Manual de Montaje Estructuras

Rev: 01 SHOUGANG HIERRO PERU Order No.
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PRELIMINARY ERECTION MANUAL
This ERECTION MANUAL enables an experienced erection company to execute the erection of
ThyssenKrupp Resource Technologies (TKRT) supply with advisory services of TKRT personnel.
CONTENT
1. SAFETY
1.1. Safety Policy on Construction Sites of TKRT
2. PRECONDITIONS FOR ERECTION

2.1. Demands on the Erection Personnel
2.2. Space Requirements, Conditions of the Area, Nature of the Ground
2.3. Transport and Storage Regulations
2.4. Gearboxes
2.5. Instructions for Fabrication and Erection
2.6. Welding Procedure for Rail Joints
3. ERECTION SEQUENCES
3.1. General Notes for Erection
3.2. Prior Starting Erection
3.3. Drum Reclaimer
3.4. Stacker - ST 1500 - with Tripper Car
3.5. Stacker – ST 4500 – with Tripper Car
3.6. Bucket Wheel Reclaimer - R 6000
4. PROCEDURE AND SEQUENCE OF ELECTRICAL INSTALLATION

4.1. Drum Reclaimer
4.2. Stacker – ST 1500
4.3. Stacker – ST 4500
4.4. Bucket Wheel Reclaimer – R 6000
5. HYDRAULIC INSTALLATION AND ASSEMBLY
6. PAINTING SPECIFICATION
7. COMMISSIONING
© 2014 THYSSENKRUPP RESOURCE TECHNOLOGIES
ThyssenKrupp Resource Technologies 1/1

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1. Safety

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THYSSENKRUPP RESOURCE TECHNOLOGIES
SAFETY POLICY
on Construction Sites
GENERAL GUIDELINES
These Guidelines are binding for all Erection-Sites controlled or supervised by

ThyssenKrupp Resource Technologies including all its subsidiaries.
H. J. Wiedenhues T. Frericks
President Head of Erection Dept.
Issued by the Erection Department Head Office Essen
Revised issue 1999

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TABLE OF CONTENTS
1. Introduction for our Employees
2. Introduction for our Subcontractors
3. The ThyssenKrupp Resource Technologies's Safety Principals
4. General Safety Rules
5. Emergency Procedures
6. Emergency Evacuation
7. Drug Abuse / Contraband Policy
8. Personal Protective Equipment
9. Material Handling and Storage
10. Hand and Portable Power Tools
11. Motor Vehicles and Mobile Equipment
12. Lifting Equipment
13. Ladders
14. Scaffolds
15. Safety Barriers
16. Arc/autogenous welding and flame cutting
17. Fire Protection
18. Hot Work Permits
19. Excavations
20. Lockout/Tagout
21. Housekeeping

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22. Safety Meetings
23. Competent Safety Advisers
24. Training
25. Thorough Investigation and Follow-up of Accidents
26. Safety - Check List

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1. Introduction for our Employees
Almost all accidents that occur on our jobs can be prevented by a sound program of safety
engineering. Such a program requires the participation of each employee. In turn, each employee will
benefit as an individual by lessening the possibility that they may experience the loss of income and
suffering that go hand in hand with construction accidents.
Safety rules are produced by experience, not by imagination. Yet, as helpful as they are, safety rules
alone cannot prevent accidents. The indispensable ingredients of a safe working environment are; an
interested management, a knowledgeable supervisory staff, and a concientious workforce. All
dedicated to the principal that accident prevention is an integral part of planning and efficient
execution of every job.
The regulations included in this booklet are intended to assist you to recognize, understand and
control the common hazards encountered on the job. It contains many rules and safe practices which
follow various safety standards, yet we cannot cover all the conditions which may arise on the jobsite.
Your performance with this company will be judged by your ability to work safely and efficiently.
Working safely is part of your job, every member of this company is a member of our safety program.
It is the duty of each employee to execute their individual work assignments in accordance with
recognized safe procedures. If there is any doubt regarding proper methods of executing your work,
you should consult your supervisor for specific safety instructions.
Our international engagement requires to observe the national and international Rules and
Standards, whichever are the more stringent.

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Any employee, regardless of position, whose actions are considered unsafe or causes others to be
placed in unsafe conditions will be subject to disciplinary action up to and including removal from the
jobsite.
2. Introduction for our Subcontractors
The Contractor for Erection shall in the execution of the work be fully responsible for compliance with:
a) relevant local, national and international laws and regulations,
b) local, national and international standards or codes of practice whichever are the more stringent
unless specified otherwise,
c) the ThyssenKrupp Resource Technologies's regulations.
The Contractor shall be fully responsible for supervision of its personnel to ensure that they strictly
adhere to all applicable safety requirements.
The Contractor shall appoint one of its personnel on the work site as its safety adviser and shall seek
the ThyssenKrupp Resource Technologies's approval for the individual so appointed.
The Contractor's manager in charge on site shall be responsible for coordinating the Contractor's
safety activities. He and the ThyssenKrupp Resource Technologies's representative shall be the focal
points for all safety matters.

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3. ThyssenKrupp Resource Technologies's Safety Principals
The ThyssenKrupp Resource Technologies's philosophy regarding safety is best expressed by our
Safety Principals. This principals are applicable to each person that works for us and our
Subcontractors.
The management and employees of ThyssenKrupp Resource Technologies, believe in spite of the
existing risks that :
- Accidents and injuries are preventable.
- Each of us has a personal responsibility for our safety and the safety of others both on and off the
job.
- No business objective is so important that it will be pursued at the sacrifice of safety.
- Safe conduct of operations is a condition of employment.
- A job is well done only if it is done safely.

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4. General Safety Rules
1. Each individual must accept the responsibility to remain alert and use good judgement in the
performance of their job.
2. Safety programs are initiated with the sole purpose of reducing accidents, minimizing the
severity of injuries to employees, and to protect property.
3. Each employee is encouraged to consider it their duty to family and to fellow workers to
participate in First-Aid and other training classes provided from time to time.
4. It is expected that all employees will cooperate in promoting and maintaining and effective
safety program.
5. Learn your job, learn the hazards and safety precautions to eliminate or to minimize the
hazards involved. Wear the proper safety apparel recommended, ask questions when in doubt,
and report all injuries to your foreman no matter how slight.
6. Horseplay is not permitted. Do not distract or interfere in any way with a person performing
their job. You will make many friends in the course of your employment, however, don't let your
friendship and familiarity be the basis for playing a practical joke or prank which may end in an
injury.
7. Signs posted throughout your jobsite are messages to warn of danger or to give you
instructions on what to do or what not to do. Read and comply with all signs and posters.

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8. If you are in doubt about the safe or proper way to perform a specific job or duty, get
instructions from your supervisor before proceeding.
9. When you are relieved from a job that has unusual, partially concealed or concealed hazards,
immediately inform the person replacing you that such hazards exist. Be specific!
10. You may notice conditions from time to time which appear hazardous. Notify your foreman or
supervisor of such conditions so that he may have them corrected.
11. If you observe an employee performing his job in an unsafe manner, bring it to his attention. If
this does not help, report it to your foreman or supervisor along with your suggestion for its
corrective action. You need not mention any names. The mere fact that such practices get to
the proper authority may prevent someone, who perhaps does not realize their actions are
dangerous, from getting hurt.
12. Many of the machines, tools and other equipment may fascinate your, however, do not attempt
to use or to operate any machine, tool or other equipment unless you have been taught how to
operate them safely and are authorized to do so. Watch out for and report defective tools and
equipment to your supervisor or foreman.
13. All unjuries, not matter how slight, are to be immediately repoted to a foreman or a field
supervisor. Do not try to treat yourself.
14. The use of gasoline as a cleaning solvent is strictly forbidden. An approved cleaning solvent
must be used to clean tools, machinery and similar equipment.
15. Good housekeeping should be maintained in all work areas.

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16. When equipment has to be moved into and out of the shop, contact the shop supervisor for
proper entry and exit procedures.
17. When working in a mine inquire for the safely regulations in force.

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5. Emergency Procedures
1. Determen for every Erection Site and pin on Black board
- Name of Safety Officer
- Telephone of Fire Brigade
- Telephone of next Doctor or Hospital
- Telephone of Ambulance
2. If an emergency should arise, insure your own safety first. Then, the person witnessing the
emergency shall turn in an alarm to the Safety Officer.
The following information shall be given to the Dispatcher:
- Name of the witness
- Nature of emergency
- Number of people involved
- Other pertinent information
3. All personnel shall yield (grand) the right-of-way to emergency equipment with emergency lights
flashing.
4. If you are not involved in the emergency, stay out of the area.

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5. All vehicles, unless necessary to render aid, shall park a minimum of 300 feet/ 100 m from the
scene of the emergency.
6. When emergency personnel arrive, be sure to provide them with all the information concerning
the accident.

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6. Emergency Evacuation
1. In the event of fire, hurricane, earthquake, chemical release, or similar type emergency, it may
be necessary to evacuate a jobsite. If possible this will be coordinated with the customer.
2. A warning system will be set up to notify personnel of impending danger.
3. The jobsite is to be quickly secured to avoid a more hazardous situation. Shut off compressed
gas cylinders, secure mobile equipment, etc. The project manager or site manager should be
notified of anything left in an unsafe condition due to the necessity to evacuate the area. Steps to
correct any situation will be based upon immediate or foreseeable conditions.
4. Each crew shall have a predetermined place to meet their supervisor for a head count and
further instructions. Employees are not to leave the jobsite until they have checked in with their
foreman and have been given permission to leave the jobsite or to return to work.

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7. Drug Abuse / Contraband Policy
The company prohibits the use, possession, or distribution on its premises, facilities, or work places
any of the following: intoxicants and narcotics, illegal or authorized drugs (including marjuana), "look
alike" (simulated) drugs, drug related paraphernalia, inhalants, firearms and unauthorized explosives.
Company employees must not report to work under the influence of any drug, alcoholic beverage,
intoxicant or narcotic or other substance (including legally prescribed drugs or medicines) which will
in any way adversely affect their working ability, alertness, coordination, response, or adversely affect
the safety of others on the job.
All applicants for employment and employees of the Company may, as a condition of employment or
continued employment, be required to submit to a drug and/or alcohol screening test at the discretion
of the company.
Entry into, or presence on company premises, facility or work place by any person is conditioned by
the Company's right to search the person, personal effects, vehicles, lockers and baggage of any
employee or other entrant for any substance described in the above paragraph. By entering into or
being present on Company premises, facility or work place, any person is deemed to have consented
to such searches which may include periodic and unannounced searches of anyone while on,
entering or leaving Company premises, facility or work place. These searches may include the use of
electronic detection devices, scent trained dogs, or the taking of blood, urine or saliva samples for
testing to determine the presence of substances named above.
The taking of blood, urine, or saliva samples for testing may also be required from any person on
Company premises, facility, or work place who is suspected of being under the influence of drugs or
alcohol, or who is involved in an accident involving a Company vehicle, or who is injured in the course
of employment.

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This program is designed to notify, identify, and to provide penalties for those employees and
applicants who by their possession, use, or sale of an illegal drug or alcohol pose unnecessary and
unacceptable risks to a safe, healthful, and efficient operation.
Any person who refuses to submit to a search, screening or testing as described in this policy or who
is found using, possessing or distributing any of the substances described above, or who is found
under the influence of any such substances, is subject to disciplinary action up to and including
immediate discharge of an employee, voluntary withdrawal of employment application, or removal
from the premises, if not our employee.
Legally prescribed drugs may be permitted on Company property or work locations provided the
drugs are contained in the original prescription container and are prescribed by an authorized
practitioner for the current use of the person in possession. Any person in possession of a valid
prescription drug when on or entering Company premises or work place may be required to complete
a "Prescription Drug" form and the Company may, as it deems appropriate, determine if the drug
produces hazardous effects.

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8. Personal Protective Equipment
1. Good heavy work boots shall be worn on the job: Employees are encouraged to purchase and
wear boots with steel toes, sole penetrating and ankle protection. Some jobsites require the
wearing of steel toe safety boots. Employees will be expected to comply.
2. You must wear clothing suitable for the work you are doing. Minimum requirements are long
pants, and a T-shirt with short sleeves. No shorts, cutoffs, tank tops or mesh shirts are
allowed.
3. Approved hard hats shall be worn at all time while engaged in daily work except while working
in offices, driving vehicles or operating equipment in enclosed cabs. Alterations shall not be
made to the hard hat or to the suspension system. Hard hats with damage to the suspension
or to the shell are to be discarded.
4. Approved industrial safety glasses are required. Face shields shall be used for grinding and
chipping operations. Welding hoods shall be worn when arc-welding. During acetylene welding
or cutting operations, cutting goggles shall be worn.
5. Welding helmet/hardhat and faceshield/hardhat combinations shall be worn on all field erection
sites.
6. Any employee whose work places them outside a protected area without guardrails or work is
to be performed on suspended scaffolds or any work surface where they max be subject to a
fall of six (6) feet/2 m or more, shall be secured by a safety belt or harness, lanyard and
lifelines as needed.

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7. Respirators of the proper type shall be worn whenever toxic dusts, fumes, gases or other
harmful atmospheres are present. When respiratory equipment is required to be worn in areas
of hazardous substances, beards, goatees, sideburns, or any other type of facial hair which
would prevent the respiratory equipment from obtaining a proper seal, shall not be permitted
and must be removed.
8. Employees are not to enter manholes, underground vaults, chambers, tanks, silos, vessels or
other similar places that receive little or no ventilation, unless it has been determined that the
air contains no flammable or toxic gases or vapors and that the oxygen content is adequate.
Such areas shall be thoroughly ventilated and monitored. Employees entering confined spaces
are required to wear a harness and lifeline. A self contained or oxygen supplied breathing
apparatus may be required.
9. Hearing protection shall be worn when working in or around high noise level areas or where
posted.
10. All persons shall wear approved life vests where there is danger of falling into water.
11. Plastic coated or rubber gloves and boots are to be worn when working with caustic, acids,
concrete, cement, solvents or other similar type materials.
12. Modifications or alterations to personal protective equipment is strictly prohibited. Damaged or

defective personal protective equipment must be turned in for replacement.

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9. Material Handling and Storage
1. When attempting to carry a load, make sure before you start out that it is not too heavy to
carry. If a load is too heavy for you, get help or move it by mechanical means.
2. When carrying loads with other workers, always give adequate warning of any action on your
part, such as lowering your portion or end of the load. Plan the route in which to carry the load
ahead of time so that every one works together. Keep in step, it makes the load easier to
handle.
3. Never carry a load that blocks your vision, as you may trip or run into another object.
A number of serious back injuries and hernias have occurred over the years because of
employees using improper lifting procedures. The following recommendations are to help you
avoid such injuries.
4. When lifting - bend your knees - get a firm grip - keep your back nearly vertical - keep your feet
apart - then push up evenly with your leg muscles. In this way, strain is relieved from the
weaker back muscles and most of the weight is transferred to the stronger leg muscles.
5. When lowering the object the same rules apply. Set your load down by bending your knees
while keeping your back nearly vertical. Set one corner down first to avoid pinching your
fingers.
6. Do not try to lift beyond your strength! Ask for help.

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7. All material must be properly stacked and secured to prevent sliding, falling, or collapse.
Aisles, stairways and passageways must be kept clear to allow safe movement of employees
and equipment and to provide access in an emergency.
8. Materials must not be stacked in such a way that they block access to fire exits or to
emergency equipment.
9. Pipe, conduit, or bars should be stored in racks or stacked to prevent movement.
10. The amount of material stored on scaffolds, platforms, or walkways must not exceed the
quantity required for one days operation or the rated capacity of the scaffold or platform.

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10. Hand and Portable Power Tools
Each tool and piece of equipment is to be visually inspected before use. Defective tools are to be
"tagged out" and not used. Employees are not permitted to use unsafe tools or equipment.
Employees are expected to comply with manufacturer's instructions as well as the following safe
practices.
General
1. Tools and equipment must be maintained in good condition.
2. Only qualified persons are to operate tools and equipment.
3. Tools or guards are not to be altered.
4. Personal tools are subject to inspection at any time, and may be removed from the jobsite if
defective.
5. Tools are to be used only for their designed purpose.
6. Cords and hoses must be secured to prevent their being damaged by other equipment or
materials.
7. Electrical and pneumatic tools must be disconnected prior to performing maintenance or

bit/blade changes.

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8. Power tools must be hoisted or lowered by a hand line or bucket, never by the cord or hose.
9. Wrenches, including adjustable, pipe, end, and socket wrenches are not to be used when the
jaws are sprung to the point that slippage occurs.

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Electrical Tools
1. Electrical tools must be three prong grounded or double insulated. Electrical tools must be
maintained as per the company's "Ground Assurance Program" or through the use of "Ground
Fault Interrupters".
2. Hand-held power tools must be equipped with controls requiring constant hand or finger
pressure to operate the tools or shall be equipped with friction or equivalent safety devices. (No
trigger locks.)
3. Extension cords used with portable electric tools and appliances shall be 3-wire type and be
designed for hard or extra hard usage. Electrical cords must be maintained as per the
company's "Ground Assurance Program" or through the use of "Ground Fault Interrupters".
4. Damaged or defective electrical tools and cords must be tagged out of service and returned to
the tool room for repair.
5. All electrical cords and cables must be covered or elevated to protect them from damage and to
eliminate tripping hazards.
6. Electrical cords are not to be fastened with staples, hung from nails or suspended by wire or
welding rods.

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Pneumatic Tools
1. All pneumatic hose and tool connections must be fastened securely and safety clips or retainers
installed to prevent accidental disconnection.
2. Safety chains must be used at connections on pneumatic hose of 1-inch inside diameter or
larger.
3. An approved safety shut-off valve must be installed at the manifold outlet of each supply line for
hand held pneumatic tools.
Fuel Powered Tools
1. All fuel powered tools must be shut down while being refueled.
2. Smoking is prohibited during refueling operations. Other nearby sources of ignition, such as
welding and cutting must also be stopped during refueling operations.
3. Fuel powered tools are not to be used inside a building or excavation without adequate
ventilation or vented exhaust.

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11. Motor Vehicles and Mobile Equipment
General
1. All mobile equipment and motor vehicles must be operated and maintained as required by
established standards and manufacturer's specifications.
2. All cranes, hoists, motor vehicles, and mobile equipment must be inspected prior to use on
each shift. Operators of such equipment are required to complete inspection records as
required. (Check with your supervisor for forms.)
3. Rated load capacity charts, recommended operating speeds, special hazard warnings, or any
other essential information must be posted in all mobile equipment and followed by all
operators.
4. Operators are to take signals from only one person; however, in an emergency a STOP signal
can be given by anyone.
5. Only standard hand signals are to be acknowledged.
6. Employees are prohibited from riding the hook or the load.
7. Routine maintenance, fueling, or repairs are not to be performed while the equipment is in use
or the power is on.

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8. No one shall ride on the fender, running board, cab or tool box of motor vehicle. When riding in
the back of a pickup, riders are required to sit in the loading bed of the truck.
9. The driver is responsible for the safety of all passengers and the stability of materials being
hauled.
10. Seat belts shall be used at all times. Employees shall not ride as a passenger on forklifts,
cherry pickers or other mobile equipment rated for a single operator.
11. Keep out from under loads and keep clear of moving equipment.
12. No crane or other equipment should be operated within 10 feet/3 m of energized electrical
transmission or distribution lines. Additional clearance is required for lines rated over 50 kV.
13. Any overhead line must be considered energized unless a responsible client or utility company
representative is present and states that the line is not energized.
14. Loads must not be suspended on an unattended crane.
15. Use of crane suspended work baskets (man baskets) must meet safety requirements.
16. Do not operate any vehicle or equipment that you feel is unsafe. Report any unsafe vehicle or
equipment to your supervisor.
17. Unattended motorized equipment must not be left running.

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12. Lifting Equipment
1. You will be provided with equipment that is safe to use. You are responsible for inspecting your
equipment before using it. If the equipment becomes defective in any way, notify your
supervisor at once and place a DO NOT USE tag on it.
2. Cable slings shall be inspected regularly and destroyed if defective. Slings should be hung up
when not in use.
3. Slings should be protected on sharp corners of loads and should not be jerked when moving
the load.
4. Cable slings are to be destroyed when there are ten randomly broken wires in one rope lay or
five broken wires in one strand in one lay and when there is evidence of excessive wear,
kinking, gouging, bird caging or other damage.
5. Know the proper use of chains, chain pull, come-a-longs, chockers, shackles, slings and
clamps.
6. Know the weight capacities of the rigging equipment and the weights of loads.
7. Make sure the load is slung correctly and that the chockers, shackles and rigging equipment
used for the lift is of sufficient size and strength to maintain a proper safety factor.
8. Taglines must be used to control all loads.
9. Ensure that the sling angle is always greater than 45 degrees.

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10. If the load does not ride properly, lower it and have it re-adjusted.
11. Never wrap a sling completely around a hook, the sharp radius will damage the rope.
12. Never point load a hook unless specifically designed and rated for such use.
13. All hooks must have a safety latch attached and be in good working order.
14. Nylon slings must not be used when the colour band in the webbing indicates excessive wear.
15. Nylon slings should not be used against rough surfaces or wrapped over sharp corners since
they have a tendency to cut without notice.

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13. Ladders
1. Ladders are not to be painted except for letters or numbering.
2. Ladders are to be inspected for damage prior to use.
3. Face the ladder at all times. A safety belt may be required when working from a ladder.
4. When ascending or descending a ladder, do not carry anything that will prevent holding on with
both hands. Use a handline or bucket to lift tools.
5. Only one person on a ladder at a time.
6. Straight and extension ladders should be placed so that the rise (A) is four (4) times the run
(B).
(A)
(B)
7. Straight and extension ladders are to be equipped with non-skid feet and a tie off rope.
8. Straight and extension ladders must extend at least 3 feet/1 m beyond the supporting object or
landing and the ladder must be adequately tied off.

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9. Job made ladders must be constructed to conform with the established safety standards.
10. Broken or damaged ladders must not be used. ladders which need repairs must be reported to
your supervisor, tagged out, and removed from the work area.
11. Step ladders must always be used in the full open position with the spread out lock spreaders
in place. Do not use as a straight ladder. never stand on the platform or the top step of a
stepladder. Do not place tools or materials on steps or the platform.

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14. Scaffolds
1. All scaffolds must be erected level and plumb, on a firm base.
2. Before starting work on a scaffold, visually inspect to determine that:
a) Handrails, midrails, toeboards and decking are in place
b) All wheels are locked on mobile scaffolds.
c) Cross braces and locking pins are in place at each level.
3. Safety belts must be worn and employees tied off on any scaffold not equipped with standard
handrails, midrails, or complete deck.
4. Do not ride on a mobile scaffold while it is being moved. Remove or secure all tools and
material on the deck before moving.
5. Do not climb on, or work from handrails, midrails or any brace member. Use the ladder to get
on the scaffold.
6. Scaffolds must be tied off or stabilized with outriggers when the height is more than three times
the base. Scaffolds are to be tied off horizontally every 10 m.
7. When space permits, scaffolds must be equipped with standard handrail, midrail, and toeboard
on all four sides and completely decked with safety plank or manufactured scaffold decking.
8. Cleat the underside of planks to prevent their movement.

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9. Be sure you know the safe working loads on all scaffolds.
10. Do not alter any scaffold member by welding, burning, cutting, drilling, or bending.
11. Swinging stages, man baskets, boatswain (bos'n) chairs, swings and timber scaffolds require
special personal protective equipment and approval prior to use.
15. Safety Barriers
1. Barriers are required around most excavations, holes or openings in floor or roof areas, at the edges
of roofs, and elevated work platforms, and around certain types of elevated work. Barriers must be erected
whenever necessary to warn people against falling in, through, off, or of overhead hazards.
ANY ONE WHO MAKES A HOLE OR OPENING IS RESPONSIBLE FOR HAVING IT SECURED BY
BARRIERS
2. Barriers must be 42 inches/1 m high, vertical and level.
3. Keep barriers 5 feet/2 m back from the edge of the hazard.
4. Barriers are to be constantly maintained.

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16. Arc/autogenous Welding and Flame Cutting
General
1. Inspect all leads, grounds, clamps, welding machines, hoses, gauges, torches and cylinders
before each days use.
2. Each welder is responsible for constraining sparks and slag and/or removal of flamable
substances to prevent fire.
3. No welding is to be done on a closed vessel or tank, or on any vessel or tank which has not been
properly cleaned.
4. Avoid breathing fumes. Use an exhaust system, a blower or a respirator.
5. Approved fire extinguishers must be close at hand before starting any welding, burning, or open
flame work. Know how to operate the fire extinguisher.
6. In some areas a Welding and Burning Permit may be required. Check with your supervisor
before striking an arc or lighting a torch.
7. Hoses or welding cables are to be protected from damage.
8. Flash back arrestors must be installed in accordance to safety regulations.

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Electric (Arc) Welding
1. Each work piece must have a separate and adequate ground. Ground connections must be
made from each welding machine.
2. Do not leave a rod in the holder when you lay it down. Put stub ends in proper container
reserved for it and not on the ground or floor.
3. You are responsible for turning off your machine at the end of your shift.
4. An approved welding helmet is required. Use no less than a # 10 filter lens, with a safety lens on
both sides of the filter.
5. All leads must be adequately insulated from the machine connection to the electrode holder.
6. All arcs are to be shielded in operating areas.
Autogenous welding
1. Compressed gas cylinders must be tied off vertically to an adequate support while in storage,
transit or use.
2. Gas cylinders in storage must be separated from oxygen cylinders or other sources of ignition
by a distance of 20 feet/6 m.
3. Before connecting regulators to cylinders, carefully open the valve slightly and immediately
close it. This is known as "cracking" and will blow out any foreign particles such as dust and
dirt. After regulator is connected, stand to one side of gauge and open cylinder valve slowly.

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4. Open valves on gas cylinders (acetylene, map gas, propane) 1/4 turn only. Open oxygen
cylinder valves wide open. Valve wrenches must be kept in reach during use.
5. Do not exceed 15 psi on the torch side of the regulator when usign acetylene.
6. When lighting a torch, open the gas valve on the torch before opening the oxygen valve. Use
an approved striker, do not use matches, cigarette lighters or other sources of heat to light the
torch.
7. Keep oil and grease away from oxygen regulators, hoses and fittings. Do not store grease
covered tools in the same area with oxygen equipment.
8. Do not use oxygen to clean your clothing or to clean your work area.
9. All equipment used for cuttig must be dismanteled at the end of each days work. Regulators
are to be removed and protective caps screwed on hand tight.
10. Approved cutting goggles must be worn when cutting or burning. Use at least a # 3 filter with a
safety lens on both sides of the filter.
11. Welding or cutting gas cylinders are not to be taken into enclosed or confined spaces. never
leave a torch in an enclosed or confined area because of the potential hazard of leakage.
12. Never use oxygen as a substitute for compressed air or other gases.

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17. Fire Protection
1. Smoking is prohibited at or in the vicinity of operations which are considered a fire hazard, and
shall be conspicuously posted as: "NO SMOKING OR OPEN FLAME".
2. Access to all fire fighting equipment is to be maintained at all times.
3. All fire fighting equipment shall be regularly inspected and maintained. Defective or discharged
equipment is to be repaired or replaced immediately.
4. Learn the Classifications of Fires:
Class A - Ordinary combustible materials such as wood, paper or fabrics where wetting and
cooling is the extinguishing method.
Class B - Flammable petroleum products or other flammable liquids where oxygen must be
excluded to extinguish the fire.
Class C - Fires in or near energized electrical equipment. Since the use of water would be
hazardous, a "nonconductive" fire extinguishing agent must be used.
Class D - Fires in combustible metals. A special powder is used.
5. Fire extinguishers are to be located in the following areas:
a) At combustible liquid storage areas
b) On each piece of mobile equipment

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c) In close proximity to any welding or cutting operation
d) At permanent electrical installations
e) Located at any area where the hazard of fire exists.
6. You must use approved solvents for cleaning and degreasing. The use of gasoline and similar
flammable products for this purpose is prohibited.
7. Flammable and combustible liquids must be handled only in approved, properly labeled safety
containers.
8. You are expected to know the location of all fire fighting equipment in your area.
9. Oily rags are to be kept in approved covered containers.
10. Do not start any work involving a source of ignition near a pit, sewer, drain, manhole,
excavation or enclosed space where flammable gases may exist. Wait until tests have been
made with an approved combustible gas meter by a qualified person and the area has been
determined safe for hot work.

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18. Hot Work Permits
Any time a tool is used which generates sparks or involves the use of open flame in the plant or other
areas which have been identified as hazardous, the following procedures shall be implemented:
1. All machinery and dust-producting operations shall be shut down prior to clean-up and remain
inoperative until a final inspection is made at the completion of the work.
2. The area where open flame or spark-producting equipment is to be used shall be washed down
prior to usage of equipment.
3. All combustible material or materials which could be damaged from the operation shall either be
removed from the work area or protected by covering with flame-proof material.
4. At least one portable fire extinguisher shall be in the immediate area where open flame or spark-
producting equipment is being used.
5. The work area shall be tested for methane by a certified or qualified person immediately prior to
beginning operations and every two hours while the permit is in effect.
6. To insure that the previous five steps have been followed, your supervisor shall personally check
the area and fill out and sign the Hot Work Permit form prior to work commencing.
7. Upon completion of work involving cutting or welding, the area shall be wet down to insure all
potential hot spots are eliminated.
8. When all work has been completed, the following procedures shall be followed to release the
permit:

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a) The area shall be inspected to make sure that all work is completed and that there are no
fires.
b) The time the work is completed shall be noted on the permit form.

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19. Excavations
1. All excavation and trenching operations and work performed in such areas must conform with
established standards and regulations.
2. Trenches 5 feet or deeper must be shored or sloped as required by safety regulations.
3. Spoil material must be placed 2 feet or more from the edge of the excavation. Precautions must
be made to prevent such materials from falling into excavation.
4. Where vehicles or equipment operate near excavations, the sides of the excavation must be
shored and braced to withstand the additional loading caused by the equipment. Stop logs or
other Barriers may be required.
5. Each excavation must be inspected daily and after each rain, snow, freeze, etc. by a competent
person. If evidence of cave-ins or slides is evident, all work in the excavation must cease until
the necessary precautions have been taken to safeguard employees.
6. Materials used for sheeting or shoring must meet the requirements of the safety regulations.
7. Safe access must be provided in all excavations. Excavations 4 feet(1,2m) or more in depth
must have ladders spaced so that employees lateral travel does not exceed 25 feet(7,5m).
Ladders must extend 36 inches (90cm) above ground level.
8. Walkways, bridges or ramps with standard guardrails must be provided where employees or
equipment are permitted or required to cross over the excavation.

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9. In locations where oxygen deficiencies or concentrations of hazardous or explosive gases or

dusts are possible, the atmosphere in the excavation must be tested by a qualified person prior
to the start of work and at intervals as required.

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20. Lockout/Tagout
1. The intent of the Lockout/Tagout rules are to prevent the unexpected operation of equipment
which has been intentionally shut down for repairs or goes down due to mechanical failure and
subsequent repairs are started. Employees will be issued locks and tags which you must use to
insure that systems and equipment which you are to work on cannot be accidently energized or
set into motion without your permission.
2. Any employee whose duties required him to expose himself or fellow workers to the hazards of
industrial equipment, whatever their nature, must assure safety awareness of the hazards by
taking appropriate steps to Lockout/Tagout energized systems prior to servicing or repairing
equipment.
3. You must Lockout/Tagout the job yourself. Never work under the protection of another
employee's lock. In certain cases group locks and tags will be issued. In those cases the
foreman or leadman will be responsible for safe start-up of the equipment.
4. When an amployee is required to repair, adjust, clean or oil any piece of equipment or power
driven machine - MAKE SURE THAT IT CANNOT BE ENERGIZED OR SET IN MOTION WITHOUT
YOUR PERMISSION.

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21. Housekeeping
1. Keep material and equipment out of aisles and walking areas. Always return tools and
equipment to their proper place after using them.
2. Keep floors free of grease and oil or any material which may cause slips or falls. Spilled liquids
can cause safety or health problems and should be cleaned up immediately. If you need
assistance, notify your supervisor to arrange for the necessary cleanup.
3. Never leave loose objects on stairs, floors or working areas.
4. Dispose of empty boxes, cans, oily rags or other trash promptly. They cause fires. Trash
containers should be located in all work areas. If you need one in your immediate work area,
notify your supervisor.
5. Keep all machinery and equipment as clean as possible at all times.
6. Keep all obstructions away from electrical switches, fire fighting equipment and exits.
7. If you see something on the floor or ground that might cause someone to trip or fall, pick it up
and put it in a safe place.
8. Toilets, washup facilities, drinking fountains, and water cans are provided. You are expected to
help keep them clean and sanitary. Report any problems to your supervisor.
9. It is the responsibility of each employee to maintain good housekeeping in their immediate area.

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22. Safety Meetings
1. The Company shall be responsible for maintaining and enhancing the safety awareness of its
personnel and Sub-contractor's personnel, including arranging its own safety meetings and
participating as appropriate in safety meetings held by the Erection-Sub-contractor.
2. The Contractor will inform the Company representative of the time and place of safety meetings
arranged by it.
3. Copies of minutes of the Contractor's safety meetings shall be sent to the Company. The
Contractor's and Sub-contractor's personnel are to be encouraged to contribute actively to safety
meetings and to identify safety topics for inclusion in the agenda for a safety meeting.
4. Holding regular safety meetings on Site on the following minimum basis:
Work Site Management - Weekly
Contractors Management - Weekly
Safety Team - Daily safety topic
Erection Crew tool box meeting - 2 x weekly

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23. Competent Safety Advisers
Selection and Appointment:
 On what criteria has the safety adviser been selected?
- Career development?
- Professional status?
 What training has he received?
- Training in required specialisation, e.g. drilling, radiation, chemical?
- Institute training?
- Safety management training?
 What qualifications and experience does he have?
- Competence for the job being carried out?
- Does knowledge and experience match advice required?
- Does management in charge follow advice offered?
 What is his reporting relationship with management in charge?
- Does he have direct access to Chief Executive?
Is the role of the safety adviser well defined?
 Is the Safety Department involved in:

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- Preparing and monitoring departmental action plans?
- Formulation and suitability of Safety Rules?
- Planned inspections and audits together with management in charge?
- Measuring safety performance of departments and units?
- Promotional material?
- Safety training?
- Contractor assessment, training and auditing?
- Occupational health monitoring?
- Supporting accident investigation introduced by the management in charge?
 Is guidance given on:
- Operating and Emergency Manuals?
- Emergency plans?
- Training for fire fighting teams, first aiders, etc.?
- Emergency drills and exercises?
- Protective equipment and rescue?
 Is safety included in:
- Induction Courses?
- Craft Training?
- Training of supervisory personnel?
- Training of management in charge?
- Training in auditing techniques?
 Is contact and liaison with government departments maintained?

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24. Training
1. General
It is recommended that all parties concerned in the erection, maintenance and dismantling have
a basic training in the relevant code of practice and safety regulations. The training should deal
with safety procedures and technical aspects at various levels. It is in the interest of
ThyssenKrupp Resource Technologies ensure that courses are available for all parties
concerned.
Training for Supervisors should familiarize them with the relevant standards and legislation,
safety inspections and safe erection with a basic introduction of structural mechanics.
Films/video clips on safety are important aids in the training programme for Users.
The ThyssenKrupp Resource Technologies should also ensure that a new Contractor is made
fully aware of the Company's activities being carried out on site and should be given full notice of
potential hazards through Contractor's introduction training.
The Contractor is responsible for providing technical and practical training required for his
Foremen. It is essential that qualified and competent staff are employed to erect, maintain,
modify and dismantle.
2. Recruitment, Training and Key Personnel
The ThyssenKrupp Resource Technologies Company may, if it so wishes, monitor the

Contractor's staff recruitment criteria. The Contractor shall provide the relevant information for
this.

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When asked to do so by the Company, the Contractor's personnel shall demonstrate their ability
and skills relative to their qualifications.
The Contractor shall submit details of its supervisors in key positions and other key personnel for
the Company's approval.
The Contractor shall at its own expense ensure that all its personnel and Sub-contractor's
personnel have been given the necessary safety, survival and job-related training required by
law, Company regulations and good practice, prior to the start of the work, and will provide
certificates to that effect (if so required).
The Contractor's personnel shall participate in any additional training which may be provided by
the Company.
The Company may refuse access to its work site by the Contractor's personnel who, in its
opinion, do not comply with Company standards for safe and good workmanship owing to
attitude, lack of skill or insufficient training or experience.
3. Effective Safety Training
Training Plans
The safety training must include the following:
- Safety management
- Job procedures
- Road safety
- health control and services

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- Auditing
- Accident investigation and reporting
- Safety adviser skills
- Supervisory development
- Safety meetings
- Fire
- Work procedures
- Hazard awareness and reporting
- Occupational health
- Security
- General rules and procedures
- Legislative requirements

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25. Thorough Investigation and Follow-up of Accidents
1. Investigation
Is it clear that the main purpose of accident investigation is prevention of future accidents?
2. Reports
- Are fatalities reported to the Service Companies within 24 hours?
- Are other lost-time injuries reported to the Chief Executive within 24 hours?
- Are all minor injuries/near-misses reported?
- Is a form used to report accidents?
If so, by whom is it initiated?
Is it reviewed/signed by the manager in charge?
- Who is the investigation team leader and who are the members in case of:
a fatality?
a lost time injury?
a vehicle accident?
a fire or other material damage?
- Are minor injuries and near-misses investigated?

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- How long does it take to form an investigation team and start the investigation?
- Is the scene of the accident visited and by whom?
- Is an accident statistic kept?
- Who endorses the investigation report?
Follow-up of accidents
- Is a schedule set for the implementation of recommendations?
- Is responsibility for carrying out recommendations clear?
- Are recommendations carried out and on schedule?
- How is the follow-up monitored?
3. Reporting of Accidents by Contractor
The Contractor shall have an accident reporting system compatible with that of the Company.
The Contractor shall immediately notify the Company of all accidents resulting in
- fatalities and other lost-time injuries to its personnel or Sub-contractor personnel
- comparable injury to third parties
- damage to plant or equipment

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- leakage of substances
- actual or potential damage to the environment
- an outbreak of fire.
The those accidents referred to in the above and those resulting in less serious injuries shall be
recorded and the statistics reported periodically to the Company (period to be specified).
Upon completion of the work under the contract and/or on an annual basis, whichever is more
frequent, the Contractor shall prepare a summary report of its safety performance including
statistics.

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26. Safety - Check List
A broadly-based check list will be generally applicable to all the activities of Erection and
Commissioning work of ThyssenKrupp Resource Technologies Companies - Subsidiaries and Sub-
contractors.
The intend is to check safety standards to all levels of management and all work activities.
Erection Site - Management
- Ensuring that management decisions and Company practices are consistent with the principles of
the Company's stated safety policy and objectives?
- Making adequate resources available?
- Discussing safety with employees?
- Visiting all work areas regularly?
- Wearing the required personal protective equipment?
- Carrying out Unsafe Act Auditing, and focusing on people first and equipment second?
- Commending safe working?
- Coaching employees who need to do better?
- Taking disciplinary action for serious and/or repeated breaches of safety rules?
- Encouraging employee participation in formulation of work procedures and safety rules?
- Refusing to order or sanction "short-cuts" to save time or money at the expense of safety
standards?
- Putting safety first on the agenda of all business meetings?
- Ensuring there is an effective structure to manage safety?

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- Reviewing minutes of subordinates' safety meetings, and following up on action items?
- Being part of accident investigation teams?
- Responding to all accident investigation reports and following up on action items?
- Participating in regular audits, and following up action items on audit reports?
- Insisting that contractors meet acceptable and agreed standards?
- Communicating the Company's safety objectives to Government and other authorities?

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2. PRECONDITIONS FOR ERECTION
2.1. Demands on the erection personnel
Exclusively reliable personnel is allowed to carry out erection works on the plant!
The legally permissible age is to be observed!
It is obligatory to employ only well-trained and qualified specialists who are able to assemble the
machine according to the manuals and drawings, put at their disposal!
The erection of the electrical equipment has to be realised according to the electrotechnical
regulations exclusively by electrical specialists or by instructed persons under the direction and
supervision of an electrical specialist!
The assembly of the hydraulic / lubrication equipment has to be effected by personnel having good
specialised knowledge and experiences in hydraulics!
2.2. Space requirements, conditions of the area, nature of the ground
The dimensions of the erection area provided for the whole erection scope must allow pre-
assembly works as well as final erection works. In order to be able to effect the delivery of the
constructional and mechanical components per truck, rail or ship to the site and to realise the pre-
assembly and assembly using a truck crane, the approach roads as well as the erection area must
be sufficiently compacted (min. 50 N/cm²) and must be cleared from building materials.
The storage and preassembly areas should be situated as near as suitable to the final erection
place.
The runways / foundations for our scope must be ready to bear the designed loads. A
dimensioning report has to be submitted prior to the start of the erection.

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Provision should be made for an air-conditioned office with telephone installation (IDD), staff
accommodations with all water supply and draining pipes as well as storage depots for tools and
auxiliary equipment in the close proximity of the erection area.
A current supply point for 380/220 V, 200 KVA, has to be available in the erection area.
2.3. Transport and storage regulations
The single parts will be transported in form of individual components or as constructional groups.
Special attention has to be paid to the fact that all parts are lifted off the transport vehicles and put
down on the storage area by using the suitable tackles.
After the delivery to the jobsite, all parts have to be inspected for damages occurred during
transport and in case, there are any, be reported in a transport damage report. The parts to be
provided with a protection against humidity, contamination and damages, be stored on wooden
timbers. Under no circumstances, it is permitted to deposit the components directly on the ground!
Motors, couplings, gearboxes, measuring and control instruments, other electrical and lubrication
parts have to be kept dry in well aerated / air-conditioned rooms.
2.4. Gearboxes
The lifting devices have to be attached only to the corresponding points provided for.
Gearboxes which are equipped with oil pumps and pipes call for an especially careful transport. It
is useful to remove the pipes prior to transport and to close all pipe connection pieces and
openings by means of weatherproof and shock-resistant sealing covers, thus preventing the
penetration of foreign particles.
Attention has to be paid to the fact that the covers can be easily removed.

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2.5. Instructions for Fabrication and Erection
Doc. No. 2516896 Rev. 04

PROJECT
ThyssenKrupp Industrial Solutions AG
Business Unit Resource Technologies
Drg. No.: 2516896
Instructions for design, fabrication and erection

KFR-TDE0014483
Instructions for design, fabrication and

erection
Structural steel work
Becker EN-12 1/40

Rev. 4 Status: April 2013
PROJECT
Drg. No.: 2516896

KFR-TDE0014483
Contents:
• Bolted connections Pages 3-9

• Welded connections Pages 10 - 22
• Advices for fabrication and machining Pages 23 - 31
• Tolerances Page 32 - 39
• Corrosion protection and symbols used in drawings Page 40
Remark: DR=VA; DR15.02, DR15.03,

DR 15.04 are not valid anymore
Remarks: The first chapters – bolted connections, welded connections, advices for fabrication and machining,
tolerances, corrosion protection and symbols used in drawings – are partly corresponding to
specific requirements from relevant specialized standards.
Relevant specialized standards comprise DIN EN 1993, DIN EN 1090-2, ISO 5049/1, FEM 1001,
FEM 2131/2132, DIN 15018, DIN 4132 etc. with special importance being attached to DIN EN
1090-2 „Technical requirements for the execution of supporting steel structures“ which
consequently has to be considered accordingly.
Execution classes:
According to annex B related to DIN EN 1090-2, the following execution classes have been
determined for our products:
EXC2 for structures which are predominantly subjected to static loading, f. ex. belt conveyor
systems
EXC3 for structures which are predominantly subjected to non-static loading, f. ex. handling
equipment
Becker EN-12 2/40

PROJECT
Drg. No.: 2516896

KFR-TDE0014483
Bolted connections
Guidelines for high strength (HS) bolts, systematically pre-stressed

On the basis of the corresponding indications in the drawings, there is determined which type of the following
connecting means should be used.
HS connections: Connections with effective shear bearing areas, systematically (100%) pre-stressed
HS fit connections: Connections with effective shear bearing areas, provided with fit bolts and systematic
(100%) pre-stressing
HSFG connections: Friction-grip connections with systematic (100%) pre-stressing
HSFG fit connections: Friction-grip connections with fit bolts and systematic (100%) pre-stressing
As in principle HSFG and HSFG fit connections are used in device/machine structures, they need to be provided
with specially treated contact areas (friction-grip coat); in this connection refer to the corrosion protection parts lists.
All contact areas are to be coated, i.e. also the areas which result from using shim plates.
As in principle HS and HS fit connections are used in normal steel structure. Because of possible settings and in
consequence loss of the pre-stressing of the bolts the contact areas has to be coated with the primer coat only
according the TKF corrosion protection parts list.
HS bolts DIN EN 14399-4 grade 10.9 tZn (hot galvanized)

HS fit bolts DIN EN 14399-8 grade 10.9 tZn (hot galvanized)
HS nuts DIN EN 14399-2 grade 10 tZn (hot galvanized)
HS washers DIN EN 14399-6 HK 300 tZn (hot galvanized)
Provision has to be made for placing one washer each DIN EN 14399-6 under every bolt head and nut (DIN 6917
for inclined flanges of I-sections, DIN 6918 for inclined flanges of U-sections).
Generally, the nuts of hot galvanized HS bolts are delivered in a Molykote-treated condition. In exceptional cases
when pre-stressing is not executed on the nut, but on the bolt’s head, it is the washer under the bolt’s head which
must be treated with Molykote. It is not allowed to use oil as lubricant due to the fact that it creeps into gaps and
openings, thus destroying friction-grip contact areas.
Burs which would prevent the parts to be connected from sitting on one another are to be removed from the contact
areas of FG- and FG fit connections. When assembling, the contact areas must be free from all contaminations
(such as oil, dirt).
To obtain a coefficient of friction of at least µ = 0.5, the contact areas of FG- and FG fit connections are to be
abrasive-blasted with the blasting shot and grain sizes (Sa 2 ½) usual in structural steel work.
Unless abrasive-blasted contact areas of FG- and FG fit connections are assembled or coated immediately after the
surface treatment, rust films or loosely-lying material has to be removed by using a wire brush prior to their
assembly or coating. When brushing the surfaces, care must be taken that these are neither damaged nor
smoothed.
It is permitted to coat abrasive-blasted contact areas of FG- and FG fit connections with a zinc silicate system,
provided that the manufacturer of the coating substance is able to prove the required minimum coefficient of friction
of µ = 0.5 according to BN 918 300, sheet 85 by presenting an acceptance inspection certificate. Care must be
taken that the drying periods to be determined by the manufacturer are observed.
Becker EN-12 3/40

PROJECT
Drg. No.: 2516896

KFR-TDE0014483
The application of other coatings in FG- and FG fit connections is only allowed on condition that evidence has been
given of having reached the required minimum coefficient of friction of µ = 0.5 in an operational research test.
A description on how to prepare the contact areas for FG- and FG fit connections has been included in TKF’s
coating instructions.
Irrespective of their execution type, hot galvanized bolts and nuts are to be procured from the same bolt
manufacturer in order to ensure the fitting accuracy of bolt- and nut thread.
It is obligatory to only use the a.m. matching sets from the same bolt manufacturer. The bolt manufacturer has to
ensure that through an appropriate lubrication the nuts show a uniform tightening behaviour according to the
specifications when being delivered.
For bolts of the property class 10.9, an acceptance inspection certificate 3.1. in accordance with DIN EN 10204 is
always required to prove the strength properties. If the bolts are marked with a batch code, so that the manufacturer
always can rely on parameters determined by reason of the factory-owned manufacturing check, it is allowed to
renounce the acceptance certificate.
The difference in thickness resulting from manufacturers’ tolerances must not exceed 1 mm for butt strap
connections subjected to shear stress. For reaching an adaptation, use has to be made of shim plates of steel with
a minimum thickness of 1 mm. In case there are used more than three shim plates, these must be previously tied
up, e.g. by tack-welding.
For systematically pre-stressed connections with additional tensile stress, the bolt thread has to project at least one
turn beyond the nut after the bolts have been tightened.
For compensating the grip of a bolted connection, it is admissible to use up to three washers with a total thickness
of maximum 12 mm on the side where no screwing takes place. For HS fit connections, DIN EN 14399-8 has to be
complied with.
Threads projecting into the shear plane are allowed provided that this fact had been considered when designing the
respective connections.
Prior to starting the screwing works, an execution manual has to be drawn up. Compliance with the instructions and
directives given in this manual must be documented.
For systematically pre-stressed sets, there are not needed any additional safeguards.
The pre-stressing is carried out on the basis of the torque procedure in accordance with DIN 18800-7 section 8.6.2.
Pre-stressing of a connection is obtained by turning the nut. Only in this case, the set values given in the following
table are applicable for systematically pre-stressed sets.
The pre-stressing of the bolts has to be documented in conformity with annex 8 to the procedural rule VA 9.01.
If a set, systematically pre-tensioned to the regular pre-stressing force, is released at a later date, it has to be
removed and replaced by a new one.
Systematic pre-stressing according to DIN 18800-7:2002-09 (remains valid for

the present, as the respective instructions are missing in EN 1090-2)
Torque (MV) to be applied by means of torque wrench with hot galvanized HS bolts, where the
nuts have been treated with Mo S2.
(DIN 18 800-7)
Bolts Ø M 12 M 16 M 20 M 22 M 24 M 27 M30 M 36
MV Nm 100 250 450 650 800 1250 1650 2800
(kpm) 10 25 45 65 80 125 165 280
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Check of friction-grip connections
Immediately prior to their assembly, the contact surfaces are to be submitted to a visual inspection.
Apart from the coefficient of friction offered by the contact surfaces of the components to be connected, it is mainly
depending upon the pre-stressing of the bolts how efficient the friction grip connections are. The check of the pre-
stressing force covers 10% of all bolts within the connection for the execution class EXC3, and 5% of all bolts within
the connection for the execution class EXC2. It is carried out on the basis of a sequential sampling plan according
to chapter 12.5.2.3 of EN 1090. In chapter 12.5.2.4, there is described the check of a set which had been pre-
stressed according to the torque procedure.
The calibration certificate of the tightening device has to be examined.
Bolt symbols
Bolt symbols according to DIN ISO 5845-1

Symbol for bolt or rivet installed Symbol for
Bolt countersunk
rivet,
or rivet without countersinking countersinking countersinking
countersinking on the front on the back on both sides
drilled and installed

in the workshop
drilled in the
workshop and
installed on site
drilled and installed

on site
Note: To distinguish between bolts and rivets, it is necessary to include the symbol for the thread type by
placing it in front of the bolt designation.
Example: The designation of a bolt with a metric screw-thread reads M12 x 50, whereas a rivet is designated
by Ø 12 x 50.
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Symbols for holes according to DIN ISO 5845-1

Hole Symbol for hole
without countersinking countersinking on the countersinking on the countersinking on
front back both sides
drilled in the
workshop
drilled on site
Hole clearance
Bolt
Execution of holes
If not stated otherwise, the holes relating to EXC2 can also be produced by means of punching without reaming. For
EXC3 punching without reaming is not admissible.
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HS – Bolt - Connection
Washer Nut
DIN EN 14399-6 DIN EN 14399-4
Bolt Washer
DIN EN 14399-4 DIN EN 14399-6 or
DIN EN 14399-5
Guidelines for hexagonal bolts to be used in steelwork structures

Alternatively this type of bolt connection can be used in secondary or auxiliary structures only, but not in main
supporting structures.
Bolt Nut DIN EN ISO 4032 or

DIN 7990 DIN EN ISO 4034
Washer DIN 7989-1 or

DIN 7989-2
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Gaps in bolted connections

Tolerable gaps after bolt tightening ≤ 2 mm (at the edge ≤ 4 mm)
Tolerable gap
Not tolerable gap
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Filling of air-gaps by shim-plates

To minimize air-gaps by means of shim-plates is allowed by EN 1090-2. Spezial prepared shim-plates should be
available on site.
Proper filling execution is required on site.
Examples of not suitable fillings
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Welded connections
Fabrication requirements
When giving evidence of the efficiency of the fabrication requirements before an acknowledged inspection authority
(business quality audit), the fabrication- or erection company must furnish proof of being able to fulfil the respective
relevant requirements according to DIN EN ISO 3834-2 to 3834-4 and of having available the necessary welding
staff.
Depending upon the respective execution class, the following parts of EN ISO 3834 apply:
- EXC2: part 3 “Standard quality requirements”
- EXC3: part 4 “Comprehensive quality requirements”
Welding may only be carried out by welders examined according to DIN EN 287-1 or DIN EN 1418.
Welding supervision must be ensured during the execution of the welding work by sufficient qualified welding
supervision staff that must have experiences in the welding work to be supervised as stipulated in EN ISO 14731.
With respect to the welding work to be supervised, the welding supervision staff must have technical knowledge as
described in the tables 14 and 15 according to chapter 7.4.3. of DIN EN 1090.
For the fabrication provided for, the welding workshop must have at its disposal the installations required for weld
seam preparation, for welding, testing and transport.
Execution requirements
Welding has to be executed according to qualified procedures for which, in compliance with the ruling part of EN
ISO 15609, EN ISO 14555 or EN ISO 15620, a respective welding instruction must be available depending upon the
case of use.
By means of an appropriate test, it has to be ensured that the steel structure corresponds to the requirements given
in the present instructions.
Both test plans and test instructions will be established by TKF. Test instructions are also to be taken from the
welding references in the drawings or from the lists of ultrasonic testing (attached to the parts lists).
The test is carried out and documented by the manufacturer.
After completion of the welding operation, every weld seam has to be subjected to a visual inspection. The visual
inspection and the measures taken due and following to this inspection have to be completed, before a weld seam
becomes inaccessible by works carried out subsequently or is subjected to an additional non-destructive testing.
Further scope of testing is described in chapter 12.4.2.2 of DIN EN 1090.
Non-conformities detected during in-process testing such as fractures or other inadmissible irregularities must not
be welded over and are always to be removed prior to applying the next welding run.
Systematic weld seam irregularities, i.e. recurring irregularities at regular distances are to be evaluated separately. It
is obligatory to take adequate measures for preventing such systematic irregularities from happening.
The reworked components have to comply with the specifications required.
Final examinations relevant to quality are to be carried out by inspecting staff who are able to fulfil the respective,
applicable requirements according to DIN EN 473.
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A welding plan has to be drawn up as integral part of the required design in view of product realization of the ruling
part of EN ISO 3834.
Check – external condition:
Unless in the drawings are given different values for the admissible irregularities, in the case of components for
secondary structures such as railings, staircases, walkways etc., compliance must be ensured with the admissible
limit values for irregularities indicated in the evaluation group C according to ISO 5817 when applying arc welding
processes.
For components of main supporting structures, the admissible limit values indicated in the evaluation group B
according to ISO 5817 are to be complied with when using arc welding processes.
The characteristic no. 1.17 „root recoil” and 1.8 „root notch“ which are in any case inadmissible have been excluded
from this regulation.
Sharp junctions with existing admissible edge offset as given under characteristic 3.1 are to be worked off.
In case of admissible tubular pores, there must not be a connection with the seam surfaces (root run and capping
run).
Apart from the inspection of the external characteristics of irregularities according to ISO 5817, the following
checking steps have to be carried out:
a.) inspection of the presence and correct position of all weld seams;
b.) inspection of the surface condition and shape of the welding;
c.) inspection of the weld seam measures (weld seam thickness/weld seam length).
Should the external condition be negative, there might be required an additional non-destructive testing for the
rework, taking into account the existing weld seam stress.
In addition to the visual inspection according to DIN EN 970, it is allowed to use the following surface crack test
procedures:
a.) penetration method of testing according to DIN EN 1289, where the admissible limit 1 has to be reached;
b.) magnetic particle testing according to DIN EN 1291, where the admissible limit 1 has to be reached.
Check – internal condition:
In case the proof of the seam quality must be furnished because of doubts concerning the external execution, or if
provided for in the inspection certificate according to the testing requirement given in the drawings or the indications
in the weld seam check lists reading BG2 100%, the following test procedure will have to be applied:
Ultrasonic testing according to DIN EN 1714 test class B with the class of admissibility 2 according to DIN EN
1712.
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General
Surfaces where welding works are to be carried out must be dry and free from rust, corrosion protection and
contaminations.
The weld seam preparation must be suitable for the welding process.
Filler materials are to be stored in such a way that their properties as guaranteed by the vendor are maintained.
Filler materials which are damaged or show visible deterioration must not be used.
There must be made provision for appropriate protection against direct atmospheric exposure to cold, wind, rain
and snow both for the welder and the work piece.
Auxiliary assembly structures connected by means of tack welding or bolted connections must be removed in such
a way that the quality requirements specified for the main component will be complied with.
In case of not predominantly static stress, adequate test will have to ensure that the base material is crack-free in its
surface zone.
Additional requirements such as grinding and finishing of the completed seams are to be determined in the
execution directives.
Arc strikes are to be avoided. In case of their occurrence, the surface has to be slightly ground and inspected. The
visual examination should be completed by a penetration method of testing or a magnetic particle testing.
Spatters are to be removed.
Intermittent fillet welds must not be used where capillarity might lead to rust blistering.
Tack welding seams must have a minimum length of 50 mm. All tack welding seams which will not be included in
the final seam have to be removed. Tack weld seams to be included in a final seam must have a form appropriate
to this effect. Torn tack weld seams are to be removed.
Fabrication coats (shop primer) must not be left on the sides of the seams.
With butt welds, there are to be used auxiliary plates at the beginning and at the end of the weld seams in order to
ensure the full seam thickness at the edge.
In case shrinking seams are acting vertically referred to the component’s thickness, the recommendations for
preventing lamellar tearing should be taken into account (refer to DIN EN 1993-1-10).
On principle, electrodes are initiated on the seam sides. Cracks, holes, lacks of fusion and torn tack weld seams
must not be welded over.
Prior to their use, welding electrodes have to be dried according to SEW 088, tables 2 and 3.
The welding current return must not take place via mobile machine elements such as shafts, bolts, bearings etc. A
cable with a sufficiently large section will have to be used.
Seam sections which need touching-up will have to be removed by grooving-out and/or grinding and will be
reworked in a specialist manner.
While carrying out welding, grinding and burning works during erection, protection has to be provided for the steel
structures and machine elements.
The structural components to be welded must be aligned, fixed in their position by means of tack welding seams or
external auxiliaries and have to remain held during the initial stage of welding. The assembly has to be carried out
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such that the fit of the connections and the final dimensions of the components lie within the determined range of
tolerance. Appropriate allowances for warping and shrinkage are to be taken into account.
Preheating
In case of too low heat introduction and its too quick dissipation as well as with low material temperatures of the
work piece, there must be effected a preheating of the welding zones depending upon the respective material.
The temperature required for preheating when welding and burning depends upon the material grade and/or
material thickness.
Material thickness Steel group / temperature in °C

mm S235 JR S355 J2+N
0 - 20 5 5
> 20 - 50 approx. 60 100 – 120
> 50 - 100 80 – 120 120 – 180
> 100 120 – 180 150 – 200
The preheat temperature has to be measured at a distance of 50 mm from the point of welding/intersection.
Preheating with open flame is only permitted on condition to cover a large-surface area by using a propane mix.
With outdoor temperatures below +5°C there is always required preheating to reach a working temperature of
50°C.
Preheating may also become necessary with thicker components or an accumulation of weld seams, as well as with
T-shaped connections, in order to avoid the occurrence of internal stresses or lamellar tearing. Reference is also
made to the indications in EN ISO 13916 and EN 1011-2.
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Welding in cold-formed areas

In case welding work is carried out in cold-worked areas including the adjacent 5 t zones, the minimum limit values
r/t as given in the table are to be kept. Between the values in lines 1 to 5 linear interpolation is possible.
The values of forming degrees according to the table need not be complied with, if cold-worked parts have been
subjected to normalizing prior to welding.
Conditions for welding in cold-formed areas and adjacent material:
Weld seam symbols (according to ISO 2553)

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Elementary symbols
No. Designation Illustration Symbol
1 Butt weld between plates with raised edges; edge flanged

weld (USA) (the raised edges being melted down
completely.)
2 Square butt weld
3 Single-V butt weld
4 Single-bevel butt weld
5 Single-V butt weld with broad root face
6 Single-bevel butt weld with broad root face
7 Single-U butt weld
8 Single-J butt weld
9 Backing run; back or backing weld (USA)
10 Fillet weld
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Combinations of elementary symbols
No. Designation Illustration Symbol
1 Double V-butt weld (X weld)
2 Double-bevel butt weld
3 Double-V butt weld with broad root face
4 Double-bevel butt weld with broad root face
5 Double-U butt weld
6 Double-U butt weld with broad root face
7 V-U weld
8 V-seam with backing run
9 Double fillet weld
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Supplementary symbols for characterizing the shape of the external surface
Shape of weld surface or weld Symbol

a) flat (usually finished flush)
b) curved (convex)
c) hollow (concave)
Supplementary symbols for weld execution
Weld execution Symbol
d) root grooved out and backing run executed
e) seam levelled through additional machining
f) seam transitions notch free, machined if need be
g) permanent backing strip used M
h) removable backing strip used MR
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Examples of application of supplementary symbols
Designation Illustration Symbol
Flat single-V butt weld
Convex double-V weld
Concave fillet weld
Flat single-V butt weld with flat backing run
Single-V butt weld with broad root face and backing run
Single-V butt weld with broad root face, root grooved out and
backing weld executed
Flat single-V butt weld, levelled from the top work piece surface
through additional machining
Fillet weld with smooth blended face
Complementary symbols
Signification Symbol
weld seam running round about
site welds
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Reference mark (here with checking instruction)
BG2 100%
Ultrasonic testing as required under check class B according to DIN EN 1714 with 100%
Thickness of fillet welds
z=a* 2
a z
Requirements to weld seams and checking
The required checking instruction can be seen from the reference mark on the weld seam to be tested represented
in the drawings or indicated in the checking lists.
For the internal condition the check is carried out according to DIN EN 1714 check class B with the admissible limit
2 as per DIN EN 1712.
For the external condition the check is effected as follows:

- for secondary structures such as railings, walkways, staircases etc. according to ISO 5817 evaluation group
C
- for main supporting structures according to ISO 5817 evaluation group B
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Joint preparations for butt welds

Dimensions
Recommended welding
preparation
root face
Thickness of
Depth of
preparation
thickness
Symbols (acc.
Material
Type of
to ISO 2553)
process c)d)
Ref. No.
Angle Gap
Cross-section a) b)
Weld illustration Remarks
t mm α, β b mm c h
3
raised Usually without filler
1.1 ≤2 - - - - 111
edges metal
141
3
1.2.1 ≤4 ≈t 111
Square
- 141
preparation
13
1.2.2 3<t≤8 6≤t≤8 With backing strip
141
Single-V 40°≤α≤ 111 Where applicable

1.3 3<t≤10 ≤4 ≤2
preparation 60° 13 with backing strip
Steep-
flanked 5°≤β≤ 111
1.4 >16 5≤b≤15 - - With backing strip
single-V 20° 13
preparation
Single-V
preparation 111
1.5 5≤t≤40 α≈60° 1≤b≤4 2≤c≤4 - -
with broad 13
root face
60°≤α≤
Single-U 90°
111
1.6 >12 preparation 1≤b≤3 - ≈4 6≤R≤9
with V root
13
8°≤β≤
12°
60°≤α≤
Single-V 90°
111
1.7 >12 preparation 2≤b≤4 >2 - -
with V root
13
10°≤β≤
15°
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Dimensions
Recommended welding
preparation
root face
Thickness of
Depth of
preparation
thickness
Symbols (acc.
Material
Type of
to ISO 2553)
process c)d)
Ref. No.
Angle Gap
Cross-section a) b)
Weld illustration Remarks
Single-U 8°≤β≤1 111

1.8 >12 ≤4 ≤3 - -
preparation 2° 13
1.9.1
Single-
35°≤β≤ 111
5≤t≤10 bevel 2≤b≤4 2≤c≤4 - -
preparation
60° 13
1.9.2
6≤b≤12 111
Steep-
flanked 15°≤β≤
1.10 >16 With backing strip
single-bevel 60° ≈12 13
preparation
Single-J 10°≤β≤ 111

1.11 >16 2≤b≤4 1≤c≤2
preparation 20° 13
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Joint preparations for butt welds, welded from both sides

Dimensions
welding process c)d)

preparation
thickness
Recommended
Material
Type of
root face
Thickness of
Depth of
preparation
Symbols (acc.
to ISO 2553)
Ref. No.
Angle Gap Weld

Cross-section Remarks
a) b) illustration
111
≈t/2
141
Square
2.1 ≤8 - - - -
preparation
≤t/2 13
α≈60° 111
Single-V Sealing run is
2.2 3≤t≤40 ≤3 ≤2 -
preparation indicated
40°≤α≤
13
60°
Single-V α≈60° 111

preparation Sealing run is
2.3 >10 1≤b≤3 2≤c≤4 -
with broad indicated
40°≤α≤
root face 13
60°
α≈60° 111
Double-V
preparation h1=h2=
2.4 >10 1≤b≤4 2≤c≤6
with broad (t-c)/2
root face 40°≤α≤
13
60°
α≈60° 111
Double-V
2.5.1 ≈t/2
preparation
40°≤α≤
13
60°
>10 1≤b≤3 ≤2
α1≈60°
111
Asymmetri- α2≈60°
cal double-
2.5.2 40°≤ ≈t/3
V
preparation α1≤60°
13
40°≤
α2≤60
Single-U 8°≤β≤1 111 Sealing run is

2.6 >12 1≤b≤3 ≈5 -
preparation 2° 13 indicated
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Dimensions
welding process c)d)

preparation
thickness
Recommended
Material
Type of
root face
Thickness of
Depth of
preparation
Symbols (acc.
to ISO 2553)
Ref. No.
Angle Gap Weld

Cross-section Remarks
a) b) illustration
This type of joint
preparation can also
be produced
Double-U 8°≤β≤1 ≈(t- 111 asymmetrically in a
2.7 >30 ≤3 ≈3
preparation 2° c)/2 13 similar manner to
the asymmetrical
double-V
preparation
Single-
35°≤β≤ 111 Sealing run is
2.8 3≤t≤30 bevel 1≤b≤4 ≤2 -
preparation
60° 13 indicated
This type of joint

2.9.1 preparation can
also be produced
Double- asymmetrically in
35°≤β≤ =t/2 or 111
>10 bevel 1≤b≤4 ≤2 a similar manner
preparation
60° =t/3 13
to the
asymmetrical
2.9.2 double-V
preparation
Single-J 10°≤β≤ 111 Sealing run is

2.10 >16 1≤b≤3 ≥2 -
preparation 20° 13 indicated
This type of joint

=(t- preparation can
≥2
c)/2 also be produced
asymmetrically in
Double-J 10°≤β≤ 111
2.11 >30 ≤3 a similar manner
preparation 20° 13
to the
<2 ≈t/2 asymmetrical
double-V
preparation
a Angles are also larger and/or asymmetric for welding in position PC according to ISO 6947 (horizontal position)
b Dimensions given apply to the tacked condition
c The indication of the welding process does not mean that it is applicable for the whole range of the work piece thickness
d Recommended welding process in accordance with ISO 4063 condition
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Joint preparations for fillet welds

Dimensions
Recommended welding
process in acc. with
preparation
thickness
Material
Type of
Ref. No.
ISO 4063
Symbols Angle
(in accordance with Cross-section Gap Weld illustration
ISO 2553) a)
t mm α, β b mm
t1>2 111
Square
3.1.1 70°≤α≤100° ≤2 13
t2>2 preparation 141
t1>2 111
Square
3.1.2 - ≤2 13
t1>2 111
Square
3.1.3 70°≤α≤120° ≤2 13
t1>3 111
Square
4.1.1 13
t1>2 111
Square
4.1.2 13
3≤t≤30
111
Square
4.1.3 13
t1>4
preparation 141
t2>4
a The indication of the welding process does not mean that it is applicable for the whole range of the work piece thickness
b Symbol is only applicable for α =90°
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Advices for fabrication and machining
Essential elements
Essential elements for the fabrication are the workshop drawings with the appertaining documents and the relevant
DIN standards: DIN EN 1090-2 “Technical guidelines for the execution of supporting steel structures”.
The fabrication of the components has to reach such a degree of fitting accuracy, reference is made to the chapter
„Tolerances“, that touch-up works will not be required during the final assembly.
Sections cut too short must not be lengthened by means of welding.
It is inadmissible to shear or punch parts destined for supporting structures.
Tie rods and/or stayings must exclusively be fabricated of sectional steels such as flats, rounds etc.
Materials
With respect to the quality group, the steel grades have been chosen according to the intended use and their
suitability for welding, and are in conformity with DIN EN 10025.
Further, DIN EN 1993-1-10 “Steel grade selection in view of fracture toughness and properties in the direction of
thickness” has to be considered.
If need be, steel products with improved deformation properties existing vertically to the surface of their production
according to DIN EN 10164 are to be used in cases of loading which is acting in the direction of thickness (cross
joints).
Plates and broad flats in main supporting structures for supporting framework with not predominantly static stress
(execution class EXC3) which are subject to tensile loading in the direction of thickness (welded cross joints) will
have to be submitted to ultrasonic testing. The testing has to be effected in accordance with DIN EN 10160 with the
grade of class S1 being required for the surface and of class E1 for the edge zone.
If a check for lamination is required in the drawings - the respective marking being done with „L“ -, this check is
effected via ultrasonic testing in accordance with DIN EN 10160 of quality classes S3 and E4.
For products made of the steel grades S355 according to DIN EN 10025 for welded structures, the indication of the
following 14 elements of the ladle analysis is required in case of order and their enumeration is to be given in the
test certificate: C, Si, Mn, P, S, Al, N, Cr, Cu, Mo, Ni, Nb, Ti, V.
In this connection with manufacturing thicknesses below 30 mm, the maximum value in the ladle analysis of 0.18%
C has to be kept, if there is included Ti, Nb or V > 0.03%.
In case of products for welded structures of the steel grading S355, there is to be agreed upon a maximum of the
carbon equivalent according to table 6 of DIN EN 10025 when ordering and to be indicated in the test certificate.
The condition of the individual steel products at the time of their delivery must be indicated in the respective test
certificates. With products for welded structures of steel grades according to DIN EN 10025, the delivery condition
M is only admissible if it was agreed upon.
Defective material (laminations, notches, etc.) must not be used in any case. Repairs of faults in material need to be
previously approved by TKF.
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Certificates
For products of S235 it is sufficient to establish a work’s test certificate 2.2 indicating the chemical composition
according to the ladle analysis and characteristics of the mechanical properties which are obtained during the in-
process realization of the workshop-owned product monitoring.
For all other products the material characteristics must be given evidence of in an acceptance certificate 3.1 where
are listed the chemical composition according to the ladle analysis, the CEV value and the characteristics of the
mechanical properties.
The above mentioned certificates as per DIN EN 10204 have to include the mechanical and chemical figures.
All material must be clearly identifiable, i.e. by assigning it to the parts lists of high-grade structural steels
(S355J2+N) after cutting to size.
It is possible for foreign suppliers to have their respective materials approved as far as these comply with the
directives of DIN EN 10 025 and by delivering the required proofs.
The results of the tests according to DIN EN 10164, DIN EN 10160 and SEP 1390 have to be evidenced in
acceptance test certificates for products with special properties (improved behaviour of deformation in the direction
of the thickness, ultrasonic testing, weld bead bend test).
Fabrication
Possibility of identification:
At every moment of the fabrication, it must be ensured that every steel structure part or every package containing
steel structure parts of the same kind can be clearly identified by means of an appropriate system.
Cutting:
Separating cuts are to be made by using appropriate cutting procedures.
With the execution classes EXC2 and EXC3, the cut surfaces obtained through flame cutting must have a
perpendicularity or angularity tolerance “u” and a mean surface roughness “Rz5” in zone 4 according to DIN EN
9013. The highest admissible hardness value (HV 10) within the cut surface amounts to 380.
In case of shearing cuts and punched notches in components subject to tensile stress, there are to be worked off
the zones in near proximity of the cuts which have been damaged and compacted in the cut surfaces, unless the
zone concerned will be melted open through welding.
Apart from that, the cut surfaces are to be executed so as to be free from notches and fractures, if need be these
surfaces will have to be reworked.
Forming, heat treatment and flame redressing:
Forming, heat treatment and flame redressing must not cause inadmissible changes in the material’s properties.
The recommendations of the relevant material directives, standards and guidelines, such as SEW 088 are to be
considered and complied with. Forming within the blue temper heat range (250°C to 380°C) and quenching are not
permitted. Hot forming of steels in delivery condition M is not admissible.
It is possible to make use of forming by means of controlled heat treatment provided that the conditions fixed under
6.5.2 and 6.5.3 according to DIN EN 1090-2 are complied with.
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Formed components which show cracking, lamellar tearing or damaged surface coatings are considered to be non-
conforming products.
Punching:
Apart from drilling, it is permitted to fabricate holes by means of punching and reaming by at least 2 mm, as well as
machine-aided flame cutting according to DIN EN ISO 9013 in compliance with quality range 4.
All holes for fasteners or bolts must fit to each other in such a way that it is possible to set the fasteners without any
hindrance into the assembled components at a right angle to the component’s exterior which is in contact.
The admissible tolerances for hole diameters are described in chapter 6.6.2 according to DIN EN 1090-2.
Punching is admitted unless the component’s nominal thickness is larger than the nominal diameter of the hole.
With EXC2 it is allowed to produce the holes by means of punching without any reaming unless stated otherwise.
With EXC3 punching without any reaming is not admitted. The holes will have to be punched with a dimension
smaller than the diameter by a minimum of 2 mm.
External edges of holes must be broken.
Screw and bolt holes have to be without any burrs.
Cut-outs:
Re-entering edges and notches have to be hollowed with a minimum radius of 8 mm.
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Machining
Machining of the surfaces and production of bores are to be carried out in accordance with the indications in the
drawings on the basis of the surface texture symbols (see table below). Prior to that, the structural elements have to
be exactly aligned for the respective machining process.
Comparison of surface texture symbols
Surface texture Average

symbol acc. to roughness
DIN 3141 Ra
Row 2 DIN ISO 1302
smooth
rough
12,5
3,2
0,8
0,1
All machined surfaces must be protected with Tectyl, unless otherwise specified by the buyer.
Machining is to be carried out only after completion of the welding works.
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Pre-assembly at the workshop

Reference is also made to the chapter „Tolerances“.
Fitting of the individual components has to be done at the workshop with the joints being reamed to their finished
sizes for screwed connections and the butt straps being marked.
For welding on site, the welds joints are to be completely matched and prepared, as well as they are to be provided
with auxiliary erection angles according to workshop standard, if need be.
The railings are to be adapted and assembled to sizes suitable for transport.
Trial assembly serves to assemble a sufficient number of components of an entire supporting structure in order to
check their fit. In case such a check is not possible with the help of templates or measuring, the possibility for
assembling components should be examined.
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Construction characteristics
Web stiffeners / cross stiffeners as well as formation of bulkhead plates in corner zones:
• In rolled steel sections
• in welded steel sections and bulkhead plates
The z measure of the cut-out

is slightly higher than the z
dimension of the longitudinal seam
First carry out continuous welding

of the longitudinal seam
Welding connection of stiffener angle with a bulkhead
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Shaping of gusset and connection plates on continuous elements acc. to notch cases K2
and K3
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Tolerances
General:
The tolerances for assembled steel structures have to be chosen such that the functioning and/or fitness for use will
not be affected in any way.
The tolerances to be complied with must fulfil the requirements according to DIN 18800-1 up to 18800-4 as well as
of the specialized standards.
Fabrication tolerances:
All tolerance values given in the drawings must be strictly kept, among others they correspond to the shape- and
position-related tolerances according to DIN ISO 1101.
Basic tolerances:
The basic tolerances have to correspond to D.1 according to DIN EN 1090. The values fixed are admissible
deviations. In case the actual deviation exceeds the admissible value, then according to section 12, the value
measured has to be considered a non-conformity.
In certain cases it may be possible to justify a not corrected deviation from a basic tolerance by means of the
dimensioning of the supporting structure provided that the excessive deviation will be explicitly considered in a new
calculation. If not, a correction of the non-conformity will be required.
Rolled steel sections:

Hot-rolled, hot formed or cold-formed products have to be in compliance with the admissible deviations which are
fixed in the respective product standards. These deviations remain valid as long as they are not replaced by other
stricter characteristics fixed in D.1.
A pre-assembly in the workshop is required in order to ensure that all components separated by site joints will fit
together according to the tolerances. In this connection, the structure will be laid out in the workshop, then
measured and marked, and, if required, machined.
Surfaces to be machined or bores which must be in true alignment have to be worked on in one mounting as far as
possible. Should this not be possible, the parts must be measured and marked prior to their mounting on another
lathe.
A measuring record of the pre-assembly is absolutely required.
All relevant dimensions will have to be entered into the measuring record. Special care must be taken with the
dimensions provided with tolerance indications in the drawings or the respective parts lists (measurement result),
those dimensions marked with „D“ have to be included in the record with this same marking.
Irrespective of the above mentioned procedure, the manufacturer (supplier) has to guarantee the exact fit of all
components.
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For erection tolerances refer to chapter 11.2.3 in DIN EN 1090-2.
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Corrosion protection
The protection against corrosion must be executed according to the corrosion parts lists.
Symbols used in drawings
In the following, there are explained symbols which can be found in drawings.
“L” Check for lamination
„X“ Bend at forging temperature of approximately 700 °C
„Y“ Preheat prior to welding, see chapter „Welded connections“.
Weld seams marked this way must be ground so that they are notch-free, refer to the chapter
„Weld seams“.
„S“ Position of the hardness gap point (soft spot) on the ball bearing slewing rim.
„M“ It is allowed to remove the auxiliary erection angles only after adequate sufficient welding of the
respective joint. The fillet welds of the auxiliary angles have to be gauged, and the remainders of the
weld seams are to be ground. Chopping off the angles is prohibited. In case the plate thickness of the
component is reduced by more than 5% through cutting off the angles, a deposit welding will have to be
carried out which must be ground afterwards to reach a plate-level condition.
Erection item or loose part
Symmetry
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ERECTION MANUAL
2.6. Welding Procedure for Rail Joints

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Empfehlung zur Schienenschweißung mittels

Lichtbogenhandschweißung (Prozess 111 nach ISO 4063)
Recommendation for welding of rail joints by manual metal arc

welding (Process 111 acc. ISO 4063)
(USA – SMAW)
Bemerkungen / Remarks:
In die Zeichnung eintragen: Insert in the drawing:

Schienenschweißung nach WN 264 Rail welding accord. to WN 264
Ersetzt folgende Eintragung in alten Zeichnungen / Replace follow remark in old drawings
Schienenschweißung WN 264 Ausf. A Rail welding accord. to WN 264 type A
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KFR-TDE0014483
111 - E-Lichtbogenhandschweißung 111 - E-Manual Arc Welding
Bei Schienen die in die stat. Berechnung als For rails that for the static calculation must be
mittragendes oder selbstragendes Bauteil eingehen, considered as co-supporting or self-supporting
was überwiegend der Fall ist, muss die Schweißung construction components, what will be general the
gemäß dieser Werksnorm mit nicht verbleibender case, welding shall be carried out according to the
Badsicherung ausgeführt werden. present Works Standard with removable backing
strip.
1) Schienen Vorbereitung 1) Rail Preparation
a) Schiene anheben und symmetrisch unterfüttern. a) Lift rail and level symmetrically.
b) Schweißspalt „s“ herstellen. b) Produce welding gap “s”.
c) Wärmeschutzmatte über elastische c) If necessary, lay insulating mat over elastic crane
Kranschienenunterlage legen – wenn erforderlich. rail underlayer.
d) Kupferunterlage zwischen Wärmeschutzmatte und d) Lay copper plate between insulating mat and rail
Schienenfuß einlegen foot.
Lineal - rule
2000
1000 s
Kranschiene – crane rail
m
Kupferunterlage – copper plate
Wärmeschutzmatte 400 breit
Insulating mat 400 wide
Elastische Schienenunterlage
80 elast. rail underlayer
600
Trägerobergurt – girder top chord
Kranschiene – Crane rail DIN 536 A45 A55 A65 A75 A100 A120 A150
1)
m Richtwert (Überhöhung) – m Value (camber) [mm] 8 6 6 5 5 4 4
2)
s Spalt – s gap [mm] 12 12 14 16 18 20 22
Breite der Kupferunterlage – width of copper plate [mm] ≥125 ≥150 ≥175 ≥200 ≥200 ≥220 ≥220
1) 1)
Richtwert (Überhöhung) zum Ausgleich des Approximate value (camber) for balancing of
Winkelschrumpfes, bezogen auf eine Lineallänge von angle shrinkage related to rule length of 2000 mm.
2000 mm
2) 2)
Bei Instandsetzungsschweißung kann die If necessary, welding space can be enlarged for
Schweißlücke, wenn erforderlich, vergrößert werden; repair welding; 30 mm must not be passed over
30 mm sollen nach vorliegenden Erfahrungen jedoch according to present experiences.
nicht überschritten werden.
3) 3)
Werkstoff für Wärmeschutzmatte z.B. Fiberchrome- Material of insulating mat for instance
Felt 800 oder andere gleichwertige Werkstoffe. Sind Fiberchrome-Felt 800 or other similar materials.
keine elastischen Schienenunterlagen vorhanden oder Insulating mat is inapplicable if elastic rail underlayer
werden diese während der Schweißung entfernt, so is not present or if it can be removed.
entfällt die Anwendung der Wärmeschutzmatte.
Für Schiene 33E1 nach EN 13674-1 gelten Werte wie For rail 33E1 acc. to EN 13674-4 apply values as
für Schiene A120 nach DIN 536. for rail A120 acc. to DIN 536.
Für Schienen 41E1 nach EN 13674-1 und 49E1 nach For rails 41E1 acc. to EN 13674-1 and 49E1 acc. to
EN 13674-4 gelten Werte wie für Schiene A150 nach EN 13674-4 apply values as for rail A150 acc. to
DIN 536 DIN 536.
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2) Nahtvorbereitung 2) Preparation of the Weld

KFR-TDE0014483
Die zu verschweißenden Schienen sind gut zu säubern. The rail ends that are to be welded together must be
Als Nahtform wird der ganz normale I-Stoß angewendet thoroughly cleaned. As type of weld is used the normal I-
mit einem Abstand „s“ der durch Sägen oder joint with a distance “s” of the plane-parallel weld sides,
Brennschnitt hergestellten planparallelen Nahtflanken. obtained by sewing or flame-cutting. Besides that the rail
Sonst bleibt das Schienenprofil unverändert. section remains unchanged.
Skizze / sketch 2
Ober - und Seitenflächen kerbfrei schleifen
max. 20 mm
surface and sideface to be ground notch - free
A or E
Stahlunterlage / Steel insert
Cu-platte / Copper plate
3) Schweißzusatzwerkstoffe - Elektrode 3) Welding Consumables - Electrode
Für den Schweißprozess werden folgende Elektroden Electrodes for the process shall be as follows:
empfohlen:
Für Schienen mit Kohlenstoffgehalt bis 0,8%: For rail compositions with up to 0,8% carbon:
PHOENIX K 90 S oder Fox EV 63 PHOENIX K 90 S or Fox EV 63.
Durchmesser 3,2, 4,0 und / oder 5,0 mm. Diameter of the electrodes 3,2, 4,0 and / or 5,0 mm.
Für Schienen mit Kohlenstoffgehalt über 0,8%: For rail compositions above 0,8% carbon:
Rücksprache mit Schweißfachingenieur Consult Welding Engineer
4) Schweißmaschine 4) Welding Machine
Die kalkbasische Elektrode ist am Gleichstrom + Pol zu The lime-basic electrode shall be melted off at the DC-
verschweißen. Um der Blasenwirkung zu begegnen, ist plus-pole. In order to provide against the arc blow effect
das Erdkabel zu teilen und an beiden Schienen the earth cable must be split and clamped to both rails.
anzuklemmen.
5) Vorwärmung 5) Pre-heat treatment
Die Vorwärmung ist ca. 150 mm rechts und links vom Preheating shall be made at the right and the left side of
Stoß durchzuführen. Die Temperatur ist durch den the joint on an area of each 150 mm. The temperature is
ganzen Schweißprozess konstant zu halten. to be maintained throughout welding.
Die Temperatur ist mit Thermometer zu kontrollieren. The temperature shall be checked by means of
Die Vorwärmtemperatur ist abhängig vom thermometer.
Kohlenstoffgehalt in der Schiene und ist folgend The pre-heat temperature shall be dependent on the
festgelegt: carbon content of the rail as follows:
Kohlenstoffgehalt: Vorwärm- Carbon content: Pre-heat

temperatur: Temperature
bis 0,5% 200°C up to 0,5% 200°C
0,5% - 0,7% (690MPa DIN 536, R200 & 300°C 0,5% - 0,7% (690MPa DIN 536, R200 & 300°C
R220 EN 13674-1)) R220 EN 13674-1))
0,7% - 0,8% (880MPa DIN 536, R260, 350°C 0,7% - 0,8% (880MPa DIN 536, R260, 350°C
R260, R320 & R350 EN 13674-1) R260, R320 & R350 EN 13674-1)
Über 0,8% (R370 & R400 EN 13674-1) Rücksprache Above 0,8% (R370 & R400 EN 13674-1) Consult
mit SFI Welding
Engineer
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6) Schweißvorgang 6) Welding procedure
Da ein Stegabstand von 20 mm nicht ohne weiteres As a web clearance of 20 mm cannot be bridged directly
überbrückt werden kann, wird eine Stahlunterlage aus one steel insert S235, dimension: 3 mm x (s – 2) mm x
S235, Abmessungen: 3 mm x (s – 2) mm x rail foot width with the sides grinded at appr. 45° is first
Schienenfußbreite, Längsseiten auf 45° geschliffen fused together on both sides with the rail foot. Care must
zuvor auf beiden Seiten mit dem Schienenfuß be taken to ensure complete fusion between the insert
verschmolzen. Die ersten Nähten sind sorgfältig and both rail ends. At this bridge is then deposited the
auszuführen um die Durchschweißung zu garantieren. electrode material. The flat hold of the electrode ensures
An dieser Brücke wird dann das Elektrodengut that the welder can better control the slag flow. Following
abgesetzt. Die flache Haltung der Elektrode bewirkt, the welding of the root layer, with 3,2 mm electrodes, the
dass der Schweißer den Schlackenfluss besser slag must be removed using a chisel. The filling layers
beherrschen kann. Nach der Wurzellage, mit 3,2 mm must be made with 4 mm and / or 5 mm electrodes.
Elektrode geschweißt, ist die Schlacke mit dem Meißel
zu entfernen. Die Fülllagen sind mit 4 mm und / oder 5
mm Elektroden zu schweißen.
Schienenfußschweißung / Welding of rail foot
7) Wärmenachbehandlung 7) Post-heat treatment
Das Schweißstoß für mindestens 4 Stunden mit Welded joint insulate with refractors thermal blanket.
Wärmeisoliermatte abdecken (eine langsame Abkühlung This to be left in place for at least 4 hours (slow cooling
auf <50°C erforderlich) <50°C is required).
Überstehendes Schweißgut an den Seitenflächen Protruding welding material at the sides must be ground
abschleifen. smooth.
8) Inspektionen 8) Inspection
Alle Schweißnähte sollten einer visuellen Kontrolle All welds shall be subject to close visual examination and
unterzogen werden und müssen frei von folgenden shall be free from the following defects:
Fehler sein:
- Bindefehler auf der Nahtoberfläche - Surface lack of fusion
- Rissen - Cracking
- Einbrandkerben < 0,5 mm - Undercut shall not exceed 0,5 mm
- Oberflächenporen - Surface breaking porosity
9) Allgemeine Vorschriften 9) General Provisions
Die Schienenschweißung ist auf der Baustelle nicht Welding of rails on the jobsite shall never be made with
bei Sonnenbestrahlung oder bei allzu großer Kälte radiation or severe cold because of the tensile and
wegen der hierbei auftretenden Zug- und compressive stresses that can result thereof
Druckspannung auszuführen. Rails shall only be welded by an experienced welder
Die Schienenschweißung darf nur von einem hierfür familiar with this job.
ausgebildeten Schweißer durchgeführt werden.
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10)KFR-TDE0014483
Reparaturschweißung 10) Repair welding
Muss ein Zwischenstück in eine beschädigte If an intermediate piece must be welded in a damaged
Kranschiene eingeschweißt werden, so soll die crane rail the length shall be min. 1500 mm. At this one
Länge des einzubauenden Schienenstückes welding joint must be full finished. First after cooling it
mindestens 1500 mm betragen. Hierbei muss zuerst may be started with the second welding joint.
ein Schweißstoß vollständig fertiggestellt werden. It must be attended the crane rails will be travelled first
Erst nach Erkalten des Stoßes darf mit der zweiten after cooling of last rail joint to +50°C.
Schweißverbindung begonnen werden.
Es ist besonders darauf zu achten, dass die
Kranschienen erst nach Abkühlung des letzten
Schienenstoßes auf +50°C befahren werden
Auswahl der Elektroden Selection of electrodes

* TKF - Empfehlung * TKF - Recommendation
Profilkurz- Elektroden Profilkurz- Elektroden Profilkurz- Elektroden

zeichen Electrodes zeichen Electrodes zeichen Electrodes
Description Anzahl Description Anzahl Description Anzahl
Number Ø Number Ø Number Ø
A 45 7 3,2 A 100 20 3,2 41E1 (S 41) 10 3,2
DIN 536 12 / 8 4/5 DIN 536 38 / 25 4/5 EN 13674-4 22 / 15 4/5
A 55 10 3,2 A 120 25 3,25 49E1 (S49) 10 3,2
DIN 536 15 / 10 4/5 DIN 536 50 / 32 4/5 EN 13674-1 25 / 16 4/5
A 65 12 3,2 A 150 25 3,2
DIN 536 23 / 15 4/5 DIN 536 85 / 55 4/5
A 75 15 3,2 33E1 (S33) 5 3,2
DIN 536 30 / 20 4/5 EN 13674-4 20 / 13 4/5
Elektrodentyp : 1) (T-PUT - Katalog) (Former Thyssen / Böhler Welding)

Electrode make : 1) (T-PUT - Catalog) (Former Thyssen / Böhler Welding)
1. Phoenix K90 S
EN ISO 2560-A E 46 4 B 32 H5
EN ISO 2560-B E 4916A
AWS A5.1 E7016
AWS A5.1M E4916
Oder / or
Elektrodentyp : 2) (Böhler Welding - Katalog)

Electrode make : 2) (Böhler Welding - Catalog)
2. Fox EV 63
EN ISO 2560-A E 50 4 B 42 H5
EN ISO 2560-B E 5718-G A H5
AWS A5.5 E8018-GH4R
AWS A5.5M E5518-GH4R
* Grundsätzlich sind Qualität- und Mengenfestlegung der Elektroden durch die Montagefirma zu treffen
* In principle, quality and quantity of the electrodes have to be determined by the erection company.
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3. ERECTION SEQUENCES
3.1. General Notes for Erection
This Manual describes the sequence of erection and not the sequence of preparing and pre-
assembling. While some parts will be erected, other units can be pre-assembled in parallel just to
save and minimize erection time.
This Manual only shows one opportunity of erection the TKRT-supply. In case of Erection Company
wants to erect the machines in an alternative way TKRT have to be consulted for approval.
Only pre-assembled main steel structures and mechanical items are highlighted and the weights
are only given for heavy lifts. Unless otherwise in the Manual described the weights of the pre-
assembled items are summated to the maximum feasible/practicable pre-assembly degree. To
consider deviations in fabrication as well as installation of small electrical equipment (like e.g. cable
funnels, junction boxes, encoder supports) 5-10% are added to the summated weights. In case of
Erection Company wants to minimize the weights of the heavy lifts many pre-assembling works can
also be executed after lifting/installation of the main components. In this case it has to be
considered that the works have to be executed in the height and the risk of falling down (humans
as well as tools, bolts or other parts) will increase.
Secondary small items (sub-items) with lower weights have to be seen as NORMAL ERECTION and
are not described in detail in this Manual. Associated weights for lifting that items have to be taken
from the relevant packing and/or part lists.
Due to the fact that not all sub-items are described in this manual, the sum of the displayed
weights (noted as weight: / description / approx. X.XXXkg at the end of the chapter) doesn’t show
the total amount of TKRT-supply!
Attached test schedules of already executed welds during fabrication are non-relevant. In case of
part lists contains no information, these are also to be seen as non-relevant.
For execution of the erection works see also the O&M-Manuals!

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3.2. Prior Starting Erection:
Prior starting the erection special attention have to be paid to chapter 2.5 - Instructions for
Fabrication and Erection !
Also the Safety Policy (chapter 1) and the preconditions (chapter 2) have to be red/followed.
3.2.1. TKRT-Advisor
The erection and commissioning of the plant components have to be executed in the present of an
advisor of ThyssenKrupp Resource Technologies (TKRT) and have to be coordinated with him.
In case of erection workers are probably causing damages and/or unsafe situations through gross
negligence TKRT advisor got the right to stop the works and in serious cases to suspend the
responsible person(s) from the erection works!
3.2.2. Lifting
Before lifting of the parts, the weights have to be checked with the actual packing list and to be
controlled with the crane capacities!
Especially on very heavy loads and/or lifting’s that are very close to crane capacity the weight of
the parts should be double-checked by weighing system before execution of the lifting.
3.2.3. Measurement Check
Before welding steel structure items, the complete structures have to be checked regarding
alignment according to TKRT instructions and corrected, if necessary. Measurement sheets have to
be given to TKRT site representative for approval before welding! In case of any discrepancies
regarding alignment, TKRT is reserving the right to re-check the measurements!

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3.2.4. Machined Surfaces
All parts that will be mounted with machined surfaces like drive shafts, etc. will be delivered with a
removable protection coat (like e.g. grease and/or protection tape) to avoid corrosion. Care have to
be taken to preserve these protection coat! In case that these coat is damaged like (e.g. handling,
storage or weather conditions) it has to be replaced/renewed to refresh the corrosion protection.
3.2.5. Welding
The weld back current cables have to be positioned always close to the weld joints!
All welds have to be prepared, performed and checked in accordance to their drawings, welding
procedures and specifications, and have to be approved by the client! The welding procedures will
be prepared by the erection contractor and approved by TKRT.
Designated welding seams have to be checked by ULTRASONIC test. Detailed information
regarding checking procedure are displayed on the drawings and the test schedules!
3.2.6. Adaptation
It might be possible that some fitting works (re-drilling, reaming of holes, etc.) on handrails or
other minor structures will become necessary during the erection. These fitting works have to be
understood as normal erection works and will not deem to be extra work.
3.2.7. Walkways and Stairs
All walkways and staircases will be delivered in single parts and have to be installed as far as
possible together with steel structure erection during pre-assembling.
To minimize the danger of falling down caused by uncompleted and/or lose walkways, stairs,
handrails, gratings, etc., these items have to be completed and fixed (tight) as earliest as possible
during pre- and final erection!
In case of existing risks for healthy and life caused by lose and/or not and/or unsafe installed
walkways, stairs, handrails, gratings, etc., the unsafe area(s) have to be locked-out by fixed
scaffolding material (including lockout signs) and not by warning tape!

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If this will not happen, TKRT advisor got the right to stop the works until the unsafe area(s) are
locked-out or in safe condition.
3.2.8. Bearings
The installation of all bearings has to be executed according to the installation manual of the
bearing manufacturer (part of the O&M Manuals).
Bearings with shrink disc or with cone surface for fitting always have to be installed by hydraulic
pressure nut! Hereto find the following sketches for example.

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3.2.9. Quality of work
All works have to be executed only by qualified and educated erection staff! The erection works
have to be performed under experienced supervisor personnel of the erection company. If not,
TKRT is serving the right to stop the erection works until unqualified erection/supervisor staff will be
replaced by qualified.
In case of erection works will be executed in bad quality and/or not according to TKRT -
Instructions for Fabrication and Erection (chapter 2.5) these works have to be corrected until the
TKRT-quality standard has reached!
3.2.10. Extra works
It might become necessary to correct some mistakes caused by wrong fabrication or drawings. In
case of TKRT and/or fabrication company is not in condition to correct that mistakes on jobsite, the
erection company should be generally agree to execute the correction works.
Only extra works that are ordered by TKRT and countersigned by TKRT advisor(s) after execution
can be charged to TKRT (hourly/daily rates for staff and equipment have to be transmitted to TKRT
prior starting extra works).
3.2.11. Erection supports
If not contractual determined, erection supports are not part of TKRT-supply.
TKRT will also not do the statically calculation of supports and other constructions not part of
TKRT-supply. Furthermore it’s not TKRT’s task to check them and TKRT will not take the
responsibility in case of any damages/accidents caused by wrong dimensioned supports.
The weights and loads which are given in the erection sequence drawing(s) as well as in this
manual are the really expectable weights/loads, i.e. they are not multiplied by a safety factor. The
sufficient safety factor has to be considered in the erection supports and crane capacities.

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3.3. Erection Sequence Drum Reclaimer
Fig. 01: Drum Reclaimer TAS 41

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Content
3.3. Erection Sequence Drum Reclaimer..............................................................................................................1
3.3.1. General: ................................................................................................................................................3
3.3.2. Travel Gear...........................................................................................................................................5
3.3.3. Portal Structure.....................................................................................................................................6
3.3.4. Drum Body......................................................................................................................................... 11
3.3.5. Cross Conveyor ................................................................................................................................. 13
3.3.6. Rakes................................................................................................................................................. 16
3.3.7. Hydraulic System............................................................................................................................... 18
3.3.8. Lubrication System ............................................................................................................................ 19
3.3.9. Electrical Installation .......................................................................................................................... 19
3.3.10. Remaining Parts .............................................................................................................................. 20

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3.3.1. General:
Associated Drawings:
4553378 1 Drum Reclaimer TAS 41 Front View / Top View

4553379 1 Drum Reclaimer TAS 41 Side View / Sections
4553380 1 Plot Plan Drum Reclaimer TAS 41
4555026 1 Transport Sketch Drum Reclaimer TAS 41
4553398 1 Corner Loads Drum Reclaimer TAS 41
4553821 1-2 Rail Track Drum Reclaimer TAS 41
The above mentioned drawings give an overview of the parts to be erected. All erection steps
described in the following chapters have to consider these drawings.
The erection has to be executed in accordance to chapter 2 and to all the instructions especially
given on the drawings.
To get information about the dimensions of construction components see final version of packing
list, which is not included in this installation instruction.
 All weights for the parts of the reclaimer system listed in this manual are only preliminary
weights (calculated based on TKRT-Drawings).
Before lifting of each part of the reclaimer system, the real existing weights have to be
checked and controlled with the crane capacities!
 Prior to the start of the erection a reference line/reference points has to be determined to
enable the surveyor to check the dimensions and tolerances of the machine following the
erection.
 Attention! All welds have to be performed in accordance with the drawings and the welding
procedures. All welds have to be approved by the client and TKRT!
After concrete the foundations together with the adjusted anchor bolts and the base plates, they
will be aligned again according the tolerance plan above mentioned and subsequent the grouting
can be started and must be completed minimum 2 days before TKRT supply can be installed.
When aligning the rails, the admissible tolerances shall apply (see fig. 03). At the end of the rails
the buffers are to install, align and also to concrete.

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Fig. 02: Travel Track Foundation
Fig. 03: Admissible Rail Tolerances (see also Drawing 4553821 Sheet 1)

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3.3.2. Travel Gear
Preconditions:
To enable a proper erection, the rail track has to be installed, levelled, aligned and welded as well
as grouted for a minimum length of 50 m in the erection area of the reclaimer. The accessibility to
this area for mobile cranes and trucks has to be ensured until completion of erection.
The erection area has to keep free at a minimum of 80 meters in each direction and it has to be
ensured, that the erection area enables the works with mobile cranes and trucks (see also chapter
2.1 - 2.3).
4552557 1 Long Travel Gear Wheel ø630

4554961 1 Surveying Sheet Long Travel Gear ø630
4553147 1 2-Wheel Bogie Set Ø630x110 4 x 1662 kg
4552699 1 4-Wheel Bogie With buffer base 4 x 632 kg
4555064 1 Support For 4-wheel bogie 4 x 463 kg
4552707 1 Main Bolt Ø180x855 4 x 171 kg
4552707 1 Main Bolt Ø125x650 8 x 63 kg
Travel Drive WUB100QS KBA125B4 8 x 704 kg
A reference line has to be determined across the rail track and rectangular to the Reclaimer
travelling direction to define the exact centerline of the bogies. The reference line as well as the
centre line of the bogies should be punch marked onto the rails.
According to the marking and in accordance with the drawings, the travel mechanisms has to be
lifted, set down onto the rails and secured against tilting and drifting. It shall be ensured by
geometrical survey that the travel mechanisms on both sides are placed exactly opposite to each
other and that the runner wheels are exactly in parallel as shown on drawing 4554961. This is to
be ensured preferably by using e.g. a theodolite or a piano wire being tensioned alongside the
travel mechanisms.
The drives should be installed after installation of the main steel structure parts in accordance to
the respective drawings as well as in accordance to the O&M Manuals.

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3.3.3. Portal Structure
3.3.3.1. Preassembly Bridge Girder
4553447 1 Portal Structure General Arrangement

4553469 1 Camber & Tolerances Portal Structure
4553457 1-2 Bridge Girder A-Side (E-House) 10953 kg
4553458 1-2 Bridge Girder Center Section 9208 kg
4553459 1-2 Bridge Girder B-Side 9171 kg
4553465 1 Bridge Girder Sections 5767 kg
4553466 1 Bridge Internal Walkway 892 kg
4553456 1 Portal End Section „A“ Side Portal Structure 3261 kg
4553462 1 Splice Plate Details 1317 kg
4553460 1 E-House Floor 708 kg
4553461 1 E-House Flooring 1636 kg
4553468 1 Access Steps To Hydr. Power Pack 80 kg
4553449 1 Thrust Guide Rollers Assembly 512 kg
The bridge girder will be delivered in 3 parts plus end section at “A-side” (fixed side) and layed
down on temporary supports for leveling, welding as well as installation of all other supports and
all other parts that need to be connected before lifting. During preassembly and before putting
together, all components that need to be fixed inside of the bridge girder like transformer, e-house,
lubrication system, etc. should be installed before, because of an easier access.
Fig. 04: Preassembly Bridge Girder

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The specified camber according drawing 4553469 has to be considered during adjustment and
welding. The tolerances – specified in this drawing too – also have to be checked after adjustment
of the girder joints and after tack welding again. The welding of these joints have to be executed in
such a manner that no or as less as possible distortion enters the construction.
The drum guide rollers can be installed after installation of the bridge girder.
3.3.3.2. Installation of Mounting Parts
4553463 1 Miscellaneous Portal Structure 4346 kg

4553450 1 Personnel Door Arrangement 3 x 123 kg
4553484 1 Rake Support Rail Assembly 2 x 1769 kg
4555117 1 Rake Suspension Tower Details 2318 kg
After welding of the bridge girder main structure, all useful mounting parts can be installed inside
and outside of the portal.
3.3.3.3. Preassembly Fixed Leg (A-Side)
4553488 1-6 Left Pier Leg A-Side 6992 kg

4553475 1-6 Right Pier Leg A-Side 6920 kg
4553495 1 Drum Suspension A-Side 4460 kg
4553448 1 Drum Support Bogie Assembly 2 x 2331 kg
4553482 1 Settings of Ecc. Bearing Settings for Commissioning
4553351 1 Drum Drive Arrangement 11550 kg
4553480 1 Drum Guards “A” & “B” Side 311 kg

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The fixed leg parts – drum suspension, driven riding ring, left and right leg, drive device and drum
guard - will be mounted onto the travel gear as shown in the sketch below and secured against
tilting and drifting.
Fig. 05: Preassembly Fixed Leg (A-Side)
Because of the later possibility of adjustment of the drum drive device, the bolts shall be mounted
only hand tight.
3.3.3.4. Preassembly Drum Suspension (B-Side)
4553473 1 Drum Suspension “B”-Side - Lower Section 4314 kg

4553472 1 Drum Suspension “B”-Side – Mid Section 2 x 1557 kg
4553464 1 Portal End Section “B”-Side Detail 5264 kg
4553480 1 Drum Guards “A” & “B” Side 311 kg
4553452 1 Sherical Bearing “B”-Side 482 kg
4553448 1 Drum Support Bogie Assembly 2 x 2331 kg
The drum suspension parts at B-side – drum suspension, riding ring, left and right leg, portal end
section at B-side and drum guard - will be mounted onto supports equipped with hydraulic jacks
for an easier removal as shown in the sketch below and secured against tilting and drifting. It has

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to be considered that the upper part of the spherical bearing is already installed at the workshop. A
tempoary support - also with hydraulic jacks on top for adjustment - will be installed next to the
suspension, to lay down the bridge girder until installation of the pendulum leg.
Fig. 06: Preassembly Drum Suspension (B-Side)
3.3.3.5. Installation of the preassembled Bridge Girder
After the bridge girder is completed as far as feasible, it can be lifted by two cranes with load
spreaders and carefully installed between the A-side fixed legs and at the B-side end section by
butt joints with splice plates. After connection, the A-side fixed leg is able to bear the loads of the
bridge girder while on the B-side the temporary support has to take over the incoming loads until
the pendulum leg is installed.

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Fig. 07: Installation of Bridge Girder
3.3.3.6. Preassembly Pendulum Leg
4553485 1 End Beam “B”-Side – Detail 5721 kg

4553452 1 Spherical Bearing “B”-Side 482 kg
4553462 1 Splice Plates Details 1317 kg
The pendulum leg has to be preassembled on ground, together with the tension rod. It must be
checked that the lower part of the spherical bearing has already been installed in the workshop.
The travel gear B-side has to be installed – if not already done before – and secured against tilting
and drifting.
The pendulum leg will be lifted, set onto the travel gear and swinged under the bridge-head while
the bridge girder at the B-side together with the drum suspension - which was previously exempt
from the gying - will lifted a little bit by a separate crane. If the pendulum leg is fixed onto the travel
gear supports, the bridge can be lowered again carefuly. It is to ensure that the bearing upper and
lower part fits to each other. If so and the splice plates are also installed, the bridge can be taken
off from the cranehook.

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Fig. 08: Installation Pendulum Leg
The edge-region of the spherical bearing has to be filled up with grease and the guard ring will be
installed subsequently as well as the locking device against lift-off.
3.3.4. Drum Body
3.3.4.1. Preassembly Drum Body
4553120 1 Drum Assembly 177319 kg

4553124 1 Strucure Details Drum
4553126 1 Transport Cradles For Drum 3 x 1921 kg
4553123 1 Manufacturing Tolerances Drum
The drum body will be delivered in 3 parts and must be supported on trestles which should be
equipped with rollers for adjustment and welding. The preassembly should be executed next to the

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portal structure and in the final working position, so that later the bridge girder with legs and travel
gear can be moved over the drum for connection.
The drum parts should be already preassembled in the workshop, aligned and provided with weld
seam preparation as well as connecting elements so they can be relatively easily reassembled at
site.
After adjustment, the parts will be tack welded inside while the drum is rotated on the roller trestles
and subsequent the alignment have to be checked again. For the final welding, a “Welding
Procedure Specification” (WPS) is to prepare in time by the responsible welding engineer and
submit to ThyssenKrupp for check and approval. The welding procedure is to be designed so that
no or as less as possible distortions enters the construction. The tolerances from drawing 4553123
must be observed also on the construction site. Al welders must have a valid test certificate
according DIN EN 287-1 or DIN EN 1418. Welding supervision must be ensured during the
execution of the welding works by sufficient qualified welding supervision staff that must have
experience in the welding work to be supervised in EN ISO 14731. With respect to the welding work
to be supervised, the welding supervision staff must have technical knowledge as described in the
tables 14 and 15 according to chapter 7.4.3. of DIN EN 1090.
Fig. 09: Preassembly Drum Body
All drum-welds have to be checked with visual tests for every welding seam, surface crack tests for
root-weldings and ultrasonic tests for final weldings and have to be reported to ThyssenKrupp.
Surface defects that are encountered during welding have to be grinded and re-welded
immediately.
3.3.4.2. Drum-Installation
After welding and check, the drum body can be connected with the portal.
Therefore, the drum body should be supported by trestles with hydraulic jacks underneath for
adjusting during installation of the butt straps. The portal will be moved carefully by winches on the
own travel gear over the drum body until the riding rings and the drum body match each other. The
hydraulic jacks can be used to bring the drum in the right position to the riding rings. If so, the
connection of the drum body and the rinding rings can be done by the butt straps. Afterwards the

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trestles will be lowered by the help of the hydraulic jacks and removed. The drum body should
hang in the suspensions now.
Fig. 10: Installation Drum Body
Subsequent, the buckets can be installed.
3.3.5. Cross Conveyor
3.3.5.1. Preassembly
4553423 1 Cross Conv. Arrangement BW 1500 / 45° 69247 kg

4553424 1 Ring Chute Arrangement BW 1500 / 45°
4553425 1 Tail End Elevations & Sect. Gantry
4553426 1 Head End Elevations & Sect. Gantry
4553427 1 Mid Section Elev. & Sect. Gantry
4553428 1 Head Chute Arrangement
4553431 1 Take-up Assembly
4553435 1 Walkway Drive End
4553436 1 Walkway Mid Section

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The cross girder framework will be laid down for preassemby on temporary supports on ground
according the a.m. drawings, adjusted and welded. During this procedure it has to take into
account that the specified camber for the cross girder will be observed. The walkway at the tail as
well as the protection grids should be mounted after installation of the cross girder into the drum.
Fig. 11: Preassembly Cross Conveyor
The conveyor belt with idlers, drums and the drives can be installed and the take-up system at the
tail as well as the head chute also.
The walkway will also preassembled and fixed onto the

cross conveyor – but inclined with the handrail to the
conveyor for an easier installation through the drum. The
ring chute parts will be stored carefully onto the conveyor
belt, because after the cross conveyor is installed into the
drum, it becomes more difficult to bring these parts inside.
Fig. 12: Cross Conveyor – Cross Section

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3.3.5.2. Installation into the Drum
4553443 1 Erection Brackets Temporary

4555963 1 Installation Roller Assembly & Detail
4553432 1 Suspension Pin & Spaces Gantry
4552433 1 B-Side Suspension Arrangement
If the preassembly-progress of the cross girder is as far as feasible, the installation rollers together
with the temporary erection bracket will be prepared inside the drum and the cross tie at the lifting
point according drawing 4553443 must be bolted. The connection parts – pins for A-side and
suspension with pins for B-side – must be placed ready for use and a steel rope with winch (or
optional a caterpillar) at A-side for pulling the cross conveyor must be installed in the drum.
The cross conveyor will be lifted by two cranes and moved with the take-up side to the front into
the B-side drum, as shown in drawing 4553443. If the one of the crane hooks reach the drum, the
installation rollers will be fixed onto the bottom of the cross conveyor and this side is lowered and
released from this hook, while on the drive side the conveyor continues remains on the crane hook.
The winch or the wheel loader pulls it carefully by the help of the temporary rollers through the
drum and simultaneously the crane follows. Before it can reach the end, it may be necessary to lift
the drive-girder a little bit, to pass with the conveyor. When it is in the right position, it will be fixed
by bolts at both sides – on B-side together with the suspension prepared before. The installation
roller inside the drum must be removed again.
Fig. 13: Cross Conveyor Installation

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Afterwards, the ring chute can be installed and the walkway straightned and completed again.
3.3.6. Rakes
3.3.6.1. Preassembly
4558060 1 Rake – PB Width 38m General Arrangement

4557709 1-5 Rake Assembly Drawings 2x 12.370 kg
4558270 1 Rake Structure 2 x 708 kg
4558725 1 Rake Structure Head 2 x 1.860 kg
4558784 1 Diagonal Struts 4 x 859 kg
4558225 1 Box Girder F. Hydr. Cyl. Force Transm. 2 x 2.735 kg
4557783 1 Supporting Bracket For Sheave Wheel 2 x 723 kg
4555117 1 Rake Suspension Tower 1 x 2.309 kg
4555099 1 Bogie For Rake Travel 4 x 3.196 kg
4558071 1-3 Sheave Suspension Assemby & Details 1 x 3.274 kg
4555119 1 Rod End & Wear Plate For Rake Cylinder 4 x 43 kg
4555113 1 Angle Indicator 2 x 46 kg
4555104 1 Maintenance Rope 1 x 304 kg
Winches Zollern ZHP 4.20 2 x 450 kg
Steel Wire Rope ø16 2 x 80m 1960 N/mm² 2 x 95 kg
Hydraulic Cylinder 160/110 x 2020 2 x 770 kg
The drum reclaimer is equipped with two rakes what allows reclaiming in each direction. The
preassembly of the parts should be done on ground as far as feasible before lift and installation.

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3.3.6.2. Tower for Rake Suspension
If not already installed before, the preassembly of the tower should be done according drawing
4555117 on ground, lifted and fixed onto the portal by but straps and high strength bolts.
Afterwards the winches can be installed already at the appropriate locations on the tower.
Fig. 14: Tower for Rake Suspension
3.3.6.3. Rake Preassembly and Installation
The rake-parts should be preassembled on ground including supporting brackets, rope sheaves,
diagonal struts as well as bogies and all other equipment what can be installed easier on ground.
Afterwards, the rake will be lifted, set with the wheels onto the rails at the bridge girder and
suspended by the help of the two maintenance ropes until the steel wire rope is reeved and
connected to the rake and the winch. Subsequent the cylinders for rake-moving will be installed

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and the remaining parts which are necessary for the completion. The same procedure is done on
the opposite side.
Fig. 15: Rake Installation
If the installation is done and the ropes are reeved, the locking against lift of at the bogies still must
be installed.
3.3.7. Hydraulic System
4558704 1 Hydraulic Circuit Diagram Rake Actuating

4558705 1 Hydraulic Power Pack HPP1 Rake Actuating
4558707 1 Hydraulic Piping Layout Rake Actuating
The hydraulic power pack for the cylinder has to be lifted onto the provided space on the portal
girder and connected to the cylinders with tubes and/or hoses. The tubes, hoses and fittings have
to be fitted according to the regulations of the supplier.

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 Note: Before set in operation of the hydraulic power pack, the hydraulic system has
to be flushed by using an external flushing unit. For the cleanness grade of the
system, please refer to the Hydraulic Manual. The cylinder and the whole
hydraulic system have to be free of air. The works have to be executed in the
presence of a ThyssenKrupp Supervisor. ( See hereto Hydraulic Manual )
3.3.8. Lubrication System
4558243 1-2 Central Lubrication Drum, Rake

4558256 1 Central Lubrication Travel Gear
The pre-installed lubrication systems will be completed parallel to the mechanical / electrical pre-/
final erection and will be executed in accordance with the relevant standards, drawings, safety
regulations and technical specification. ( See hereto O&M Manual )
3.3.9. Electrical Installation
Associated Drawings and Documents:
4552364 1 Arrangement Drawing Drum Reclaimer

4552361 1 Consumer List Drum Reclaimer
4552362 1 Device List Drum Reclaimer
4552363 1 Electrical Diagram Drum Reclaimer
The electric equipment will be installed in conjunction to the mechanical erection and has to be
executed in accordance to the relevant electrical standards, safety regulations and technical
specification. ( See hereto O&M Manual )

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3.3.10. Remaining Parts
Carrying out of all pending works for example:
- Completion of walkways, stairways, ladders, hand railing;

- Completion and adjustment of safety facilities, such as limit switches, sensors, pull cord
switches and belt misalignment switches etc.;
- Completion of lubrication systems;
- Adjusting of skirting, belt cleaners;
- Adjusting of brakes;
- Setting of travel way and emergency limit switches;
- Completion of painting/touch-up works;
- The storm locking device will be assembled into the foundation when the stacker is completed
and the boom is in the storm tie down (park) position. Care has to be taken by the exact
positioning of the frames for the locking devices;
- etc.
 General note: It might be possible that some fitting works on handrails or other
minor structure ( re-drilling, reaming of holes, etc. ) will become
necessary during the erection of the Reclaimer. These fitting work to
be understood as normal erection works and will not deem to be
extra work.

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3.4. Erection Sequence Stacker ST-1500-941 with Tripper Car
Fig. 01: Stacker ST 1500-941
Fig. 02: Tripper Car

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Content
3.4. Erection Sequence Stacker ST-1500-941 with Tripper Car .............................................. 1
3.4.1 General ................................................................................................................. 3
3.4.2 Rail Track............................................................................................................... 4
3.4.3 Travel Gear ............................................................................................................ 6
3.4.4 Portal .................................................................................................................... 7
3.4.5 Boom .................................................................................................................... 9
3.4.6 Hydraulic Equipment (construction group: 84.000) .................................................... 11
3.4.7 Electrical Installation (construction group: 81.000) ..................................................... 11
3.4.8 Lubrication System (construction group: 97.100)....................................................... 11
3.4.9 Counterweights..................................................................................................... 12
3.4.10 Tripper Car......................................................................................................... 14
3.4.11 Remaining Items ................................................................................................. 16

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3.4.1 General
Drawing Description 1 Description 2

4553578 CORNER LOADS ST 1500 / 29,5 x 1,0
4553819 RAIL TRACK ST 1500 / 29,5 x 1,0
4555133 Transport Sketch ST 1500 / 29,5 x 1,0
4552746 PLOT PLAN STACKER ST 1500/29,5x1
4556198 Assembly dwg. /sh.1 ST 1500/29,5x1
4553877 STACKER ST 1500/29,5x1
Attention: The weld back current cable has to be positioned close to the weld
joint to prevent a destruction of sensitive components due to current
flowing therethrough such as e.g. bearings! All welds have to be
performed and checked in accordance to their drawings, welding
procedures and specifications, and have to be approved by the
client! The welding procedures will be prepared by the erection
contractor and approved by TKF.
Welding seams that have to be checked by ULTRASONIC are
designated on the drawings and the test schedules!

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erection.
will be aligned again according the tolerance plan and subsequent the grouting can be started and
must be completed minimum 2 days before TKRT supply can be installed. When aligning the rails,
the admissible tolerances shall apply (see page 05). At the end of the rails the buffers are to install,
align and also to concrete.
3.4.2 Rail Track
To enable a proper erection of the machine, the rail track has to be installed, levelled, aligned and
welded as well as grouted for a minimum length of 80 m in the erection area of the reclaimer. The
accessibility to this area for mobile cranes and trucks has to be ensured until completion of
erection.
2.1 - 2.3).
Fig. 03: Rail Track

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Fig. 04: Admissible Rail Tolerances (see also Drawing 4553819)

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3.4.3 Travel Gear
Drawing Description 1 Description 2 weight

4552748 LONG TRAVEL GEAR WHEEL Ø630
4554943 SURVEYING SHEET LONG TRAVEL GEAR
4552523 5-Wheel bogie 2x1172kg
4553852 3-Wheel bogie with buffer base 2x494,2kg
4553315 2-Wheel bogie set 630/2DD 2x1473,9kg
4553320 2-Wheel bogie set 630/2DD/RC-L 1809,9kg
4553322 2-Wheel bogie set 630/2DD/RC-R 1809,9kg
4553295 2-Wheel bogie set 630/ND 1313,4kg
4553323 2-Wheel bogie set 630/ND/E-L 1328kg
4553409 1-Wheel bogie set 630/1DD-R 822kg
4553410 1-Wheel bogie set 630/1DD-L 822kg
4553296 1-Wheel bogie set 630/ND 4x734,5kg
4552707 Main bolt Ø125x630 4x60,7kg
4552707 Main bolt Ø125x650 2x62,6kg
4552707 Main bolt Ø165x825 2x138,5kg
4552707 Main bolt Ø210x1030 2x280kg
4554559 Buffer support beam 2x189,2kg
4554902 Buffer beam adaptor 2x109,25kg
4556083 Rail clamp 150kN CTHV-LH-150-045-LE-06 2x590kg
4558178 Travel drive BK 80-8.6kW i=171.5 (5xL, 5xR) 10x463kg
For errection of travel gear a reference line has to be determined across the rail track and
rectangular to the Reclaimer travelling direction to define the exact centerline of the bogies. The
reference line as well as the centre line of the bogies should be punch marked onto the rails.
lifted, set down onto the rails and secured against tilting and drifting. It shall be ensured by
geometrical survey that the travel mechanisms on both sides are placed exactly opposite to each
other and that the runner wheels are exactly in parallel as shown on drawing 4552748. This is to
be ensured preferably by using e.g. a theodolite or a piano wire being tensioned alongside the
travel mechanisms.

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Fig. 05: Travel Gear
3.4.4 Portal

4553732 Portal Column ST 1500/29,5x1 12540 kg
4553731 Portal ST 1500/29,5x1 4681 kg
4553736 STAIRCASE TO BOOM ST 1500/29.5x1 1036 kg
4553733 Platform ST 1500/29.5x1 1639 kg
4553734 Platf. Gratings ST 1500/29.5x1 566 kg
4275530 SUPPORT TO 5-WHEEL BOGIE 2x361 kg

4539176 UPPER PART ST 1500/29.5x1 5522 kg
4556059 Hinge Point CYLINDER ø280/160x1800 1315 kg
4558415 HYDRAULIC-CYLINDER 280/160x1800 ST 1500 / 29,5x1 1252 kg
Preconditions:
The e-house platform together with the big column of Tripper Car has to be assembled already
(see hereto chapter 3.4.10.1)
Before lifting of the portal columns, the hinge points for boom luffing cylinder can be installed
because of an easier access.
Assembly:
Prior erection of the portal/pylon, supports have to be installed below the position of the fixed pylon
and the portal connecting beam to TC . The supports have to be equipped with hydraulic jacks to
allow the levelling of the portal.Now the portal connecting beam has to be lifted, lowered on the
support and secured against tilting by staying ropes. Now the partial erected Tripper Car has to be
shifted and connected by pin to the connecting beam.

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The fixed pylon part has to be lifted, connected to the connecting beam, lowered on the supports
and secured by staying ropes against tilting.
Afterwards the portal legs have to be attached to the main beam and the travel gear.
Now portal/pylon structure has to be aligned and welded according to the drawings, welding
procedures and specifications.
 Note: The levelling/adjusting of the portal/pylon has to be executed with respect to

an exact horizontal position of the machined surface of the boom hinge point.
After adjustment and welding of the main structure, the supports can be removed again and the
cylinders shall be installed and secured with staying ropes against tilting.
Afterwards the platform and stairs including safety devices like railings and gratings, as well as the
upper part can be installed.
Fig. 06: Portal

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3.4.5 Boom

4553391 BOOM CONVEYOR BW 1000 7870 kg
4553742 SUSPENSION AND PYLON ST 1500/29,5 x1 3300 kg
4553738 BOOM - FRONT PART GRATING ST 1500/29,5 x1 1130 kg
4553737 BOOM - FRONT PART ST 1500/29,5 x1 7166 kg
4553741 LADDER AND CROSSING ST 1500/29,5 x 1 442 kg
4553739 BOOM-REAR PART ST 1500/29,5 x 1 14336 kg
4553740 PLATFORM BOOM REAR PART ST 1500/29,5 x 1 2638 kg
4554591 BOOM HINGE POINT Ø 240 BOOM FIXED BEARING 304 kg
4556074 BOOM HINGE POINT Ø 240 BOOM FLOATING BEARING 304 kg
Preassembly boom rear part

The rear part of the boom should be preassembled with the boom suspension pylon. The
walkways, gratings, crossing with ladders, idler stations, skirting, supports, drive pulley, drive unit,
etc. can be installed. Please note the maximum lifting capacity of each lifting lug. Lifting traverses
have to be used to avoid diagonal load of the lifting lugs.
Preassembly boom front part

The boom front part will be delivered in 2 pieces. These pieces have to be lowered onto temporary
erection supports on ground, adjusted and fixed by butt straps with high strength bolts, which have
to be tightened after adjusting. Please note the maximum lifting capacity of each lifting lug. Lifting
traverses have to be used to avoid diagonal load of the lifting lugs.
The walkways, gratings, crossing with ladders, idler stations incl. idlers and the take-up station,
etc. can be installed. Also the boom suspension adjusting spindles/items should be installed prior.
The longer suspension flat bars have to be preassembled, adjusted and tightened to one piece
before installation.
Installation of the boom:

a. The preassembled boom rear part will be lifted, bolted to the hinge point (fixed pylon).
b. The luffing cylinder (by-passed) will be connected to the boom rear part and have to be
locked after connecting (by-pass closed).
c. Prior installation of the boom front part, the erection support – equipped with hydraulic
jacks for adjusting) has to be positioned.
d. Boom front part will be lifted, bolted to the boom rear part and lowered to erection support
/ hydraulic jacks

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Fig. 07: Boom Installation
Installation steps of the boom suspension:

a. The nuts of the boom suspension adjusting spindles have to be loose to its maximum
position to provide the minimum distance between the two connection points of the
suspensions.
b. First the shorter, than the longer suspension flat bars will be installed
c. For installation the flat bar endings will be connected first on the upper end to the
suspension pylon on boom rear part and then to the adjusting spindles on boom front part.
In case the flat bar do not reach both endings the suspension has to be pulled with a chain
block or similar means. If the suspensions flat bars still not reach both endings please
contact to TKRT advisor!
d. When flat bars are installed the adjusting spindles (tensioning devices) have be tightened
e. The screws of the connection joint between boom rear and front part have to be tightened
by torque now.
Attention: For the case that an unusual process happens, TKRT have to be
informed immediately!

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3.4.6 Hydraulic Equipment (construction group: 84.000)
All hydraulic parts like power packs, pipes, hoses, cylinders, etc. are partly installed at workshop
and to be completed at site, in accordance to the specifications and regulations of the supplier.
See installation instruction hydraulic.
Special attention is to be paid to the fact that for the hydraulic piping installation, only cold bending
or fittings are allowed. In no case, hot bending of hydraulic pipes will be acceptable. Furthermore,
it should be made sure that after cutting and bending of the pipes, these are to be blown out by
compressed air and the pipe end edges must be smoothly ground inside and outside before
having installed the cutting rings of the fittings.
Note: Prior setting hydraulic systems in operation, they have to be flushed by using a by-pass set.
The systems have to be air extracted. The works have to be executed in the presence of a
ThyssenKrupp advisor. ( See hereto Hydraulic Manual)
3.4.7 Electrical Installation (construction group: 81.000)
3.4.8 Lubrication System (construction group: 97.100)
The pre-installed lubrication systems will be completed parallel to the mechanical / electrical pre-
/final erection and will be executed in accordance with the relevant standards, drawings, safety
regulations and technical specification. Please also refer to the manufacturer’s manual!

4554918 CENTR. LUBRICATION SYSTEM FOR TRAVEL GEAR 34
4554920 LUBRICATION PIPING FOR BELT PULLEYS 29

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3.4.9 Counterweights
4553743 Counterweight ST 1500/29.5x1 72.782 kg
Before installation of the counterweight, the hydraulic system has to be installed, flushed and set in
operation.
Now the counterweights have to be installed.

During balancing procedure care has to be taken to the bending of the boom  the nuts of the
tensioning/adjusting spindles (suspension) have to be final tightened until the boom has reached
his tolerances (for an easier tensioning the boom should be lowered again onto the erection
support).
Conditions of the Stacker prior to balancing of the boom:
 The boom lays free and is not fixed in any kind the auxiliary support / hydraulic jacks.
 The boom must be completely erected including all mechanical and electrical items. The
belt must be pulled and spliced.
 The hydraulic cylinder must be hydraulically blocked and ready for safe operations, with
respect to the mechanical and electrical equipment.
 The complete boom should be free of erection remains and lifting appliances.
 The balancing procedure should have to be carried out with a minimum of wind influence.
Attention: The counterweight blocks should be take place as shock less as

possible during installation at boom back part!
The counterweights should be erected step by step. The theoretical counterweight weight is 714
kN. See drawing no. 4553743 for Counterweights.

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Balancing procedure:
Two glycerine pressure gauges with a measuring accuracy of  1% will be connected to the
control block measuring points, MA ( rod side ) and MFB ( piston side), at the hydraulic cylinder.
 Note: The measured pressure in bar and the exact weight of the counterweights
shall be immediately submitted to TKRT`s Structural Steelwork Department
for checking!
A further adjusting of the counterweights may become necessary as a result of the final verification
by our engineers.
Upon completion of the balancing procedure, the boom shall be lifted and lowered several times
and during these operations the pressures at the upper and lower boom end positions (if possible)
as well as in the horizontal position shall be read at MA.
MFB must be set equal 0, the oil flows out of the measuring point to the tank. The pressure MFB
will be checked, recorded (see record data sheet “Control of the forces in the hydraulic cylinder of
the boom”) and transmitted to ThyssenKrupp.
The max. deviation shall not exceed 2 - 3 % of the data’s given in TKRT`s calculation.

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3.4.10 Tripper Car
3.4.10.1 E-house Platform

4553752 small column (1-wheel) Tripper car 1.984 kg
4553755 protection roof Tripper car 1.214 kg
4553761 staircase to E-house platform Tripper car 1.435 kg
4553762 staircase to E-house platform Tripper car 820 kg
4553763 E-house platform- c.p.1- Tripper car 10.374 kg
4553764 E-house platform- right part 1 Tripper car 7.705 kg
4553765 E-house platf.-left p.3 Tripper car 6.852 kg
4553766 E-house platform- edges part 1 Tripper car 3.813 kg
4553767 w. mesh guard cable reel Tripper car 1.242 kg
4553745 assembly dwg. Tripper car
4553773 E-house platf. cableway Tripper car 479 kg
4553750 big column Tripper car 7.471 kg
4553758 suspension and pylon Tripper car 5.275 kg
4553770 E-house platform - grating Tripper car 3.860 kg
4553775 cable direction change Tripper car 119 kg
4553774 Stand - Cable reel Tripper car 560 kg
4553751 middle column (1-wheel) Tripper car 3.133 kg
4426026 support 2-wheel bogie ( D=630) Tripper car 2 x 77 kg
4556080 Bolt Ø 120 Connection Portal T.C. STD4500, STD1500 13 kg

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The erection of the Tripper Car has to be executed in parallel to the Stacker!
The erection of the TC-travel gear has already been described in chapter 3.4.3 in this description.
At first, e-house platform including the columns on the travel gears have to be assembled and
adjusted on supports and on the prepared travel gear at its final height level and position and fixed
by high tensioning bolts.
After completion of the E-house platform and connection to the stacker, the upper part of the big
column as well as the front diagonal and the middle column have to be installed onto the e-house
platform to accommodate the conveyor framework later on.
During a.m. erection steps the stairs, gratings, walkways and hand rails have to be installed as far
as practicable to enable a safe access for workers.
3.4.10.2 Main Girder

4553746 main girder front part Tripper car 8.502 kg
4553747 main girder middle part Tripper car 6.003 kg
4553748 main girder rear part Tripper car 5.986 kg
4553760 ladder and crossing Tripper car 249 kg
4553749 main gird.walkw.+railing Tripper car 3.944 kg
4553759 platform a. staircase Tripper car 1.457 kg
4553769 main gird.(grating)-walk. Tripper car 3.237 kg
4553392 Tripper Car Conveyor BW 800 5922 kg
4555795 Trafo & Housing
4558194 E-House ST 1800
4556081 Bolt Ø 100 Connection Main Girder STD4500, STD1500 8 kg
Before installation of the main girder the transformer house as well as the e-house should be
installed.
The front- middle- and rear part of the main girder shall be laid down onto temporary supports on
the ground, aligned and tightend and welded.
The girders have to be assembled with the walkways, gratings, hand rails, etc. as well as the
mechanical items to minimize the work in the height.

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After finishing preassembly/preparations the main girder have to be lifted using lifting traverses
and connected to the columns.
The remaining bracings have to be installed immediately after the installation progress of main
girder parts.
Subsequent the preassembled rear part will be lifted, lowered onto the already installed travel gear
and fixed by bolts onto the main tripper car.
After splicing of the conveyor belt the remaining parts can be installed like scraper, switches, etc.
as well as the accesses from TC-platform to the main girder.
3.4.11 Remaining Items
Erection of remaining Items
- Installation of chute and skirting
- Completion of walkways, stairways, ladders, hand railing
switches, emergency limit switches, belt misalignment switches, etc.
- Adjusting of skirting, belt cleaners, etc.
- Adjusting of brakes and rail clamps
- Completion of painting works
- etc.

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3.5. Erection Sequence Stacker STD-4500 with Tripper Car
Fig. 01: Stacker STD 4500 (rotating and luffing)

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Content
3.5. Erection Sequence Stacker STD-4500 with Tripper Car ..................................................... 1

3.5.1. General...................................................................................................................... 3
3.5.2. Rail Track................................................................................................................... 4
3.5.3. Travel Gear ................................................................................................................ 6
3.5.4. Portal ........................................................................................................................ 8
3.5.5. Slewing Part............................................................................................................... 9
3.5.6. Boom ...................................................................................................................... 10
3.5.7. Hydraulic Equipment (construction group: 84.000) ...................................................... 12
3.5.8. Electrical Installation (construction group: 81.000)....................................................... 12
3.5.9. Lubrication System (construction group: 97.100)......................................................... 13
3.5.10. Counterweights....................................................................................................... 13
3.5.11. Tripper Car ............................................................................................................. 15
3.5.12. Remaining items ..................................................................................................... 17

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3.5.1. General
4556199 1 Assembly Drawing STD 4500/29.5x1.2

4553414 1 Stacker STD 4500/29.5x1.2
4552745 1 Plot Plan STD 4500/29.5x1.2
4553820 1 Rail Track STD 4500/29.5x1.2
4553571 1 Corner Loads STD 4500/29.5x1.2
contractor and approved by TKF.

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erection.
will be aligned again according the tolerance plan above mentioned and subsequent the grouting
can be started and must be completed minimum 2 days before TKRT supply can be installed.
When aligning the rails, the admissible tolerances shall apply (see fig. 04). At the end of the rails
the buffers are to install, align and also to concrete.
3.5.2. Rail Track
Fig. 03: Travel Track Foundation

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3.5.3. Travel Gear
Preconditions:
To enable a proper erection, the rail track has to be installed, levelled, aligned and welded as well
as grouted for a minimum length of 80 m in the erection area of the stacker and tripper car. The
erection.
2.1 - 2.3).
4552747 1 Long Travel Gear Wheel ø630

4554959 1 Surveying Sheet Long Travel Gear 630
4539519 1 6-Wheel Bogie With Buffer Base 2x 1.944 kg
4538574 1 4-Wheel Bogie With Buffer Base 2x 834 kg
4552438 1 3-Wheel Boegie 2x 466 kg
4553315 1 2-Wheel Bogie Set Ø630 / 2DD 4x 1.474 kg
4553320 1 2-Wheel Bogie Set Ø630 / 2DD / RC-L 1x 1.810 kg
4553322 1 2-Wheel Bogie Set Ø630 / 2DD / RC-L 1x 1.810 kg
4553295 1 2-Wheel Bogie Set Ø630 / ND 3x 1.314 kg
4553323 1 2-Wheel Bogie Set Ø630 / ND / E-L 1x 1.328 kg
4553269 1 1-Wheel Bogie Set Ø630 / ND 4x 735 kg
4552707 1 Main Bolts Ø220/ø180/ø165/ø125 ∑= 1.370 kg
4539669 1 Rail Cleaner
4539002 1 Rail Cleaner With Plow
4543567 1 Rail Cleaner For Rail Clamp
4541494 1 Earthing Col. Shoe
4539331 1 Wheel Cover For 2-Wheel Bogies
4554564 1 Buffer Adaptor Ø177,8 x 786
4554557 1 Buffer Beam Adaptor L=598
4554559 1 Buffer Support Beam For 2x018112-200x200-A
Cellular Buffer Wampfler 018112-200x200-A

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4556083 1 Rail Clamp 150 kN Hillmar CTHV-LH-150-045-LE-06 2x 590 kg

4558202 1 Travel Drive BK 80-8.6 KW 12x 463 kg
4556615 1 Reinforcement For Wheel Cover
4275531 1 Support to 6-Wheel Bogie 2x 469 kg
Prior to the erection of the travel mechanisms the rail tracks have to be leveled, aligned and welded
according to the admissible tolerances.
A reference line has to be determined across the rail track and rectangular to the stacker travelling
direction in order to enable the supervisor to define the exact centerline of the bogies. The
reference line as well as the centre line of the bogies should be punch marked onto the rails. See
also the drawing of the railtrack ( dwg. 4553820 )
According to the marking and in accordance with the drawings, the travel mechanisms have to be
lifted, bearded onto the rails and secured against tilting and drifting. Then, the travel drive
mechanisms have to be measured and aligned.
Travel drives should be installed later when the electrical installation will be started.
Fig. 05: Travel Gear for Stacker and Tripper Car

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3.5.4. Portal
4553667 1-5 Portal STD 4500/29,5x1,2 18.004 kg

4553668 1-3 Ring Platform STD 4500/29,5x1,2 4.132 kg
4553669 1 Stairs from TC to Ring Platf. STD 4500/29,5x1,2 780 kg
Prior erection of the portal, supports have to be installed below the position of the portal and the
connecting beam to TC. The supports have to be equipped with hydraulic jacks to allow the leveling
of the portal. The portal has to be lifted, assembled and afterwards aligned by the above
mentioned hydraulic jacks.
 Note: The leveling/adjusting of the portal has to be executed with respect to an exact
horizontal position of the machined surface for the slew bearing.
Now the partial erected Tripper Car has to be shifted and connected by pin to the connecting beam
and the portal has to be final adjusted and welded according to the drawings, welding procedures
and specifications.
Fig. 06: Preassembled Portalparts before welding and Tripper Car
After finish welding the TC has to be disconnected and shifted back again, to enable the installation
of the slewing and boom back part.
Subsequent the ring platform, gratings and hand rails as well as the starirs can be completely
installed.

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3.5.5. Slewing Part
4553670 1-6 Slewing Part STD 4500/29,5 x 1,2 15.063 kg

4553671 1 Ring Protection Slewing Part STD 4500/29,5 x 1,2 48 kg
4553672 1-2 Access to Boom STD 4500/29,5 x 1,2 1.123 kg
4556649 1 Ball Bearing Slewing Ring 061.60.3000/200.41.1522 2.063 kg
4555065 1 Slewing Gear STD 4500 5.707 kg
4555152 1 Protection Box 113 kg
4554942 1 Central Lubrication System For Slewing Gear 116 kg
4556121 1 Hoisting Gear General Arrangement
4556073 1 Boom Hinge Point ø240 Boom Floating Bearing 304 kg
4554573 1 Boom Hinge Point ø240 Boom Fixed Bearing 304 kg
4558416 1 Hydraulic Cylinder 1800 STD 4500/29,5 x 1,2 1.675 kg
4556077 1 Hinge Point ø140 Cylinder ø320/180x1800
Before lifting of the slewing part, the ball bearing slewing ring has to be installed at the bottom.
Special attention has to be paid for the correct position of the ring regarding the hardness gap “S”.
 Note: Attention has to be given to the exact horizontal position of the machined
surface for the slew bearing. The backlash of the slew bearing and the drive
pinion has to be adjusted according to dwg. 4555065.
The slewing part has to be preassembled on ground as far as practically including the fixed and the
floating bearings for the boom and the hydraulic cylinder.
After completion the slewing part has to be lifted by the help of lifting traverses, set onto the portal
also with care regarding the right position of the hardness gap “S” and bolted at the ball bearing
slewing ring. After adjustment and check, the ball bearing will be tightened according the
instructions given by the manufacturer.
Subsequent the cylinder can be installed, fixed on the lower bearing and secured against tilting by
chain hoists.

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Fig. 07: Installation Slewing Part and Luffing Cylinder
3.5.6. Boom
4553673 BOOM - FRONT PART STD 4500-295 x 12 7166 kg

4553680 SUSPENSION AND PYLON STD 4500-295 x 12 3300 kg
4553674 BOOM - FRONT PART GRATING STD 4500-295 x 12 1130 kg
4553676 BOOM-REAR PART STD 4500-295 x 12 14336 kg
4553677 PLATFORM BOOM REAR PART STD 4500-295 x 12 2638 kg
4553678 LADDER AND CROSSING STD 4500-295 x 12 441 kg
4553075 BOOM CONVEYOR BW 1200 17612 kg
4554573 BOOM HINGE POINT Ø 240 BOOM FIXED BEARING 304 kg
4556073 BOOM HINGE POINT Ø 240 BOOM FLOATING BEARING 304 kg
Preassembly boom rear part

The rear part of the boom should be preassembled with the boom suspension pylon. The
walkways, gratings, crossing with ladders, idler stations, skirting, supports, drive pulley, drive unit,

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etc. can be installed. Please note the maximum lifting capacity of each lifting lug. Lifting traverses
have to be used to avoid diagonal load of the lifting lugs.
Preassembly boom front part

The boom front part will be delivered in 2 pieces. These pieces have to be lowered onto temporary
erection supports on ground, adjusted and fixed by butt straps with high strength bolts, which have
to be tightened after adjusting. Please note the maximum lifting capacity of each lifting lug. Lifting
traverses have to be used to avoid diagonal load of the lifting lugs.
The walkways, gratings, crossing with ladders, idler stations incl. idlers and the take-up station,
etc. can be installed. Also the boom suspension adjusting spindles/items should be installed prior.
The longer suspension flat bars have to be preassembled, adjusted and tightened to one piece
before installation.
Installation of the boom:

a. The preassembled boom rear part will be lifted, bolted to the hinge point (fixed pylon).
b. The luffing cylinder (by-passed) will be connected to the boom rear part and have to be
locked after connecting (by-pass closed).
c. Prior installation of the boom front part, the erection support – equipped with hydraulic
jacks for adjusting) has to be positioned.
d. Boom front part will be lifted, bolted to the boom rear part and lowered to erection support
/ hydraulic jacks
Fig. 08: Installation Boom front part

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Installation steps of the boom suspension:

a. The nuts of the boom suspension adjusting spindles have to be loose to its maximum
position to provide the minimum distance between the two connection points of the
suspensions.
b. First the shorter, than the longer suspension flat bars will be installed
c. For installation the flat bar endings will be connected first on the upper end to the
suspension pylon on boom rear part and then to the adjusting spindles on boom front part.
In case the flat bar do not reach both endings the suspension has to be pulled with a chain
block or similar means. If the suspensions flat bars still not reach both endings please
contact to TKRT advisor!
d. When flat bars are installed the adjusting spindles (tensioning devices) have be tightened
e. The screws of the connection joint between boom rear and front part have to be tightened
by torque now.
Attention: For the case that an unusual process happens, TKRT have to be
informed immediately!
3.5.7. Hydraulic Equipment (construction group: 84.000)
Special attention is to be paid to the fact that for the hydraulic piping installation, only cold bending
or fittings are allowed. In no case, hot bending of hydraulic pipes will be acceptable. Furthermore,
it should be made sure that after cutting and bending of the pipes, these are to be blown out by
compressed air and the pipe end edges must be smoothly ground inside and outside before
having installed the cutting rings of the fittings.
3.5.8. Electrical Installation (construction group: 81.000)

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3.5.9. Lubrication System (construction group: 97.100)

4554921 CENTR. LUBRICATION SYSTEM FOR TRAVEL GEAR 108 kg
4554941 LUBRICATION PIPING FOR BELT PULLEYS 29 kg
4554942 CENTRAL LUBRICATION SYSTEM FOR SLEWING GEAR 45 kg
regulations and technical specification. Please also refer to the manufacturer’s manual!
3.5.10. Counterweights

4553681 Counterweight ST 4500/29.5x1 72.375 kg
operation.
Now the counterweights have to be installed.

During balancing procedure care has to be taken to the bending of the boom  the nuts of the
tensioning/adjusting spindles (suspension) have to be final tightened until the boom has reached
his tolerances (for an easier tensioning the boom should be lowered again onto the erection
support).
Conditions of the Stacker prior to balancing of the boom:

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The counterweights should be erected step by step. The theoretical counterweight weight is
710kN. See drawing no. 4553681 for Counterweights.
control block measuring points, MA ( rod side ) and MFB ( piston side), at the hydraulic cylinder.
shall be immediately submitted to TKRT`s Structural Steelwork Department
for checking!
by our engineers.
The max. deviation shall not exceed 2 - 3 % of the data’s given in TKRT`s calculation.

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3.5.11. Tripper Car
E-house Platform
4553687 Big column Tripper car 7175 kg

4553688 middle column (2-wheel) Tripper car 3022 kg
4553689 Small column (1-wheel) Tripper car 1985 kg
4553693 Protection roof Tripper car 1214 kg
4553698 Staircase to E-house platform Tripper car 1435 kg
4553699 Staircase to E-house platform Tripper car 820 kg
4553700 E-house platform- c.p.1 Tripper car 10374 kg
4553701 E-house platform- right part 1 Tripper car 7581 kg
4553702 E-house platf.-left p.3 Tripper car 6884 kg
4553703 E-house platform- edges part 1 Tripper car 3701 kg
4553704 w. mesh guard Tripper car 1762 kg
4553709 Platform cable reel Tripper car 283 kg
4553708 Self closing safety gate Tripper car 7 kg
4553712 E-house platf. cableway Tripper car 561 kg
4553695 suspension and pylon Tripper car 5280 kg
4553705 wire mesh guard-walk. Tripper car 401 kg
4553688 middle column (2-wheel) Tripper car 3022 kg
4553707 E-house platform - grating Tripper car 3738 kg
4553711 cable direction change Tripper car 208 kg
4553710 Stand - Cable reel and hose reel Tripper car 1587 kg
4556080 Bolt Ø 120 Connection Portal T.C. STD4500, STD1500 13 kg

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The erection of the Tripper Car has to be executed in parallel to the Stacker!
The erection of the TC-travel gear has already been described in chapter 3.4.3 in this description.
At first, e-house platform including the columns on the travel gears have to be assembled and
adjusted on supports and on the prepared travel gear at its final height level and position and fixed
by high tensioning bolts.
After completion of the E-house platform and connection to the stacker, the upper part of the big
column as well as the front diagonal and the middle column have to be installed onto the e-house
platform to accommodate the conveyor framework later on.
During a.m. erection steps the stairs, gratings, walkways and hand rails have to be installed as far
as practicable to enable a safe access for workers.
Main Girder

4553684 main girder middle part Tripper car 6013 kg
4553685 main girder rear part Tripper car 5986 kg
4553683 main girder front part Tripper car 9902 kg
4553706 main gird.(grating)-walk. Tripper car 3069 kg
4553686 main gird.walkw.+railing Tripper car 3878 kg
4553696 platform a. staircase Tripper car 1450 kg
4553697 ladder and crossing Tripper car 249 kg
4555795 Trafo & Housing ST 4500 ~1950 kg
E-House ST 4500
4553141 Tripper Car Conveyor BW 1200 9454 kg
4556081 Bolt Ø 100 Connection Main Girder STD4500, STD1500 8 kg
Before installation of the main girder the transformer house as well as the e-house should be
installed.
The front- middle- and rear part of the main girder shall be laid down onto temporary supports on
the ground, aligned and tightend and welded.
The girders have to be assembled with the walkways, gratings, hand rails, etc. as well as the
mechanical items to minimize the work in the height.

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After finishing preassembly/preparations the main girder have to be lifted using lifting traverses
and connected to the columns.
The remaining bracings have to be installed immediately after the installation progress of main
girder parts.
Subsequent the preassembled rear part will be lifted, lowered onto the already installed travel gear
and fixed by bolts onto the main tripper car.
After splicing of the conveyor belt the remaining parts can be installed like scraper, switches, etc.
as well as the accesses from TC-platform to the main girder.
3.5.12. Remaining items
Erection of remaining Items
- Installation of chute and skirting
- Completion of walkways, stairways, ladders, hand railing
switches, emergency limit switches, belt misalignment switches, etc.
- Adjusting of skirting, belt cleaners, etc.
- Adjusting of brakes and rail clamps
- Completion of painting works
- etc.

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3.6. Erection Sequence Bucket Wheel Reclaimer R 6600
Fig. 01: Bucket Wheel Reclaimer R 6600
ThyssenKrupp Industrial Solutions 1/23

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Content
3.6. Erection Sequence Bucket Wheel Reclaimer R 6600....................................................... 1
3.6.1 General ................................................................................................................. 3
3.6.2 Rail Track............................................................................................................... 4
3.6.3 Travel Gear (Step 1) ................................................................................................ 6
3.6.4 Undercarriage (Step 2)............................................................................................. 8
3.6.5 Slewing mechanism (Step 3) .................................................................................. 11
3.6.6 Central Chute and Pylon (Step 4)............................................................................. 13
3.6.7 Preassembly and Installation of Boom (Step 5 and 6)................................................. 15
3.6.8 Counterweight Boom (Step 7 and 8) ....................................................................... 17
3.6.9 Bucket Wheel (Step 9) ........................................................................................... 19
3.6.10 Hydraulic Equipment (construction group: 84.000)................................................... 20
3.6.11 Lubrication systems............................................................................................. 20
3.6.12 Electrical Equipment (construction group 81.000) .................................................... 20
3.6.13 Counterweights (Step 10) ..................................................................................... 21
3.6.14 Remaining Parts (Step 11).................................................................................... 23

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3.6.1 General
Drawing Description 1 Description 2

4553250 BUCKET WHEEL RECLAIMER R 6600-870x1600/45
4552750 PLOT PLAN RECLAIMER R 6600-870x1600/45
4552427 ERECTION SEQUENCE Pack. 10 - 945-RC-100 Bucket-Wheel-Recl.
4552601 TRANSPORT SKETCH SHOUGANG HIERRO PERU
4553804 CORNER LOADS R6600-870x1600/45
4553818 RAIL TRACK R6600-870x1600/45
The above mentioned drawings especially drawing 4552427 give an overview of the parts to be
erected. All erection steps described in the following chapters have to consider these drawings.
contractor and approved by TKIS.
weights (calculated based on TKIS-Drawings).

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erection.
procedures. All welds have to be approved by the client and TKIS!
will be aligned again according the tolerance plan and subsequent the grouting can be started and
must be completed minimum 2 days before TKIS supply can be installed. When aligning the rails,
the admissible tolerances shall apply (see page 03). At the end of the rails the buffers are to install,
align and also to concrete.
3.6.2 Rail Track
To enable a proper erection of the machine, the rail track has to be installed, levelled, aligned and
welded as well as grouted for a minimum length of 50 m in the erection area of the reclaimer. The
erection.
2.1 - 2.3).
Fig. 02: Rail Track

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3.6.3 Travel Gear (Step 1)

4552489 Long Travel Gear Wheel ø630
4554960 Surveying Sheet Long Travel Gear ø630
4553315 2-Wheel Bogie Set 630/2DD 6 x 1474 kg
4553320 2-Wheel Bogie Set 630/2DD/RC-L 1810 kg
4553322 2-Wheel Bogie Set 630/2DD/RC-R 1810 kg
4553295 2-Wheel Bogie Set 630/ND 4 x 1313 kg
4553855 1-WHEEL BOGIE SET 630/ND/E 13 x 749 kg
4553296 1-WHEEL BOGIE SET 630/ND 734 kg
4553896 MAIN BOGIE 630/12 2 x 7258 kg
4553897 MAIN BOGIE 630/6 6 x 1543 kg
4552438 MAIN BOGIE 630/3 8 x 466 kg
4553852 MAIN BOGIE 630/3/BUFFER BASE 4 x 494 kg
4552707 Main bolt Ø125x630 12 x 61 kg
4552707 Main bolt Ø165x825 12 x 139 kg
4552707 Main bolt Ø220x1050 4 x 316 kg
4552707 Main bolt Ø220x1060 2 x 316 kg
4552707 Main bolt Ø350x1395 2 x 1054 kg
4558203 Travel drive BK 80-8,6 kW (8xL,8xR) 16 x 463 kg

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For erection of travel gear a reference line has to be determined across the rail track and
rectangular to the Reclaimer travelling direction to define the exact centerline of the bogies. The
reference line as well as the centre line of the bogies should be punch marked onto the rails.
lifted, set down onto the rails and secured against tilting and drifting as shown on drawing
4552427 Step 1. It shall be ensured by geometrical survey that the travel mechanisms on both
sides are placed exactly opposite to each other and that the runner wheels are exactly in parallel as
shown on drawing 4554960. This is to be ensured preferably by using e.g. a theodolite or a piano
wire being tensioned alongside the travel mechanisms.

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3.6.4 Undercarriage (Step 2)

4552612 VERLAGERUNGSBOCK SUPPORT TO 12-WHEEL BOGIE 630 2 x 3350kg
4275531 VERLAGERUNGSBOCK SUPPORT TO 6-WHEEL BOGIE 630 2 x 938kg
4552603 CROSS TRAVERSE UNDERCARRIAGE 10837 kg
4552602 UNDERCARRIAGE UNDERCARRIAGE 71142 kg
4552605 SUPPORT PLATFORM UNDERCARRIAGE 2997 kg
4552604 CIRCULAR WALKWAY UNDERCARRIAGE 4254 kg
4552606 PLATFORM FOR REEL UNDERCARRIAGE 6702 kg
4552610 PLATFORM INSIDE UNDERCARRIAGE 1915 kg
4552611 WALKWAY TO PLATF. INSIDE UNDERCARRIAGE 1607 kg
4552609 STAIRCASE TO CIRCULAR UNDERCARRIAGE 748 kg
WALKWAY
4552608 STAIRCASE LEFT SIDE UNDERCARRIAGE 1950 kg
4552607 STAIRCASE RIGHT SIDE UNDERCARRIAGE 1538 kg
4552613 SUPPORT GUIDING DEVICE UNDERCARRIAGE 225 kg
Preassembly Undercarriage
Erect the under carriage nearby the travel gear. The erection area has to be even and sustainable.
You have to place supports upon these area.
Supports for bogies

Mount the supports to the travel gear
Cross traverse
Place the cross traverse (DWG: 4552603) upon supports

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Undercarriage
Place the portal undercarriage (DWG: 4552602) upon travel gear and cross traverse
Fig. 06: Undercarriage
Circular walkway
Mount the circular platform (DWG: 4552604) to the under carriage
Platforms and staircases

Mount the platforms and staircases to the under carriage.

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Platform for reel (Trailer)

Pre-mount the platform for reel.
Attach it to the undercarriage only after the uppercarriage is installed (see Step 8).

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3.6.5 Slewing mechanism (Step 3)

4552621 SLEWING PLATFORM SLEWING PLATFORM 42350 kg
4552620 TOLERANCE SLEWING PLATFORM SLEWING PLATFORM
4552622 STAIRS TO PLATFORM SLEWING PLATFORM 2816 kg
4552626 E-HOUSE PLATFORM SLEWING PLATFORM 6602 kg
4552625 SLEWING PLATFORM INSIDE SLEWING PLATFORM 1630 kg
4552624 STAIRS TO BOOM SLEWING PLATFORM 575 kg
4552623 RAILING SLEWING PLATFORM 1422 kg
4555875 SLEWING GEAR SLEWING PLATFORM 19685 kg
4552882 DREHWERKSANTRIEB A - KS3P 160-4
4558259 DRILLING PLAN ROTHE ERDE NO. 121.60.5000.100-112
4560131 ENERGY CHAIN RECLAIMER R6600
Slewing bearing
Before mounting of the slewing platform the ball bearing slewing ring has to be installed to the
undercarriage. Attention has to be paid for the correct position of the ring ( “S” soft spot ) see
drawing 4555875.
 Note: Attention has to be given to the exact horizontal position of the machined
surface for the slew bearing.
Energy chain
Lift the energy chain and its support into the undercarriage before mounting the slewing platform.
Pay attention to the correct orientation of the chain.

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Slewing platform
The slewing platform has to be assembled as far as practically with gratings, stairs and handrails.
After completion the slewing part have to be lifted ( by the help of a lifting beam ) and bolted with
the ball bearing slewing ring ( care has to be taken again regarding the “S” soft spot ).
Fig. 07: Slewing Part
Slewing Drive
The slewing drives have to be mounted according to drawing 4555875. Afterwards backlash of the
slew bearing and the drive pinion has to be adjusted.

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3.6.6 Central Chute and Pylon (Step 4)

4553193 CENTRAL CHUTE ARRANGEMENT 11948 kg
4552631 PYLON PYLON 33172 kg
4552630 TOLERANCE PLAN PYLON PYLON
4555753 ROLLER TABLE BW1600 / 35° / ø159 6616 kg
4552632 ARRANGEMENT WALKWAY PYLON
4552633 STAIRS AND WALKWAY PYLON 5670 kg
4552634 LADDER TO BOOM PYLON 555 kg
4552635 STAIR TO PLATFORM PYLON 3682 kg
4552636 GRATING PYLON 1979 kg
4552639 TROLLEY GIRDER PYLON 2282 kg
Central chute
Erect the central chute to the reclaimer as shown in drawing 4553193.
Roller Table
Preasemble the roller table and mount it to the undercarriage.

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Pylon
Erect the pylon to the reclaimer as shown
Fig. 08: Portal
Walkways and staircases
Mount the walkways and staircases as shown in the above mentioned drawings

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3.6.7 Preassembly and Installation of Boom (Step 5 and 6)

4552643 BOOM BACK PART BW-BOOM 12600 kg
4552642 BOOM MIDDLE PART BW-BOOM 27018 kg
4552641 BUCKET WHEEL BOOM HEAD BW-BOOM 21180 kg
4552640 TOLERANCE PLAN BOOM BW-BOOM
4552646 BOOM WALKWAY BW-BOOM 3935 kg
4552647 GRATING BOOM BW-BOOM 3570 kg
4552644 STAYING BUCKET WHEEL BW-BOOM 14836 kg
4552645 WALKWAY A. STAIRS TO BW. HEAD BW-BOOM 5464 kg
4552648 PLATFORM AND STAIR BW-BOOM 1362 kg
4552649 SUPPORT CABIN PLATFORM BW-BOOM 1216 kg
4552650 CABIN PLATFORM BW-BOOM 1116 kg
4552651 SUPPORT CABLE GUIDE BW-BOOM 936 kg
4552652 PROTECTION COVER BW-BOOM 1120 kg
4552539 BOOM BELT CONVEYOR BELT SCHEME 22166 kg
Boom preassembly (Step 5)

Place the boom on supports on ground level for preassembly. Assemble all necessary parts, e.g.
platforms, stairs, walkways and support as far as feasible from the drawing list, to the boom
Fig. 09: Boom preassembly

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Boom installation (Step 6)

Erect a temporary support for the boom (together with hydraulic jacks on top for adjustment) as
you can see in the erection sequence. Take up the pre-assembled boom and mount to the slewing
part and upon the support.
Fig. 09: Boom Installation
Staying
Mount the stayings to the boom and place it upon supports as shown in the erection sequence.

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3.6.8 Counterweight Boom (Step 7 and 8)
Drawing Description 1 Description 2 Weight

4553321 HOISTING GEAR BOOM + CABIN
4552661 CW-BOOM FRONT PART SH. 3 COUNTERWEIGHT BOOM 22598 kg
4552662 CW-BOOM MIDDLE PART SH.2 COUNTERWEIGHT BOOM 6992 kg
4552663 CW-BOOM BACK PART SH. 2 COUNTERWEIGHT BOOM 18686 kg
4552664 CW-BOOM SUSPENSION PART SH. 2 COUNTERWEIGHT BOOM 16983 kg
4552665 CW-BOOM PLATFORM AND LADDER SH. 2 COUNTERWEIGHT BOOM 922 kg
4552666 CW-BOOM MAINTENANCE PLATFORM COUNTERWEIGHT BOOM 464 kg
4552660 TOLERANCE PLAN CW-BOOM COUNTERWEIGHT BOOM
4553000 HINGE POINTS ARRANGEMENT 7142 kg
Counterweight boom front part (Step 7)

Mount the 2 hoisting cylinders and the ready for operating hydraulic system to the slewing part.
Pre-assemble the counterweight boom front part upon supports on ground level. Mount the middle
part to the front part and connect it to the slewing part and the hoisting cylinder.
Fig. 10: Counterweight Boom Front Part

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Counterweight boom back part (Step 8)

Erect a temporary support at the back part like shown in the erection sequence. Assemble the
counterweight boom back part to the front part and upon the support and the last part of the
middle part to the front part and the back part.
Fig. 11: Counterweight Boom Back Part
Steering Rod
Mount the steering rod to the counterweight boom and the boom staying.
Platform for reel (Trailer)

Attach the trailer to the undercarriage by means of the dedicated bolts. Mount the steering rods
between the trailer and the main machine wheel bogies.

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3.6.9 Bucket Wheel (Step 9)

4552823 BUCKET WHEEL HEAD RECLAIMER R 6600-870x1600/45 36038 kg
4552833 INFORMATIONS BUCKET WHEEL HEAD MOUNTING
4552842 SCHAUFELRADANTRIEB A-K2Sg450 - P335
Bucket wheel
Mount the pre-assembled bucket wheel with shaft and bearings to the boom head and install the
drive.
Subsequent the control cabin and the platform and access can follow.
Fig. 12: Bucket Wheel

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3.6.10 Hydraulic Equipment (construction group: 84.000)
3.6.11 Lubrication systems
regulations and technical specification.

4555014 CENTRAL LUB SYSTEM 1 TRAVEL GEAR 21 kg
4557997 LUBRICATION SYSTEM SLEWING GEAR-DETAILS 234 kg
4557999 LUBRICATION SYSTEM BUCKET WHEEL SHAFT BEARING - DETAILS 103 kg
3.6.12 Electrical Equipment (construction group 81.000)

4559063 ELECTRICAL EQUIPMENT ARRANGEMENT + HYDRAULIC POWER PACKS 27935 kg
4535907 GROUNDING HINGE POINTS; E-HOUSE; ETC.

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3.6.13 Counterweights (Step 10)
Drawing Description weight

4552670 Counterweight 217.500 kg
operation!
The counterweights should be erected step by step. The theoretical counterweight weight is 2134
kN. See drawing no. 4552670 for counterweights.
Fig. 13: Counterweights

Conditions of the Reclaimer prior to balancing of the boom:

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control block measuring points, MA ( rod side ) and MFB ( piston side), at the hydraulic cylinders.
shall be immediately submitted to TKIS`s Structural Steelwork Department
for checking!
by our engineers.
The max. deviation shall not exceed 2 - 3 % of the data’s given in TKIS`s calculation.

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3.6.14 Remaining Parts (Step 11)
- Completion of walkways, stairways, ladders, hand railing;

switches and belt misalignment switches etc.;
- Completion of lubrication systems;
- Adjusting of skirting, belt cleaners;
- Adjusting of brakes;
- Setting of travel way and emergency limit switches;
- Completion of painting/touch-up works;
- Installation of storm locking bracket . Care has to be taken by the exact positioning of the
frames for the locking devices;
- etc.
 General note: It might be possible that some fitting works on handrails or other
minor structure ( re-drilling, reaming of holes, etc. ) will become
necessary during the erection of the Reclaimer. These fitting work to
be understood as normal erection works and will not deem to be
extra work.

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4. Procedure and Sequence of Electrical Installation
Doc. No. 4536706 Drum Reclaimer (DR 1)

Doc. No. 4536703 Stacker ST 1500 (ST 2)
Doc. No. 4536704 Stacker ST 4500 (ST 1)
Doc. No. 4536700 Bucket Wheel Reclaimer R 6000 (RE 1)

TKF- DRWG. NO. – 4 536 706 Chapter 4.1
TKF- ORDER NO. - N-033-00114 Issue 25. 08. 2014 Page 1
KFR-TDE0014483
PROCEDURE AND SEQUENCE OF ELECTRICAL

INSTALLATION
Drwg. No. 4 536 706
N-033-00114
SHOUGANG HIERRO
DRUM RECLAIMER DR1
931-RC-100
PACK. 06: PRIMARY ORE CONCENTRATE STOCKYARD
SHOUGANG HIERRO, PERU
THYSSENKRUPP INDUSTRIAL SOLUTIONS

A Company of ThyssenKrupp Engineering
KFR-TDE0014483
TABLE OF CONTENTS
1. General information
2. Documents concerning the installation of electrical equipment
3. Identification system
3.1 Labelling of groups

3.2 Labelling of devices
3.3 Labelling of terminal strips
3.4 Cable numbering
3.5 Identification code of localities
4. Sequence of the installation work
5. Installation of external devices
6. Installation of cable trays
7. Installation of cables
8. Connection of cables
9. Shielding
9.1 General of shielding
9.2 Shielding of encoders
10. Termination of the installation work
11. Installation examples

1.KFR-TDE0014483
General information
The present description does contain general instructions and remarks concerning
the installation of electrical equipment. More details about the fixation of external
devices and limit switch curves are indicated on the mechanical drawings. The
routing of the cables, as well as the arrangement of external devices can be seen
from the layout drawings. In particular cases, the type of the cable fastening and
cable trays should be decided in accordance with this description. When executing
the electrical installation work, the regulations of the VDE 0100 are to be adhered
to.
For carrying out the electrical installation work, the following documents are made
available:
a) circuit diagram
b) terminal drawing
c) parts list
d) layout drawings for switch cabinets, control desks and terminal boxes
e) list of cables
f) list of local devices
g) lay-out drawings showing the external devices and the cable routes
h) mounting- and operating instructions of the manufacturer of the equipment to
be installed
i) Overview of cables and cable glands
j) Mechanical support drawings
For the electrical equipment, provision has been made for an identification system
where the labelling of the individual equipment and devices is based on the DIN
standard.
The identification number indicated is composed, as follows:
=XXXX +ZZZ-YXXX
. . .
. . .
. . ...... labelling of devices as per DIN 40719 with
. . annexed device number ( e.g. –S0601 )
. .
. ..........…….identification code of localities ( e.g. +L61 )
.
.
................…………labelling of groups ( e.g. =D6 – Travel drive )


KFR-TDE0014483
The whole equipment has been divided into individual groups; each of them is
forming a self-contained construction unit. The labelling of groups is composed of
figures with sign of equality set in front of them.
=DR1._1 FEEDING
=DR1._2 GENERAL SAFETY CIRCUITS
=DR1._3 LIGHTING- AND AUXILIARY CIRCUITS
=DR1._4 CONTROL VOLTAGE DISTRIBUTION
=DR1._5 GENERAL CONTROL
=DR1._6 TRAVEL DRIVES
=DR1._11 HOISTING GEAR
=DR1._13 LUBRICATION
=DR1._18 DRUM DRIVE
=DR1._23 CROSS CONVEYOR
=DR1._24 CABLE REEL
=DR1._26 SIGNAL EXCHANGE TO CCR
=DR1._31 HPP
=DR1._50 PLC
_ WILD-CARD CHARACTER FOR

C COMMON PART
M CONTROL CIRCUITS
D DIRECT DRIVE; POWER CIRCUITS
J VARIABLE DRIVES ( VFD )
EXAMPLE:
=DR1.J23+X-M2301 CROSS CONVEYOR MOTOR

=DR1.M23+X-S2301 CROSS CONVEYOR PULL ROPE SWITCH LHS


KFR-TDE0014483
All devices have been labelled on the basis of the DIN standard 40719.
To simplify the identification of devices, and for obtaining a better survey, we
indicated in the circuit diagrams on the right, beside the title block, both the labelling
of the group and the number of the switch cabinet. Thanks to this, the devices
represented in the electrical documents can be exactly identified with the help of
their label. Only devices influencing the circuit of other constructional components
are represented by their complete labelling number.
The terminal strips have been defined by the labelling of their place of installation
and by the sign of the device ‘-X24’ etc. The identification code of a locality to be
seen in the terminal diagram on the right, beside the title block, corresponds to the
labelling of the switch cabinet or the terminal box where the strip is to be installed.
In order to obtain a better survey, the terminal strips are additionally divided into
blocks. The meaning of the terminal strip labelling is, as follows:
-X24 - SIGNAL CIRCUITS 24V

-X24I - INTERFACE PLUG-IN TERMINALS 24V
-X24S - THREE WIRE TERMINAL FOR SENSORS AND SWITCHES
-X25 - ANALOGUE SIGNALS
-X30 - EMGERENCY STOP CIRCUITS
-X230 - AUXILIARY CIRCUITS 230V
-X230I - INTERFACE PLUG-IN TERMINALS 230V
-X460 - MAIN CIRCUITS 460V
-X4610 - FEEDING 4610V
3.4 Cable numbering
The cables will be marked, as follows:
N1-N2.N
N1: Code of source location
N2: Code of destination location
N: Consecutive number for multiple cables between equal locations ( optional )

Examples:
KFR-TDE0014483
E5-L311.2
SECOND CABLE BETWEEN PANEL +E5 AND LOCAL CONTROL STATION +L311
E2-B0603
FIRST CABLE ( ONLY 1 CABLE ) BETWEEN PANEL +E2 AND SWITCH =M6+X-B0603
The identification codes of localities for all switch cabinets, control stations and
terminal boxes are indicated in detail in the following:
+X EXTERNAL DEVICES ON DRUM RECLAIMER

+X1 EXTERNAL DEVICES ON DRUM RECLAIMER
+F E-HOUSE
+E1 460V FEEDING GENERAL SAFETY CIRCUITS
+E2 TRAVEL GEAR
+E3 CROSS CONVEYOR AND CABLE REEL
+E4 DRUM DRIVE
+E5 HPP, RAKE CAR AND HOISTING WINCH
+E6 400V FEEDING & DISTRIBUTION FOR LIGHTING AND AUXILIARY
CIRCUITS 230VAC
+E7 DISTRIBUTION FOR AUXILIARY CIRCUITS 24VDC
+E8 PLC AND FIELD DEVICE CONNECTION
+P1 OPERATOR DESK
+C OPERATOR CABIN
+L61 LOCAL CONTROL STATION TRAVEL DRIVE FIXED SIDE
+L62 LOCAL CONTROL STATION TRAVEL DRIVE PENDULUM SIDE
+L181 LOCAL CONTROL STATION DRUM DRIVE
+L231 LOCAL CONTROL STATION CROSS CONVEYOR
+L311 LOCAL CONTROL STATION RAKE 1 - HPP AND WINCH
+L312 LOCAL CONTROL STATION RAKE 2 - HPP AND WINCH
+M50 CONTROL TERMINAL BOX OF WIND SENSOR
+M61 CONTROL TERMINAL BOX NEAR TRAVEL POSITION SWITCHES
+M241 CONTROL TERMINAL BOX ON CABLE GUIDING DEVICE
+M311 CONTROL TERMINAL BOX HPP
+N241 POWER TERMINAL BOX MIDDLE OF TRAVEL WAY
+N242 POWER TERMINAL BOX SLIPRING BODY

4.KFR-TDE0014483
Sequence of the installation work
4.1 Installation of the switchgears in the E-House ( inside the Reclaimer bridge )
4.2 Connect the busbars and the plug terminal blocks ( –X24I und –X230I ) between
transport units oft he switchgear.
4.3 Inspection of the place of installation of all external devices ( see drawing No.
4558494 Page 1 – Arrangement of electrical equipment ), the limit switch curves,
the terminal boxes, the local control boxes, as well as the lighting equipment.
4.4 Installation of the cable trays ( see drawing No. 4558494 Page 2 – Arrangement of
lighting, maintenance and cable routes ), the cable protection tubes, as well as the
cable clips which might be necessary.
4.5 Installation and fixation of the cables in accordance with the cable list.
4.6 Realization of the insulation test by using power cables.
4.7 Inspection of the cable routes and fastening, as well as the installation of the switch
cabinet and the electrical devices by the site manager.
4.8 Insert the cables at both the external devices and the terminal boxes, and connect
them in accordance with the circuit diagram, the terminal drawing and the
respective instructions of the cable manufacturer.
4.9 Insert the cables into the switch cabinets and the control desk arranged in the E-
house and connect them in accordance with the circuit diagram and the terminal
drawing.
4.10 When executing the earthing work, the following points are strictly to be observed:
 Installation of a separate earthing cable running from the feeding panel to the
machine.
 Verification of the earthing of the runway rails.
 Installation of a separate earthing cable for bridging the gearboxes within the
area of the shafts.
 Installation of a separate earthing cable leading from the slipring body housing of
the power cable reel to the machine.
4.11 Verification of all connections for completeness and correctness.
4.12 Additional sealing of all cable inlets by means of a sealing compound

(Silicon).
4.13 Advice that the equipment is ready for operation by the site manager.

5.KFR-TDE0014483
Installation of external devices
The installation places of the external devices are shown on the respective layout
drawing. More detailed information on the arrangement of these devices, as well as
the limit switch curves can be seen from the detail drawings representing the
mechanical equipment (the corresponding drawing numbers are indicated in the list
of local devices).
When mounting the devices, the respective installation- and operating instructions
of the manufacturer are to be adhered to.
At all electrical devices installed on site must be permanently fixed, in a good visible
way, a type plate.
The cable trays must also be installed in accordance with the layout drawings
showing the external devices and the cable routes. They will either be directly fixed
to the construction or by means of holders made of angle- or U-sections. All iron
parts must be properly protected against corrosion and grounded after execution of
the welding work. The present instructions for the installation of the cable trays are
only to be considered as general ones. In particular cases, the exact routing and
the type of fixation of the cable trays are to be decided by the site manager.
Both the cable list and the layout drawing representing the external devices and the
cable routes serve as basis for the cabling. The structure of the cable numbering
has already been explained in Para. 3.4. The labels indicating the cable numbers
must be fixed permanently, in a good visible manner, to both the cable ends.
The cables are directly to be laid from the cable drum, and must only be cut at their
connection place, taking into account the cable length needed for the connection to
the terminals.
The cable to be wound onto a reel, composed of the following components:

- MV feeding cable
- control wires
- fiber optic cables with ST-connectors
The cable which is wound onto the reel connects the terminal box in the middle of
the runway with the slipring body of the motor cable reel.
When laying and winding the cable onto the motor cable reel, the instructions given
within the documentation of the manufacturer have to be absolutely adhered to.

All cables on the cable trays are fixed with cable ties. When not being installed on
cable trays, the cables are protected by cable protection tubes which are equipped
KFR-TDE0014483
on both ends with end bushes. The cross-section of the cable to be inserted must
not exceed 40 % of that of the tube itself. For facilitating the cabling work, cable
protection tubes will not be used for bends or curves. Here, the tubes will be
installed with an offset, equipped with end bushes, and the cable installed in an
open way. In case of cables with less charge, such as control cables, it is possible
to install several cables in one and the same cable protection tube. As a rule, power
cables will always be laid singly. Screened cables and signal lines are to be
installed separately, keeping a distance between the power cables.
The cable inlets on machines, motors, terminal boxes and local control boxes are to
be executed as cable glands. In addition, the latter will be sealed by using a sealing
compound before finishing the installation work.
Should the screwed connections not be suitable for receiving the cable weight, the
cables will be relieved from traction just before having them inserted into the cable
gland. If an outgoing cable from the cable tray runs across a lateral string piece,
sharp edges will be covered and the cable fixed in such a manner that a scrubbing
is avoided during future operation. When installing the lighting, only one cable is
outgoing from the lighting distribution for ensuring the current supply to commonly
secured lamp- or socket groups. A further branching to the individual lamps,
switches or sockets is achieved within the branch boxes to be installed on the spot
at respective places.
Only expert personnel are to be entrusted with the connection of the cables. The
work is to be executed in accordance with the terminal drawing, the circuit diagram
and the operating- and mounting instructions of the manufacturer of the electrical
equipment to be installed.
When removing the outer sheath of the cable, care has to be taken that the
insulation of the individual cores does not get damaged. For having insulated the
core ends, only use such tools where it is ensured that the uncovered conductor will
not be scratched in order to avoid a reduction of the cable cross-section or later
breaks.
Prior to the connection of flexible cables to terminals, the insulated conductor must
get an end sleeve to be pressed on by use of squeeze pliers with locking device. A
soldering of the conductor ends is to be avoided. Basically, one terminal serves the
purpose of connecting two cores only. When using screwed connections, e.g. for
the supply cable running to the power switch in the feeding field or for motors, the
insulated core ends must get cable lugs to be pressed on by means of a notching
pliers.

9.KFR-TDE0014483
Shielding
9.1 General of Shielding
Shield gaps
 Bridge shield gaps (at terminals, circuit breakers, contactors, and so on) with
minimum impedance and the greatest possible surface area (see the following
picture).
Laying the motor supply cable separately.

 The distance between the motor power cable and signal cable should be >20
cm. Do not lay signal cables and motor cables in parallel to each other.

Cable installation
KFR-TDE0014483
 Cables that are subject to or sensitive to interference should be laid as far
apart from each other as possible.
 Spare cores of signal and data cables must be grounded at both ends to
achieve an additional shielding effect.
 If it is impossible to avoid crossing cables, conductors or cables that carry
signals of different classes must cross at right angles, especially if they carry
sensitive signals that are subject to interference.
o Class 1:
unshielded cables for ≤ 60VDC
shielded analogue signal cables
shielded bus and data cables
operator panel interfaces, incremental/absolute encoder
lines
o Class 2:
unshielded cables for > 60VDC and ≤ 230VDC
unshielded cables for > 25VAC and ≤ 230VAC
o Class 3:
unshielded cables for > 230V AC/DC and ≤ 1000V
AC/DC

Shield connection
KFR-TDE0014483
 Shield must not be used to conduct electricity, In other words, they must not
simultaneously act as neutral or PE conductors.
 Apply the shield so that it covers the greatest possible surface area. You can
use ground clamps, ground terminals, or ground screw connections.
 Avoid extending the shield to the grounding point using a wire (pigtail)
because this will reduce the effectiveness of the shield to 90%.
 Attach the shield to a shield bar directly after the line inlet into the cabinet.
Insulate the entire shielded cable and route the shield up to the device
connection, but do not connect it again.
I/O interfacing
 Create a low-impedance ground connection for additional cabinets, system

components, and distributed devices with the largest possible cross-section
(at least 16mm²).
 Ground unused lines at one end in the cabinet.
 Avoid unnecessarily long cable loops.

KFR-TDE0014483
9.2 Shielding of Encoders

KFR-TDE0014483
Prior to the advice that the equipment is ready for commissioning, the complete
system, in particular, the cable connections are to be checked by the site manager.
Tools and materials used for carrying out the electrical installation work must be
taken away from the machine, and the inside of the switch cabinets, terminal boxes
etc. be cleaned. All modifications, which turned out to be necessary during the
installation work, are to be carried over into the electrical documents. The latter are
to be kept on hand for the commissioning, as well as for a later revision of the
drawings.
A. Cable clamp rail below terminal boxes
- C-type rail of stainless steel

- BBS clamp of stainless steel with counter bed of plastic material
- Fastening of the C-type rail onto the substructure by means of threaded Hilti bolt
( with material thicknesses >= 8mm ) or by means of screw connection

B. Shielding connection within terminal boxes to existing shielding rail

KFR-TDE0014483
- Shielding rail and metal cable tie

C. Shielding connection within switch cabinet via existing cable clamp rail
KFR-TDE0014483
- BBS clamp with counter bed of metal ( cable sheathing must be stripped in the area
of the clamp )

D. Cable connection within switch cabinet via existing cable clamp rail
KFR-TDE0014483
- BBS clamp with counter bed of plastic material

E. Fastening of cable protection conduits onto steel surfaces

KFR-TDE0014483
- Fastening of the conduit clips onto the substructure by means of threaded Hilti
bolts, washer ( thickness of 5mm ), normal washer and nut M8 with material
thicknesses >= 8mm ( all materials of stainless steel ) or by means of screw
connection

F. Fastening of cable protection conduits onto railing

KFR-TDE0014483
- Mounting clamp MKD21E, hexagon socket screw IKK 8X10E and washer ( all
materials of stainless steel )
- Conduit clip of stainless steel

G. Fastening of cable protection conduits onto C-type rail

KFR-TDE0014483

- BBS clamp of stainless steel without counter bed

KFR-TDE0014483

INSTALLATION
Drwg. No. 4 536 703
N-033-00114
SHOUGANG HIERRO
STACKER ST2
941-ST-100
PACK. 10: PRIMARY ORE CONCENTRATE STOCKYARD

KFR-TDE0014483
TABLE OF CONTENTS

3.4 Cable numbering
9. Shielding

1.KFR-TDE0014483
General information
to.
available:
a) circuit diagram
b) terminal drawing
c) parts list
e) list of cables
be installed
standard.
=XXXX +ZZZ-YXXX
. . .
. . .
. .
.
.


KFR-TDE0014483
=ST2._1 FEEDING
=ST2._2 GENERAL SAFETY CIRCUITS
=ST2._3 LIGHTING- AND AUXILIARY CIRCUITS
=ST2._4 CONTROL VOLTAGE DISTRIBUTION
=ST2._5 GENERAL CONTROL
=ST2._6 TRAVEL DRIVES
=ST2._7 HPP II+III RAIL CLAMPS
=ST2._21 TRIPPER CAR
=ST2._23 BOOM CONVEYOR
=ST2._24 CABLE REEL / HOSE REEL
=ST2._26 SIGNAL EXCHANGE TO CCR
=ST2._31 HPP I - BOOM HOISTING
=ST2._50 PLC

C COMMON PART
M CONTROL CIRCUITS
EXAMPLE:
=ST2.D23+X-M2301 BOOM CONVEYOR MOTOR
=ST2.M23+X-S2301 BOOM CONVEYOR PULL ROPE SWITCH LHS


KFR-TDE0014483

3.4 Cable numbering
N1-N2.N

Examples:
KFR-TDE0014483
E2-L61.2
E5-B2102
FIRST CABLE ( ONLY 1 CABLE ) BETWEEN PANEL +E7 AND SWITCH .M21+X-B2102
+X EXTERNAL DEVICES ON STACKER

+X1 EXTERNAL DEVICES ON STACKER
+F E-HOUSE
+E2 TRAVEL DRIVE AND RAIL CLAMPS
+E3 ET200M, BOOM CONVEYOR, CABLE REEL AND BOOM HOISTING
+E4 400V FEEDING & DISTRIBUTION AND LIGHTING & AUXILIARY
CIRCUITS
+E5 PLC, FIELD DEVICE CONNECTION AND VALVE CONNECTION
+P1 OPERATOR DESK
+L61 LOCAL CONTROL STATION TRAVEL DRIVE
+L231 LOCAL CONTROL STATION BOOM CONVEYOR
+L311 LOCAL CONTROL STATION BOOM HOISTING
+M71 CONTROL TERMINAL BOX AT HPP II RAIL CLAMP 1
+M72 CONTROL TERMINAL BOX AT HPP III RAIL CLAMP 2
+M231 CONTROL TERMINAL BOX ON BOOM CONVEYOR
+M241 CONTROL TERMINAL BOX AT GUIDING DEVICE OF CABLE REEL
+N241 CONTROL AND POWER TERMINAL BOX MIDDLE OF TRAVEL WAY
+N242 CONTROL AND POWER TERMINAL BOX SLIPRING BODY
+M311 CONTROL TERMINAL BOX BOOM HEAD
+M312 CONTROL TERMINAL BOX AT HPP I
4.1 Installation of the E-house

KFR-TDE0014483
drawing.
machine.
area of the shafts.

(Silicon).
of local devices).
way, a type plate.

6.KFR-TDE0014483
Installation of cable trays
the terminals.

- MV feeding cable
- control wires

KFR-TDE0014483
breaks.
pliers.

9.KFR-TDE0014483
Shielding
Shield gaps
picture).


Cable installation
KFR-TDE0014483
o Class 1:
lines
o Class 2:
o Class 3:
AC/DC

Shield connection
KFR-TDE0014483
I/O interfacing

(at least 16mm²).

KFR-TDE0014483


KFR-TDE0014483
drawings.



KFR-TDE0014483

KFR-TDE0014483
of the clamp )

KFR-TDE0014483


KFR-TDE0014483
connection


KFR-TDE0014483


KFR-TDE0014483


KFR-TDE0014483

INSTALLATION
Drwg. No. 4 536 704
N-033-00114
SHOUGANG HIERRO
STACKER ST1
930-ST-100
PACKAGE 06: PRIMARY ORE CONCENTRATE STOCKYARD

TABLE OF CONTENTS
KFR-TDE0014483

3.4 Cable numbering
9. Shielding

1.KFR-TDE0014483
General information
to.
available:
a) circuit diagram
b) terminal drawing
c) parts list
e) list of cables
be installed
standard.
=XXXX +ZZZ-YXXX
. . .
. . .
. .
.
.


KFR-TDE0014483
=ST1._1 FEEDING
=ST1._2 GENERAL SAFETY CIRCUITS
=ST1._3 LIGHTING- AND AUXILIARY CIRCUITS
=ST1._4 CONTROL VOLTAGE DISTRIBUTION
=ST1._5 GENERAL CONTROL
=ST1._6 TRAVEL DRIVES
=ST1._7 HPP II+III RAIL CLAMPS
=ST1._13 SLEWING GEAR LUBRICATION
=ST1._14 SLEWING GEAR
=ST1._21 TRIPPER CAR
=ST1._23 BOOM CONVEYOR
=ST1._24 CABLE REEL / HOSE REEL
=ST1._26 SIGNAL EXCHANGE TO CCR
=ST1._31 HPP I - BOOM HOISTING
=ST1._50 PLC

C COMMON PART
M CONTROL CIRCUITS
EXAMPLE:
=ST1.D23+X-M2301 BOOM CONVEYOR MOTOR
=ST1.M23+X-S2301 BOOM CONVEYOR PULL ROPE SWITCH LHS


KFR-TDE0014483

3.4 Cable numbering
N1-N2.N

Examples:
KFR-TDE0014483
E2-L141.2
E5-B2102
+X EXTERNAL DEVICES ON STACKER

+X1 EXTERNAL DEVICES ON STACKER
+F E-HOUSE
+E2 TRAVEL DRIVE, RAIL CLAMPS, LUBRICATION SLEWING GEAR AND
SLEWING GEAR
+E3 ET200M, BOOM CONVEYOR, CABLE REEL AND BOOM HOISTING
+E4 400V FEEDING & DISTRIBUTION AND LIGHTING & AUXILIARY
CIRCUITS
+E5 PLC, FIELD DEVICE CONNECTION AND VALVE CONNECTION
+P1 OPERATOR DESK
+L141 LOCAL CONTROL STATION SLEWING GEAR
+M71 CONTROL TERMINAL BOX AT HPP II RAIL CLAMP 1
+M72 CONTROL TERMINAL BOX AT HPP III RAIL CLAMP 2
+M141 CONTROL TERMINAL BOX ON SLEWING PLATFORM
+M242 CONTROL TERMINAL BOX AT GUIDING DEVICE OF HOSE REEL
+M311 CONTROL TERMINAL BOX BOOM HEAD

4.KFR-TDE0014483
Sequence of the installation work
drawing.
machine.
area of the shafts.

(Silicon).

5.KFR-TDE0014483
of local devices).
way, a type plate.
the terminals.

- MV feeding cable
- control wires

KFR-TDE0014483
breaks.
pliers.

9.KFR-TDE0014483
Shielding
Shield gaps
picture).


Cable installation
KFR-TDE0014483
o Class 1:
lines
o Class 2:
o Class 3:
AC/DC

Shield connection
KFR-TDE0014483
I/O interfacing

(at least 16mm²).

KFR-TDE0014483


KFR-TDE0014483
drawings.



KFR-TDE0014483

KFR-TDE0014483
of the clamp )

KFR-TDE0014483


KFR-TDE0014483
connection


KFR-TDE0014483


KFR-TDE0014483


KFR-TDE0014483

INSTALLATION
Drwg. No. 4 536 700
N-033-00114
SHOUGANG HIERRO
BUCKET WHEEL RECLAIMER RE1
945-RC-100
PACKAGE 10: PRIMARY ORE CONCENTRATE STOCKYARD

KFR-TDE0014483
TABLE OF CONTENTS

3.4 Cable numbering
9. Shielding

1.KFR-TDE0014483
General information
to.
available:
a) circuit diagram
b) terminal drawing
c) parts list
e) list of cables
be installed
standard.
=XXXX +ZZZ-YXXX
. . .
. . .
. .
.
.


KFR-TDE0014483
=RE1._1 FEEDING
=RE1._2 GENERAL SAFETY CIRCUITS
=RE1._3 LIGHTING- AND AUXILIARY CIRCUITS
=RE1._4 CONTROL VOLTAGE DISTRIBUTION
=RE1._5 GENERAL CONTROL
=RE1._6 TRAVEL DRIVES
=RE1._13 LUBRICATION
=RE1._14 SLEWING GEAR
=RE1._18 BUCKET WHEEL
=RE1._23 BOOM CONVEYOR
=RE1._24 CABLE REEL
=RE1._25 BELT SCALE
=RE1._26 SIGNAL EXCHANGE TO CCR
=RE1._31 HPP I - BOOM HOISTING
=RE1._32 HPP II - CABIN ADJUSTMENT
=RE1._50 PLC

C COMMON PART
M CONTROL CIRCUITS
EXAMPLE:
=RE1.J23+X-M2301 BOOM CONVEYOR MOTOR
=RE1.M23+X-S2301 BOOM CONVEYOR PULL ROPE SWITCH LHS


KFR-TDE0014483

3.4 Cable numbering
N1-N2.N

Examples:
KFR-TDE0014483
E2-L141.2
E7-B2303
+X EXTERNAL DEVICES ON BUCKET WHEEL RECLAIMER

+X1 EXTERNAL DEVICES ON BUCKET WHEEL RECLAIMER
+F E-HOUSE
+C OPERATOR CABIN
+E2 TRAVEL DRIVE, LUBRICATION SLEWING GEAR AND SLEWING
GEAR
+E3 BUCKET WHEEL AND BOOM CONVEYOR
+E4 CABLE REEL, BOOM HOISTING AND CABIN ADJUSTMENT
+E5 400V FEEDING & DISTRIBUTION, LIGHTING & AUXILIARY CIRCUITS
+E6 400V FEEDING & DISTRIBUTION, LIGHTING & AUXILIARY CIRCUITS
+E7 PLC AND FIELD DEVICE CONNECTION
+P1 OPERATOR CHAIR LHS
+P2 OPERATOR CHAIR RHS
+P3 OPERATOR CHAIR HMI
+L141 LOCAL CONTROL STATION SLEWING GEAR
+L181 LOCAL CONTROL STATION BUCKET WHEEL
+L321 LOCAL CONTROL STATION CABIN ADJUSTMENT
+M51A CONTROL TERMINAL BOX ON FIXED PART LHS (ENERGY CHAIN)
+M51B CONTROL TERMINAL BOX ON FIXED PART RHS (ENERGY CHAIN)
+M52 CONTROL TERMINAL BOX SLEWING PLATFORM (ENERGY CHAIN)
+N51A POWER TERMINAL BOX ON FIXED PART LHS (ENERGY CHAIN)
+N51B POWER TERMINAL BOX FIXED PART RHS (ENERGY CHAIN)
+N52 POWER TERMINAL BOX SLEWING PLATFORM (ENERGY CHAIN)
+M141 CONTROL TERMINAL BOX ON SLEWING PLATFORM
+M181 CONTROL TERMINAL BOX NEAR BUCKET WHEEL
+N231 POWER TERMINAL BOX ON BOOM CONVEYOR
+M251 CONTROL TERMINAL BOX BELT SCALE


KFR-TDE0014483
+M321 CONTROL TERMINAL BOX AT HPP II
+M322 CONTROL TERMINAL BOX INSIDE OPERATOR CABIN
drawing.
machine.
area of the shafts.

(Silicon).

5.KFR-TDE0014483
of local devices).
way, a type plate.
the terminals.

- MV feeding cable
- control wires

KFR-TDE0014483
breaks.
pliers.

9.KFR-TDE0014483
Shielding
Shield gaps
picture).


Cable installation
KFR-TDE0014483
o Class 1:
lines
o Class 2:
o Class 3:
AC/DC

Shield connection
KFR-TDE0014483
I/O interfacing

(at least 16mm²).

KFR-TDE0014483

KFR-TDE0014483
drawings.



KFR-TDE0014483

KFR-TDE0014483
of the clamp )

KFR-TDE0014483


KFR-TDE0014483
connection


KFR-TDE0014483


KFR-TDE0014483


Date: 2014-10 MACHINES N-033-00114
KFR-TDE0014483
ERECTION MANUAL
5. HYDRAULIC INSTALLATION
5.1. Qualification of the personnel
Commissioning may only be carried out by trained and qualified personnel.
5.2. Preparation
– Visual check for transport damage caused and contamination. Long storage times can lead
to the seals becoming brittle and that the anti-corrosion oil becomes resinous (see section
IV storage)
– Check the completeness of commissioning components.
5.3. Carrying out
5.3.1. Cleanliness
During all kinds of work, great emphasis is to be placed on cleanliness, as contamination can lead
to faults and can influence the correct function of the components. Before loosening fittings and
components, the immediate outside area has to be cleaned. All openings are to be closed by
means of protective caps so that contamination cannot enter the system. Rags are not to be used
for cleaning purposes.
After cutting the end edges must be ground inside and outside. After preparation of the pipes,
these have to be internally cleaned by blown out with compressed air. The endings also have to be
cleaned before installation of the cutting rings of the fittings.
5.3.2. Installation and fixing of units and groups
Only cold bending of hydraulical pipes is allowed! In no case, hot bending of hydraulic pipes will be
accepted.
Care has to be taken to ensure that there is sufficient space available for access, operation and
maintenance, as well as the orientation and mounting of components and systems so that stability
and operational reliability are ensured.

Date: 2014-10 MACHINES N-033-00114
KFR-TDE0014483
ERECTION MANUAL
5.3.3. Connecting the hydraulic drive
The interconnecting pipes are to be dimensioned in accordance with the performance data stated
within the circuit (rated pressure, rated cross section).
The pipes are to be cleaned of dirt, slag and chips before installation. Welded pipes in particular
must be internally clean and flushed. Rags must not be used for cleaning purposes. While piping
pay attention to a good fixture of the pipes. Do not use any violence to avoid tensions along the
pipes and instruments.
The installation instructions of the fitting manufacturer are to be observed. Fittings with a soft seal
at the interface between the body of the fitting and the component into which it is to be fitted are
recommended (pipe thread to ISO 1179-2, metric threads to ISO 9974-2).
Sealing materials such as hemp and putty are not permissible as they cause contamination and
can therefore cause functional faults.
Hoses must comply with all of the associated European and/or international standards (see section
I safety references – Direction for hosepipes).
If no other directions are at hand the hosepipes should be checked before the first commissioning
and afterwards at least once a year for their safe work condition by a member of the personnel.
Connection ratings are to be checked before electrical installation of the drive and controls.
5.3.4. Flushing
After completion the hydraulic system must be flushed before set in operation!
Only flushing with an external flushing unit is allowed! These external flushing unit (bypass-pump,
filter system, tank, connecting hoses, etc.) has to be provided by the company responsible for
erection of the hydraulic system and is not part of TKRT-supply.
The cleanliness of the hydraulic oil has to fulfill level 6 of NAS 1638 (formerly 1964) as well as the
given limits of the installed hydraulic components (see hereto O&M-Manual). The cleanliness level
has to be verified and reported to TKRT.
It has to be flushed with the identical hydraulic oil that will be filled in for set in operation.

Date: 2014-10 MACHINES N-033-00114
KFR-TDE0014483
6. PAINTING SPECIFICATION
Doc. No. KFR-TDE0014375_1 Rev. 03 01.09.2014

ThyssenKrupp Industrial Solutions
KFR-TDE0014483
Document No.: KFR-TDE0014375_1 Page1/20
Specification on protection
against corrosion
Order: Shougang Hirro Peru
Order No.: N-033-00114

Designation: Conveyor System
Bucket wheel reclaimer
Stacker
Drum reclaimer
03 Chapter 4: colour for steel structure 01.09.2014 Fitsch Handzik

02 Chapter 3.1 Hardtop XP optional 24.06.2014 Fitsch Handzik
01 Chapter 3.1-No. 5.2 and 5.3, Chapter 3.2.1 02.04.2014 Fitsch Handzik
00 For approval 28.10.2013 Fitsch Handzik
Rev. Date Prepared Approved
Document No.: KFR-TDE0014375_1 Page 2/20
Rev. 03
___________________________________________________________________________________________________________
KFR-TDE0014483
Table of contents
1 General information
1.1 Environmental conditions
1.2 Other remarks
1.3 Standards and regulations
2 Execution of corrosion protection work
2.1 Surface preparation
2.2 Paint materials
2.3 Quality assurance
3 Execution in the workshop
3.1 Paint structure of corrosion protection systems
3.2 Special items / special surfaces
4 Colour scheme
5 Execution on site
5.1 Touch-up of degradation of coating
6 Transport- and erection instructions
7 Annexes
Rev. 03
___________________________________________________________________________________________________________
1 General information
KFR-TDE0014483
1.1 Environmental conditions
Place of use Peru

Moderate industrial atmosphere
Category of corrosiveness C3
(acc. to ISO 12944 part 2)
Temperature Extreme conditions min. / max. +8° / +32 °C

Designe temperature +40°
Relative humidity max 85 %
Average annual rain fall 10,8 mm
1.2 Other remarks
Material to be handled Lump ore
1.3 Standards and regulations
EN ISO 12 944 Corrosion protection of steel structures by protective paint

systems
part 1 General introduction
part 3 Basic design considerations
part 4 Types of surfaces and surface preparation
part 5 Protective paint systems
part 7 Execution and supervision of paint work
EN ISO 8501 parts 1-2 Preparation of steel surfaces prior to applying paint materials
EN ISO 8503 parts 1-2 Surface roughness characteristics of blast-cleaned steel

surfaces
EN ISO 2808 Determination of film thickness
ISO 2409 Cross-cut test
EN ISO 1461 Zinc coatings on steel elements produced via hot dip galva-
nized coating
DIN EN 1090 part 2 Execution of carrying steel structures
ISO 4628 parts 1-10 Evaluation of degradation of coating
Technical data sheets of the paint manufacturer

Rev. 03
___________________________________________________________________________________________________________
2 Execution of corrosion Protection work

KFR-TDE0014483
All corrosion protection works are to be executed, supervised, inspected and recorded by
complying with the instructions and regulations given in parts 3, 4, 5 and 7 of the standard
EN ISO 12944.
Coating materials must not contain any toxic or carcinogenic substances

(ISO 12944 part 1).
2.1 Surface preparation
2.1.1 Steel parts without previous treatment
The initial state of the steel surface has to correspond to the rust grades A or B as per
ISO 8501-1.
Prior to the abrasive blasting process, the surfaces must be free of oils, greases, salts, etc.
Cleaning procedures appropriate to reach this effect are described in DIN EN 12944-4.
Prior to painting, the machined connecting surfaces must be free from emulsion residues.
Edges are to be rounded off with a radius of 2 mm or to be broken (DIN EN ISO 12944-3).
Hard surface layers (>380 HV) resulting from flame cutting, as well as unevennesses shall
be ground off prior to blast cleaning.
Weld seams have to be free from roughnesses, undercuts, pores, craters and spatters.
Existing defects in welding have to be ground.
Blast-cleaning works must not be carried out when the percentage of the relative atmos-
pheric humidity exceeds 85 %, and the difference between surface temperature and dew
point amounts to less than 3° C.
There is only allowed to use blasting means which produce a rough surface (grit blasting).
Unless there are given other indications in the data sheets, the surface including the welds
and flame-cut edges must have a surface roughness in the range from 40-80 µm.
This corresponds to the reference sample type „G“ segment 2-3 according to ISO 8503-1.
The blasted surface has to be cleaned from dust by means of sweeping, blowing-off with
the use of oil-free compressed air or by means of sucking-off operation. With the adhesive
tape test according to ISO 8502-3, classes 0 - 2 are admissible.
Thin plates with a thickness of ≤ 4 mm which are impossible to sweep must be degreased,
manually de-rusted or etched, and their roughness has to be increased by using appropri-
ate means.
2.1.2 Hot dip galvanized surfaces
Oxidation products, salts and oils are to be removed by washing the surfaces with clean
water where purifier has been added, thereby using a plastic fleece with abrasive material
embedding (Scotch sponge), and subsequent final cleaning with warm water.
As an alternative, this cleaning process can be executed by using the high-pressure, steam
jet or sweeping method.
Rev. 03
___________________________________________________________________________________________________________
KFR-TDE0014483
2.1.3 Machined connecting surfaces
The surfaces are to be clean while making use of an appropriate fat dissolving agent.
Apply the cleansing agent at first to difficultl accessible points with the help of a hard brush.
Make then use of a well impregnated cleaning cloth to wipe the surface. While doing so,
wiping must go beyond the edges.
The cleaning clothes are to be changed in good time.
Finally, wipe the surfaces by means of dry clothes. Oil-free compressed air enables difficult
accessible points to be dried.
The surfaces must be absolutely dry.
So, a cleansing agent is to be used that evaporates without leaving deposits.
2.2 Paint materials
2.2.1 Storing
The paint materials are to be stored at a temperature between 5° and 30° C in a closed
room. They must not be exposed to direct sun light or stored in immediate vicinity of other
sources of heat.
Coating materials whose expiration date has expired, which have produced a firm film on
their surface or whose sediment is impossible to stir up, must not be used any more.
2.2.2 Working conditions
The figures given in the data sheets for ambient temperature, processing temperature and
surface temperature of the component, for admissible air humidity, pre-reaction time, pot
life and recoat period must be complied with when carrying out the application work.
In case of missing data, the following figures are to be met:
Ambient temperature 5° - 30°C
Air humidity max. 85 %
Surface temperature of the component min. 10°C / max. 30 °C
min. 3° C above the dew point
Optimum processing temperature 15° - 20 °C
2.2.3 Preparation of the paint materials
Prior to processing or before picking partial quantities, the bunches are to be properly
stirred up by means of an automatic stirrer (4 - 5 minutes).
When mixing partial quantities, the mixing ratio indicated must be complied with.
Mixing has to be realized by using an automatic stirrer (4 - 5 minutes).
Adding thinning agent is only admitted when keeping to the quantities indicated by the re-
spective manufacturer.
It is allowed to only use the thinners recommended by the manufacturer.
Rev. 03
___________________________________________________________________________________________________________
2.2.4 Application
KFR-TDE0014483
The application of the paint materials should be executed immediately after completion of
the blasting process. In case this is not possible, prior to applying the paint a new inspec-
tion of the required surface cleanliness is absolutely needed. A new blasting has to be
done, if the specified grade is not existent any more.
For the application, use has to be made of the procedures specified in the data sheets.
The prime coat has to be applied by using the appropriate brushes on those areas which
are difficult to access.
In exceptional cases, it is permitted to make use of a paint roller for the intermediate and
finishing coats.
In critical zones such as edges, corners and weld seams, borings etc. an additional edge
protection covering a width of 25 mm has to be applied with the help of a brush. In case
there are used zinc dust primers, the edge protection must consist of zinc phosphates.
While applying the paint, the thickness of the wet film has to be constantly checked by
means of a wet film gauge.
2.3 Quality assurance
2.3.1 General
For the use of shop primers, there is needed the prior approval of TKF.
The colour shades of the individual layers must clearly differ from one another.
The colour shade of the intermediate coat has to be chosen such that the covering capacity
of the finishing layer is ensured.
The coats must be free from runs, sags, draining, overspray, craters, and pinholes.
Every dry layer has to be checked for its uniformity, covering capacity, runs, defective
spots, wrinkling, craters, cracks, flaking and air bubbles in a visual inspection.
2.3.2 Reference areas
Quantity: later
Size: 1.5 – 3 m² (each)
Recorded: reference area record annexed
The marking of the reference areas has to be done as follows:

- Localization of the area by means of white boundary lines at the edges, leg length ap-
proximately 100 mm, width 10 - 15 mm,
- serial number of the reference area, type height about 100 mm
The components which are selected for the application of reference areas shall be exposed
to different typical climatic conditions.
The access to these areas must be ensured upon final assembly of the machine / plant.
Flame-cut edges and weld seams have to be included in these areas.
Rev. 03
___________________________________________________________________________________________________________
2.3.3 Authorized painting material manufacturers

KFR-TDE0014483
Hempel
International
Jotun
The manufacturers are listed in purely alphabetical order which does not imply any quality
grading
Other manufacturers are to be approved by TK.

Products similar to 3.1 and 5.1
2.3.4 Supply of paint material for touch-up work
5 % of the quantity of paint materials which are needed in the workshop are to be supplied
to the job site for carrying out touch-up works (for paint materials refer to point 5.1).
KFR-TDE0014483
Rev. 03
__________________________________________________________________________________________________________________________________________________________________
3 Execution in the workshop
3.1 Paint structure of corrosion protection systems
No. Component Surface Prime coat Intermediate Finishing coat PC IC FC Total Remarks
preparation coat µm µm µm µm
min
1 Steel structure
1.1 Main supporting structures, SA 2 ½ 2-pack epoxy 2-pack epoxy 2-pack 70 110 60 240
P2 zinc-dust resin micaceous polyurethane
iron ore
Hempel Hempadur Zink Hempadur Mas- Hempathane
17360 tik 45880 Topcoat 55210
International Interzink 52 Intergard 475 Interthane 990S
Jotun Barrier 77 Penguard Mi- Hardtop Flexi

dcoat MIO Hardtop XP
1.2 Not tightly closed hollow components SA 2 ½ 2 pack surface- 80 80
tolerant epoxy
Hempel Hempadur Mas-
tik 45880
International Interplus 256
Jotun Primastic
universal
1.3 Surfaces that will be walked over (accessi- SA 2 ½ 2-pack epoxy 2-pack epoxy Anti-slip finish- 70 110 60 240 see 3.2.2
ble smooth plates) P2 zinc-dust resin micaceous ing coat
iron ore
Hempel Hempadur Zink Hempadur Mas- Hempathane
17360 tik 45880 Topcoat 55210
International Interzink 52 Intergard 475 Interthane 990S
Jotun Barrier 77 Penguard Mi- Hardtop Flexi
dcoat MIO Hardtop XP
2 Wear plates of steel (high-grad steel ‘Har- SA 1 2 pack surface- 60 60
dox, Dilidur’) tolerant epoxy
shim plates
Hempel Hempadur Mas-
tik 45880
Jotun Primastic
universal
KFR-TDE0014483
Rev. 03
__________________________________________________________________________________________________________________________________________________________________
min
3 Electric house / operator cabin / machine Bright or hot-
house galvanized
steel sheets.
3.1 Outer surface of according to EN 2-pack epoxy 2-pack epoxy 2-pack

ISO 12944-4,
electric house, section 12
resin zinc phos- resin micaceous polyurethane
operator cabin, phates iron ore
machine house,
inner surface of machine house
Hempel Hempadur Hempadur Mas- Hempathane 80 100 60 240
15553 tik 45880 Topcoat 55210
International Intergard 269 Intergard 475 Interthane 990S 40 140 60 240
Jotun Primastic Uni- Penguard Mi- Hardtop Flexi 80 100 60 240

versal dcoat MIO Hardtop XP
3.2 Inner surface of according to EN 2-pack epoxy 2-pack 80 60 140
ISO 12944-4,
electric house, section 12
resin zinc phos- polyurethane
operator cabin . phates
machine house
Hempel Hempadur Hempathane 80 ---- 60 140
15553 Topcoat 55210
International Intergard 269 Intergard 475 Interthane 870 40 80 80 200
Jotun Primastic Uni- Hardtop Flexi 80 ---- 60 140

versal Hardtop XP
4 Machined connecting surfaces
4.1 Machined connecting surfaces, functional Temporary, washable preservation Protective life of the preservation:
elements such as shaft step for gearbox / 18 months when being stored in the open,
coupling, spindles etc. 24 months when being stored within buildings
KFR-TDE0014483
Rev. 03
__________________________________________________________________________________________________________________________________________________________________
min
4.2 Machined connecting surfaces which are no Free of oil 2 pack surface- 2-pack epoxy 2-pack 80 100 80 240
functional surfaces (outside of covers etc.) and grease tolerant epoxy resin micaceous polyurethane
See 2.1.3 iron ore
Hempel Hempadur Hempadur Mas- Hempathane
15553 tik 45880 Topcoat 55210
International Intergard 269 Intergard 475 Interthane 870
Jotun Penguard Penguard Mi- Hardtop Flexi

Primer dcoat MIO Hardtop XP
5 Surfaces of systematically pre-stressed
screwed connections
5.1 Abutting surfaces for friction-grip connec- SA 3 Alkali silicate zinc 40 - 40 - see 3.2.1.1
tions, (>SA 2 ½) dust or ethyl 60 60
shim plates for friction-grip connections Average silicate zinc dust
HFSG DIN EN 14399-4 roughness for coefficient of
HFSG fitted bolt DIN EN 14399-8 Ra ~ 12.5 friction of 0.5
Hempel Hempel’s Gal-
vosil 15702
International Interzink 22
Jotun Resist 78
5.2 Abutting surfaces of systematically pre- SA 2 ½ 2-pack epoxy 70 70 see 3.2.1.2

stressed connections, surfaces under P2 resin zinc dust
washers
HS bolt 100% pre-stressed Hempel Hempadur Zink
HS fitted bolt 100% pre-stressed 17360
Fv=100% International Interzink 52
Jotun Barrier 77
5.3 Abutting surfaces of pre-stressed connec- Painting system 1.1 See 3.2.1.3
tions
Fv=50% and others (handrails, ladders,
stairs, steps..)
KFR-TDE0014483
Rev. 03
__________________________________________________________________________________________________________________________________________________________________
min
6 Tightly closed hollow components, Without coating / protection against corrosion For parts to be
running rails and rail clamps (laid on the partly embed-
ground), ded, see 3.2.8
parts to be embedded in concrete,
stainless steels,
nonferrous metals,
type plates /nameplates,
plastics,
rubber,
wood
7 Grating Hot galvanized according to EN ISO 1461, without any further coating
stairs,
cable ducts,
water pipes,
fixing material for pipes
8 Bought-in items
8.1 Motors, gearboxes, pulleys, drums, idlers, Standard of the manufacturer, suitable for the existing environmental conditions
hoists, cable reels, incidentals for electric Min DFT 120 µm
and hydraulic equipment etc.
8.2 Bought-in items to be heated for mounting, Primer, suitable to be coated with 2pack Epoxy
such as running wheels, couplings, etc.
Rev. 03
_____________________________________________________________________________________________________________

KFR-TDE0014483
3.2.1 Surfaces of systematically pre-stressed connections
(DIN EN 1090 – 2)
3.2.1.1 Abutting surfaces for friction-grip connections

Shim plates for friction-grip connections
Friction-grip connections have to be marked for identification on design drawings by:

„HVGV DIN EN 14399-4“ or „HSFG DIN EN 14399-4“
„HVGVP DIN EN 14399-8“ or HSFG fitted bolt DIN EN 14399-8“
Paint material
Alkali silicate zinc dust or ethyl silicate zinc dust with proven coefficient of friction of µ= 0.5
according to
- TL918 300 sheet 5
- TL/TB KOR – steel structures, sheet 85
- DIN EN 1090-2 attachment G
- ASTM D1894; ASTM A-325 or ASTM A 490
The areas to be coated must be enlarged all round their circumference by 10 mm, so that
their size exceeds the dimensions as required for the contact areas.
In case of machined areas, these are to be sandblasted as well.
The coated and dried areas have to be protected from mechanical degradation, further coat-
ing, and contamination (f. ex. overspray) by applying adhesive tape.
3.2.1.2 Abutting surfaces of systematically pre-stressed connections

Surfaces below the washers
Systematically pre-stressed connections are to be marked for identification on design draw-

ings as follows:
HV-Schraube 100% vorgespannt HS bolt 100% pre-stressed
HVP-Schraube 100% vorgespannt HS fitted bolt 100% pre-stressed
Fv = 100%
The coated and dried areas have to be protected from mechanical degradation, further coat-
ing, and contamination (f. ex. overspray) by applying adhesive tape.
3.2.1.3 Abutting surfaces of pre-stressed and other connections
Pre-stressed connections are to be marked FV = 50% and connections without marking

(handrails, ladders, stairs and steps)
Rev. 03
_____________________________________________________________________________________________________________
KFR-TDE0014483
3.2.2 Anti-slip coating
Accessible plates are to be provided with an anti-slip coating. On drawings, surfaces to be

walked over are marked with „anti-slip coating“.
- Apply prime coat and intermediate coat,

- apply finishing coat,
- sand the wet film with appropriate additives,
- after the coating has become dry, sweep off the additive which has not been
incorporated,
- apply the 2nd finishing coat.
Appropriate additives (grain size 0.5 - 2 mm) are

- fire-dried silica sand,
- silicon carbide,
- aluminium oxide.
3.2.3 Site weld seams
3.2.3.1 Main supporting structures

- By applying appropriate adhesive tape protect the area of the weld seam over a
width of approx. 200 mm on both sides of the welding edge.
- Apply the primary coating in its nominal film thickness by bringing the coat near the
adhesive protection edge.
- Retreat every further coat by approx 50 mm from the edge of the preceding one.
- The adhesive tape is left in its place.
3.2.3.2 Secondary structures

(Catwalks, stairs, railings etc.)
- By applying adhesive tape protect the area of the weld seam over a width of approx
50 mm on both sides of the welding edge.
Alternative: Apply a welding primer with a DFT of 20 - 25 microns which needs not
be removed.
- Apply the primary coating in its nominal film thickness by bringing the coat near the
adhesive protection (primer) edge.
- Retreat every further coat by approx 50 mm from the edge of the preceding one.
- The adhesive tape is left in its place.
3.2.4 Stainless steels
Sweeping or etching has to be used to remove scales and tempering colours from weld
seams. Sweeping is to be carried out only with non-ferrous abrasives (f. ex. glass beads).
In case of welded connections between normal steel and stainless steel items
(black/white connections), approx. 50 mm of the stainless steel area is to be coated.
Priming: zinc phosphates
Rev. 03
_____________________________________________________________________________________________________________
KFR-TDE0014483
3.2.5 Joints, gaps
All open joints and gaps, where the paint structure as provided for cannot be realized, have
to be sealed with a permanently elastic sealing compound to be overpainted after comple-
tion of the prime and intermediate coat (Sikaflex 221 or equivalent).
3.2.6 Bearings
Unless filled with grease, bearings are to be preserved.
Minimum protective life of the preservation:

18 months when being stored in the open or
4 years when being stored within buildings
3.2.7 Coating of bought-in components in the workshop

In the workshop, both an intermediate and finishing coat are to be applied to bought-in items,
such as pillow block housings etc., which at their delivery are only provided with a prime
coat.
3.2.8 Partly embedded parts
For components which are to be partly embedded, the coat has to be applied up to approxi-
mately 50 mm below the concrete edge.
3.2.9 Screwed connections
3.2.9.1 Screwed connections

HS connections see parts list
Other screwed connections see parts list
(steel structures)
3.2.9.2 Screwed connections for special steels

Stainless steel / stainless steel screws of stainless steel
Stainless steel / steel screws of stainless steel
Rev. 03
_____________________________________________________________________________________________________________
4 Colour Scheme
KFR-TDE0014483
Colour shade for finishing coat
Components Colour shade RAL
Steel structures pastel green 6019
Ladders, stairways, walkways such as:

handrails signal yellow 1003
safety guard rails
toe boards
vertical posts
other safeguards
Electric house / operator cabin /

machine house
outside Gentian blue 5010
inside cream 9001
electrical cabinets light grey 7035
Bought-in items standard of the

manufacturer
Rev. 03
_____________________________________________________________________________________________________________
5 EXECUTION ON SITE
KFR-TDE0014483
5.1 Touch-up of degradation of coating
Surface preparation: derusting with mechanical brush as per PSt 2/PSt 3;
Grind by using abrasive paper with a granulation
ranging from 80 to 100. When doing so, create flat, soft
transfers towards the intact zone.
Whet once by using abrasive paper of a granulation
between 60 and 80.
Paint structure painting material Type of paint Application NDFT

manufacturers method / (µm)
Products
Prime coat Surface-tolerant brush / spray 100
System No. 1.1 2-pack epoxy
and 1.3
Hempel Hempadur Mastik 45880
Jotun Primastic universal
Prime coat see 3.1 brush / spray 3.1 +

all other systems 20µm
Intermediate coat see 3.1 brush / spray 120
/ roll
Finishing coat see 3.1 brush / spray 60
/ roll
Dry film thickness 280
5.2.1 Systematically pre-stressed connections (see 3.2.1)
5.2.1.1 Friction-grip connections

- - Wash off zinc salt from the still visible area of the prime coat by using water and sponge
(ScotchBrit). If need be, carry out a touch-up of the prime coat according to 5.1.
- Apply intermediate coat as per indication under 5.1. Take care to thickly apply the paint
materials in the zone of adjacent contact areas.
- Seal the broader joints with a permanently elastic sealing compound to be overpainted
(Sikaflex 221 or equivalent).
- Apply finishing coat according to the description under 5.1. Take care to thickly apply the
paint materials in the zone of adjacent contact areas.
Rev. 03
_____________________________________________________________________________________________________________
5.2.1.2 Surfaces with prime coat, including the fasteners

KFR-TDE0014483
- Clean prime coat, carry out a touch-up of possibly existing degradation according to 5.1.
- Remove the grease from fasteners; apply prime coat.
- Apply intermediate and finishing coat as per indication under 5.1.
5.2.2 Site weld seams (see also 3.2.3)
5.2.2.1 Main supporting structures

- Completely remove the protection made of adhesive tape.
- After the welding process, mechanically clean the area of the weld seam as well as
the coating zone which was damaged due to the heat effect.
- Sandblast the area of bright metal on both sides of the weld seam according to SA 2 ½.
- Apply the coating as described under 5.1.
5.2.2.2 Secondary structures

as described under 5.1
5.2.3 Pins for bogies

Surface preparation: temporary, washable preservation has to be removed;
see 2.1.3
Paint structure: as described under 3.1 No. 4.2
5.2.4 Screws (general)

Hot-galvanized screws: to be degreased
Paint structure: as described under 5.1
5.2.5 Hydraulic pipes, lubricating lines

Surface preparation: remove oil, derusting as per PSt2
Paint structure: as described under 5.1
5.2.6 Touch-up of hot-galvanized items

Surface preparation: grease has to be removed;
derusting with mechanical brush as per PSt 3;
Coat: zinc spray, grey,

DFT: 80 up to 100 microns;
5.2.7 Commercial goods / catalogue goods

will have to be touched up according to the standard corrosion protection of the
manufacturer.
5.2.8 Machined surfaces / bright surfaces

Those machined or bright surfaces which, for functional reasons, cannot be provided with a
permanent corrosion protection are to be coated with a temporary corrosion protection agent
(Tectyl, Shell Ensis oil, Molykote oil, etc.).
When selecting the respective products, additional characteristics, such as lubrication-, flow
properties, etc. should be considered.
The above corrosion protection is to be renewed at regular intervals in accordance with the
manufacturer’s instructions.
Rev. 03
_____________________________________________________________________________________________________________
6 Transport- and erection instructions

KFR-TDE0014483
To avoid degradation being caused to coats, the following instructions must be adhered to:
- Open hollow components are to be closed to prevent ingress of water.

- Possibly existing rust damages caused due to spatters or sanding dust to parts of stain-
less steel are to be removed prior to packing.
- There are to be shipped only components whose paint coats have completely dried /
cured!
- Greatest care to be taken with internal transport, packing, loading and unloading!
- Use suspension lugs or eyes, wherever existing!
- Always put down on timber!
- When suspending, always put / mount edge-protecting material between the
sling means and the component.
- When bundling, the coat is to be protected by intermediately placing timbers or rubber
strips both between the components themselves, and the components and the lashing
material.
7 Annexes
Record of reference areas

Paintwork record on inspection of coating
KFR-TDE0014483
Record on paintwork execution
Order Specification No.: Component Company carrying out the coating Reference area no.
work
Order no.: Drawing no.: Paint material manufacturer
Rust grades Degree of surface preparation

Primer 1) 1) 1) Finishing coat
Designation of product
Batch no.
Shade of colour
Coating procedure
Ambient temperature °C
Relative air humidity %
Surface temperature °C
Dew point / dew point difference °C
Temperature of the paint material °C
Thinner (type and quantity)
Wet film thickness min / max µm
Dry film thickness min / max µm
Other measurements
Date
Company carrying out the

coating work
Paint material manufacturer
TKF
1) Further operations such as application of edge protection, intermediate coat, cleaning

KFR-TDE0014483
Record on paintwork execution
Order Order no.: Specification no.: Company carrying out the coating work Serial
number
Date Time Operations carried out Component Execution General Temperature Relative Dew point/ Remark Signature /
drawing no. in a in the weather air com- air humi- dew point initials
hall open conditions ponent dity difference
Date: 2014-10 MACHINES N-033-00114
KFR-TDE0014483
ERECTION MANUAL
7. COMMISSIONING
The first commissioning has to be carried out under supervision of THYSSENKRUPP and under
the assistance of the erection company, as otherwise no warranty will be assumed.
7.1. Checks prior to Commissioning

Upon completion of erection and prior to the initial test runs all plant components shall be checked
in accordance with the following check list and all material remnants, tools and erection aids
removed.
– Has the rail system been laid in accordance with instructions and have all the bolted
connections been firmly tightened?
– Have the electric connections been tested for correct wiring?
– Has the following control equipment been installed and checked for proper functioning?
 Pull rope switches

 Speed monitor
 Proximity switches
 Misalignment switches
 Collision protection switches
 Limit switches
 Level switches
 Emergency-off switches
 All other switches
– Have the central lubrication systems been fitted and have they been checked for proper
functioning?
– Have all the drives and couplings been mounted and adjusted?
– Has the sense of rotation been checked on all motors?
Note: Use hydraulic jacks to lift up the portal structure for making a clearance
between the driven wheels and the rail!
– Have the brakes on the drive units been checked for proper functioning?
– Have all platforms, ladders and protective devices been properly fitted?
– Have the hydraulic systems been checked for correct installation?
– Have the hydraulic pipes been flushed correctly accordance to the suppliers information?

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Rev: 01 SHOUGANG HIERRO PERU Order No.

Date: 2014-10 MACHINES N-033-00114

2. PRECONDITIONS FOR ERECTION

4. PROCEDURE AND SEQUENCE OF ELECTRICAL INSTALLATION

5. HYDRAULIC INSTALLATION AND ASSEMBLY

ThyssenKrupp Resource Technologies 1/1

Date: 2014-10 MACHINES N-033-00114

ThyssenKrupp Resource Technologies 1/53

Date: 2014-10 MACHINES N-033-00114

THYSSENKRUPP RESOURCE TECHNOLOGIES

These Guidelines are binding for all Erection-Sites controlled or supervised by

President Head of Erection Dept.

Issued by the Erection Department Head Office Essen

Revised issue 1999

ThyssenKrupp Resource Technologies 2/53

Date: 2014-10 MACHINES N-033-00114

1. Introduction for our Employees

2. Introduction for our Subcontractors

3. The ThyssenKrupp Resource Technologies's Safety Principals

4. General Safety Rules

7. Drug Abuse / Contraband Policy

8. Personal Protective Equipment

9. Material Handling and Storage

10. Hand and Portable Power Tools

11. Motor Vehicles and Mobile Equipment

12. Lifting Equipment

15. Safety Barriers

16. Arc/autogenous welding and flame cutting

17. Fire Protection

18. Hot Work Permits

ThyssenKrupp Resource Technologies 3/53

Date: 2014-10 MACHINES N-033-00114

22. Safety Meetings

23. Competent Safety Advisers

25. Thorough Investigation and Follow-up of Accidents

26. Safety - Check List

ThyssenKrupp Resource Technologies 4/53

Date: 2014-10 MACHINES N-033-00114

1. Introduction for our Employees

ThyssenKrupp Resource Technologies 5/53

Date: 2014-10 MACHINES N-033-00114

2. Introduction for our Subcontractors

a) relevant local, national and international laws and regulations,

c) the ThyssenKrupp Resource Technologies's regulations.

ThyssenKrupp Resource Technologies 6/53

Date: 2014-10 MACHINES N-033-00114

3. ThyssenKrupp Resource Technologies's Safety Principals

- Accidents and injuries are preventable.

- No business objective is so important that it will be pursued at the sacrifice of safety.

- Safe conduct of operations is a condition of employment.

- A job is well done only if it is done safely.

ThyssenKrupp Resource Technologies 7/53

Date: 2014-10 MACHINES N-033-00114

4. General Safety Rules

ThyssenKrupp Resource Technologies 8/53

Date: 2014-10 MACHINES N-033-00114

15. Good housekeeping should be maintained in all work areas.

ThyssenKrupp Resource Technologies 9/53

Date: 2014-10 MACHINES N-033-00114

ThyssenKrupp Resource Technologies 10/53

Date: 2014-10 MACHINES N-033-00114

1. Determen for every Erection Site and pin on Black board

- Name of Safety Officer

- Telephone of Fire Brigade