chute at the end of a
boom (e.g. a ship-loader chute) if the mass loss is substantial.
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A.63 Clause 3.5.6 Excess material on conveyors (FF)

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Maximum material on the belt is to be calculated by using the greatest material bulk density, assuming
the belt is full to overflowing and with a surcharge at the angle of repose (i.e. not the dynamic surcharge
angle, which is normally taken to be at least 20°). The angle of repose has been adopted, because
there have been instances where belts have become overloaded and the conveyors have stalled after
becoming fully overloaded over their entire length. At such a slow speed, the dynamic surcharge angle
is not likely to be relevant. The angle of repose is taken to be at least 35°, which is relevant for a wide
range of carried materials and applies also to surcharges on blocked chutes and hoppers.
The circumstances by which this load case can occur (e.g. the emptying of a blocked chute and its
volume) and the loading which can eventuate from those conditions need careful consideration,
particularly if the magnitude of this case is desired to be limited.
Clause 3.5.6 is substantially unchanged from the 1995 edition, with the following exceptions/changes:
(a) The addition of the statement that this load is a requirement.
(b) The reference to the requirement to define the setting and action upon activation of a load
limiting device/control.
(c) The cross-section calculation should be used as the default option.
Where bucket wheel output is greater than the cross-section of the conveyor, the difference should be
included as a spillage type load under Clause 3.5.5.

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A.64 Clause 3.5.7 Travelling device obstructed (LL)

An obstruction of the travelling device is to be treated as a rapid deceleration event over 300 mm at the
rails. This is more extreme than ISO 5049-1, which ignores dynamics of the stopping process.
The 2017 edition has introduced the ability to vary the stopping distance, as very large machines may
not be able to stop in that shorter distance and application of the 300 mm distance would result in an
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overly conservative load.

It also recognizes that it may not be practical to design for this load condition on equipment with a large
rail gauge distance and means of limiting this load, e.g. skew control, which will then need to be defined
in the technical specification.
In the case of long travel collision prevention systems it is recommended that “cow catcher” limit switch
devices be installed in such a manner that allows the machine to activate the device and stop within a
safe distance to prevent damage to the structure.

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Consideration may also be given to the use of rail clearing devices and anti-drop/anti-derailment pads.
There may be situations involving small towed tripper cars where it is not practicable to design for
the full drive and inertia forces. In these circumstances, the allowances for travel device obstructed of
those tripper car legs is subject to definition within the technical specification.

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AF
Analysis and design methods for load cases including inertia and impact loads may be treated via use of
complex analysis models, provided that all elements of a collision situation are accounted for.

A.65 Clause 3.5.8 Lateral collision of boom (FS)

ISO 5049-1 requires consideration of a lateral collision between a boom and an obstruction, but
incorrectly limits the calculated load to either the slewing coupling limit or the force resulting from
dissipating the kinetic energy of the structure. The collision force is required to be calculated from a
consideration of the sum of the above two effects.
The 2017 edition introduced the ability for a technical specification to define the extent to which this
load is applied to the design, particularly in recognition of machines with fixed boom systems. The
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derivation of the load magnitude has not been altered.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
On non-slewing machines such as ship-loaders and stackers where the boom is fixed at right angles to
the long travel tracks, it is usually not practical to design for a boom-collision load case at full speed and
it may be necessary to rely on anti-collision systems. This is to be defined in the technical specification.
Consideration of collision scenarios on counterweight booms may also be required, dependent upon
stockpile or berth layout. For instance, for ship loader installations where ships can be loaded on either
side of the berth consideration needs to be made for the potential of a machines counterweight to
interact with the bridge, or other structure associated with a ship positioned to the rear of a ship loader.
For yard machine installations where there are multiple machines operating in parallel, consideration
needs to be made to the ability for machine booms and counterweight components to interfere with
each other. It is common for facilities to exist with the potential for this interaction and robust anti-
collision systems are required to prevent structural damage from occurring.
Protection systems need to give consideration to the likely stopping distance and conversely this may
require an iterative assessment of likely applied load due to deflection of the boom at the collision point.
Analysis and design methods for load cases including inertia and impact loads may be treated via use of
complex analysis models, provided that all elements of a collision situation are accounted for.

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A.66 Clause 3.5.9 End-on collision of boom (FT)

An end-on collision of a boom is a load case that has been considered during the design of some machines
in Australia and elsewhere, but which has not previously been incorporated into another Standard. The
determination of the inertial force component is best made by considering conservation of linear and
angular momentum.
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The derivation of the load magnitude has not been altered.

For ship loader installations, it is prudent to consider the swing arc of the bow of a vessel during berthing
and de-berthing operations when designing the park location and configuration of a ship loader.
This load case is not required for equipment without a motion capability in the direction of the boom,
e.g. a non-slewing machine.
Analysis and design methods for load cases including inertia and impact loads may be treated via use of

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complex analysis models, provided that all elements of a collision situation are accounted for.
The 300 mm stopping distance may be varied by use of the technical specification, where it is impractical
to design for this case, or where there are other considerations.

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A.67 Clause 3.5.10 Wind while idle (WWp and WWu)
AF
Clause 3.5.10 modfications in the 2017 edition included the following:
(a) The addition of the statement that this load is a requirement.
(b) The specification of determination of the minimum permissible stress design wind speed
from the ultimate limit state design loading standards, with the ultimate limit state wind
speed reduced by a factor of the square root of 1.5.
(c) The specification of the 85 % rule has been relocated to Appendix A (see below) as guidance.
(d) Allowing the use of wind tunnel testing and computational fluid dynamics to be used for the
calculation of wind loading as an alternative to AS/NZS 1170.2.
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Wind loading has been specified in accordance with AS/NZS 1170.2.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Consideration is required of wind directions other than along the main axis of the structure and at
right angles to the main axis. To assess wind loads at 45° to the main axis of the structure, it is sufficient
to simultaneously apply 85 % of the wind loads calculated individually for the directions along the
main axis of the structure and at right angles to the main axis of the structure. The 85 % rule for a 45°
direction is based on consideration of drag coefficients on some typical sections at different angles, as
well as the results of studies on trussed structures.
The defined wind speed for design is to be taken as at the conventional 10 m reference height (above
ground or water surfaces) per AS/NZS 1170.2.
Where additional restraints are applied (shear keys, cradles, etc.), the relevant restraining conditions
need to be considered in the design.

A.68 Clause 3.5.11 Buffers (OO)

The view that buffers should be fitted to rail-mounted machines and that buffers and machines should
be capable of surviving a collision involving the machine being driven at rated speed into the buffers
has been adopted. This arises from a collapse of a reclaimer after heavy buffering following apparent
malfunction of travel-speed control devices. The unit and its buffers have been rebuilt to satisfy
the requirements of Clause 3.5.11 at minimal extra cost, compared to a design conforming only to
ISO 5049-1 requirements.

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 DR AS 4324.1:2024 86

Clause 3.5.11 is substantially unchanged from the 1995 edition, with the following exceptions/changes:
(a) The addition of the statement that this load is a requirement.
(b) The reference to the requirement to define the setting and action upon activation of a load
limiting device/control.
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(c) Specific consideration of other motions that may require buffers.

The technical specification needs to clearly define the responsibility for design and/or checking of the
fixed buffer structures.
Analysis and design methods for load cases including inertia and impact loads may be treated via use of
complex analysis models, provided that all elements of a collision situation are accounted for.

A.69 Clause 3.5.12 Earthquakes (EQp and EQu)

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Clause 3.5.12 is unchanged from the 1995 edition, except for the updated reference to AS 1170.4 and the
addition of the statement that the load is a requirement.

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A.70 Clause 3.5.13 Burying (ZZ) AF
The requirement for including the burying load condition needs to be defined in the technical
specification.
There have been instances where machines have been severely damaged or completely lost as a result
of slippage of the bank. The desirability for addressing this possibility and factor into the design some
degree of conservatism has been identified. However, this burying load case is extreme and a design
that avoids any damage at all may be impractical.
Consideration is needed regarding the loading that may occur when burying of a bucket wheel boom
tip occurs, including the potential for the chute to become filled during the burying event, plus the
subsequent transfer of material load on to the conveyor belt (at possibly an FF level). These detailed
requirements are to be defined in the technical specification. An appropriate risk assessment should be
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conducted to establish the loading to be considered for design purposes.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
A.71 Clause 3.5.14 Bucketwheel and gearbox loss or loss of boom equipment
(BL)
This load case was originally introduced primarily for situations where the bucket wheel is on a
cantilevered section of shaft. Where the bucket wheel is not cantilevered, but held captive by the boom
support structure and the discharge/circular chute in case of shaft failure, this load event may not be
applicable. The document has been revised to reflect this, but also to include that partial loss (i.e. the
drive and/or gearbox and/or part of the bucket-wheel shaft assembly, etc.) may require consideration.
The 2017 edition incorporated greater detail is prescription of the requirements of this load.
The 2024 edition has included a case for loss of chutes/telescopic chutes as loss of boom equipment.
Several instances of chute loss from shiploaders has been experienced in the industry and the potential
effects (similar to rapid loss of loads on cranes) should be considered in the design.

A.72 Clause 3.5.15 Abnormal friction (RR)

Clause 3.5.15 is substantially unchanged from the 1995 edition.
The requirement for including this load case need to be defined in the technical specification.

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A.73 Clause 3.5.16 Extra loads (EL)

Clause 3.5.16 is substantially unchanged from the 1995 edition.
The requirement for including this load case needs to be defined in the technical specification.
Extra load circumstances may include:
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(a) The failure of a rope, strap, stay or luff cylinder in accordance with Clause 5.7.
(b) High yard belt tensions on a stacker due to the failure of a tail pulley brake to release and the
application of full torque from a head end drive motor.
The relevant load combinations, and the defined load type (I, II or III) should be defined by the technical
specification (i.e. whether only type I load combinations need to be considered in combination with the
failed element support condition, or whether all load combinations require inclusion). In general, it is

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considered unwarranted to combine 2 extreme occurrences unless they are related (i.e. blocked chute
and flooded belt is an example of a related load condition).
In general, the factor of safety or limit state load factors should align with the type III combinations as a
minimum [i.e. 1.2 and 1.0 (to the extra load) respectively] unless there is justification for a lower value.
Where the extra load is a circumstance that is more frequent, it may need to be considered as a type II

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or even type I combination.

A.74 Clause 3.6 Fatigue loads

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Fatigue is required to be assessed using a stress range (spectrum) approach. Clause 3.6 provides some
guidance on the frequency of occurrence of loadings and defines modifying factors to be applied to
the loads calculated in Clause 3.3 to obtain an equivalent cyclical loading that is expected to be
representative of an average loading occurring for each machine operational movement or cycle as
defined in Clause 3.6. It is intended that combinations of loading events that contribute to fatigue stress
ranges be as realistic as possible, without unnecessarily complicating the analysis procedure.
In general, larger fatigue stress ranges over fewer cycles are comparatively more damaging than small
stress ranges over many cycles. This should be considered when calculating design stress spectrums.
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The addition of several simultaneous loads also requires inclusion.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
The magnitude of fatigue loads should be subject to measurement and review upon commissioning
of machines to verify that the design assumptions have been complied with. When assessing existing
machines, actual measurements and factors may be used to assess long term performance.

A.75 Clause 3.6.1 General

Clause 3.6.1 is unchanged from the 1995 edition, except the addition of the statement that the load is a
requirement.

A.76 Clause 3.6.2 Dead loads and encrustation (+/+E and +/+V)
Clause 3.6.2 is unchanged from the 1995 edition, except the addition of the statement that the load is a
requirement.

A.77 Clause 3.6.3 Inclination (+/−N)

Clause 3.6.3 is substantially unchanged from the 1995 edition.

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A.78 Clause 3.6.4 Live loads on conveyors (+/0CF.F)

Clause 3.6.4 is substantially unchanged from the 1995 edition.
Where a fatigue bulk density is used for the calculation C.F = 1.0 should be used.
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A.79 Clause 3.6.5 Normal digging resistance (+/0CU.U)

Clause 3.6.5 is substantially unchanged from the 1995 edition.

A.80 Clause 3.6.6 Lateral digging resistance (+/−CS.S)

Clause 3.6.6 is substantially unchanged from the 1995 edition. Where S is calculated as 0.3 x U, the
technical specification should confirm whether the purchaser requires a CS value of 0.7 or 1.0 to be

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applied.

A.81 Clause 3.6.7 Permanent dynamic effects (+/−D)

Clause 3.6.7 is substantially unchanged from the 1995 edition.

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A.82
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Dynamic amplification may occur and require inclusion in a fatigue assessment.

Clause 3.6.8 Conveyor elements (+/+G)

The 2017 edition has adjusted the conveyor elements load range to be representative of the change due
to material load changes, rather than an arbitrary zero to maximum range.

A.83 Clause 3.6.9 Friction (+/−R)

Clause 3.6.9 is substantially unchanged from the 1995 edition, except noting that the extent of inclusion
in the design is to be defined by the technical specification.
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Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
A.84 Clause 3.6.10 Travel (+/−L)
Clause 3.6.10 is substantially unchanged from the 1995 edition.

A.85 Table 3.6

This table is substantially unchanged from the 1995 edition.
The factors prescribed in Table 3.6 are minimum (and appropriate) factors for design purposes. They
tend to accommodate most operating circumstances.
However, there are some facilities where these factors may be lower bound. In the case of iron ore, these
factors may require increasing (dependent upon the calculation of loads U and S) to 1.0 for digging
cases. For coal, they tend to be above the magnitudes experienced in operations.

A.86 Clause 3.7 Load cases

Clause 3.7 was substantially unchanged from the 1995 edition, except with reference to the two
Tables 3.7(A) and 3.7(B).

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A.87 Tables 3.7(A) and 3.7(B) Load combinations for design of machine
structures
Clause 3.7 was substantially changed in the 2017 edition, with significant modification of the ultimate
limit state design load factors.
Tables 3.7(A) and 3.7(B) are key parts of this document since they summarize the load case combinations
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to be analysed and the required factors of safety (permissible stress design) and the ultimate limit state
load factors to be used for strength design, as well as the minimum stability ratios against overturning.
Except for some variations, the permissible stress design factors of safety are generally consistent with
ISO 5049-1, namely, 1.5 for Case I, 1.33 for Case II and 1.2 for Case III.
The variations occur mainly for certain extreme loads (e.g. for Case III, full grounding or burying)
where factors of safety and stability ratios lower than 1.2 have been specified, so that they are similar

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to the German Code, BG—1986 Regulations. For the Case III load combination for slight grounding, the
factor of safety and stability ratio are slightly higher, because it is judged to be more comparable with a
Case II loading, despite appearing in the Case III grouping.
The stability ratios against overturning are based on the machine mass and its distribution being
known accurately in accordance with Clause 5.9. For load case III/10, a stability ratio of either 1.2 or 1.5

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is required to be defined by the technical specification.
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The ultimate limit-state-load factors defined by Table 3.7(B) have been developed from reliability
analyses conducted, and have been aligned with the application of individual load factors applied to
individual loads.

A.88 Section 4 Overturning and drifting

This section defines the requirements for assessment of overturning resistance (stability) and drifting
resistance.
The selection of a minimum stability ratio of either 1.2 or 1.5 for load combination III/10 is required
to be defined in the technical specification. The selection of 1.2 generally aligns with other type III
load combinations; however, in some circumstances may result in a lower reliability for extreme wind
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conditions when compared to other facilities on a particular site, if those facilities have been design

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
using ultimate limit state strength wind speeds. This is likely to be the case in Regions C and D (or other
regions for small machines) where storm/cyclonic wind forces tend to govern stability design.

A.89 Clause 4.1 Stability against overturning

Clause 4.1 is substantially unchanged from the 1995 edition, except for the addition of a clarification
paragraph in respect of special configurations may be needed for stability under storm tie down or
major maintenance activities.
Designers should be aware that the stability of a machine under wind while idle loading (WW) as
assessed in the permissible stress method as a type III load combination does not produce the same
level of reliability as would be achieved under assessment for ultimate limit state conditions.

A.90 Clause 4.2 Resistance against drifting

Clause 4.2 was changed in the 2017 edition to include the addition of a new check required in respect
of the driving power against wind forces. This requirement is again modified in the 2024 edition. This
requirement needs to be calculated to enable the determination of power requirements that determine
structural load cases.
The 2024 edition has incorporated additional requirements associated with the stranded from tie-
down situation.

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Resistance against drifting may also need to take into account the prescription of redundancy
requirements for drives. Contemporary specifications ordinarily detail the redundancy requirement
for multiple drive systems (slew and long travel) while still meeting the operational requirements. This
may be in the form of —
(a) general percentage: e.g. 10 % for the drives/brakes removed;
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(b) quantity: e.g. 1 drive/brake removed per wheel group (leg); or

(c) combination: e.g. 10 % of drives/brakes removed with no greater than 2 units per wheel
group.
The redundancy requirements should also be considered for drive and brake sizing with respect to
Clause 3.4.2 Wind during operating including “relocation” and “stranded from tie-down” requirements.
There is a tendency for operations and maintenance stakeholders to request an increasing proportion

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of drive and brake redundancy. However this should be assessed with caution. The higher the level of
redundancy drive/brakes, the higher the loads applied to the machine for non-permanent dynamics
(DD), long travel obstructed (LL), lateral and end-on collision (FS/FT), and buffer impact (OO) as the loads
are calculated based on all drives/brakes in service. It is recommended that drive/brake redundancy
requirements be minimised to reduce the impact on design loads produced when all drives/brakes are

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in service. AF
The following additional guidance is provided on brake and clutch settings:
(i) General brake and clutch settings and maintenance testing — Brake torque settings are critical
to maintaining the dynamic effects on machines to within their design allowances. If brake
torque settings are —
(A) too low, there is insufficient torque to provide resistance against drifting or bring
the machine to rest in the most adverse wind conditions; or
(B) too high, higher decelerations are imposed, impacting both strength and fatigue
life.
(ii) OEM brake setting inaccuracy — The requirements of AS4324.1 use a positive or negative
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10 % uncertainty factor for several load calculations. However brake and clutch OEM setting

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
inaccuracy may be far greater than this assumption. As-measured setting inaccuracy for
several make/models of brake units for slew and long travel have ranged from −30 % to
+40 %.
Some specifications have nominated that the design consider a range of −10 % to +35 % for
slew brakes only due to the design typically having a small number of drives. The specification
does not include a similar requirement for long travel as there are many more drives and the
average brake setting for a group approaches a range of ±10 %.
For machines in operation, the torque of all slew and long travel brake units should be regularly
tested and the total brake torque assessed against design requirements. Should the sum of
the brake group not achieve the required range, the outliers should be adjusted/replaced
until the required brake torque for the group is achieved.
(iii) Static vs. dynamic brake torques — In some circumstances, the brake torques nominated by
the supplier are unclear if the torque nominated is dynamic or static. Dynamic brake torque
refers to the torque applied when decelerating, while the static brake torque is the torque
required for the brake to slip from a static position. Static brake torque is often 20 % to 40 %
higher than the dynamic value. Dynamic brake torque is required for resistance against
drifting and non-permanent dynamic (DD) calculations.
It is important to recognize the relationship between static and dynamic torque values when
undertaking design and when developing brake testing procedures for when the machine is static.

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When testing brakes statically, it is important to test in both the clockwise and counterclockwise
directions multiple times to obtain an accurate figure of the current static brake torque.
The speed rating of the brake units should also be checked. Some brake units are not suitable
operating at over-synchronous motor speeds. Long travel system are often designed to operate at over-
synchronous speeds for high speed relocation.
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It is imperative for machine designers to select equipment which allows for testing of brakes and
clutches. Special tools are often required to lock rotating components to test.

A.91 Section 5 Structures

The 2017 edition undertook a substantial review and modification of Section 5. This was performed on
the basis that structural design relies on the established structural design Standards, aside from minor
machine-specific requirements.

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This philosophy will reduce duplication and allow structural design to be performed to the most up-to-
date Standards without the revision of this document.
Designers should take particular care when using angles in compression, due to the eccentric effects of
the section and connections.

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A.92
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Clause 5.1 Loads and load cases
Clause 5.1 refers to Tables 3.7(A) and 3.7(B) but notes that the load cases may comprise variations as
some loads may be at their maximum value coincident with other loads being at their minimum value.

A.93 Clause 5.2 Fatigue design life

The 2017 edition has modified the fatigue design life requirement to be as defined in the technical
specification, but subject to a minimum 100 000 operating hours.
The minimum 100 000 operating hours requirement is not intended to be the default option, but rather
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establish a lower bound design basis. A minimum design life of 25 years is recommended. Designers are

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
required to undertake a process of calculation of likely machine motions and operating characteristics
to estimate the likely fatigue stress ranges and spectrum that the structure will experience throughout
its service life.

A.94 Clause 5.3 Steels having high yield to ultimate tensile strength ratio
Clause 5.3 is changed from the 1995 and 2017 editions, by modification of the 0.7 factor to 0.8. This
has been altered on the basis that most grade 350 type materials were previously reduced in design
yield by a nominal and immaterial amount (compared to the effort required), that several international
standards allow a higher ratio and that the ductility of the steels is addressed in Section 2.
The equation now used is —

 Y  0.8  R
 Ym 
2
The equivalent ISO 5049-1 equation is referenced to Fe510 (S355) steel strength properties, and
produces a modified yield value of the specified yield for materials with a yield strength of less than
355 MPa.

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 DR AS 4324.1:2024 92

A.95 Clause 5.4 Design methods to allow for strength and serviceability
The 2017 edition allows selection of the design method for assessment of strength and serviceability to
be either the permissible stress design method or the ultimate limit states method.

A.96 Clause 5.4.1 General

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Clause 5.4.1 requires the strength and serviceability design to be undertaken in accordance with either
the permissible stress design or ultimate limite state method, and the fatigue design, in accordance with
AS 4100 unless more rigorous assessments are specified. It further requires that complex fabrications
should utilize finite element analysis methods.
In relation to the bases for use of FEA/FEM and plate buckling, modern design Standards can be
referenced, in particular the Eurocode 3: Design of steel structures series, being EN 1993-1-1 through
EN 1993-1-12, plus possibly EN 1993-2 and EN 1993-6.

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DIN 18800 has traditionally been used for the design of plated structures (and while superseded by
EN 1993 may still be used by industry).
The use of FEA/FEM and its extent should be prescribed in the technical specification. Guidance on the

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use of FEA/FEM/simulations may be obtained from organizations such as NAFEMS.
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The 2024 edition has clarified the requirement for design analysis methods to use elastic design and
that structures should remain in the elastic region for permissible and serviceability limit state loading.
Plastic design should not be used on dynamic structures.

A.97 Clause 5.4.2 Permissible stress design method

This clause defines how to apply the permissible stress design method to machine design in accordance
with this document.

A.98 Clause 5.4.2.1 Application

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See Clauses 5.4.2.2 to 5.4.2.7.

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A.99 Clause 5.4.2.2 General
The basic structural assessment requirements of yield, buckling and fatigue strength criteria are to be
considered.

A.100 Clause 5.4.2.3 General design approach

The approach for use of the conventional structural design Standards, such as AS 3990, while using the
safety factors defined by this document is to adjust the overall result by use of AS 3990 and then vary
that result to achieve a variation of overall reliability.
This is to be achieved by undertaking checks against the conventional structural design Standard and
adjusting the stress ratio by a factor associated with this document’s safety factor.

A.101 Clause 5.4.2.4 Determination of permissible stress with respect to yield

strength
Clause 5.4.2.4 was substantially modified/simplified in the 2017 edition, and describes the process of
use of this document and AS 3990.
Where FEA is used, the von Mises stresses calculated should be less than Fy/va

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A.102 Clause 5.4.2.5 Permissible stresses and loads causing buckling

Clause 5.4.2.5 was substantially modified/simplified in the 2017 edition, and describes the process of
use of this document and AS 3990.

A.103 Clause 5.4.2.6 Plates and shells

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Clause 5.4.2.6 was substantially modified/simplified in the 2017 edition and describes the use of
established and recognized Standards which is seen as the most pragmatic method of maintaining the
availability of the most up-to-date Standards.
If those Standards are in the ultimate limit state format, for plate and shell buckling purposes, then a
nominal load factor of 1.5 on the applied stress determined from loading from this document is seen as
a simple and appropriate method, which will have minimal overall effect on thicknesses/mass.

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A.104 Clause 5.4.2.7 Connections
Clause 5.4.2.7 was substantially modified/simplified in the 2017 edition and describes the process for
use of this document and AS 3990.

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A.105
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The specific requirements for friction grip bolting have been simplified.

Clause 5.4.3 Limit state design method

The 2017 edition substantially modified the derivation of load combinations, but generally allows
application of the determined design actions via the use of AS 4100 design rules.
In a similar manner to the crane Standard, AS 1418, the 2017 edition allowed use of the limit states
method to AS 4100. Where the limit states design method is used, care needs to be taken so that the
design gives an appropriate degree of safety/reliability.

A.106 Clause 5.4.4 Serviceability

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Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Serviceability of structures is required to be included in the design. The technical specification should
define any special or particular requirements. This may include the effects of displacement and elastic
deformation on mechanical components, such as drive couplings, belt tracking, uneven load distribution
through slew bearings, geometrical relationships between substructures and catch hooks, etc.
Serviceability load cases should be checked to ensure the steel remains in the elastic region for all load
cases.

A.107 Clause 5.5 Fatigue strength of structural components and joints

Clause 5.5 describes the requirements for fatigue design. Fatigue design is in accordance with AS 4100.
The revision to the document permits more rigorous fatigue assessment to be carried out to EN 1993,
the Eurocode 3 series, BS 7608 or International Institute of Welding methods as prescribed in the
technical specification.

A.108 Clause 5.5.1 General

AS 4100 fatigue design procedures are generally consistent with the precedent European practice (e.g.
ECCS—Technical Committee 6—Fatigue, Recommendations for the Fatigue Design of Steel Structures)
and the use of AS 4100 for assessing fatigue of welded joints is favoured, except where joint details are
not adequately covered by AS 4100. AS 4100 tends to be more conservative than BS 5400-10, which
has long been used as a substitute in lieu of the somewhat limited fatigue provisions of AS 3990, which

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should not be used. AS 4100 requires the use of lower design stresses in members that are not on a
redundant load path and where the plate thickness is more than 25 mm.
The 2017 edition introduced the ability to use state of the art procedures developed by the International
Institute of Welding, or EN 1993 Eurocode 3 or BS 7608.
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A.109 Clause 5.5.2 Permissible stress ranges

Welded joints subjected to substantial stresses both normal and parallel to the weld are required to be
assessed according to an equation of von Mises formulation to ensure that the combined overall fatigue
stress field is acceptable.

A.110 Clause 5.5.3 Compressive stress ranges

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Stress ranges include compressive stress ranges, in accordance with modern standards.

A.111 Clause 5.6 Bolts and riveting

See connections (Clauses 5.4.2.7 and 5.4.3.7). This clause has been retained.

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A.112
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Clause 5.7 Steel wire ropes, straps and stays, and hydraulic cylinders
The (1995) approach adopted for assessing wire ropes aims at achieving consistency with AS 1418.1, as
well as ISO 5049-1 and the FEM Rules.
This edition (2024) has undertaken to simplify the requirements for rope, strap and stay and hydraulic
cylinder design. Because ropes are used on mobile equipment in such a way that failure could often
lead to severe damage to the equipment or loss of life, this document requires redundancy where such
instances may occur.
For ropes, the safety factors are based on the original geometrical and strength properties of the rope.
To ensure that an adequate safety factor remains once a rope is subject to wear or corrosion, a basis for
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discarding the rope is required. The following should be considered as a basis for deciding replacement

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
of ropes that run over sheaves:
(a) The wear of the rope or necking of the cross-section causes the overall rope diameter across
the wires to be less than the original loaded rope diameter by more than 8 %.
(b) The wear of the rope or the effect of wire breakages over a length equal to one lay causes the
total metal area to be less than the original rope metal area by more than 15 %.
(c) The outer wires of the rope have lost 33 % of their diameter due to wear.
(d) Ropes have been in service for a period of 50 000 h, subject to a maximum of 12 years. The
period of service may be taken to include the sum of the time the rope is actively used in
service and the period while the rope is exposed to the elements without adequate protection
against corrosion.
(e) Visible signs of damage (such as corrosion and other defects referred to in AS 2759) are
present, which may affect the load carrying capacity of the rope.

A.113 Clause 5.7.1 General

Clause 5.7.1 is substantially unchanged from the 1995 edition.

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 95 DR AS 4324.1:2024

A.114 Clause 5.7.2 Factors to be considered

Clause 5.7.2 is substantially unchanged from the 1995 edition, except a minimum dynamic amplification
factor has been defined for a rope breakage situation.

A.115 Clause 5.7.3 Duplication for operator’s cabin

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Clause 5.7.3 is substantially unchanged from the 1995 edition.

A.116 Clause 5.7.4 Duplication

The 2017 edition added Clause 5.7.4 to require duplication of ropes, straps and stays to be a pair, on
the basis of simplified and reduced factors of safety in Clause 5.7.5, and the prudent management of the
consequence of a rope failure. The 2024 edition has reduced this to a recommendation on the basis of

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research associated with a varying factor of safety for single compared to dual rope systems.

A.117 Clause 5.7.5 Safety factor

The 2017 edition simplified the requirements for factor of safety of ropes, straps and stays.

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The 2024 edition further clarifies the requirements for dual and single (side) ropes, straps and stays
systems, with a varying factor of safety requirement.

A.118 Clause 5.7.6 Chains and racks

The 2017 edition has added the requirement to consider chains and racks against the same criteria
where the integrity of sub-assemblies are reliant upon those items.

A.119 Clause 5.7.7 Hydraulic cylinders

The 2017 edition had added Clause 5.7.7 to assist with clarifying the requirements for hydraulic
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cylinders.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
The requirement for inclusion of a failed hydraulic cylinder is intended to prevent a catastrophic
collapse. A technical specification may specify the limiting load combinations that require consideration
of this criterion.
The design and limitations of the hydraulic system may also require detailed consideration.
The 2024 edition added design requirements for hydraulic cylinders in compression. These
requirements align with DNV design rules for buckling factors (for the normal case, where a buckling
factor of 4 is prescribed by DNV-ST-0194). Table 5.7.7 has been added.
Buckling capacities of hydraulic cylinders can be calculated using established standards such as DNV
rules or EN 13001‑3‑6.

A.120 Clause 5.8 Slewing race safety hooks to prevent separation at the slew
race
There have been several instances in Australia and overseas where stacker-reclaimers have lost a
bucket wheel and separated at the slew race. These machines had open ball paths for the slew race and
the catch hooks, where fitted, failed to prevent the separation of the race. In one instance, the machine
was totally destroyed and the operator was killed.
This document requires that catch hooks be installed on machines with an open ball path. For all
machines, they are required to be of such a design as to prevent separation of the race for a grounding

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event, and also for bucket wheel machines in the event of a bucket wheel and gearbox loss. Hooks may
be designed so as to yield progressively throughout the dynamics of stopping separation of the race,
provided the total failure energy for the hooks exceeds four times the energy necessary to prevent
separation. It is envisaged that a material having a large elongation before breaking would be required.

A.121 Clause 5.9 Mass and centre of gravity of machine

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The design should consider the method of weighing to be able to determine the mass and centre of
gravity of the machine.
The stability ratios against overturning are based on the machine mass and its distribution being
known accurately. Clause 5.9 requires the machine to be weighed on completion, to confirm the as-
built weights are within 5 % of the design loads used for analysis and design (E). This should include
assessment of underweight and overweight tolerances.

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The as-built machine should be subject to assessment of the following:
(a) The final as-constructed mass in comparison to the design mass used in calculations and
assessed against the 5 % variation allowance.
(b) The final as-constructed stability in comparison to the requirements of this document.

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(c)

(d)
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The final as-constructed state of balance, both regarding the eccentricity of a rotating
superstructure on a slew bearing and the position of the centre of gravity of a pivoting
superstructure (and therefore consideration of the as-built forces within hydraulic cylinder
or rope support systems in comparison to design values).
The final as-constructed wheel loads in comparison to design wheel loads.
Purchasers should assess the criticality of masses to items of supporting structure in specifying
the weighing requirements in the technical specification. Balanced machines require this as built
verification to confirm stability, whereas stable structures (such as trippers) may require the
information for verification of loading to the tripper support structure/galleries/runways.
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A.122 Clause 5.10 Lifting beams and lugs

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
The 2017 edition updated terminology to working load limit (WLL) or maximum rated capacity (MRC).

A.123 Section 6 Ancillary structures

The boundary for application of this document is the wheels and the buffers.
This section was a new section introduced for the 2017 edition. It is intended to simply require the
technical specification to prescribe how the loads from Clause 3.7 are applied to items “off-board” of the
machine.

A.124 Clause 6.1 Loads and load cases

The technical specification is used to nominate how the loads from Clause 3.7 are applied to items “off-
board” of the machine.
Some items may not necessarily consider all loading cases from the machine design.

A.125 Clause 6.2 Supporting structures and rails

The technical specification is used to nominate how the loads from Clause 3.7 are applied to supporting
structures and rails.

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Some items may not necessarily consider all loading cases from the machine design.

A.126 Clause 6.3 Tie-downs and restraints

The technical specification should nominate how the loads from Clause 3.7 are applied to supporting
structures and rails.
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Some items may not necessarily consider all loading cases from the machine design.

A.127 Clause 6.4 Major maintenance works

The technical specification is used to nominate how the loads in Clause 3.7 are applied to structures for
major maintenance works. Some items may not necessarily consider all loading cases from the machine
design.

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The design should incorporate requirements for —
(a) machine jacking (and weighing), including accounting for eccentricities;
(b) support and jacking for slew bearing changes;

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(c)

(d)
changes; and
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support and changes in support configurations for bucket wheel and bucket wheel drive

support and and changes in support configurations for luff cylinder changes.

A.128 Appendix A Explanatory notes

Appendix A is provided as guidance to users of this document. It was expanded for the 2017 and
2024 editions, particularly to provide additional information in relation to changes made during that
revision.

A.129 Appendix B Information to be supplied within the technical specification

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The normative Appendix B specifies the items that need to be provided in a technical specification
for the application of this document. The appendix was significantly expanded for the 2017 and 2024
editions, particularly to provide additional information in relation to changes made during the revision.
The main purpose is to align the requirements of this document with the information in the technical
specification to ensure the purchaser and supplier are in agreement on the details of supply.
While this document does not describe who is responsible for development of the technical specification,
it would ordinarily be prepared by a purchaser or their representative. Suppliers should not deviate
from any of this document’s requirements without explicit and documented direction and/or approval
from the owner or purchaser within the technical specification. Exclusion of requirements by a
prospective supplier through tender responses should not be considered approval.

A.130 Appendix C Normative references

Normative references have been relocated from Appendix C to Clause 1.4 in the 2024 edition. Documents
that are informative and provided for information purposes only have been relocated to Bibliography.

A.131 Appendix D Quantity symbols (retitled as Symbols and abbreviated

terms)
Quantity symbols, retitled as Symbols and abbreviated terms, have been relocated from Appendix D to
Clause 1.5 in the 2024 edition.

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A.132 Appendix E Typical types of mobile continuous bulk handling equipment

Appendix E is unchanged from the 1995 edition.

A.133 Appendix F Basic digging parameters for bucket wheel machines

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Appendix F is unchanged from the 1995 edition.

A.134 Appendix G Loose measure volumetric capacity of digging elements

Appendix G is unchanged from the 1995 edition.

A.135 Appendix H Typical bulk densities of handled material

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Appendix H is unchanged from the 1995 edition.

A.136 Appendix I Live loads on conveyors

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Appendix I is substantially unchanged from the 1995 edition, excepting for an additional guidance note
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on specifying requirements in the technical specification.
The equations in Clause I.1.3 have been corrected.

A.137 Appendix J Plate buckling

The content of Appendix J was deleted in the 2017 edition and a guidance note provided that refers
designers to the use of modern design Standards that address plate buckling, as described by
Clause 5.4.2.6.
The reasoning behind this revision is that structural design theory and standards will continue to
develop over time, and that this document should refer to use of state of the art, or modern standards
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that address this form of structural behaviour.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
A.138 Appendix K Functions for a design audit engineer during audit of a
structure
This appendix is provided for information only to give an overview of an auditing process to assess
conformity to this document. Requirements for auditing and conformity assessment are not within the
scope of this document.
The use of a design audit engineer can provide additional confidence in the design. The use of design
audit engineers on machines of this type has generally been derived from the regulatory requirements
in the coal mining regions of Germany, whereby “experts” and their certification was required. The use
of a design audit engineer may be an owner/purchaser’s decision or may be a requirement of the state
regulatory authority.
Appendix K provides the generic scope of what a design audit engineer should perform. It includes
tasks during preparation of a technical specification, during the tendering or enquiry process (if so
conducted) and then following placement of a contract.
Where the design audit engineer is not party to tasks prior to placement of a contract, the ability of
the design audit engineer to rectify defects in the requested supply is severely limited, and is likely to
result in additional cost to an owner.

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The extent of the design audit engineers’ functions should be defined by the owner/purchaser, including
the following:
(a) Confirmation of the tasks required as defined by Appendix K.
(b) Whether the design of any critical items of mechanical equipment (i.e. slew bearings, luff
cylinders, etc.) are also required to be subject to design audit.
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(c) The extent of independent analyses and design checks that are required to be conducted.
Purchasers need to be cognisant that the design audit engineer should not replace the function of the
designer.
Owners/purchasers may also require a design audit engineer to be involved in review of the fabrication
and construction process, in varying levels of detail. If this be the case, clear definition of responsibility
is required, as post construction approval of quality is impractical, and quality surveillance can be an

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extensive task, which requires adequate resources.
The technical specification may include directions for the supplier on what information and/or access
to designers and design information to provide the design audit engineer to undertake their tasks.
Consideration of intellectual property issues can affect the process employed.

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It is recommended that, where possible, the design audit engineer should be engaged directly by the
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owner or their representative, to avoid any potential conflicts of interest, and to be independent from
the supplier.

A.139 Appendix L 1995 ultimate limit state factors

Appendix L was a record of the values of the ultimate limit state factors from the 1995 edition of this
document. They should no longer be used. The appendix has been deleted in the 2024 edition.

A.140 Bibliography
Informative references have been relocated from Appendix A in the 1995 edition to the Bibliography
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herein.

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Appendix B
(normative)

Information to be supplied within the technical specification

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This document specifies relevant information that shall be supplied within a technical specification.
Table B.1 provides clause and appendix references and descriptions to indicate information that shall
be nominated in any technical specification in order to allow a machine to be appropriately designed, in
accordance with this document.

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NOTE The technical specification should be prepared by the owner/purchaser and be the technical agreement
between the owner/purchaser and the supplier. In some instances, the purchaser and supplier may jointly
develop the technical specification. The information contained in Table B.1 is the expected minimum degree of
information to be included in the technical specification for use of this document. Additional information for
other discipline design and other operational and maintenance matters will be required for overall supply of a
machine in most circumstances.

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Absence or omission of technical specification requirements does not absolve the designer from their
general duties associated with providing a design that is appropriate, nor from requesting information
from the purchaser in order to achieve an understanding upon which the machine will be operated.
Notwithstanding the technical specification requirements, a designer should provide a design that errs
on the side of conservatism where defined values are not possible to be determined at the design stage.
For unusual operating conditions, site requirements or special purpose machinery, it may be appropriate
to specify further load cases in addition to those identified in Tables 3.7(A) and 3.7(B).
Misapplications in the past of so-called “standard” bulk handling machines have resulted in severe
financial and production losses to the various parties involved. Many of these losses could have been
avoided if technical specifications had been more comprehensive and accurate in respect of local
conditions and the nature of the materials to be dug and handled.
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Whereas it is reasonable to require tenderers to familiarize themselves with site conditions before

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
bidding, it is often impractical and unreasonable to expect tenderers to make comprehensive geological,
geotechnical and other basic studies at their own cost without the certainty of being awarded a contract.
It is also beneficial for owners/purchasers who have prior experience with the type of machine and
operating conditions to clearly describe their requirements to the supplier.
There are a number of options permitted by this document, and these need to be nominated in a
technical specification. Examples of such options are the inclusion, exclusion or modification of certain
load cases, the choice of the structural steel design code to be adopted for acceptability of loadings
and stresses in steel members and fabricated plates, as well as a choice in design philosophy for
accommodating certain special loads, such as burying loads.
NOTE 1 Purchasers of mobile equipment for continuous handling of bulk materials are advised to contract a
design audit engineer to audit the design of the machine that is being ordered.

NOTE 2 Appendix K lists the functions and services that a design audit engineer should be asked to perform.

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Table B.1 — Information to be included in a technical specification

Reference Details
Clause 1.9 Nominate minimum specified rates/anticipated production requirements/performance
characteristics of the machine over the foreseeable service life and the intended mode of
operation.
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Clause 1.10 Nominate where corrosion allowances are to be made in the design and to what degree (i.e.
thickness loss).
Clause 1.11 Nominate the Standards to be used for the design of mechanisms/mechanical equipment,
electrical and controls and any requirements for manufacture, construction, commissioning,
operation and asset management.
Clause 2.1 Nominate whether materials other than those covered by relevant Australian Standards are
acceptable. The technical specification should prohibit the use of structural materials having
an ultimate tensile strength of more than 550 MPa or a yield strength greater than 450 MPa
if they do not satisfy the requirements of Section 2.

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Clause 2.2 Nominate where this clause (2.2) is required to be applied if the specification defines that
high strength materials are required for certain components.
Nominate whether test specimens required by Clause 2.2 are to be kept beyond the
commissioning period and, if so, for what period of time.

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Clause 2.3 Nominate which materials and fabrication Standards the design is to be carried out upon.
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Nominate if alternative construction materials or fabrication Standards are permissible and
if considered necessary which Standards will be accepted.
Nominate the expected procedure for approval to be obtained for alternative Standards.
Nominate the requirements for materials testing where non-Australian Standards materials
are used.
Clause 3.1.1 Nominate whether any deviation of the load cases and magnitudes will be permitted.
Nominate the process for approval upon which a load case is considered to be omitted or
modified.
Clause 3.1.2 Nominate the requirements to provide the type and setting of protective/load limiting
devices and the information required to be provided.
Nominate any special requirements for protective/load limiting devices and controls
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systems associated with structural design.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Nominate the Standard in relation to levels of integrity and reliability of protective/load
limiting devices and controls.
Clause 3.1.3, Nominate the respective bulk densities (γ) for volumetric, power, structural, encrustation
Appendices G, and fatigue design purposes, swell factors (α), dynamic surcharge angles and angles of
H, I repose (if greater than 35 degrees) of each of the materials to be handled.
Nominate which bulk density is to be used for which purpose as necessary.
Nominate whether the “sticky” material definition is applicable for encrustation allowances.
Clause 3.3.2 Nominate the method by which the design mass is required to be estimated and assessed.
Nominate the requirements with regards to submission and traceability of dead load mass
information (both design estimates and as-built measurements and tracking).
Clause 3.3.3 Nominate whether special allowances, other than those nominated in the Standard, are to
be made for encrustation (e.g. for sticky or very sticky materials, where greater than the
nominal 10 % F allowance is required), and whether safety devices may be used in lieu of
accounting for the effect of additional encrustation load at points where high spillage can
occur, and whether “excessive” encrustation is permitted to be considered a “Special” load.
Clauses 3.3.4 State the maximum inclination (angle from horizontal) of the ground or rails on which the
machine will work in normal operations.
Nominate if this inclination is required to be considered for structural design purposes.
For rail-mounted machines, nominate the rail tolerances and the expected support structure
deflections where applicable.

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 DR AS 4324.1:2024 102

Table B.1 (continued)

Reference Details
Clause 3.3.5 Nominate the required design methods for determination of material loads, including
whether the loading is to be calculated based upon conveyor geometry (and/or bucket wheel
output for reclaimers) or whether upstream limitations are permitted to be used.
Nominate a design surcharge angle if 20 degrees is not sufficient for the material being
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handled.
Clause 3.3.6 Nominate allowable (or conversely those not permitted) protective/load limiting devices/
controls to be used for derivation of design loads, and any required modifications to the
minimum design load magnitudes.
Clause 3.3.7, Nominate the type and setting of load limiting devices/settings and any required
Appendices F, G, modifications to the minimum design load magnitudes.
H and I
For the purposes of calculating design digging-resistances for an operating machine, this

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Standard requires that the actual power of the bucket wheel or bucket chain drive motor
and the characteristics of the torque limiting setting/device be taken into account. However,
the required motor power is first to be determined from a consideration of the difficulty of
digging the material and the required material handling rate. The likely digging resistances
can be determined from standard tests, the results of which should be included in the
specification. In particular:

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(a) For excavators, a comprehensive geological and geotechnical survey should be made
AF
of the deposit to be dug. The specification should nominate maximum, minimum and
weighted average digging resistances for each of the materials to be dug, at their
corresponding annual average effective hourly outputs in bank cubic metres.
(b) For reclaimers, the specification should nominate, for each type of material to be
reclaimed, full details of each stockpile. These details should include the ratio of the
bulk density of each material as stacked and compacted (known as SPCM or stock pile
cubic metres) to that as reclaimed (known as RCM or reclaimed cubic metres), the
digging resistance of each material as determined by the standard penetration test
(known as SPT, or other method as has been found to adequately quantify the digging
resistance) and the required annual average effective hourly outputs (in tonnes per
hour).
(c) For stackers, ship-loaders and the like, for each type of material to be handled, the
bulk density (known as LCM or loose cubic metres, which is the same as RCM), the
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corresponding annual average and maximum hourly handling rates in LCM and the

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
corresponding tonnes per hour should be specified.
Clause 3.3.8 If other appropriate information is available regarding the lateral resistance for normal
operation (S), a value higher than that determined from Clause 3.3.8, should be specified.
If the machine is not a bucket wheel reclaimer (i.e. for example a scraper reclaimer) and
Clause 3.3.8.2 is not to be used, nominate the method of calculation to be used.
Nominate the fatigue loading value if the value in Clause 3.3.8.2 is not sufficient.
Nominate the type and setting of load limiting devices/settings and any required
modifications to the minimum design load magnitudes.
Clause 3.3.9 Nominate the required methods for determination of permanent dynamic effects and
the information required to be provided associated with protections/controls to limit
permanent dynamic effects.
Clause 3.3.10 Provide the belt parameters including type, speed and tensions for conveyors that are not
part of the machine supply.
Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.
Nominate if any extreme maximum possible tension design cases require inclusion in the
design.
Clause 3.3.11 Nominate which rotating pins or pivot points are required to be considered.
Nominate the minimum friction coefficients for specialized proprietary bearings.
Clause 3.3.12 Nominate the appropriate friction factor for crawler-mounted machines.

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 103 DR AS 4324.1:2024

Table B.1 (continued)

Reference Details
Clause 3.4.2 Nominate the required wind speeds for operation, Wo, relocation, Wr, and if the design
requires, for stranded from tie-down, Ws.
Nominate any special loading or restraint conditions for the cases Wr and Ws.
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Nominate whether wind tunnel testing or computational fluid dynamics techniques are
acceptable for the determination of wind loading.
Specify any special requirements for design associated with wind loading for both structural
and mechanical design (i.e. design loading for power calculations).
Nominate the level of redundancy of long travel and slew drive systems.
Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.

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Clause 3.4.3 Nominate the expected service-life temperature range, including any special temperature
considerations.
Clause 3.4.4 Nominate the type and setting of load limiting devices/settings and any required
modifications to the minimum design load magnitudes.
Nominate allowable (or conversely those not permitted) protective/load limiting devices/

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controls. AF
Clause 3.4.5 Nominate the type and setting of load limiting devices/settings and any required
modifications to the minimum design load magnitudes.
If not a slewing machine, nominate the method of calculation of lateral load if Clause 3.4.5.2
is not to be used.
Nominate allowable (or conversely those not permitted) protective/load limiting devices/
controls.
Clause 3.4.6 Specify the requirements for a skew control system, if applicable.
Specify the rail type and alignment tolerances applicable.
Specify the number of drives that are to be considered out-of-service for calculations of the
drive force centroid.
Clause 3.4.7 Specify any special requirements in relation to “emergency stop” type situations to be
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considered in the design.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Nominate the extent to which emergency stop events are to be accounted for in the
determination of the stress spectrum for the purposes of fatigue design.
Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.
Clause 3.4.8 Nominate whether an allowance for loading due to snow, ice and hail to be made, and the
basis for determining the magnitude of such loading, including if consideration of locations
other than final siting is required.
Clause 3.4.9 Nominate whether any proportion of the accessway loads (P) calculated in accordance with
Clause 3.4.9 needs to be taken into account for the stability assessment, or as other than a
locally acting load on the structure for determining strength of the structure.
Clause 3.4.10 Nominate the detail design requirements for these temporary conditions, including the
extent to which calculations and design auditing will be conducted.
Nominate the wind speed to be used for design if WW is not to used.
Clause 3.4.11 Nominate the detail design requirements for these temporary conditions, including the
extent to which calculations and design auditing will be conducted.
Nominate the wind speed to be used for design if WW is not to used.
Nominate the detail requirements for the design of jacking points, including the required
tolerances/allowances for variation in (as-built) balance and centre of gravity parameters.

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 DR AS 4324.1:2024 104

Table B.1 (continued)

Reference Details
Clause 3.4.12 State the maximum inclination (angle from horizontal) of the ground or rails on which the
machine will work in abnormal operations.
Nominate if this inclination is required to be considered for structural design purposes.
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Clause 3.5.2, Nominate whether there are circumstances that justify the machine to be designed
3.5.2.1, 3.5.2.2, without taking into account the full extent of the requirements for grounding contained in
3.5.2.3, 3.5.2.4 Clause 3.5.2.
Nominate if grounding of the counterweight boom is to be considered by the design.
Nominate what additional protection, if any, is to be provided against the possibility of
failure of protective devices to prevent full grounding of a bucket wheel or of a boom.
Stockpile, wharf, vessel and other parameters affecting the operational envelope of the
machine should be nominated, with particular regard to the potential of these interfaces to

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cause a “mid-point” boom or counterweight boom grounding condition.
Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.
Clause 3.5.3 For rail-mounted machines, nominate acceptable maximum and average wheel loadings for
normal working and extreme loading situations.

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Clause 3.5.4

Clause 3.5.5
AF
Nominate any rail tolerances that the machine design should adhere to.
For crawler-mounted machines, nominate maximum and average crawler ground-pressures
for normal working and extreme loading situations, and the basis for calculating ground
pressure where this may differ from Clause 3.5.4.
Nominate any specific requirements that are to be considered in the design for blocked
chutes and hoppers.
Nominate where upstream conveyor run-on need not be entirely retained within the
machine transfer chutes.
Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.
Clause 3.5.6 Nominate whether any limitations to the load are allowable, or whether the full cross-
section is to be considered.
DR
Nominate the type and setting of load-limiting devices, settings and any required

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
modifications to the minimum design load magnitudes.
Clause 3.5.7 Nominate whether any limitations/modifications to the load are allowable, including
whether the 300 mm stopping distance may be altered.
Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.
Clause 3.5.8 Nominate the extent to which this load requires consideration (for non-slewing and fixed
boom configurations).
Nominate if this load case is to consider collision at locations other than the end of the boom.
Nominate whether there is to be an interlock to prevent or limit simultaneous travel and
slew motions.
Nominate if a stopping distance of greater than, or less than, 300 mm is to be used design.
Nominate if this load case is to be applied to the counterweight boom.
Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.

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Table B.1 (continued)

Reference Details
Clause 3.5.9 Nominate whether this load requires consideration (for non-slewing and fixed boom
configurations that are unable to collide end on in accordance with Clause 3.5.9).
Nominate whether there is to be an interlock to prevent or limit simultaneous travel and
slew motions, or long travel motion with the boom outside of the conveyor protection
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envelope.
Nominate if this load case is to be applied to the counterweight boom.
Nominate if a stopping distance of greater than, or less than, 300 mm is to be used for design.
Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.
Clause 3.5.10 Nominate any requirements in relation to machine configuration and location for loading of
this case.

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Nominate whether wind tunnel testing or computational fluid dynamics techniques are
acceptable for determination of wind loading.
Specify any special requirements for design associated with wind loading for both structural
and mechanical design including the minimum wind speed below which the machine is to
satisfy the resistance against drifting requirements.

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Clause 3.5.11
AF
Nominate whether a fully redundant cut-out system is to be provided to shut down the travel
drive as the machine approaches the buffers.
Nominate any special considerations required such as dual stage or dual buffers.
Nominate the required maximum and minimum stopping distances permissible.
Nominate the design and checking responsibilities and boundaries for the fixed buffer
structures.
Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.
Clause 3.5.12 Nominate the relevant parameters for consideration of loading to AS 1170.4.
Clause 3.5.13 If the machine is an excavator or reclaimer, nominate whether a burying design load case is
to be considered, and the basis for determining the design load.
DR
Nominate what factors of safety are required for strength and stability in accordance with a

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
permissible stress design assessment.
Nominate the extent to which other loads are to be considered in combination with the
burying load, including the UU, VV and FF loads, but also preventing a duplication of loading.
Nominate whether localized damage to secondary structures is permissible in consideration
of the burying condition.
The following load case description is indicative of the type of load case situation that a
technical specification might include in order to provide some protection against a burying
accident:
With the bottom of the bucket wheel at bench level, base the calculated load due to burying
the bucket wheel on the volume of material slumped over and supported on the bucket wheel
head vertically above walkways, chutes and drives at the sides of the wheel, and sloping
down from the top of the bucket wheel body at the angle of repose of the dug material. Base
the calculated mass of this volume on the largest bulk density (loose) of the dug material,
and take this to be a force acting downward through the centre of the wheel. Note that
the blocked chute volume and its associated force (VV) would become part of the load so
calculated for ZZ.
Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.

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Table B.1 (continued)

Reference Details
Clause 3.5.14 Nominate the detail requirements for consideration (or mitigation) of this load case and the
necessary proving calculations to be provided.
Nominate which parts shall be included as lost for design purposes.
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Nominate how resultant dynamic amplification of loads due to the sudden loss of mass
should be considered.
Clause 3.5.15 Nominate which rotating pins or pivot points are specifically required to be considered.
Clause 3.5.16 Nominate any extra loads (EL) to be included in the design load case combinations and how
they should be combined with other loads. In particular, nominate whether failure of safety
devices is to be considered and how the resulting loads are to be determined.
Nominate what factors of safety are required for strength and stability in accordance with a
permissible stress design assessment.

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Nominate the type and setting of load-limiting devices, settings and any required
modifications to the minimum design load magnitudes.
Clause 3.6 Nominate any additional fatigue loadings and any alternative provisions for determining
fatigue loads.
Nominate any changes to the modifying factors CF, C U, CS

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Clause 3.6.3 to
3.6.10
Clause 3.7,
AF
If available, nominate operating characteristics and production parameters to enable
calculation of the stress range spectrum.
Specify to what extent each load is to be treated as a fatigue load (i.e. as defined in the
Standard or modified).
Nominate any applicable changes, modifications, additions or allowable omissions from the
Tables 3.7(A) load combinations.
or (B)
Clause 4.1 Nominate any considerations with regards to preferred configurations for relevant loading
conditions. Nominate the minimum stability ratio for LCIII/10.
Clause 4.2 Nominate any special requirements for assessment of drifting; particularly with regards to
drive power and drive braking. Nominate any special requirements associated with Ws.
Clause 5.1 Define any special load case/combination considerations. Nominate whether the limit-state-
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design method or the permissible stress design method is to be used for strength design.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Clause 5.2 Nominate the fatigue design life to be used for design purposes. This may include a time-
based value or an operating spectrum.
Clause 5.4.1 Nominate whether the limit-state-design method or the permissible stress design method is
to be used for strength design.
Nominate whether any specific design provisions from alternative Standards are to be used.
Irrespective of which approach is specified for assessing strength (i.e. resistance to yielding
or buckling), Clause 5.5 requires that the design for fatigue conform to AS 4100. Specify if
alternative Standards may be used for more rigorous analyses and assessment of the fatigue
design (also see Clause 5.5).
Specify the minimum extent to which the structure is to be subject to a finite element
analysis to verify acceptability of stresses; and the minimum extent to which independent
verification by finite element analysis will be undertaken by the independent design audit
engineer.
Clause 5.4.2 Nominate any special requirements over and above this Standard for use of the permissible
stress design method.
Clause 5.4.2.6 Nominate the requirements with regards to any minimum buckling (eigen) factor values
and/or the requirement to agree on a design basis with the audit engineer.
Clause 5.4.3 Nominate any special requirements over and above this Standard for use of the limit state
design method.
Clause 5.4.3.6 Nominate the requirements with regards to any minimum buckling (eigen) factor values
and/or the requirement to agree on a design basis with the audit engineer.

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Table B.1 (continued)

Reference Details
Clause 5.4.4 Nominate any specific requirements in relation to serviceability criteria.
Clause 5.5 Nominate any special requirements for fatigue design. Nominate where redundancy
provisions are required to be applied to the fatigue design, or a lower fatigue strength used.
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Clause 5.7 Nominate the items that will be subject to the rules of Clause 5.7.
Clause 5.7.1 Nominate any special requirements for rope, strap, stay and hydraulic cylinder design.
Clause 5.7.2 Nominate any special requirements for factors to be considered.
Clause 5.7.3 Nominate any special requirements for duplication associated with operators cabins.
Clause 5.7.4 Nominate any special requirements for duplication of ropes, straps, stays and hydraulic
cylinders.
Clause 5.7.5 Nominate any special requirements for safety factors.

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Clause 5.7.6 Nominate any special requirements for chains and racks.
Nominate whether Clauses 5.7.1 to 5.7.5 apply.
Clause 5.7.7 Nominate any special requirements for hydraulic cylinders.
Clause 5.8 Nominate any special requirements for slewing race catch hooks.
Clause 5.9 Nominate the extent of verification required to determine actual machine mass and its

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Clause 5.10
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distribution as required by Clause 5.9.
For machines with an under-carriage and a slewable or luffable upper structure,
determination of the upper structure mass and its distribution may be necessary in order to
confirm the acceptability of the stressing and the stability properties.
Nominate requirements for lifting items.
Clause 6.1 Nominate the extent to which loading from Clause 3.7 is applied to ancillary structures.
Clause 6.2 Nominate the extent to which loading from Clause 3.7 is applied to supporting structures
and rails.
Clause 6.3 Nominate the extent to which loading from Clause 3.7 is applied to tie-down and restraints.
Clause 6.4 Nominate the extent to which loading from Clause 3.7 is applied to major maintenance
works.
Other Geometrical requirements or limitations to be provided—i.e. stockpile layouts, berth
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layouts, etc.

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024

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 PUBLIC COMMENTING DRAFT DR AS 4324.1:2024

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108

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Appendix C
(informative)

AF
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109

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Appendix D
(informative)

AF
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© Standards Australia Limited 2024

DR AS 4324.1:2024

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 DR AS 4324.1:2024 110

Appendix E
(informative)

Typical types of mobile continuous bulk handling equipment

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B u c ket wheel b o o m

D i s c h ar g e b o o m

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B u c ket wheel

C ounter weight b o o m

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Crawle r
AF
(a) C o m p a c t t y p e
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Crawle r s
B u c ket lad d er S l ewa b l e d i s c h a r g e c o nveyor

Pla n i n g p i e c e

(b) N o n - s l ew ing bucket c hain t y p e

Figure E.1 — Bucket wheel excavators and bucket chain excavators — Crawler mounted

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 111 DR AS 4324.1:2024

S t o c k p i le
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B u c ket wheel bri d g e

Rail

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B u c ket wheel

(a) Bri d g e - m o u nte d bu c ket wheel rec l a i m er

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AF
S t o c k p i le
DR
oo m
el b
whe

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ket
Buc
Rail

Yar d c o nveyor

(b) Rail - m o u nte d bu c ket wheel rec l a i m er

Figure E.2 — Reclaimers

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 DR AS 4324.1:2024 112

B u c ket wheel unit

R i s i n g c o nveyor

Stacking
Ya r d
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conv
eyor
belt

ing
laim
Rec
Tr i p p er

NOTE The travel gear of the bucket wheel unit has been drawn at 90° to the travel gear of the rising conveyor
and the tripper, so that both stacking and reclaiming operations are depicted on the one diagram.

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Figure E.3 — Stacker-reclaimer

Stac ker

Tr i p p er

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AF Connec
ting bri
dge

(a) Crawl er- m ounted tripper and craw l er- m ounted stac ker wit h h ig h balla st b o o m

ridg e Stac ker

Tr i p p er ec ting b
Conn
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
(b) Rail - m o u nte d tr i p p er and c r aw l er- m ounted stac ker w i t h l ow balla st b o o m

Stac ker

Tr i p p er
br i d g e
C o n n e c t i ng

(c) Rail - m o u nte d tr i p p er and c r awl er- m ounted stac ker wit h h ig h balla st b o o m

Figure E.4 — Tripper-stackers

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 113 DR AS 4324.1:2024

Por t al frame
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S t o c k p i le

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S c r a p er c o nveyor

(a) Po r t a l s c r a p er- re c l a i m er

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H arrow
AF S t o c k p i le

Bridge

Rail S c r a p er c o nveyor Rail

DR
Yar d c o nveyor

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
(b) Br i d g e t y p e s c r a p er c o nveyor

Figure E.5 — Scraper-reclaimers

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 DR AS 4324.1:2024 114

Stac ker b o o m C o nveyor

C o u nter we i g ht

Yar d c o nveyor
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S t o c k p i le Rail

(a) Rail - m o u nte d s i n g l e b o o m stac ker

Stac ker b o o m C o nveyor Stac ker b o o m

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Yar d c o nveyor

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S t o c k p i le AF Rail

(b) Rail - m o u nte d t w in boom stacker

S to c k p i l e

C ounter weight b o o m

C o nveyor
Stac ker b o o m
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Yar d c o nveyor
S t o c k p i le Rail

(c) Rail - m o u nte d stac ker wit h s l ew i n g b o o m

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 115 DR AS 4324.1:2024

S h u t t l e c o nveyor
B e l t c o nveyor
Bridge

Pi vot
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Rail
S t o c k p i le

(d) Circular stac ker w i t h rever s i b l e s h u t t l e c o nveyor

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Sta
c ke
r bo
o m
S t o c k p i le

Rail Pi vot

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AF (e) R ad i a l (b o o m) stac ker

Figure E.6 — Stackers

DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Figure E.7 — Belt wagon — Crawler mounted type

Lu f fing winch hous e

C o n t r o l c a b in

Tr i p p er
Boom Te l e s c o p i c s p o u t
(o ptional)

C o nveyor g a l ler y
Tr im m er (o pt i o n a l)

Bogies

NOTE A travelling gantry type is illustrated. Other types include linear, single or double quadrant, and slewing
bridge.

Figure E.8 — Ship loaders

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 DR AS 4324.1:2024 116

Boom

C ounter weight
Re c l a i m er, t y p i c a l ly
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b u c ket wheel, buc ket C o n t r o l c a b in S l ew r i n g

c hain or auger

C o nveyor, u nd er g r o u n d in t h i s
c a s e to ke e p whar f d e c k c l ear

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NOTE A travelling gantry type is illustrated. Other types include linear, single or double quadrant, and slewing
bridge.

Figure E.9 — Continuous ship unloaders

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AF
DR

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© Standards Australia Limited 2024

 117 DR AS 4324.1:2024
PUBLIC COMMENTING DRAFT

(i) S h own for tr ansver se trave l

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AF
(ii) S h own for l o n g i t u d i n a l trave l

(a) C o nveyor dri ve w i t h c r aw l er- m ounted transpor ter

DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
(b) C o nveyor dri ve unit w i t h hydrauli c walk ing foot

Figure E.10 — Conveyor drive heads and their transporters

© Standards Australia Limited 2024

 DR AS 4324.1:2024 118

Appendix F
(informative)

Basic digging parameters for bucket wheel machines

PUBLIC COMMENTING DRAFT

F.1 Quantity symbols for Appendix F

The quantity symbols used in this appendix are not consistent with those used throughout the rest of
this document. Appendix D does not apply to this appendix. The quantity symbols used in Appendix F
are given in Table F.1.

T
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AF
DR

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© Standards Australia Limited 2024

 119 DR AS 4324.1:2024

Table F.1 — Quantity symbols used in Appendix F

Quantity symbol Quantity
A Area of slice in vertical plane
C Length of chord of slice of material
D Diameter of bucket wheel at cutting circle
PUBLIC COMMENTING DRAFT

G Centroid of A
g Radial distance of G from centre of bucket wheel
H Height of block of material
h Height of terrace
L Length of block
QA Annual production during normal operation
Qe

T
Annual average effective output during normal operation, in an hourly rate
Qi Instantaneous output of machine, in an hourly rate
Rg Horizontal radius of centroid G from machine slew axis
Rm Mean value of Rg
rh Horizontal radius of centre of bucket wheel from machine slew axis

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S
s
T
Tθ
Vc
AF
Width of block
Discharge rate, in buckets per minute
Thickness of segment at line of advance
Thickness of segment at slew angle of θ
Cutting speed
Vs Slewing speed at line of advance
Vsθ Slewing speed at angle
W Width of shape cut by bucket
xs Horizontal coordinate of G in firm-standing material

xf Horizontal coordinate of G in free-flowing material

DR
Vertical coordinate of G in firm-standing material

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
ys
yf Vertical coordinate of G in free-flowing material

θ Angle of slew
θw Angle of run-out wedge
ϕ Vertical angle of cut of bucket wheel, in radians
Ψ Angle of repose of free-flowing material, in radians

F.2 Basics for calculations

Figures F.1 to F.4 depict some basics of bucket wheel operations that can affect a structural design.
At the start of a project to design a bucket wheel excavator or a bucket wheel reclaimer, the basic layout
of the machine may be developed from the following parameters:
(a) Maximum digging height (H).
(b) Front batter angle (commonly known as FBA).
(c) Side batter angle (commonly known as SBA).
(d) Angle of repose (Ψ).

© Standards Australia Limited 2024

 DR AS 4324.1:2024 120

(e) Annual production of the machine and its transport (delivery) system during normal operation
(QA). For bucket wheel excavators, QA is given in bank cubic metres (commonly known as
BCM) of ore and waste. For bucket wheel reclaimers, QA is given in tonnes, or stockpile cubic
metres (commonly known as SPCM) for each type of material.
(f) Annual average effective hourly output under normal operation conditions (Qe), given in bank
cubic metres, tonnes, or stockpile cubic metres. Typical bulk densities are given in Appendix H.
PUBLIC COMMENTING DRAFT

(g) Guaranteed hourly output during normal operation, given in bank cubic metres, stockpile
cubic metres, or tonnes.
Normal operation is considered to be that of the whole system through complete and successive blocks
of material with the delivery plant able to convey the material at the various rates from the bucket
wheel excavator or bucket wheel reclaimer.
The above parameters can be used to determine the diameter of the bucket wheel, the geometry of

T
the bucket wheel head, the basic layout of the machine, and the proportions of the operating block, as
shown in Figures F.1 and F.2.
The instantaneous output of the machine (Qi) can then be determined, which is the nominal rate at
which the machine is able to dig terraces, as shown in Figures F.1 to F.4.

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To allow for variations of the instantaneous output of a machine (Qi), caused by moving between the
stages of digging (such as moving between terraces and moving to start another block), the required
digging rate (Qi) needs to be determined (see Figure F.1), as follows:
Volume of block of material = H × S × L
Volume of terrace of material = h × S × L
Volume of segment (i.e. slice) of material = h × S × T (see Figure F.1)
Volume of material cut by a bucket at an angle θ of 0° = h × T × W
= h × T × Vs/s
Volume of material cut by a bucket at an angle θ = h × Tθ × Vsθ/s
DR

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Tθ =   T cos θ
Qi at θ of 0° = h × T × Vs × 60, in bank cubic metres per hour
Qi at θ° = h × Tcosθ × Vsθ × 60, in bank cubic metres per hour
For a steady Qi, Vsθ should be controlled at Vs/cosθ.
From experience with many machines over a long time —
For bucket wheel excavators:
Qe = Qi / (1.5 to 1.9, depending on mining conditions)
For bucket wheel reclaimers:
Qe = Qi / (1.6 to 2.2, depending on reclaiming conditions)
QA = Qe / (system annual hours at Qe in normal operation)
Calculate the radius (Rg) to slice centroid (G) from Figure F3. Then, determine the required slew speeds
Vs and Vsθ to give a steady value of the required Qi.
Figure F.1 shows the shape cut by each bucket. This may be used to get the maximum combined radial
area of all buckets cutting simultaneously. This sum can then be used with the spectrum of digging

© Standards Australia Limited 2024

 121 DR AS 4324.1:2024

resistances of materials to be dug, and bucket wheel cutting speeds Vc, to evaluate bucket wheel drive
power, and from these and the factors in Clauses 3.3.7 and 3.6.5, the forces U and +/0C U.U can be derived.
Coordinates for slice centroid (G):
For Figure F.3:
PUBLIC COMMENTING DRAFT

 sin 2  T
D   
xs   
  
 2 1  cos   2 4  2

ys = h / 2

For Figure F.4:

T
2D sin4 
xf 

3 2  sin 2 
2D cos sin3 
yf 
 

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3 2  sin 2 AF
C  h cosec 
 D sin


A  D2 2  sin 2 / 8 
g = C 3 / 12 A
DR

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© Standards Australia Limited 2024

 PUBLIC COMMENTING DRAFT

W
Lin

h
e
angle (S BA)
S i d e bat ter
H

of
h
DR AS 4324.1:2024

ad

G
v

VIE W A
T
an
ce
θ
=

Rg

© Standards Australia Limited 2024

Sl
0°

ew
A

Tθ
T

S
T
122

VIE W B
DR L
J

h
B

AF
Figure F.1 — Bucket wheel excavator — Typical terracing cut
θw
L

VIE W C
T
T

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 PUBLIC COMMENTING DRAFT

ψ
B at ter angle (s h ow n
steeper than actual)
S EC T I O N A L V I E W B O F C U T S

S
123

VIE W A
DR
+ H

h
S
AF
+ 0.0
A
θ

T
Figure F.2 — Bucket wheel reclaimer — Firm standing stockpile
Line of advan c e
θ = 0°

© Standards Australia Limited 2024

DR AS 4324.1:2024

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 PUBLIC COMMENTING DRAFT DR AS 4324.1:2024

S l ew a x i s

© Standards Australia Limited 2024

φ
δφ

x
xs

Rg
rh

Rm
124

δG
DR
y
G

δy

Figure F.3 — Bucket wheel reclaimer — Slice centroid

AF
xs
φ
ys

G
h

2
T
+ H
x
T
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Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
 PUBLIC COMMENTING DRAFT
+ H

+ 0.0
ψ
Flow area
125

DR h

yf
2

g
G
C

xf
ψ

AF A
D

Figure F.4 — Bucket wheel excavator — Free flowing stockpile

© Standards Australia Limited 2024

DR AS 4324.1:2024

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 DR AS 4324.1:2024 126

Appendix G
(normative)

Loose measure volumetric capacity of digging elements

PUBLIC COMMENTING DRAFT

G.1 General
When converting from volume of output from bank to volume of resultant loose material, the largest
possible swell factor shall be used. The swell factor (α) is the ratio of loose volumetric measure to initial
bank volumetric measure. See Appendix H for typical values.

T
G.2 Bucket wheels
For bucket wheels as shown in Figure G.1, the carrying volume shall be the total of the following:

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(a) Bucket volume (I1) — the struck volume of the bucket outside the body of the wheel and
AF
excluding teeth.
(b) Cell or ring space volume (I2):
(i) Cell-type bucket wheels — the volume of the cell in the bucket wheel body.
(ii) Cell-less bucket wheels — the ring space of the cell-less wheel (i.e. the cavity radially
between the base of the bucket and the ring chute that seals the buckets during
digging).
(c) Overfill volume (O) — the maximum volume which can be heaped on top of I1 and I2 during
digging but excluding spill between completion of digging and emptying.
In Figure G.1, Ψ is the angle of repose of the material as dug.
DR

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
G.3 Bucket chains
For bucket chains as shown in Figure G.2, the carrying volume shall be the total of the following:
(a) Bucket volume (I1) — the struck volume of the bucket excluding teeth.
(b) Cell or ring space volume is not applicable.
(c) Overfill (O) — the maximum volume that can be heaped on top of I1 and be pushed ahead of
the bucket as it moves up the chute.

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 127 DR AS 4324.1:2024

B u c ket ,1 ,1 B u c ket

,2 ,2 Ring
space
C e ll
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(a) C e ll t y p e buc ket wheel (b) C e l l - l e s s t y p e b uc ket wheel

T
O

ȥ B u c ket wheel radii

0°

H o r izo nt al 0° M ȥ

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A

,1
,2
AF B u c ket

VIE W A

(c) Det a i ls of vo l u m e s

Figure G.1 — Carrying volumes of a bucket on a bucket wheel

DR

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© Standards Australia Limited 2024

 PUBLIC COMMENTING DRAFT DR AS 4324.1:2024

© Standards Australia Limited 2024

S e e Det a i l A

DE TAIL A
O
128

,1
DR
Chute
Driving tumble r

Cr u s h er or imp a c t t a b le

AF D i s t r i b utor belt

Figure G.2 — Carrying volumes of a bucket on a bucket chain

T
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 129 DR AS 4324.1:2024

Appendix H
(informative)

Typical bulk densities of handled material

PUBLIC COMMENTING DRAFT

The values for bulk densities and swell factors used for design purposes should be determined from
experimental tests on sample material or estimated using experience from handling comparable
materials at the same or a similar operating location. Purchasers of mining equipment should make
themselves aware of the significance of variability of the actual values, and ensure that the values
used for design purposes will adequately satisfy the required performance capacity of the machine
during use. The maximum digging capacity of a bucket wheel needs to be considerably greater than the

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nominal capacity required for the rest of the machine, because of the digging efficiency of the bucket
wheel and the overall availability of the machine due to breakdowns and maintenance. Also, the peak
loading on the conveyor belts may be considerably greater than that during the machine’s nominal
rated throughput.
Bulk density refers to the density of the loose material being handled after it has been cut from a bank

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AF
or a stockpile by an excavator or a reclaimer. This density should be distinguished from the density
of uncut material, which is greater by the swell factor. In most applications, the bulk density of the
handled material will vary and suitable values for use in design should preferably be determined from
tests on the material in question.
In coal terminals, bulk densities can be significantly affected by the extent of compaction from
bulldozing during build-up of the stockpile.
Typical densities of commonly handled materials are given in Table H.1, for guidance purposes. They
may be used at the preliminary design stage, or where detailed test results are not available during the
design stage.

Table H.1 — Typical bulk densities and swell factors of some commonly handled materials
DR
Bulk density (γ) as handled

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
Typical swell factor
Material (i.e. loose), t/m3
Strength calculations Volumetric calculations (α)
Overburden 1.8 1.3 1.1–1.6
Coal—
lignite 0.85 0.75 1.5
bituminous 1.2 1.0 1.2–1.5
anthracite 1.4 1.2 1.1–1.3
Bauxite 1.45 1.3 —
Oil and tar 1.6 1.3 —
sands
Iron ore 3.2 1.6 —

© Standards Australia Limited 2024

 DR AS 4324.1:2024 130

Appendix I
(normative)

Live loads on conveyors

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I.1 Nominal capacities of conveyors

I.1.1 Units with no built-in digging device
NOTE 1 Clause I.1.3 may apply to units that travel while operating and are connected to a yard conveyor. The

T
requirements of the technical specification apply in relation to using the cross-sectional area for calculation of
material live loads unless a lesser value is agreed.

The main live load (F) and the special live load (FF) (each in tonnes per metre) shall be calculated using
the following equations:

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F  Sx   AF
FF  S m  

where

Sx = the conveyor cross-sectional area, in square metres, as defined in Clause I.2

Sm = the maximum cross-sectional area of material on conveyor, in square metres, as defined in

Clause I.3

Y = the maximum bulk density of material, in tonne per cubic metre as loaded onto the
DR
conveyor, as specified in the technical specification

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
NOTE 2 For determination of belt width (B), see Clause I.2. The minimum value of γ should be used.

Where the carrying capacity of upstream conveyors is lower than that of downstream conveyors, the
downstream conveyors may be deemed to have the same capacity as the lowest capacity upstream
conveyor, only if defined in the technical specification. The main load (F) for these conveyors shall be
calculated using the following equation:

Vo
F  Fo 
Vc
where

Fo = main load on the lowest carrying capacity upstream conveyor, in tonnes per metre

Vo = belt speed of the lowest carrying capacity upstream conveyor, in metres per second

Vc = belt speed of the conveyor, in metres per second

Where the carrying capacity of a conveyor is limited by an automatic device, the load on that conveyor
and all downstream conveyors may be assumed to be that which results from the capacity thus limited,
only if defined in the technical specification and provided that in the event of malfunction of the device,
all conveyors will automatically be stopped until the fault in the device is corrected.

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 131 DR AS 4324.1:2024

I.1.2 Units fitted with digging or reclaiming device

The main load (F) and the special load (FF) (each in tonnes per metre) shall be calculated using the
following equation:

Qth
F
PUBLIC COMMENTING DRAFT

Vc  3600

Qths
FF 
Vc  3600
where

Qth = the theoretical output, in tonne per hour, calculated using

T
Qth = 1.5  I1    smin  60

or

 

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Qth = 1.3  I1  I2    smin  60
AF
The greater of the two shall apply.

Qths = the theoretical output, in tonne per hour, calculated using

Qths = 1.5  I1    smax  60

or

Qth =  
1.3  I1  I2    smax  60

The greater of the two shall apply.

DR
I1 = the bucket struck volume, in cubic metres, as defined in Appendix G

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
I2 = the bucket wheel ring space, in cubic metres, as defined in Appendix G

smin = the minimum wheel speed in number of bucket discharges per minute

smax = the maximum wheel speed in number of bucket discharges per minute

γ = the material bulk density of the material as per Clause I.1.1

If the value of F and FF, so derived, is less than F and FF from Clause I.1.1, then the values from Clause I.1.1
shall be used.

I.1.3 Units that are loaded by and travel during operation with a yard conveyor or the
like
The main load (F) and the special load (FF) (each in tonnes per metre) shall be calculated using the
following equations:


F  S x    V0  Vt / Vc 
 
FF  S m    V0  Vt / Vc (subject to a maximum of FF as defined by Clause I.1.1)
where

© Standards Australia Limited 2024

 DR AS 4324.1:2024 132

Sx = the cross-sectional area of the yard conveyor, in square metres, as defined in Clause I.1

Sm = the maximum cross-sectional area of the yard conveyor, in square metres, as defined in
Clause I.2

γ = the material bulk density as per Clause I.1.1

PUBLIC COMMENTING DRAFT

V0 = the yard conveyor belt speed in metres per second

Vc = the unit conveyor belt speed in metres per second

Vt = the unit travel speed in metres per second

I.2 Load cross-sectional area (S) for main live load (F)

T
Symbols:

B = total width of belt in metres as shown in Figures I.1 to I.5

bu = useable belt width, in metres

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Sx
=

=
0.9B – 0.05, where B < 2.0 m
AF
B – 0.25, where B ≥ than 2.0 m

total cross-sectional area of material on the belt, in square metres

S1, S2 = cross-sectional areas of portions of material on the belt, in square metres

and S3

ρ = surcharge angle in degrees (minimum value to be used is 20°)

λ, λ1 = troughing angle, in degrees

and λ2
DR
For conveyors with suspended idlers, the troughing angles shall be those when the belt has a total

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
cross-sectional area corresponding to Figures I.2 to I.5.

l 1, l 2 = effective roller lengths, in metres (refer to Figures I.3 to I.6)

and l m

For Clause 3.3.5, the cross-section of material handled by horizontal belt conveyors with carrying idlers
shall be as derived in accordance with Figures I.1 to I.5.
B
bu
ρ

Sx

bu2  2 
Sx    sin2 
8 sin   57.3
2

Figure I.1 — Cross-sectional area of material on a flat belt

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 133 DR AS 4324.1:2024

B
bu
PUBLIC COMMENTING DRAFT

ρ
S1

S2

T
bu2 cos2   2 
S1    sin2 
8 sin2   57.3 
bu2

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S2  cos2  tan  AF
4
S x  S1  S 2

bu2 cos2   1  2  
    sin2   tan  
4  2 sin2   57.3  
   
Figure I.2 — Cross-sectional area of material on a two-roller belt
DR

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© Standards Australia Limited 2024

 DR AS 4324.1:2024 134
PUBLIC COMMENTING DRAFT

B
bu

ρ
S1

T
S2

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λ AF Im

c2  2 
S1    sin2 
8 sin2   57.3 

S2 
4

1 2 2

c  lm tan 

S x  S1  S 2
DR
where

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
 
c  lm  bu  lm cos 

Figure I.3 — Cross-sectional area of material on a three-roller belt

© Standards Australia Limited 2024

 135 DR AS 4324.1:2024

B
PUBLIC COMMENTING DRAFT

bu
c1
c2
ρ

S1

T
S2

λ2
I2 S3

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AF λ1
I1

c12 2 
S1    sin2 
8 sin   57.3
2


S2  
1 2 2

c  c tan 2
4 1 2
1
S3  l12 sin2 1
2
S x  S1  S 2  S3
DR

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where

 
c1  2l1 cos 1  bu  2l1 cos 2

c2  2l1 cos 1

Figure I.4 — Cross-sectional area of material on a four-roller belt

© Standards Australia Limited 2024

 DR AS 4324.1:2024 136

bu
PUBLIC COMMENTING DRAFT

c1
c2
ρ

S1

S2

T
λ2
I2 S3

λ1

I1

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S1 
c12  2

8 sin2   57.3

 sin2 

AF Im

S2  
1 2 2

c  c tan 2
4 1 2
1

S3  c22  lm
4
2

tan 1

S x  S1  S 2  S3
where
DR

 

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
c1  lm  2l1 cos 1  bu  lm  2li cos 2

c2  lm  2l1 cos 1

Figure I.5 — Cross-sectional area of material on a five-roller belt

I.3 Maximum load cross-sectional area (Sm) for special load (FF)
For calculations of the areas in Figure I.6, symbols as in Clause I.2 apply plus the following:

CB = chord length of surcharge portion above maximum belt width (B)

[see Figure I.6(a)]

Ch = height of belt conveyor crowding board

CW = chord length of surcharge portion above crowding boards [i.e. width between crowding
boards, see Figure I.6(b)]

Ψ = angle of repose of conveyed material, in degrees

Minimum value to be used is 35 degrees unless otherwise prescribed in the technical specification.

© Standards Australia Limited 2024

 137 DR AS 4324.1:2024

B
CB
PUBLIC COMMENTING DRAFT

ψ
S 1m

S 2m

T
Im

(a) Belt without crowding board or skirt plate

CB

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AF CW
ψ
S 1B m
Ch S 3Bm

S 2Bm

Im
DR
B

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
(b) Belt with partial height crowding board
Cw
ψ
S 1B m

Ch S 3Bm

S 2Bm
λ

Im

(c) Belt with full height crowding board

S2m  
1 2 2

C  l tan 
4 B m

© Standards Australia Limited 2024

 DR AS 4324.1:2024 138

CB2  2 
S 1m    sin2 
8 sin   57.3
2

S m  S2m  S1m
where
PUBLIC COMMENTING DRAFT


CB  lm  B  lm cos  
CW
2
 2 
S1Bm    sin2 
8 sin   57.3
2


S2Bm 
1 2 2

C  l tan  

T
4 B m
S3Bm  C W  C h

S m  S1Bm  S2Bm  S3Bm

where

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S1Bm 

CB  lm  B  lm cos 

CW
2
 2



8 sin2   57.3

 sin2 

AF
S2Bm 
1 2
4

C W  lm
2
tan  
S3Bm  C W  C h

S m  S1Bm  S2Bm  S3Bm

DR
Figure I.6 — Typical maximum cross-sections

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024

© Standards Australia Limited 2024

 139 DR AS 4324.1:2024

Appendix J
(informative)

Plate buckling
PUBLIC COMMENTING DRAFT

Assessment of plate or shell buckling resistance is required to be carried out according to an appropriate
recognized Standard, such as the Eurocode 3: Design of steel structures series, being EN 1993-1-1 through
EN 1993-1-12, plus possibly EN 1993-2 on steel bridges and EN 1993-6 on crane supporting structures.
DIN 18800 has traditionally been used for the design of plated structures (and while superseded by
EN 1993 may still be used by industry).

T
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AF
DR

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© Standards Australia Limited 2024

 DR AS 4324.1:2024 140

Appendix K
(informative)

Functions for a design audit engineer during audit of a structure

PUBLIC COMMENTING DRAFT

A design audit engineer may be engaged by the owner/purchaser of the equipment for new supply, or
where the design of existing equipment is to be modified.
A design audit engineer who is auditing the design of mobile equipment for continuous handling of bulk
materials should perform the following functions and services:

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(a) Prior to placement of a contract for the supply of a machine, review jointly with the purchaser,
the project manager (if any) and the supplier, the following:
(i) The basic technical data and design of the machine.
(ii) The design code and Standards under which the machine is to be built.

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(iii)

(iv)
(v)
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The extent to which finite element analysis will be used by the supplier’s design
engineer and by the auditing engineer to determine stress levels within the machine.
Any statutory requirements for design and construction of the machine.
Any other local conditions to be considered for satisfactory strength and stability of
the machine.
(vi) The structural materials to be used.
(vii) The range of tests on structural and other load carrying materials.
(viii) The design and test parameters for joints and welded parts.
(ix) The range and individual values of the load assumptions proposed by the supplier,
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which should be based on Tables 3.7(A) or 3.7(B).

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(x) The supplier’s proposed drawing lists and calculation lists for structures and other
main load carrying members.
(xi) The weight of the complete machine (or its superstructure).
(b) Prior to and during a review of the owner’s contract, the design audit engineer should check
the terms and details in Item (a) above and advise the owner of any changes that should be
made prior to placement of a contract with a supplier, and which of the supplier’s drawings,
calculations and other design data will need to be submitted to the design audit engineer for
auditing purposes.
NOTE It should be a condition of the owner’s contracts with other parties that they will cooperate
readily and fully with the design audit engineer to expedite completion of the design audit engineer’s
functions.

(c) After placement of an owner’s contract for the supply of a machine, the following action is
advised:
(i) The supplier should submit the following information to the design audit engineer
for a preliminary review:
(A) The range and individual values of any changes in the load assumptions
that may be proposed by the supplier.

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 141 DR AS 4324.1:2024

(B) The supplier’s preliminary stability analyses.

(C) The supplier’s general arrangement drawings.
(D) Any changes to manufacturing methods proposed by the supplier.
The design audit engineer’s preliminary report including any requests for revision
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of the foregoing should be given within a period to be agreed between the parties.
(ii) Progressively during the validity of the owner’s contract on the supplier and at
times and in quantities mutually agreed with the supplier, the design audit engineer
should check the following:
(A) Selected arrangements and detail drawings of structures and other main
load carrying members that could affect the strength and stability of the
machine (e.g. travel gear, main frames, equalizers). Such drawings should

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show joint details.
(B) Selected calculations for structural and other main load-carrying parts.
(iii) The supplier should not commence manufacture of any part of the machine for which
the design is subject to review by the design audit engineer, until confirmation has

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been given in writing by the design audit engineer that the checks have shown a
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satisfactory result. The design audit engineer should complete the review and
submit confirmation in writing that the checks have shown a satisfactory result
prior to the supplier commencing manufacture.
(iv) Erection should be in accordance with the owner’s contract with the supplier and
should not commence until the design audit engineer has claimed satisfaction
that the selected drawings and calculations conform to the regulations, codes and
Standards that are specified in the owner’s contract with the supplier. Structures
and other parts subject to review by the design audit engineer should have passed
the inspections that are included in the owner’s contract with the supplier.
(v) On completion of erection, the design audit engineer should personally attend
weighing of the machine (or its superstructure) as specified by the design audit
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engineer and together with the supplier should determine what strength and

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
stability adjustment including ballasting should be made.
The design audit engineer should personally inspect the completed machine and
should compile the following lists:
(A) Items that are to be corrected before the machines goes into service.
(B) Items that are to be corrected within one year of being put into service.
(vi) When items in Item (c)(v)(A) above have been completed, a certificate of clearance
for operation should be issued to the owner and the supplier.
(d) A design audit engineer’s final report should be provided within one year of putting the
machine into service, during which the following actions should have been taken:
(i) Review, with the owner and the supplier, any modifications that need to be made to
drawings, so that the design audit engineer’s report may be finalized.
(ii) Obtain confirmation from the owner and the supplier that items under Item (c)(v)
(B) above have been completed.
(iii) The design audit engineer to compile an opinion report on the machine, which should
be in the English language, include the load assumptions for the machine as built,
report on the checks carried out by the design audit engineer and carry a statement

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 DR AS 4324.1:2024 142

to the effect that the design audit engineer has no objections on structural grounds
to the machine being allowed to operate.
(e) The design audit engineer should also carry out such other services as may be arranged by
the owner prior to placement of his contract with the design audit engineer.
Examples of well-established practices in functions of a design audit engineer are given in the German
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Code, BG—1986 Regulations, and 1989 Directives.

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© Standards Australia Limited 2024

 143 DR AS 4324.1:2024

Bibliography

AS 1735.5, Lifts, escalators and moving walks, Part 5: Escalators and moving walks
AS 2759, Steel wire rope—Use, operation and maintenance
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AS 3597, Structural and pressure vessel steel—Quenched and tempered plate

AS 4024 (all parts), Safety of machinery
AS 5104, General principles on reliability for structures
AS 61508 (all parts), Functional safety of electrical/electronic/programmable electronic safety-related
systems

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AS ISO 13822, Basis for design of structures—Assessment of existing structures (ISO 13822:2001, MOD)
AS/NZS ISO 31000, Risk management—Principles and guidelines
AS ISO 55000, Asset management—Overview, principles and terminology

Licensed to Paul Yakimoff of ME-043 at 09:12 (AEST) on Wed Oct 30 2024 for Committee and Standards Australia use only.
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ISO 2394, General principles on reliability for structures
ISO 5049-1, Mobile equipment for continuous handling of bulk materials — Part 1: Rules for the design of
steel structures
BS 970-1, Specification for wrought steels for mechanical and allied engineering purposes, Part 1: General
inspection and testing procedures and specific requirements for carbon, carbon manganese, alloy
and stainless steels
BS 5400-10, Steel, concrete and composite bridges, Part 10: Code of practice for fatigue
BS 7608, Guide to fatigue design and assessment of steel products
DIN 18800, Steel structures (series superseded by EN 1993 series)
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Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
DIN 22261 (all parts), Excavators, spreaders and auxiliary equipment in opencast lignite mines
EN 1993-1-1, Eurocode 3: Design of steel structures, Part 1-1: General rules and rules for buildings
EN 1993-1-5, Eurocode 3: Design of steel structures Part 1-5: Plated structural elements
EN 1993-1-6, Eurocode 3: Design of steel structures, Part 1-6: Strength and stability of shell structures
EN 1993-1-7, Eurocode 3: Design of steel structures, Part 1-7: Plated structures subject to out of plane
loading
EN 1993-1-9, Eurocode 3: Design of steel structures, Part 1-9: Fatigue
EN 1993-1-12, Eurocode 3: Design of steel structures, Part 1-12: Additional rules for the extension of
EN 1993 up to steel grades S 700
EN 1993-2, Eurocode 3: Design of steel structures, Part 2: Steel bridges
EN 1993-6, Eurocode 3: Design of steel structures, Part 6: Crane supporting structures
FEM. Section II Doc 2 131/2 132—Rules for the design of mobile equipment for continuous handling of bulk
materials
FEM. International Institute of Welding, BS IIW, Fatigue design of welded joints and components:
Recommendations of IIW joint working group XIII-XV

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 DR AS 4324.1:2024 144

FEM BG—1986 Regulations, Calculations and dimensioning of large machines in open cuts. Issued by
the State Department of Mines (Bergamt) North Rhine, Westphalia, dated 3 Jan 1986, together
with the supplement dated 15 February 1991. Obtainable as publication No. 454 from Bellman-
Verlag Dortmund FRG
FEM 1989 Directives, Design and putting into service of excavators (except marine dredgers) spreaders
and auxiliary machines in open cuts. Issued by the State Department of Mines (Bergamt) North
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Rhine, Westphalia, dated 4 Apr 1989

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© Standards Australia Limited 2024

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Standards Australia
Standards Australia develops Australian Standards® and other documents of public benefit and national
interest. These Standards are developed through an open process of consultation and consensus, in which all

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interested parties are invited to participate. Through a Memorandum of Understanding with the Commonwealth
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Government, Standards Australia is recognized as Australia’s peak non-government national standards body.

For further information visit www.standards.org.au

Australian Standards®
Committees of experts from industry, governments, consumers and other relevant sectors prepare Australian
Standards. The requirements or recommendations contained in published Standards are a consensus of the
views of representative interests and also take account of comments received from other sources. They reflect
the latest scientific and industry experience. Australian Standards are kept under continuous review after
publication and are updated regularly to take account of changing technology

International Involvement
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Standards Australia is responsible for ensuring the Australian viewpoint is considered in the formulation of

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
International Standards and that the latest international experience is incorporated in national Standards.
This role is vital in assisting local industry to compete in international markets. Standards Australia represents
Australia at both the International Organization for Standardization (ISO) and the International Electrotechnical
Commission (IEC).
Australian Standards are prepared by a consensus process involving representatives nominated by organizations
drawn from major interests associated with the subject. Australian Standards may be derived from existing
industry Standards, from established international Standards and practices or may be developed within a
Standards Australia committee.

Committee ME-043, Bulk Handling Equipment, consisting of the following, is responsible for the issue
of this draft:
Australian Industry Group
Australian Steel Institute
Better Regulation Division (Fair Trading, SafeWork NSW, TestSafe)
Consult Australia
Department of Energy, Mines, Industry Regulation and Safety Western Australia
Engineers Australia
Minerals Council of Australia
Stakeholder Interest Representative
The Australasian Institute of Mining & Metallurgy

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The University of Sydney
University of Newcastle
University of Wollongong
Weld Australia
Western Sydney University

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For information regarding the development of Standards contact:
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Standards Australia Limited

Commenting on this draft is open between Tue Sep 24 2024 - Wed Nov 27 2024
GPO Box 476
Sydney NSW 2001
Phone: 02 9237 6000
Email: [email protected]
www.standards.org.au

ISBN to be allocated on publication of the final document