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1 GENERAL

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2 MATERIAL
3 SEPARATING, BENDING
4 WELDING
5 MACHINING
6 ASSEMBLING
7 PRESERVING
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8 LABELING
9 PACKAGING


10 INSPECTION
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Weitergabe sowie Vervielfltigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts sind nur
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vor unberechtigtem Zugriff Dritter zu schtzen.
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Alle Rechte aus Patent-/Gebrauchsmuster-/Markenschutz vorbehalten.


The reproduction, distribution and utilization of this document as well as the disclosure of its content to
others without prior explicit written consent of SMS Demag AG is prohibited. Holder has to protect this
document against unauthorized withdrawal of third parties. Offenders will be held liable for the payment of
damages.

All rights reserved in case of patent/utility model/trademark protection.












SMS Demag Aktiengesellschaft
Konstruktionsberatung/Normung
Telefon: (0 27 33) 29-10 93
Fax: (0 27 33) 29-10 73
E-mail: hueb@sms-demag.de

1
st
edition (September 2003)
No guarantee can be given in respect
of this translation
In all cases the latest German-language version of this
standard shall be taken as authoritative
September 2003

Manufacturing instructions

GENERAL
SN 200
Part 1

These SN 200 manufacturing instructions specify the requirements made on the products and manufacturing
methods. The instructions are classified by manufacturing methods irrespective of the product.

They describe minimum requirements that have to be complied with unless otherwise indicated in orders,
drawings or other manufacturing documents.

The Manufacturing Instructions SN 200 apply to the manufacture of components of SMS Demag and its
subsidiaries.
The applicability of SN 200 is indicated in drawings and/or contracts or purchase orders.

Every manufacturer has the obligation to comply with the overriding requirements specified in parts 7 to 10 in
addition to the manufacturing methods for the products which are contained in his scope of supply and
services.

The correct and complete delivery/performance of the supplies and services are recorded by SMS Demag in a
supplier evaluation system. This evaluation covers quality, price, faithfulness to deadlines as well as
completeness of the documents, test records and certificates associated with the supplies and services
ordered.

We recommend all suppliers introducing a quality assurance system on the basis of ISO 9001.



Referenced standards are indicated in the individual chapters.

Rules and directives are German and European sets of rules, codes and regulations
DIN standards are national standards of the Federal Republic of Germany
EN standards are standards of the European Union
ISO standards are standards of the International Organization for Standardization
DIN EN standards are European standards incorporated in German language in the national set of standards
DIN ISO standards are international standards incorporated in German language in the national set of standards
DIN EN ISO standards are international standards that were made part of the European standards and incorporated
in German language in the national set of standards.


Example: DIN ISO 286 ISO 286
DIN EN 10083 EN 10083
DIN EN ISO 9001 ISO 9001

There is, however, not a German-language version (DIN-ISO) for every international standard (ISO)!



Tolerancing principle

Contrary to the stipulations made in ISO or DIN, the tolerancing principle of "envelope requirements" applies to
tolerances of shape and parallelism in all manufacturing methods.


All dimensions are subject to the envelope requirements as specified in DIN 7167.


This means that all tolerances of shape and parallelism must be within the specified general or ISO tolerances.






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SN 200 Part 1 : 2003-09

Hazardous materials / environmental protection
If safety data sheets drawn up on the basis of the hazardous materials rules exist for substances and preparations to be
supplied by you or for substances which are used as constituents of products to be supplied by you, these sheets have to
be joined to the consignment with indication of our purchase order number.
If such sheets do not exist, you undertake to supply with the consignment, in due time and well visible, other product
information relevant for environmental protection and safety so as to allow proper transport and handling, storage and
disposal of the substances/preparations by SMS Demag or by our customer in accordance with the regulations.



Load-carrying attachments
SN 195 specifies, on the basis of the European directives and standards, the fundamental requirements made on load
carrying attachments with regard to design, manufacture and the respective scope of testing.
It aims at standardising the design, manufacture and testing of load carrying attachments and at enforcing the requirements
made in the directives of the European Union.



Pipe classification
SMS Demag has drawn up a standardisation of all components of pipe conduits. This standardisation is given in our company
standards in Group 18 and must be observed.



Material data
The material data given in drawings and bills of material are based on stipulations taken from materials and product
standards. These properties are shown in SN 359 on "Materials" and must be observed.



Radioactivity
All components and products must be free of any ionising radiation exceeding the natural characteristic radiation of the
material.
Ionising radiation exceeding the characteristic radiation of components and products is considered to exist when a radiation
value above the ambient background radiation is found at the time of an examination. SMS Demag reserve the right of
refusing the acceptance of any parts found to possess such ionising radiation.



Residual magnetism
The residual magnetism must not exceed 800 A/m at the time of delivery of the parts. Parts transported with lifting magnets
and / or checked for surface defects with full-wave direct-current testers must be demagnetised if necessary. Checks for
residual magnetism must always be performed with an appropriate field intensity meter. If requested by SMS Demag, the
check has to be proven and/or certified.

September 2003

Manufacturing instructions

MATERIAL
SN 200
Part 2
Dimensions in mm
Field of application
The manufacturing instructions laid down in this part of SN 200 apply to all parts produced by casting, forging and rolling and
to semi-finished products of ferrous and non-ferrous metals unless otherwise specified in drawings or other manufacturing
documentation.


Table of contents Page

1 Casting....................................................................................................................................................................... 2
1.1 Surface qualities................................................................................................................................................ 2
1.2 General tolerances ............................................................................................................................................ 2
1.3 Degrees of accuracy.......................................................................................................................................... 2
1.3.1 Tolerance limits................................................................................................................................................. 2
1.4 General tolerances for cast steel products ......................................................................................................... 2
1.4.1 Outer and inner curvatures ................................................................................................................................ 3
1.5 General tolerances for cast iron products ........................................................................................................... 3
1.6 Mould tapers .................................................................................................................................................... 3
1.7 Offset................................................................................................................................................................ 4
1.8 Wall thicknesses ............................................................................................................................................... 4
1.9 Machining allowances ....................................................................................................................................... 4
1.9.1 Machining allowances for cast steel and cast iron products ................................................................................ 5
1.10 Inspections........................................................................................................................................................ 5
1.10.1 Cast steel products............................................................................................................................................ 5
1.10.1.1 Internal condition .............................................................................................................................................. 5
1.10.1.2 External condition.............................................................................................................................................. 6
1.10.2 Spheroidal graphite cast iron ............................................................................................................................. 6
1.10.2.1 Internal condition............................................................................................................................................... 6
1.10.2.2 External condition.............................................................................................................................................. 6

Referenced standards..................................................................................................................................................... 6
Further standards............................................................................................................................................................ 6


2 Forging....................................................................................................................................................................... 7
2.1 Forgings................................................................................................................................................................. 7
2.2 External condition................................................................................................................................................... 7
2.3 Internal condition.................................................................................................................................................... 7
2.3.1 Surface condition.................................................................................................................................................... 7
2.3.2 Surface finish related to quality class....................................................................................................................... 7
2.3.3 Performance of the examination.............................................................................................................................. 7
2.3.4 Recording levels and acceptance criteria................................................................................................................. 8
2.4 Inspections........................................................................................................................................................... 10
Referenced standards................................................................................................................................................... 10


3 Semi-finished products............................................................................................................................................ 11
3.1 General tolerances ............................................................................................................................................... 11
3.2 Technical delivery conditions................................................................................................................................. 11
3.3 Plate .................................................................................................................................................................... 11
3.4 Inspection............................................................................................................................................................. 11

Referenced standards................................................................................................................................................... 12






Continued on pages 2 to 12
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Page 2
SN 200 Part 2 : 2003-09

1 Casting
Casting is a process for transforming, through filling of a mould, liquid steel, ferrous and non-ferrous metals into geometrically
defined parts with defined properties to obtain a shape which is close to the finished dimensions.


1.1 Surface qualities
If no drawing indications are made, the following applies according to DIN EN 1370:
for cast steel and non-ferrous metals for cast iron
4S1 for blasted surfaces 3S1 for blasted surfaces
4S2 for ground surfaces 3S2 for ground surfaces

1.2 General tolerances
The authoritative standard for the definition of the general tolerances is DIN ISO 8062. These general tolerances are
applicable to unmachined faces of metal casting blanks. Half the respective general casting tolerance is applicable to a
dimension between a machined and an unmachined surface for which no individual tolerance is indicated. The values of the
general tolerances are indicated in the tables 1 to 3 under the selected grade of tolerance CT.


1.3 Degrees of accuracy
The grades of tolerance CT shown against a shaded background in the tables 1 and 3 are SMS Demag standard for the
respective nominal dimension range.
The grade of tolerance to be selected depends upon the biggest nominal dimension of the workpiece. All blank dimensions of
this casting blank have the same grade of tolerance, this means that only one grade of tolerance can be assigned to a
workpiece. If smaller admissible casting tolerances are required, they are indicated in the drawing at the respective nominal
dimension.

1.3.1 Tolerance limits










1 nom. dimension of the unfinished casting
2 dimensions after finish-machining
3 minimum limit of size
4 maximum limit of size





1.4 General tolerances for cast steel products
Table 1
Overall casting tolerance
1)


mm
Nom. dimension of
unfinished casting
mm Tolerance grade for casting CT

Casting tolerance CT for linear dimensions
2)
,
drawing indication
Associated casting tolerance CT for wall thicknesses
3)


above
up to and
including
8 9 10 11 12 13 14 15 9 10 11 12 13 14 15 16
- 25 1,2 1,7 2,4 3,2 4,6 6 8 10 1,7 2,4 3,2 4,6 6 8 10 12
25
40
63
40
63
100
1,3
1,4
1,6
1,8
2
2,2
2,6
2,8
3,2
3,6
4
4,4
5
5,6
6
7
8
9
9
10
11
11
12
14
1,8
2
2,2
2,6
2,8
3,2
3,6
4
4,4
5
5,6
6
7
8
9
9
10
11
11
12
14
14
16
18
100
160
250
160
250
400
1,8
2
2,2
2,5
2,8
3,2
3,6
4
4,4
5
5,6
6,2
7
8
9
10
11
12
12
14
16
16
18
20
2,5
2,8
3,2
3,6
4
4,4
5
5,6
6,2
7
8
9
10
11
12
12
14
16
16
18
20
20
22
25
400
630
1000
630
1000
1600
2,6
2,8
3,2
3,6
4
4,6
5
6
7
7
8
9
10
11
13
14
16
18
18
20
23
22
25
29
3,6
4
4,6
5
6
7
7
8
9
10
11
13
14
16
18
18
20
23
22
25
29
28
32
37
1600
2500
4000
6300
2500
4000
6300
10000
3,8
4,4
-
-
5,4
6,2
7
-
8
9
10
11
10
12
14
16
15
17
20
23
21
24
28
32
-
30
35
40
33
38
44
50
5,4
6,2
7
-
8
9
10
11
10
12
14
16
15
17
20
23
21
24
28
32
-
30
35
40
33
38
44
50
42
49
56
64
1)
The tolerance zone must be arranged symmetrically to the nominal dimension.
2)
Lengths, widths, heights, center distances, diameters and curvatures.
3)
For wall thicknesses the next higher grade is applicable

necessary machining
allowance
necessary machining
allowance
see table 6
see table 6
Fig. 1
Page 3
SN 200 Part 2 : 2003-08

1.4.1 Outer and inner curvatures
In the case of outer and inner curvatures the tolerance zone according to
Table 1 is arranged in such a way that the lower tolerance limit is always zero.
Example:
Nominal dimension of the curvature is 20 mm, cast grade of tolerance CT 13;
the relevant tolerance given in Table 1 is 6 mm; thus the lower tolerance limit
applicable to the curvatures is 0, the upper limit is 6 mm.
To reduce the risk of cracking, the minimum values for inner curvatures given in
Table 2 must be used as required for the respective wall thickness.


1.5 General tolerances for cast iron products (EN-GJL and EN-GJS)
Table 3
Nom. dimension of
unfinished casting
mm
Overall casting tolerance
1)


mm
Tolerance grade for casting CT
Casting tolerance CT for linear dimensions
2)
,
drawing indication
Associated casting tolerance CT for wall thicknesses
3)


above
up to and
including
8 9 10 11 12 13 14 15 9 10 11 12 13 14 15 16
- 25 1,2 1,7 2,4 3,2 4,6 6 8 10 1,7 2,4 3,2 4,6 6 8 10 12
25
40
63
40
63
100
1,3
1,4
1,6
1,8
2
2,2
2,6
2,8
3,2
3,6
4
4,4
5
5,6
6
7
8
9
9
10
11
11
12
14
1,8
2
2,2
2,6
2,8
3,2
3,6
4
4,4
5
5,6
6
7
8
9
9
10
11
11
12
14
14
16
18
100
160
250
160
250
400
1,8
2
2,2
2,5
2,8
3,2
3,6
4
4,4
5
5,6
6,2
7
8
9
10
11
12
12
14
16
16
18
20
2,5
2,8
3,2
3,6
4
4,4
5
5,6
6,2
7
8
9
10
11
12
12
14
16
16
18
20
20
22
25
14
16
18
20
14
16
18
20
22
25
400
630
1000
630
1000
1600
2,6
2,8
3,2
3,6
4
4,6
5
6
7
7
8
9
10
11
13
18 23
22
25
29
3,6
4
4,6
5
6
7
7
8
9
10
11
13
18 23 29
28
32
37
1600
2500
4000
6300
2500
4000
6300
10000
3,8
4,4
-
-
5,4
6,2
7
-
8
9
10
11
10
12
14
16
15
17
20
23
21
24
28
32
-
30
35
40
33
38
44
50
5,4
6,2
7
-
8
9
10
11
10
12
14
16
15
17
20
23
21
24
28
32
-
30
35
40
33
38
44
50
42
49
56
64
1)
The tolerance zone must be arranged symmetrically to the nominal dimension.
2)
Lengths, widths, heights, center distances, diameters and curvatures.
3)
For wall thicknesses the next higher grade is applicable.


1.6 Mould tapers
Additional tapers on shaped elements which is required to enable the separation of a casting or a pattern from a mould. The
deviations from the nominal shape and dimensions of the casting blank resulting from the mould tapers are not considered as
exceeding of the tolerance. The mould taper must be averaged in relation to the nominal dimension, mould taper . Mould
tapers on surfaces that have to be machined must be arranged on the casting blank in such a way that the finished
dimensions are kept.

Table 4 Mould tapers for inner and outer surfaces
Height

up
to
18
>
18
to
30
>
30
to
50
>
50
to
80
>
80
to
180
>
180
to
250
>
250
to
315
>
315
to
400
>
400
to
500
>
500
to
630
>
630
to
800
>
800
to
1000
>
1000
to
1250
>
1250
to
1600
>
1600
to
2000
>
2000
to
2500
>
2500
to
3150
>
3150
to
4000
in degrees () in mm
Taper
2 1,5 1 0,75 0,5 1,5 2,0 2,5 3,0 3,5 4,5 5,5 7,0 9,0 11,0 13,5 17,0 21,0

Table 5 Mould tapers for core prints
Height up to 70 > 70
Taper 5 3













Table 2 Inner curvatures
Wall thickness
Inner curvature
min.
up to 10 6
> 10 up to 30 10
> 30
0,33 x wall
thickness

Page 4
SN 200 Part 2 : 2003-09

1.7 Offset
Unless otherwise specified, the offset shown in Fig. 2 must be within the tolerances stated in tables 1 and 3. If further
restriction of the offset is required, the maximum value is indicated in the drawing.













1 maximum permissible offset
2 minimum limit of size
3 maximum limit of size



1.8 Wall thicknesses
For wall thicknesses in the grades CT, the next higher grade is applicable (see tables 1 and 3).


1.9 Machining allowances

Machining allowances on casting blanks is excess material which makes it possible to remove casting defects from the
surface by machining and to attain the desired surface condition and the necessary dimensional accuracy.
The amount of material to be removed by machining also depends upon the actual dimensions of the casting blank. These
actual dimensions may show differences within the range of the specified and permissible general tolerances or the tolerance
indicated with a dimension. Allowance is to be understood as allowance for every surface to be machined, this means on
bodies of rotation or for machining on two sides the allowance is required two times.
The specifications stated in table 4 are based on experience gathered by SMS Demag; the values deviate from the
machining allowances given in DIN ISO 8062.
Unless otherwise specified, the necessary machining allowance as in table 4 applies to the entire unfinished casting. The
machining allowance depends on the biggest outside dimension of the casting blank and not on the casting tolerance grade
CT.
For the supply of parts in rough-machined condition, the responsibility for providing the necessary machining allowance for
attaining the rough-machined and dross-free condition rests with the foundry, irrespectively of table 4.































Fig. 2
Page 5
SN 200 Part 2 : 2003-09
1.9.1 Machining allowances for cast steel and cast iron products
Table 6
GS EN-GJL (GGL) EN-GJS (GGG) Nominal dimension range
(biggest length, width, height or
diameter of
the casting)
per
surface
for upper faces or faces in
vertical position in the mould
(taper) additionally
per
surface
for upper faces or faces in
vertical position in the mould
(taper) additionally
per
surface
for faces in vertical
position (taper)
additionally
for upper faces
additionally
(dross layer)
up to 30 4
> 30 to 50 5
> 50 to 80
> 80 to 120
> 120 to 180
6
4 4
> 180 to 250
> 250 to 315
7
> 315 to 400
> 400 to 500
8
2
5 5
5 - 45
> 500 to 630
> 630 to 800
10 6 6
> 800 to 1000
> 1000 to 1250
12
3
8 8
20 - 110
> 1250 to 1600 14 10
2
10
2
> 1600 to 2000
> 2000 to 2500
16
4
12 3 12 3
50 - 240
> 2500 to 3150 18 15 15
> 3150 to 4000 20
> 4000 to 6300 25
5
17
4
17
4
> 6300 to 10000 30 7 20 5 20 5
110 - 500
Hole not cored by foundry up to 100 mm up to 80 mm

1.10 Inspections
1.10.1 Cast steel products

1.10.1.1 Internal condition
The table below specifies SMS Demag specific requirements on the basis of DIN EN 12680-1. If required, the specifications
are indicated in the drawing or in product-specific SN standards. Severity level 5 as in DIN EN 12680-1 is not applicable to
products of SMS Demag.

Table 7 Ultrasonic testability requirements
Wall thickness
Smallest flat-bottomed hole diameter
detectable according to
item 5.2 of DIN EN 12680-1
300 3
> 300 to 400 4
> 400 to 600 6
> 600 8

Table 8 Recording levels for discontinuities
1)





Wall thickness


mm
Tested area
Reflectors without
measurable dimension
Diameter of the
equivalent
flat-bottomed hole
2)


min.
mm
Reflectors with
measurable dimension
Diameter of the
equivalent
flat-bottomed hole
2)


min.
mm
300 - 4 3
> 300 to 400 - 6 4
> 400 to 600 - 6 6
> 600 - 8 8
- Special rim zone 3 3
1)
related to a 2 MHz ultrasonic probe
2)
formula for converting the flat-bottomed hole diameter into side-drilled hole diameter see
item 5.2 of DIN EN 12680-1

Table 9 Recording levels and acceptance limits for back echo reduction
1)


Wall thickness

mm
Tested area
Recording level

min.
dB
Acceptance limit
min.
dB
300 -
> 300 to 400 -
> 400 to 600 -
> 600 -
12 12
- Special rim zone - -
1)
related to a 2 MHz ultrasonic probe
Page 6
SN 200 Part 2 : 2003-09

Table 10 Acceptance limits for volumetric discontinuities
Severity level
Feature Unit
Zone
1)
1 2 3 4 5
2)

Casting wall thickness
at the examined area
mm - 50
> 50
100
>100
600
50
> 50
100
> 100
600
50
> 50
100
> 100
600

Reflectors without measurable dimension
rim
zone Largest diameter of equivalent
flat-bottomed hole
mm
core
zone
3 8
rim z. 3 5 6 6 not used as criterion Number of discontinuities to be
recorded in a frame of 100 mm
x 100 mm
-
core
3
3)

not used as criterion not used as criterion
Reflectors with measurable dimension
rim z. Largest diameter of equivalent
flat-bottomed hole
mm
core
3 8
rim z. 15% of zone thickness Maximum values of dimension
in through-wall direction of
discontinuities
-
core 15% of wall thickness
rim z. 75 75 75 75 75 75 75 75 75 Maximum length without
measurable width
mm
core 75 75 100 75 75 120 100 100 150
rim z. 600 1000 1000 600 2000 2000 2000 2000 2000
Largest individual area
4)
mm
core 10000 10000 15000 15000 15000 20000 15000 15000 20000
rim z. 10000 10000 10000 10000 10000 10000 10000 15000 15000 Largest total area for
a reference area
4)

mm
core 10000 15000 15000 15000 20000 20000 15000 20000 20000
Reference area mm
not
permitt
ed
150 000 (390 mm x
390 mm)
100 000 (320 mm x 320 mm)

1)
rim zone = t/3, max. 100 mm, t = wall thickness in testing zone
2)
severity level 5 is not applicable to products of SMS Demag.
3)
accumulated in core zone and rim zone.
4)
indications less than 25 mm apart shall be considered as one discontinuity.

Indications which are not within the acceptance limits must be reported in writing to the SMS Demag Dept. of Quality
Inspection.

1.10.1.2 External condition
The external condition is examined on the spots marked in the drawing with magnetic particle testing as in DIN EN 1369 or
liquid penetrant inspection as in DIN EN 1371-1. The specifications are indicated in the drawing or in product-specific SN
standards. Severity level 5 is not applicable to products of SMS Demag.

1.10.2 Spheroidal graphite cast iron

1.10.2.1 Internal condition
The procedure used for determining the internal condition must be in accordance with DIN EN 12680-3.
The requirements made on the internal condition of castings made of spheroidal graphite cast iron are shown in the drawing
as SMS Demag specific indications or are specified in the product-specific SN standards. Severity level 5 as in DIN EN
12680-3 is not applicable to products of SMS Demag.

1.10.2.2 External condition
The external condition is examined on the spots marked in the drawing with magnetic particle testing as in DIN EN 1369 or
dye penetrant inspection as in DIN EN 1371-1. The specifications are indicated in the drawing or in product-specific SN
standards. Severity level 5 is not applicable to products of SMS Demag.

Referenced standards
DIN ISO 8062 Castings; System of dimensional tolerances and machining allowances
DIN EN 1369 Founding; Magnetic particle inspection
DIN EN 1370 Founding; Surface roughness inspection by visualtactile comparators
DIN EN 1371-1 Founding; Liquid penetrant inspection
DIN EN 12680-1 Ultrasonic examination; Part 1: Steel castings for general purposes
DIN EN 12680-3 Ultrasonic examination; Part 3: Spheroidal graphite cast iron castings

Further standards
DIN EN 1559-1 Founding; Technical conditions of delivery; General
DIN EN 1559-2 Founding; Technical conditions of delivery; Additional requirements for steel castings
DIN EN 1559-3 Founding; Technical conditions of delivery; Additional requirements for iron castings
Page 7
SN 200 Part 2 : 2003-09

2 Forging
Forging is a method of hot shaping in the form of die forging or open-die forging to obtain a shape which is close to the
finished dimensions of the component. The shaping process creates a largely uniform structure over the entire cross-section.

2.1 Forgings, general
The following requirements must be fulfilled:
- If no particular requirements are made, the technical conditions of delivery and quality specifications can be taken from the
relevant DIN, EN, ISO or SEW material standards. When particular requirements are made on the forgings, the respective
quality specifications are indicated in the drawings in the form of drawing stickers.
- If heat treatment is required for reasons of manufacture, this treatment has to be arranged for by the forging shop and/or by
the manufacturing company.


2.2 External condition
The external condition must be examined in the areas marked on the workpiece using magnetic particle inspection as in DIN
EN 10228-1 or liquid penetrant inspection as in DIN EN 10228-2.Surfaces to be examined must be free of scale, oil, grease,
machining marks, paint coats and any other foreign matter that could adversely affect detection sensitivity or the interpretation
of indications. The quality classes specified in the DIN EN standards are not applied. Absence of cracks must be
always be guaranteed throughout the entire workpiece.

2.3 Internal condition
The internal condition is examined by ultrasonic testing as in DIN EN 10228-3 and 4.

2.3.1 Surface condition
General
Surfaces to be examined must be free of paint, non-adhering scale, dry coupling medium and any other foreign matter and
free of surface irregularities that could adversely affect coupling conditions, hinder free movement of the probe or cause errors
in interpretation.

2.3.2 Surface finish related to quality class
The surface finish shall be compatible with the required quality class, see table 1.

Table 1
Quality class and roughness Ra
1 2 3 4 Surface finish
25 m 12,5 m 12,5 m 6,3 m
Machined x x x x
Machined and
heat-treated
x x x -
"x marks the quality class that can be achieved for the specified surface roughness.


2.3.3 Performance of the examination
Scanning shall be performed using the manual contact pulse-echo technique. The minimum scanning coverage required is
dictated by the type of forging and whether grid scanning coverage or 100% scanning coverage has been specified in the
order or the specification in the drawing.
Table 2 specifies the requirements for scanning coverage of the forging types 1, 2 and 3 with perpendicular incidence.
Table 3 specifies the requirements for scanning coverage with angular sound incidence for forging types 3a and 3b which
have outside diameter to inside diameter ratio of less than 1,6. The effective depth of circumferentially oriented scans is
limited by the angle of incidence and the diameter of the forging.







Page 8
SN 200 Part 2 : 2003-09

Table 2 Scanning coverage with normal probes
Grid scanning
1)
Type
Shape
Diameter D
in mm
Scan lines
2)
100% scanning
1)
1a
200 <
500 <
D 200
D 500
D 1000
D > 1000
2 at 90
3 at 60
4 at 45
6 at 30
Scan 100% around at
least 180 of
cylindrical surface
1
1b
Scan along the lines of a square-link grid on two perpendicular
surfaces
3) 4)

Scan 100% on two
perpendicular
surfaces
2
Scan along the lines of a square-link grid around 360 on the cylindrical
surface and one lateral surface.
Scan 100% around at
least 180 on the
cylindrical surface
and 100% of one
lateral surface
3a
Scan along the lines of a square-link grid around 360 on the outer
cylindrical surface
4)
Scan 100% around
360 on the outer
cylindrical surface
3

3b & 3c
Scan along the lines of a square-link grid around 360 on the outer
cylindrical surface and one lateral surface
4)
Scan 100% around
360 on the outer
cylindrical surface
and one lateral
surface
4 Scanning coverage shall be specified in the enquiry or order.
1)
Additional scanning (for example in both axial directions for type 3a) may be carried out if specified in the enquiry or order.
2)
100% means at least 10% probe overlap between consecutive probe traverses.
3)
For types 1a or 1b, if the presence of a bore prevents the opposite surface being reached, the number of scan lines shall be doubled symmetrically.
4)
The grid line separation shall be equal to the thickness of the part up to a maximum of 200 mm.



Table 3 Scanning coverage with shear wave probes
Type Grid scanning 100% scanning
1) 2)
3a
3
3b
Scan in both directions along 360
circumferential grid lines the separation of
which is equal to the radial thickness up to
a maximum of 200 mm
Scan 100% of outer cylindrical surface in
both circumferential directions
4 Scanning coverage shall be specified in the enquiry or order.
1)
Additional scanning coverage may be carried out if specified in the enquiry or order.
2)
100% means at least 10% probe overlap between consecutive probe traverses.




2.3.4 Recording levels and acceptance criteria
Tables 4, 5 and 6 detail recording levels and acceptance criteria which shall be applied to four quality classes.

The sensitivity of the testing system (test unit, probe, cable) must be sufficient to ensure detection of the smallest
discontinuities that are specified for the demanded recording and interpretation limits for the respective quality class.



Page 9
SN 200 Part 2 : 2003-09


Table 4 Quality classes, recording levels and acceptance criteria for normal probes
Quality class 1 2 3 4
Recording levels
Flat-bottomed holes FBB deg

in mm of diameter > 8 > 5 > 3 > 2
R ratio for abrupt attenuation of the backwall echo
1) 2)


0,1 0,3 0,5 0,6
Acceptance limits
Flat-bottomed holes in isolated point discontinuities deg

in mm of diameter 12 8 5 3
Flat-bottomed holes in extended or grouped discontinuities deg in mm of diameter 8 5 3 2

1)
R =
n Fo
Fn
,
with n = 1 for t 60 mm and n = 2 for t < 60 mm
Fn amplitude (screen height) of the n
th
reduced backwall echo
Fo,n amplitude (screen height) of the n
th
backwall echo in the nearest discontinuity-free area at the same range as Fn
2)
If the reduction in backwall echo is so heavy that the recording level is not attained, this shall be further investigated.
Ratio R applies only to heavy reduction of backwall echo caused by the presence of a discontinuity.



Table 5 Quality classes, recording levels and acceptance criteria for shear wave probes using DGS techniques with
flat-bottomed holes
Quality class 1
3)
2 3 4
Recording level
Recording level with flat-bottomed holes FBB deg in mm - > 5 > 3 > 2
Acceptance limits
Flat-bottomed holes in isolated point discontinuities deg

in mm
of diameter
- 8 5 3
Flat-bottomed holes in extended or grouped discontinuities deg
in mm of diameter
- 5 3 2
3)
shear wave scanning does not apply to quality class 1.



Table 6 Quality classes, recording levels and acceptance criteria for shear wave probes using the reference line
method, reference line based on a side-drilled hole of 3 mm in diameter
Acceptance limit
Quality class Nominal test frequency
Recording level
%
of reference line
Isolated discontinuities
4)


%
of reference line

Extended or grouped
discontinuities
4)


%
of reference line
1
3)


1 50 100 50
2
2 100 200 100
2 50 100 50
3
4 100 200 100
2 30 60 30
4
4 50 100 50
3)
Quality class 1 does not apply to scanning with shear wave probes.


4)
The indication amplitude in dB, relative to the reference line, is given in table 7.
Page 10
SN 200 Part 2 : 2003-09

Table 7 Indication amplitude in dB relative to the reference line in %

Reference line

%
Amplitude of indication
relative to reference line
dB
30 - 10
50 - 6
60 - 4
100 0
200 + 6


2.4 Inspections

The data and results of the tests set out below shall be reported by the forging shop or the manufacturing shop in an
inspection certificate as in DIN EN 10204 3.1B.

- Chemical analysis of each heat contained in the supply.
- Result of the hardness test and the mechanical properties determined per heat and heat-treatment unit.
- Result of the elevated-temperature tensile test at maximum working temperature of the material for heat-resistant
steels per heat and heat-treatment unit.
- Results of other tests/inspections specified in the drawing



Referenced standards

DIN EN 10204 Types of inspection documents
DIN EN 10228-1 Non-destructive testing of steel forgings; Magnetic particle inspection
DIN EN 10228-2 Non-destructive testing of steel forgings; Penetrant testing
DIN EN 10228-3 Non-destructive testing of steel forgings; Ultrasonic testing of ferritic or martensitic steel forgings
DIN EN 10228-4 Non-destructive testing of steel forgings; Ultrasonic testing of austenitic or austenitic-ferritic stainless
steel forgings




Page 11
SN 200 Part 2 : 2003-09
3 Semi-finished products
Semi-finished products is the collective term for products of definite shape, but with at least one indefinite dimension. Such
products are sections, bars, rods, tubes, sheets and plates, boards, panels, strips and similar types of products made by
rolling, drawing, pressing or any other method and having constant cross-section along the length.

The designation "St" is permitted for steel components without particular strength requirements. The manufacture from
different semi-finished products is then left to the discretion of the manufacturer. Suitability for welding must be ensured. The
same applies analogously if tensile strength requirements are made, but the type of smelting and treatment is left to the
discretion of the maker. In this case the indication is "St with Rm min. .


3.1 General tolerances
The relevant documents for the general tolerances of steel products are the respective DIN and DIN EN standards for semi-
finished products.


3.2 Technical delivery conditions
The technical delivery conditions are specified in DIN EN 10021 and in the corresponding standards for semi-finished
products.


3.3 Plate
The applicable standard for deviations in thickness and flatness of plates is DIN EN 10029, table 1, class A, and table 4, class
N.
The permissible deviations given in DIN EN 10029 for the nominal thickness range of 150 to 250 mm are also applicable to
plate thicknesses over 250 mm.
The plates used must have class A surface condition as in DIN EN 10163.


3.4 Inspection

The results of all below inspections/tests made on the semi-finished product (primary material) must be certified in a
document as specified in DIN EN 10204 3.1.B.
Components need not be tested again individually and certified provided the above testing has been made on the semi-
finished products. It must be ensured, however, that the components are made from the tested semi-finished products.


- Plate
Plate of thickness 100 mm and yield point
1)
250 N/mm
2
must be ultrasonically tested as specified in SEL 072, table 1,
quality class 3 and tested for tensile strength and hardness.

- Unalloyed steel
Round bar of 150 mm
Square steel of lateral length 150 mm
Flat bar of width 150 mm and thickness 100 mm

... must be ultrasonically tested as in DIN EN 10228-3, type 1, quality class 2, and tested for tensile strength/hardness.

- Alloy steel
Round bar of 80 mm
Square steel of lateral length 80 mm
Flat bar of width 80 mm and thickness 80 mm

... must be subjected to chemical analysis and tested for tensile strength/hardness.

- Heat-resistant steel
If specified in the order or the drawing, heat-resistant steel must, in addition to the chemical analysis, be subjected to an
elevated-temperature tensile test at the maximum permissible working temperature of the steel for each heat and heat-
treatment unit.

- Pipe
For pipe having outside diameter 38 mm and wall thickness 5 mm, testing as required in the technical delivery conditions
for pipes must be certified.




1)
The yield point refers to the smallest standardised material thickness.
made of unalloyed steels and yield point
1)
250 N/mm
2

made of alloy steels and yield point
1)
350 N/mm
2

Page 12
SN 200 Part 2 : 2003-09


Referenced standards
DIN EN 1370 Founding; Surface roughness inspection by visualtactile comparators
DIN EN 10021 General technical delivery requirements for steel and iron products
DIN EN 10029 Hot rolled steel plate 3 mm thick or above; tolerances on dimension, shape and mass
DIN EN 10140 Cold rolled narrow steel strip; tolerances on dimensions and shape
DIN EN 10163-1 Technical delivery conditions for the surface condition of hot rolled steel plate, wide flats and sections;
general requirements
DIN EN 10163-2 Technical delivery conditions for the surface condition of hot rolled steel plate, wide flats and sections;
plate and wide flats
DIN EN 10163-3 Technical delivery conditions for the surface condition of hot rolled steel plate, wide flats and sections;
sections
DIN EN 10204 Types of inspection documents
DIN EN 10228-3 Non-destrucive testing of steel forgings; Ultrasonic testing of ferritic or martensitic steel forgings
SEL 072 Ultrasonically tested heavy plate; technical delivery specifications

September 2003

Manufacturing instructions
THERMAL CUTTING AND FORMING BY BENDING
SN 200
Part 3

Dimensions in mm


Field of application
The manufacturing instructions specified in chapter 1 are extracts from DIN EN ISO 9013 and apply to materials which are
suitable for oxyfuel flame cutting, plasma arc cutting and laser beam cutting. Chapter 2 applies to workpieces and pipe
conduits produced by cold bending. All instructions given apply if no different instructions are shown in drawings or other
manufacturing documents.

Table of contents Page
1 Thermal cutting............................................................................................................................................................. 1
1.1 Oxyfuel flame cutting.................................................................................................................................................... 1
1.2 Plasma cutting............................................................................................................................................................. 1
1.3 Laser cutting................................................................................................................................................................ 1
1.4 Quality of the cut surface.............................................................................................................................................. 2
1.4.1 Perpendicularity or angularity tolerance ..................................................................................................................... 2
1.4.2 Mean height of the profile, RZ5 ................................................................................................................................... 2
1.4.3 Measuring points ....................................................................................................................................................... 3
1.4.3.1 Location of the measuring points ............................................................................................................................. 3
1.4.4 Perpendicularity or angularity tolerance, u .................................................................................................................. 3
1.4.5 Mean height of the profile, RZ5 ................................................................................................................................... 3
1.5 Form and location tolerances ........................................................................................................................................ 4
1.6 Dimensional tolerances................................................................................................................................................. 5

2 Forming by bending ..................................................................................................................................................... 5
2.1 Bending........................................................................................................................................................................ 5
2.1.1 Bending of flat products.............................................................................................................................................. 5
2.1.2 Bending of pipes........................................................................................................................................................ 6
2.1.3 General tolerances..................................................................................................................................................... 6
3 Inspection..................................................................................................................................................................... 7
Referenced standards ......................................................................................................................................................... 7

1 Thermal cutting

1.1 Oxyfuel flame cutting
Oxyfuel flame cutting is a process of thermal cutting which is performed with a fuel gas/oxygen flame and cutting oxygen. The
heat released by the heating flame and the heat produced during combustion permit continuous combustion by the cutting
oxygen. The oxides produced, mixed with some molten metal, are driven out by the kinetic energy of the cutting oxygen jet.
By this action, the kerf is produced.
The instructions apply to flame cuts of 3 mm to 300 mm.

1.2 Plasma cutting
Plasma cutting is a process of thermal cutting in which a constricted arc is used. Polyatomic gases dissociate in the arc and
partially ionize; monoatomic gases partially ionize. The plasma beam thus generated has a high temperature and kinetic
energy; it melts or partially vaporizes the material and blows it away. Thereby the kerf is produced.
The instructions apply to plasma cuts of 1 mm to 150 mm.

1.3 Laser cutting
Laser cutting is a process of thermal cutting in which the focused laser beam supplies the energy required for cutting, this
energy then being converted into heat in the material. Cutting is supported by a gas jet. With laser beam cutting a difference is
made between laser oxyfuel flame cutting, laser fusion cutting and laser sublimation cutting.
The instructions apply to laser cuts of 0,5 mm to 40 mm.







Continued on pages 2 to 7
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!

Page 2
SN 200 Part 3 : 2003-09


1.4 Quality of the cut surface
1.4.1 Perpendicularity or angularity tolerance
Distance between two parallel straight lines between which the cut surface profile is inscribed, and within the set angle (for
example 90 in the case of vertical cuts).

NOTE: The perpendicularity or angularity tolerance includes not only the straightness, but also the flatness deviations.
Figures 1 and 2 show the maximum effective deviations within the tolerance class.

































a = area for determining the pependicularity-angularity tolerance



1.4.2 Mean height of the profile, RZ5

Arithmetic mean of the single profile elements of five bordering single measured distances















Key
ln evaluation length
Zt1 to Zt5 single profile elements
lr single sampling length (1/5 of ln)

a) Vertical cut
b) Bevel cut
Fig. 1
Fig. 2
Page 3
SN 200 Part 3 : 2003-09



1.4.3 Measuring points
1.4.3.1 Location of the measuring points
The characteristic value of perpendicularity or angularity tolerance u is determined only in a limited area of the cut surface.
The area shall be reduced by the dimension a according to Table 1 from the upper and the lower cut surface edges (see
Figure 1).

The reason for the reduced cut face profile is to allow for the melting of the top edge.

Table 1 - Dimensions for a
Cut thickness a
mm
a
mm
3 0,1a
> 3 6 0,3
> 6 10 0,6
> 10 20 1
> 20 40 1,5
> 40 100 2
> 100 150 3
> 150 200 5
> 200 250 8
> 250 300 10




1.4.4 Perpendicularity or angularity tolerance, u


Table 2 - Perpendicularity or angularity tolerance, u
Cut
thickness
a

up to
20
>20
to
40
>40
to
60
>60
to
80
>80
to
100
>100
to
120
>120
to
140
>140
to
160
>160
to
180
>180
to
200
>200
to
220
>220
to
240
>240
to
260
>260
to
280
>280
to
300
u
for ranges
3 & 4
1,3 1,6 1,9 2,2 2,5 2,8 3,1 3,4 3,7 4,0 4,3 4,6 4,9 5,2 5,5




1.4.5 Mean height of the profile, RZ5


Table 3 Mean height of the profile, RZ5
Cut
thickness
a

up to
20
>20
to
40
>40
to
60
>60
to
80
>80
to
100
>100
to
120
>120
to
140
>140
to
160
>160
to
180
>180
to
200
>200
to
220
>220
to
240
>240
to
260
>260
to
280
>280
to
300
RZ5
for range 4
0,146 0,182 0,218 0,254 0,290 0,326 0,362 0,398 0,434 0,470 0,506 0,542 0,578 0,614 0,650



Page 4
SN 200 Part 3 : 2003-09


1.5 Form and location tolerances

Figure 3 shows the maximum deviations within the tolerance zone.


Fig. 3




































a) Through thickness b) Flat





Key
tG1 straightness tolerance (see 14.1 of DIN ISO 1101: 1983) for cut length;
tG2 straightness tolerance (see 14.1 of DIN ISO 1101: 1983) for cut width;
tw perpendicularity tolerance (see 14.8 of DIN ISO 1101: 1983) for cut width referred to A;
tp parallelism tolerance (see 14.7 of DIN ISO 1101: 1983) for cut width referred to A on sheet level;
U perpendicularity tolerance (see 14.8 of DIN ISO 1101: 1983) in cutting direction;



Page 5
SN 200 Part 3 : 2003-09




1.6 Dimensional tolerances

The dimension in the drawing shall be taken to be the nominal dimension. The actual dimensions will be determined on the
clean surfaces of the cut. The limit deviation specified in Table 4 shall apply to dimensions without tolerance indications.


Table 4 Limit deviations for nominal dimensions of tolerance class 1

Nominal dimensions
> 0
< 3
3
< 10
10
< 35
35
< 125
125
< 315
315
< 1000
1000
< 2000
2000
< 4000
Workpiece thickness
Limit deviations
> 0 1 0,04 0,1 0,1 0,2 0,2 0,3 0,3 0,3
> 1 3,15 0,1 0,2 0,2 0,3 0,3 0,4 0,4 0,4
> 3,15 6,3 0,3 0,3 0,4 0,4 0,5 0,5 0,5 0,6
> 6,3 10 - 0,5 0,6 0,6 0,7 0,7 0,7 0,8
> 10 50 - 0,6 0,7 0,7 0,8 1 1,6 2,5
> 50 100 - - 1,3 1,3 1,4 1,7 2,2 3,1
> 100 150 - - 1,9 2 2,1 2,3 2,9 3,8
> 150 200 - - 2,6 2,7 2,7 3 3,6 4,5
> 200 250 - - - - - 3,7 4,2 5,2
> 250 300 - - - - - 4,4 4,9 5,9




2 Forming by bending

2.1 Bending
2.1.1 Bending of flat products
For the cold bending of flat steel products the permissible bending radii as in Table 5 must be observed. Further specifications
are given in DIN 6935.

Fig. 4


















Table 5 Bending radii for bending angles of 90
(along the direction of rolling for steel grades of a min. tensile strength Rm of 390 N/mm)
Plate thickness s 1 1,5 2 2,5 3 4 5 6 8 10 12 15 20 25 30 35 40
Bending radius min r 2,5 3 6 8 10 16 20 24 30 40 50 60 70 100
Leg length min. l 10 16 24 32 40 64 80 96 120 160 200 240 280 320


Page 6
SN 200 Part 3 : 2003-09



2.1.2 Bending of pipes
Cold bending of pipes is preferable to welding-in of elbows. If drawings show welding elbows which can be replaced by a
cold-bent pipe taking into account the bigger bending radius, the replacement can be carried out by the manufacturing
workshop.
When pipes are shown in isometric drawings, compliance with the drawing indications must be ensured.
Bending radii for cold-bent pipes are specified in Table 6 and in SN 740-1 and -2.


Table 6 Bending radii of pipes
Pipe outside diameter Bending radius
10 to 12 2 x outside pipe diameter for wall thicknesses >1,0
> 12 to 48,3 2 x outside pipe diameter for all wall thicknesses
> 48,3 to 114,3 2,5 x outside pipe diameter for all wall thicknesses



2.1.3 General tolerances
The general tolerances are specified in tables 7 and 8 according to DIN EN ISO 13920. These general tolerances correspond
to the welding tolerances and shall be applied analogously for bent components.


The following applies:
Tolerance category B for completely dimensioned pipe conduits (e.g. pipe detail, isometric drawing) and for workpieces
produced by bending of flat products.
Tolerance category C for not completely dimensioned and freely laid pipe conduits.



Table 7 Lengths (outside, inside and stepped dimensions, diameters and radii)
Nominal dimension range
Tolerance
category

2
to
30

> 30
to
120

> 120
to
400

> 400
to
1000
>
1000
to
2000
>
2000
to
4000
>
4000
to
8000
>
8000
to
12000
>
12000
to
16000
>
16000
to
20000
>
20000


B 1 2 2 3 4 6 8 10 12 14 16
C 1 3 4 6 8 11 14 18 21 24 27






























Page 7
SN 200 Part 3 : 2003-09






Table 8 Angular dimensions
Nominal dimension range
(length of shorter leg)
Permissible deviations in degrees and minutes Permissible deviations as tangent values
Tolerance
category

up to 400
> 400
to 1000
> 1000


up to 400
> 400
to 1000
> 1000

B 45' 30' 20' 0,013 0,009 0,006
C 1 45' 30' 0,018 0,013 0,009


The shorter leg of the angle is taken as reference for the limit dimensions of the angles. Its length can also be applied from a
particular reference point shown in the drawing. (examples see Figs. 5 to 9)
The figures were taken from DIN EN ISO 13920 for welded components.













Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9




3 Inspection
Flame-cut and bent parts are inspected by the manufacturer with regard to the observance of the dimensions and angles
indicated. The manufacturer shall also inspect the surface quality (height of the profile Rz5) of flame-cut faces. Documenting of
the inspections is not required.




Referenced standards

DIN 6935 Cold bending of flat rolled steel products
DIN EN ISO 1302 Geometrical Product Specifications (GPS); Indication of surface texture in technical product
documentation

DIN EN ISO 9013 Classification of thermal cuts
DIN EN ISO 13920 General tolerances for welded constructions
DIN ISO 1101 Technical drawings; Geometrical tolerancing
SN 740-1 Bending radii for piping and tubing; minimum dimensions with bent pipes
SN 740-2 Bending radii for piping and tubing; determination of pipe lengths considering various bending angles
and radii

Ref. point
Ref. point
Ref. point
Ref. point
Ref point
September 2003

Manufacturing instructions

WELDING
SN 200
Part 4

Dimensions in mm
Field of application
The manufacturing instructions specified in this part of SN 200 are applicable to all welded components unless otherwise
specified in drawings or other manufacturing documents.
The welding standards (e.g. DIN, DVS, SEW etc.) applicable to the respective materials must be observed.
Welding is a special process whose result (quality) cannot be fully assessed by subsequent testing on the product.
The quality requirements for welding as in DIN EN 729 must be fulfilled. We recommend establishing a quality
assurance system on the basis of DIN EN ISO 9001.

Table of contents Page

1 Drawings and other manufacturing documents.......................................................................................................... 2
1.1 Indication in drawings ............................................................................................................................................... 2
1.1.1 Fillet welds ............................................................................................................................................................... 2
1.1.2 Butt welds, partly and fully bevelled welds ................................................................................................................. 2
1.1.3 Welds for subsequent machining............................................................................................................................... 2
1.1.4 Welds on pipe lines................................................................................................................................................... 2
1.2 Representation as in DIN EN 22553 (ISO 2553) ........................................................................................................ 2
1.2.1 Basic symbols for weld types .................................................................................................................................... 2
1.2.2 Combinations of basic symbols................................................................................................................................. 2
1.2.3 Supplementary symbols............................................................................................................................................ 3
1.3 Positions of symbols in drawings............................................................................................................................... 3
1.3.1 Elements of the reference symbol and indications at the symbol................................................................................. 3
1.3.2 Relation between arrow line and joint ........................................................................................................................ 3
1.3.3 Direction of the arrow line.......................................................................................................................................... 4
1.3.4 Position of the symbol relative to the reference line.................................................................................................... 4
1.3.5 Examples of application............................................................................................................................................ 5
2 General tolerances....................................................................................................................................................... 5
2.1 Linear dimensions..................................................................................................................................................... 5
2.2 Straightness, flatness and parallelism........................................................................................................................ 5
2.3 Angular dimensions .................................................................................................................................................. 5
3 Execution of welding work........................................................................................................................................... 6
3.1 Demands made on the manufacturer of welded components...................................................................................... 6
3.1.1 Equipment subject to construction-supervision regulations......................................................................................... 6
3.1.2 Equipment not subject to regulations of construction supervision................................................................................ 6
3.2 Weld preparation, general ........................................................................................................................................ 7
3.3 Filler metals.............................................................................................................................................................. 7
3.4 Preheating................................................................................................................................................................ 7
3.5 Weld execution......................................................................................................................................................... 7
3.5.1 Weld execution, general............................................................................................................................................ 7
3.5.2 Weld execution for ferritic-austenitic weld joints ....................................................................................................... 11
3.6 Notches.................................................................................................................................................................. 12
3.7 Weld preparation on fluid-carrying components, e.g.: pipelines, vessels .................................................................. 12
3.8 Weld execution on fluid-carrying components, e.g.: pipelines, vessels...................................................................... 13
3.8.1 Fluid-carrying steel components.............................................................................................................................. 13
3.8.2 Fluid-carrying components in stainless and acid-resistant steels............................................................................... 13
3.9 Quality of weld, quality level on fluid-carrying components, e.g.: pipelines, vessels .................................................. 13
4 Postweld heat treatment ............................................................................................................................................ 13
4.1 Postweld heat treatment, general ............................................................................................................................ 13
4.2 Postweld heat treatment of stainless steel ............................................................................................................... 14
4.2.1 Heat treatment of non-stabilised austenitic steels..................................................................................................... 14
4.2.2 Heat treatment of stabilised austenitic steels ........................................................................................................... 14
4.2.3 Wrmebehandlung an sogenannten Low-Carbon-Sthlen........................................................................................ 14
4.2.4 Heat treatment of ferritic-austenitic weld joints ......................................................................................................... 14
5 Filler metal.................................................................................................................................................................. 14
6 Inspection................................................................................................................................................................... 14
6.1 Inspection of load-bearing welds without full material penetration............................................................................. 15
6.1.1 Inspection directions for the quality levels of welds, general ..................................................................................... 16
6.2 Testing directions for the quality levels of welds on fluid-carrying components .......................................................... 16
7 Guideline for the quality levels of imperfections ...................................................................................................... 17
Referenced standards..................................................................................................................................... 21
Continued on pages 2 to 22

T
h
i
s

c
o
p
y

w
i
l
l

n
o
t

b
e

u
p
d
a
t
e
d

i
n

c
a
s
e

o
f

c
h
a
n
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e
s
!

Page 2
SN 200 Part 4 : 2003-09

1 Drawings and other manufacturing documents
1.1 Indication in drawings
1.1.1 Fillet welds
Fillet welds are indicated by a blacked-in triangle or welding symbols according to ISO 2553 (see 1.3) at the weld joints of the
parts to be welded, shown in sectional view or in the view of the parts to be welded.
1.1.2 Butt welds, partly and fully bevelled welds
Butt welds, partly and fully bevelled welds are shown in drawings in
sectional view or in the view with symbols according to ISO 2553 (see 1.3)
with weld depth s.
1.1.3 Welds for subsequent machining
Welds intended for subsequent machining are shown with dimensioning of
the weld depth as shown in Fig 1.
1.1.4 Welds on pipe lines
The operating pressure of the pipe line must be indicated. Welding symbols as in ISO 2553 (see 1.3) or information as in Table 13
are shown only in exceptional cases.


1.2 Representation as in DIN EN 22553 (ISO 2553)
1.2.1 Basic symbols for weld types
The various types of welds are characterised by symbols which are in general similar to the appearance of the welds. The symbols
characterises the shape, preparation and execution of the welds. The symbol does not determine the welding process to be
applied.

Table 1 Basic symbols for weld types
















1.2.2 Combinations of basic symbols
When necessary, combinations of basic symbols are used for indication. Typical examples are given in table 2.


Table 2 Combinations of basic symbols


Fig. 1
Page 3
SN 200 Part 4 : 2003-09
1.2.3 Supplementary symbols
Basic symbols may be supplemented by a symbol characterising the shape of the surface or the execution of the weld. The
absence of a supplementary symbol means that the surface shape must comply with the weld quality indicated. Combination
of more than two supplementary symbols is not permitted.

Table 3 Supplementary symbols Table 4 Complementary symbols
Shape of weld surface Symbol Execution of weld Symbol Meaning Symbol
a) flat d) toes blended smoothly circumferential weld
b) convex
g) use of permanent backing
strip
site weld
c) concave
h) use of removable backing
strip






Table 5 Examples of the application of supplementary symbols


















1.3 Positions of symbols in drawings
1.3.1 Elements of the reference symbol and indications at the symbol
- Elements of the reference symbol - Indications at the reference symbol

1 = Weld joint 1 = Main dimensions of weld thickness

2 = Arrow line 2 = Weld symbol

3a = Reference line (solid line) 3 = Weld length dimensions

3b = Reference line (dashed line) 4 = Indications for welding process

4 = Forked line for supplementary indications
(line shown only when required) quality level for welding Fig. 2
position, filler metal

1.3.2 Relation between arrow line and joint
The side of the joint to which the arrow line points is called the arrow side. The other side of the joint is called the opposite
side. The arrow line points preferably to the upper workpiece face.
The examples in figures 3 and 4 explain the terms opposite side arrow side opposite side arrow side
- arrow side of the joint of joint A of joint A of joint A of joint B
- opposite side of the joint
opposite side arrow side arrow side opposite side







a) weld on arrow side b) weld on opposite side arrow side a) opposite side arrow side b)opposite side
of joint B" of joint B" of joint A" of joint B"
Fig. 3 T-joint with fillet weld Fig. 4 Cruciform joint with two fillet welds
workshop
assembly weld

SMS Demag specification
J
o
i
n
t

A

J
o
i
n
t

B

Joint A
Joint B
arrow line
arrow line
arrow line arrow line
arrow line arrow line
Page 4
SN 200 Part 4 : 2003-09

1.3.3 Direction of the arrow line
When the butt welds are asymmetrical, the arrow line always points to the non-vertical flank of the joint, i.e. to the workpiece
which requires groove preparation. Example see Fig. 7b.

1.3.4 Position of the symbol relative to the reference line
The symbol is placed either above or below the reference line.
- When the symbol is shown on the side of the solid reference line, the weld is on the arrow side of the joint (Fig. 5a).
- When the symbol is shown on the side of the dashed reference line, the weld is on the opposite side of the joint (Fig. 5b).
- When the welds are symmetrical, the dashed line is not used (Fig. 5c).











Fig. 5 a) weld, made b) weld, made c) only for symmetrical
from arrow side from opposite side welds



1.3.5 Examples of application
Fillet welds

















Fig. 6a Fig. 6b



Butt welds



Fig. 7a






Fig. 7b



For further application examples see DIN EN 22553 (ISO 2553).






Illustration Symbolic representation
Page 5
SN 200 Part 4 : 2003-09
2 General tolerances

SMS Demag standard general tolerance classes are specified in tables 6 to 8 on the basis of DIN EN ISO 13920.
Drawing indication is not required.


2.1 Linear dimensions
The tolerances stated in the table apply to linear dimensions (external dimensions, inside dimensions, stepped dimensions,
widths and central lengths).

Table 6 Linear dimensions
Range of nominal dimensions
Tolerance
class

2
to
30
>
30
to
120
>
120
to
400
>
400
to
1000
>
1000
to
2000
>
2000
to
4000
>
4000
to
8000
>
8000
to
12000
>
12000
to
16000
>
16000
to
20000
>
20000


B 1 2 2 3 4 6 8 10 12 14 16


2.2 Straightness, flatness and parallelism
The tolerances stated in the table apply to the overall dimensions of a welded part, a welded assembly and to partial lengths.

Table 7 Straightness, flatness and parallelism tolerances
Range of nominal dimensions (length of longer side of the surface)
Tolerance
class
>
30
to
120
>
120
to
400
>
400
to
1000
>
1000
to
2000
>
2000
to
4000
>
4000
to
8000
>
8000
to
12000
>
12000
to
16000
>
16000
to
20000
>
20000


F 1 1,5 3 4,5 6 8 10 12 14 16


2.3 Angular dimensions
The shorter leg of the angle is taken as reference leg for the tolerances of the angles. Its length can also be applied from a
particular point of reference, which then has to be stated in the drawing (examples see figures 8 to 12).












Fig. 8 Fig. 9 Fig. 10 Fig. 11 Fig. 12


For conversion of angular dimensions into linear dimensions for measuring purposes, the limit deviations of the angles are
additionally indicated as tangent values.

Table 8 Angular dimensions
Range of nominal dimensions
(length of shorter leg)
Permissible deviations in degrees and minutes Permissible deviations as tangent values
Tolerance
class

up to 400
> 400
to 1000
> 1000


to 400
> 400
to 1000
> 1000

B 45' 30' 20' 0,013 0,009 0,006

The maximum permissible deviation in mm can be calculated from the tangent value x of the length of the shorter leg.





Reference
point
Reference point
Reference
point
Reference point
Reference point
Page 6
SN 200 Part 4 : 2003-09

3 Execution of welding work
3.1 Demands made on the manufacturer of welded components
The demands made on the manufacturer are split up as follows, on the basis of the legal regulations and the demands made
on the components:

3.1.1 Equipment subject to construction-supervision regulations
Table 9
Components
Place of
manufacture
Place of use Demands on the maker
worldwide Germany
Germany
outside
Germany
DIN 18800
Buildings subject to construction supervision (eg bays,
chimneys)

Machinery and equipment intended for the permanent
presence of persons (e.g. control stands, casting
platforms, stair towers)

outside Germany
outside
Germany
national regulations of user
country
worldwide Germany
Germany
outside
Germany
DIN 18800
DIN 15018 Cranes, lifting equipment and load-carrying equipment
(e.g. C-hooks, dismantling beams, see also SN 195)
outside Germany
outside
Germany
national regulations of user
country
worldwide Europe
Germany Europe
Directive 97/23/EC on
pressure equipment
Germany outside Europe
national regulations
of user country
Pressure vessels
outside Germany
outside

Europe
national regulations of user
country
The assignment to the range of equipment or buildings subject to construction supervision or to the Directive 97/23/EC on
Pressure Equipment and to the Water Resources Management Law is shown on the drawings.
3.1.2 Equipment not subject to regulations of construction supervision
Table 10
Components
Quality of weld
DIN EN 25817
(ISO 5817)
Demands on the maker
Requirements to be fulfilled by the welding shop on
the basis of DIN EN 729:
D

Basic requirements
- suitable welding equipment
- proof of welders qualification acc. to DIN EN 287, in
case of doubt, proof of qualification by trial welds
- proof of filler-metal storage and handling in
accordance with suppliers recommendations
Machinery and related equipment not
subject to construction supervision
(strand guide segments, shears,
millstands, millstand platforms,
converters, pipe lines)
B and C
Extended requirements
- fulfillment of above-mentioned basic requirements
- supervisory personnel for welding supervision as in
DIN EN 719
- appropriate storage of base materials to maintain the
marking
- prior to manufacture, proof of application/mastering of
welding procedures acknowledged in DIN EN 288
- keeping available of welding and working instructions
- use of personnel qualified acc. to DIN EN 473 for
quality inspections
Note:
If a manufacturing shop does not fulfill the above requirements, other national or international
regulations or permits (e.g. ASME) can be accepted.
Their equivalence must be proved by the contracting workshop before the beginning of manufacture.
Page 7
SN 200 Part 4 : 2003-09

3.2 Weld preparation, general
The type of weld preparation must be selected by the contracting workshop as required for the welding procedure applied.
Deviations from the drawing indications are allowed provided that the specified weld depth and the weld quality requirements
are fulfilled.

Selection of weld preparation in accordance with DIN EN 29692 (ISO 9692), Tables 11 and 12.

Deviations from DIN EN 29692 (ISO 9692) specifications:







3.3 Filler metals
All filler metals must be stored and handled with care and in compliance with DIN EN 1011-1, Item 8.2 and DIN EN 1011-2,
Item 7.

3.4 Preheating
The welding areas must be preheated as required for the respective material composition. The minimum preheating
temperature TP is determined on the basis of carbon equivalent CET as specified in SEW 086 and SEW 088. In the case of
multi-pass welds, the terms minimum preheating temperature and minimum interpass temperature have the same meaning.
These specifications apply to steel with
CET = 0,5.


10
Mo Mn
C
+
+ +
20
Cu Cr +
+
40
Ni
(%)

TP = 750 x CET 150 (C)

Fig. 13 Minimum values of preheating temperature TP as a function of carbon equivalent CET.












Measuring of the preheat, interpass and preheat maintenance temperatures must be made in accordance with
DIN EN ISO 13916.

3.5 Weld execution

3.5.1 Weld execution, general

The surfaces in the weld area must be freed from scale, slag, rust, paint, oil, grease and humidity prior to assembling.
To avoid stray currents and their effects (destruction of electric protective conductors etc.), the welding current return line
must be connected direct to the workpiece to be welded or to the workpiece support (e.g. welding table, welding grid,
assembly plates). Steel structures, rails, pipe lines, bars and similar objects must not be used as current conductors, unless
they are the workpiece to be welded.
Tack-welded areas must be at least 40 mm long. All cracks, lack-of-fusion spots and clusters of pores must be removed
before welding over.
If accessible, the roots of two-sided welds having full material penetration must be gouged, checked for absence of cracks
and counterwelded.
Unless otherwise specified in the drawing, weld seams must be closed around all corners. Exceptions to this are only ribs and
webs as in Figure 18.
Shrinkage stresses due to one-side welding-on of parts must be compensated by counterheating.
In case of postweld heat treatment, the welding shop must open all hermetically closed hollows prior to annealing by applying
a 10 mm round hole in a suitable place on the neutral axis, even if such measure is not expressly indicated in the drawing.
Upon heat treatment, these round holes must closed again. When plates are welded on, a short section is left without weld
and closed after heat treatment.
If full material penetration is required, the indication shown below is made in the drawing at the weld
concerned:
full penetration

Table 11 Groove forms for butt welds
Weld Weld groove design
Dimensions
Key
No.
Workpiece
thickness
t
Designation
Symbol
(as in ISO2553)
Representation Section Angle
1)
,
Gap
2)

b
Root height
c
Groove face
height

Recommended
welding process
3)
(as in ISO4063)
Remarks
t 4


- b t -- -
3
111
141
-
1.2
3 < t 8
Square butt
weld



- 6 h 8 - -
131
135
141
With weld pool
backup
1.3 3 t 10
Single-Vbutt
weld


40 60 b 4 c 2 - 3
With backup
strip if required
1.5 5 t 40
Single-Vbutt
weld with
broad root
face



60 1 b 4 2 c 4 -
111
131
135
141
-
1.7 t > 12
Single-U-butt
weld



8 12 1 b 4 c 3 -
111
131
135
141
-
1)
-

10 t 25
Single-bevel
butt weld



35 60 2 b 4 1 c 2 - - -
1)
SMS Demag stipulation


P
a
g
e

8

S
N

2
0
0

P
a
r
t

4

:

2
0
0
3
-
0
9

Table 11 continued

Weld Weld groove design
Dimensions
Key
No.
Workpiece
thickness
t
Designation
Symbol
(as in ISO2553)
Representation Section
Angle
1)
,
Gap
2)

b
Root height
c
Groove face
height
h
Recommended
welding process
3)
(as in ISO4063)
Remarks
1.4 3 < t 10
Single-bevel
butt weld


35 60 2 b 4 1 c 2 -
111
131
135
141
-
6 b 12 111
1.15 t > 16
Steep-flanked
single-bevel
butt weld

15 30
b 12
- -
131
135
With weld pool
backup
1.8 t > 16
Single-J butt
weld
(J-groove
weld)



10 20 2 b 4 1 c 2 -
111
131
135
141
-
- b
2
t
- -
111
141
2.2 t 8 weld



- b
2
t
- -
131
135

-
60
111
141
2.3.3 t > 10
Double-Vbutt
weld




40 60
1 b 3 c 2
131
135
-
P
a
g
e

9

S
N

2
0
0

P
a
r
t

4
:

2
0
0
3
-
0
9

Weld Weld groove design
Dimensions
Key
No.
Workpiece
thickness
t
Designation
Symbol
(as in ISO2553)
Representation Section
Angle
1)
,
Gap
2)

b
Root height
c
Groove face
height
h
Recommended
welding process
(as in ISO4063)
Remarks
1 60
2 60
111
141
2.3.3 t > 10
Asymmetric
double-Vbutt
weld



40 1 60
40 1 60
1 b 3 c 2 h =
3
t

131
135

2.7.7 t 30
Double-Ubutt
weld

8 12 b 3 c 3 h
2
c t

111
131
135
141
2.4.4 t > 10
Double-bevel
butt weld
(Kweld)



35 60 1 b 4 c 2
h =
2
t

or
h =
3
t

111
131
135
141
2.8.8 t > 30
Double-J butt
weld
10 20 b 3 c 2 -
111
131
135
141
This groove can
also be asymmetric,
similar to the
asymmetric double-
Vbutt weld
Table 11 continued
P
a
g
e

1
0

S
N

2
0
0

P
a
r
t

4

:

2
0
0
3
-
0
9

Page 11
SN 200 Part 4 : 2003-09

3.5.1.1 Slot welding









Fig. 13 Fig. 14

The slot width b depends upon the plate thicknesses t1 and t2 and the necessary weld junction,
for t1 15 mm, b min. is 0,5 x t1, but at least 4 mm
for t1 > 15 mm, b min. is 15 mm
3.5.1.2 Plug weld
Plug weld is allowed only for plate thicknesses t1 40 mm.
Hole diameter d = t1, but at least 20 mm, with preparation as in Fig. 14.
3.5.1.3 Weld thicknesses on butt welds, partly and fully bevelled welds
The weld thickness of these weld types must correspond to the
stated weld depth.
For butt and fillet welds the max. weld reinforcement () is
determined by the weld quality.
With partly and fully bevelled welds the weld reinforcement () for
single-bevel and double-bevel welds is determined to be 0 to 0.3 x
weld depth (s) and for single-J, double-J and square-edge butt welds
to be 0 to 0.2 x weld depth (s). (Fig. 15)
Fig. 15
3.5.1.4 Weld thickness on fillet welds
It is assumed that the weld is made as shown in Fig. 16. If the execution of the weld depends on the leg thickness (z), this
thickness is indicated in the drawing with the letter z as shown in Fig. 17.

e.g. z = 5





Fig. 16 Fig. 17

Contrary to DIN EN 22553 (ISO 2553), the indication (a) for fillet weld thicknesses is not made in
SMS Demag drawings.
Fillet welds are executed as set out below:

Fillet welds on both sides a = 0,3 x smallest plate thickness;
fillet welds on one side a = 0,6 x smallest plate thickness, but max. 12 mm.
Dimension (a) depends upon the thinner of the parts to be joined and must not exceed 12 mm, above 12 mm must be made
as partly or fully bevelled welds.
If the inner joint of a two-sided seam is not accessible and cannot be welded, the design department must be consulted.
3.5.1.5 Quality of weld; quality level for welding, general
The quality of weld is specified in Table 16 in quality levels according to DIN EN 25817 (ISO 5817).
Unless otherwise specified in the drawing, quality level D is SMS Demag standard. The restrictions shown in Table 14 must
be observed.
Demand joints on plates and sections must be full penetration welds with quality level B, the quality of weld must be proved
by ultrasonic or radiographic testing.
3.5.1.6 Deposit welding
Quality level D is SMS Demag standard, with restriction to the imperfections Nos. 1 to 5 and 8, see Table 16. The
specifications of SN 402 must be complied with.
3.5.2 Weld execution for ferritic-austenitic weld joints
Ferritic-austenitic weld joints are mixed joints established between structural unalloyed or structural alloy steels and austenitic
chromium-nickel steels by welding with CrNi (Mn, Mo) filler metals. Mixed joints between steels and nickel or nickel alloys also
count among the ferritic-austenitic weld joints because of the use of filler metals on nickel basis. Ferritic-austenitic weld joints
must be established by welding in accordance with the specific regulations and with filler metals whose use is permitted for
this combination.
up to t1 = 10
min. 2 or 3
half fill
above t1 = 10
Page 12
SN 200 Part 4 : 2003-09

3.6 Notches

Notches must be made as shown in figures 18 to 21. Dimension I or R in Table 12 is selected such that welding through
underneath the bracing rib is possible. Weld seams must be closed around all corners even without express mention in the
drawing:
- as shown in Fig. 18 for ribs and webs of 12 mm max. thickness;
- as shown in Fig. 19 for ribs and webs above 12 mm;
- as shown in Figs. 20 and 21 for ribs and webs without notches, if
b = 100/200 mm.
For reasons of strength and in case of seal welding, ribs and webs of this
type shall be avoided.







Fig. 18 Fig. 19 Fig. 20 Fig. 21

The types of notches are shown in the drawings without dimensioning.

3.7 Weld preparation on fluid-carrying components, e.g.: Pipelines, vessels
The weld preparation for butt welds (DIN 2559 Part 1) and corner welds is made as indicated in table 13.
For edge misalignment on connections between differing pipe wall thicknesses, the values of the required quality level apply
as in DIN EN 25817 (ISO 5817), imperfection No. 18, related to the smaller wall thickness. If edge misalignment exceeds the
admissible values, a conical transition 10 is required (DIN 2559, Parts 2 to 4).

Table 13

Key No.
Wall
thickness
s
Designation Symbol
1)
Weld groove designs
Section
Degree

Dimensions
Root opening
2)


b
Root
height
c
Groove
face
height
h
1 up to 3
Square butt
weld
- - 0 to 3 - -
22 up to 16
Single-V butt
weld


40 to 60 - 0 to 4 up to 2 -
3 up to 25
3)
Single-U-
butt weld


- 8 0 to 3 2
3)
-
4
above 25
3)
U-butt weld
on
V-root


60 8 0 to 3 - 4
all
3)
Single-bevel
butt weld
- - - - -
all
3)
(admissible only up to
max. PN 25)
Fillet weld - - - - -
1)
Additional symbols see DIN 1912.
2)
Dimensions apply to tack-welded condition.
3)
SMS Demag stipulation


Table 12

Plate thickness
of rib
l = R
up to 12 25
above 12 up to 30 40
above 30 50
Page 13
SN 200 Part 4 : 2003-09


3.8 Weld execution on fluid-carrying components, e.g.: pipelines, vessels
The surfaces in the weld area must be free from scale, slag, rust, paint, oil, grease and humidity prior to assembling of parts to
be welded.
Cracks, lack-of-fusion spots and clusters of pores must be removed before welding over.

Welding spatter is not allowed on the inner walls of pipelines; it is recommended producing the root pass by TIG
welding.

The reduction of the pipe cross-section due to root reinforcement of the weld must not exceed 20 % on pipes 25 mm outside
diameter and not exceed 15 % on pipes > 25 mm outside diameter, related to the cross-section of flow of the pipe (observe
Table 16, No. 16).
Compliance with the above shall be checked by visual inspection and, if necessary, excessive reinforcement shall be
removed, e.g. by grinding.

All welds in the interiors of vessels and chambers must be continuous welds.

The pipes of conduits in stainless and acid-resistant steels according to DIN 17456, DIN 17457, DIN 17458 must be flooded
with forming gas (e.g. N = 90%, H = 10%) both during tack-welding and welding of the root pass (observe DVS-Merkblatt =
DVS Reference Sheet 0937). The so-called forming gases remove the oxygen in the air from the heated weld areas and thus
prevent oxidation. They also have a favourable effect on root geometry and surface quality and prevent the formation of
pores.


3.8.1 Fluid-carrying steel components
Unless otherwise specified in the drawing, butt welds shall be full penetration welds.
All corner joints up to PN 25 bar must be made at least as fillet welds, over PN 25 bar, as single-bevel butt welds.
In case of postweld heat treatment, the welding shop must open all hermetically closed hollows prior to annealing by applying
a 10 mm round hole in a suitable place on the neutral axis, even if such measure is not expressly indicated in the drawing.
Upon heat treatment, these round holes must closed again. Shrinkage stresses due to one-side welding-on of parts must be
compensated by counterheating.


3.8.2 Fluid-carrying components in stainless and acid-resistant steels
Unless otherwise specified in the drawing, all weld seam joints shall be full penetration welds.
Corrosion probability of stainless and acid-resistant steels in the areas which are in contact with water can be kept low when
structure and finish are free of gaps. A gap width over 0.5 mm and a gap depth of less than half the gap width can generally
be regarded as uncritical (DIN 50930 Part 4).

3.9 Quality of weld, quality level on fluid-carrying components, e.g.: pipelines, vessels
The quality of weld is specified in quality levels as in DIN EN 25817 (ISO 5817), see Table 16.
Unless otherwise specified in the drawing, quality level D is SMS Demag standard. The restrictions shown in Table 15 must
be observed.


4 Postweld heat treatment

4.1 Postweld heat treatment, general
Any postweld heat treatment (e.g. stress relieving anneal) required for functional reasons shall be indicated in the drawing by
the designer.
Heat treatments required due to the manufacturing sequence (e.g. remachining) shall be arranged for by the contracting
workshop.
Heat treatments required from a welding viewpoint shall be performed in the own responsibility of the manufacturing shop.
The use of relieving methods other than stress relieving anneal (e.g. vibratory stress relief) shall be previously agreed with
SMS Demag.
Heat treatments on quenched and tempered steels must take place at temperatures 20 to 30 K below the tempering
temperature.
The contracting workshop shall obtain information on the tempering temperature used for the material.
All heat treatments must be proved by annealing diagrams with certificates as in DIN EN 10204 2.3 or 3.1.B.
Page 14
SN 200 Part 4 : 2003-09

General remarks on stress relieving anneal for material groups S 235 and S 355
The annealing temperature shall be between 550 C and 600 C, for S355 (St52) max. 580 C.
The heating rate shall not exceed 50 C per hour.
The holding time shall be at least 1 minute for each 1 mm of workpiece thickness (120 minutes for 120 mm thickness).
The cooling rate shall not exceed 50 C per hour.

4.2 Postweld heat treatment of stainless steel
4.2.1 Non-stabilised austenitic steels

such as 1.4301 X4CrNi 18 - 10
1.4401 X4CrNiMo 17 12 - 2
1.4436 X3CrNiMo 17 13 - 3
must never be heat treated after welding.

4.2.2 Stabilised austenitic steels

such as 1.4541 X6CrNiTi 18 - 10
1.4550 X6CrNiNb 18 - 10
1.4571 X6CrNiMoTi 17 12 - 2
1.4580 X6CrNiMoNb 17 12 - 2

shall remain without postweld heat treatment whenever possible. If heat treatment cannot be avoided, it shall take place only
after previous agreement with our specialist department (for example 750 C / holding time 1 hour / quick cooling down).



4.2.3 Postweld heat treatment of so-called low carbon steels

such as 1.4306 X2CrNi 19 - 11
1.4404 X2CrNiMo 17 12 - 2
1.4435 X2CrNiMo 18 14 - 3

shall be avoided. If heat treatment cannot be avoided, it shall take place only after previous agreement with our specialist
department (for example 750 C / holding time 1 hour / quick cooling down).


4.2.4 Postweld heat treatment of ferritic-austenitic weld joints

must take place only in exceptional cases.
If a component for which stress-relieving anneal is required has to be provided with non-detachable parts in
stainless-steel, welding-on or in of these parts must take place only after annealing.


5 Filler metal
The contents in alloy elements of the filler metal must be generally the same as or higher than those of the base material and
must be approved through suitability testing. Exact information on the properties of suitable filler metals can be found for
example in:

DIN EN 440 Wire electrodes and deposits for gas-shielded arc welding of non-alloy and fine-grain steels
DIN EN 499 Covered electrodes for manual metal arc welding of non-alloy and fine grain steels
DIN EN 1600 Covered electrodes for manual metal arc welding of stainless and heat-resisting steels
DIN EN 12536 Welding consumables; Rods for gas welding of non alloy and creep-resisting steels; Classification








Page 15
SN 200 Part 4: 2003-09


6 Inspection
Type and extent of inspection of welded parts are specified by this Part 4 of SN 200 or by drawing indications. The inspections
must be carried out by the welding shop.
If intermediate inspection is specified, this obliges the contracting welding shop to make a report to our Quality Inspection
Department for the purpose of inspection.

Dimensions having closer tolerances than the general tolerances stated in section 2 require documentation of the inspection
stating desired and actual dimensions.
Pressure or leak tests must be documented stating kind of test, test pressure, testing time and pressure medium.

If there is no suitable method of non-destructive testing to prove quality of the weld and flow, our department of quality
inspection (acceptance inspector) reserves the right to sever the pipelines at a suitable point for inspection of the welds which
are no longer visible after installation.

Visual inspections are made as specified in DIN EN 970.
Ultrasonic testing is carried out as in DIN EN 1712, 1713 and 1714.
Radiographic examinations are carried out as in DIN EN 12517 and 1435.
Magnetic-particle inspections are carried out as in DIN EN 1290 and 1291.
Dye-penetrant inspections are made as specified in DIN EN 1289.
All inspections must be certified in a document as in DIN EN 10204, 2.3, or 3.1.B.


6.1 Inspection of load-bearing welds with partial or full material penetration
These specifications apply to load-bearing welds for which the drawing indicates welding without full material penetration. The
inspection serves in particular the purpose of proving the admissible imperfections as in DIN EN 25817 (ISO 5817).
5 % of all load-bearing welds without full material penetration must be inspected. If no objections are found, the extent of
inspection may be reduced upon previous consultation with our department of quality inspection.

The welds must be inspected at the front side at a depth corresponding to weld depth + 5 mm (s + 5 mm) using the magnetic-
particle method.

Inspection is by partial grinding of the seam prior to closing at the front side, if necessary, closed welds must be opened for
inspection at the front side.

The specifications made can be applied analogously to welds with full material penetration in case non-destructive testing is
impossible or possible only in part because of insufficient accessibility.


On lifting devices which are welded to the workpiece crack detection is carried out on the weld seam and in the heat-affected
zone. extent of inspection = 100 % Evaluation according to quality level C.


Page 16
SN 200 Part 4 : 2003-09

6.1.1 Inspection directions for the quality levels of welds, general
Table 14
Quality level as in DIN EN 25817
(ISO 5817)
stringent
B
intermediate
C
moderate
D
SMS Demag standard
Cons. No. as in DIN EN 25817 (ISO 5817) all all all
Drawing indication required yes yes no
Proof of quality required yes yes no (see 6.1)
Visual inspection yes yes yes
Ultrasonic testing - -- --
Crack detection 25 %
4)
10 %
4)
--
Pressure test
w
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Required
inspections and
testing
2)

Leak test
only in exceptional cases
3

Cons. No. as in DIN EN 25817 (ISO 5817) all
all, but 9
acc. to B
all, but 8 and 9
acc. to B
Drawing indication required yes yes yes
Proof of quality required yes yes yes
Visual inspection yes yes yes
Ultrasonic testing 50 % 25 % 25 %
Crack detection 25 %
4)
10 %
4)
--
Pressure test w
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1
)

Required
inspections and
testing
2)

Leak test
only in exceptional cases
3)


6.2 Testing directions for the quality levels of welds on fluid-carrying components

Table 15
Quality level as in DIN EN 25817 (ISO 5817)
stringent
B
intermediate
C
moderate
D
SMS Demag standard
Cons. No. as in DIN EN 25817 (ISO 5817) all all
all, but 9
acc. to B
Execution for PN of
5)
> 25 bar 25 bar
Drawing indication required yes yes no
Proof of quality required yes yes no
Visual inspection yes yes yes
Nondestructive testing
e.g. radiographing
5)

25 % 10 % --
Pressure test
Required
inspections and
testing
2)

Leak test
only in exceptional cases
3)




1)
If full material penetration is required, this is indicated in the drawing as a note at the respective weld seam. (see item 3.2)
2)
The evaluation criteria for visual inspection and crack detection are DIN EN 25817 (ISO 5817) and DVS 0703. Testing
methods as in the respective DIN and AD reference sheets (DIN und AD-Merkblatt). In case of doubt, testability must be
clarified with our department of quality inspection. The percentage indication of the extent of testing refers to the length of
each individual weld seam.
3)
Pressure or leak testing is compulsory when:
- components consist of several separate chambers or hollow spaces. The test is made on each individual chamber or
hollow space.
- weld seams have undergone machining. Upon previous consultation with our department of quality inspection, crack
detection can be carried out instead of leak testing.
For all other weld seams on components pressure or leak tests are not required provided the welds have been properly
executed in the demanded quality.
4)
On lifting devices which are welded to the workpiece 100% crack detection is carried out on the weld seam and in the heat-
affected zone.
5)
Radiographing can be replaced by equivalent methods of testing of the internal condition. These tests are required only if
the contracting workshop has not secured and documented the qualification of its personnel by suitable statistical methods
and procedures. Approval by SMS Demag is required before beginning of manufacture.
Page 17
SN 200 Part 4 : 2003-09

7 Guideline for the quality levels of imperfections (excerpt from DIN EN 25817)
(ISO 5817)
Table 16 Limits for imperfections
Limits for the imperfections for quality levels
No.
Imperfection
Designation
Reference
No. as in
DIN EN ISO
6520-1
Remarks moderate
D
intermediate
C
stringent
B
1 Crack 100 All kinds of cracks, except
microcracks (hx l < 1 mm
2
),
crater cracks see No. 2
Not permitted
2 Crater crack 104 Permitted Not permitted
3 Porosity and
gas pores
2011
2012
2014
2017
The following conditions and limits for imperfections
shall be fulfilled:
a) Max. dimension of the summation of the
projected or surface crack area of the
imperfection
b) Max. diimension of a single pore for
- butt welds
- fillet welds
b) Max. diimension of a single pore



4 %

d 0,5 s
d 0,5 a
5 mm



2 %

d 0,4 s
d 0,4 a
4 mm



1 %

d 0,3 s
d 0,3 a
3 mm
4 Localized
(clustered)
porosity
2013
The total pore area within the cluster should be
summed and calculated as a percentage of the
greater of the two areas:
an envelope surrounding all the pores or a circle
with a diameter corresponding to the weld width.
The permitted porous area should be local. The
possiblity of masking other imperfections should be
taken into consideration.
The following conditions and limits for imperfections
shall be fulfilled:
a) Max. dimension of the summation of the
projected or surface crack area of the
imperfection
b) Max. dimension of a single pore for
- butt welds
- fillet welds
c) Max. dimension for localized clustered porosity













16 %

d 0,5 s
d 0,5 a
4 mm













8 %

d 0,4 s
d 0,4 a
3 mm













4 %

d 0,3 s
d 0,3 a
2 mm
5 Elongated
cavities,
wormholes
2015
2016
Long imperfections for
- butt welds
- fillet welds
Max. dimension for elongated cavities, wormholes

h 0,5 s
h 0,5 a
2 mm


Not permitted



Not permitted


Short imperfections for
- butt welds
- fillet welds
Max. dimension for elongated cavities, wormholes

h 0,5 s
h 0,5 a
4 mm or
not greater
than thickness


h 0,4 s
h 0,4 a
3 mm or
not greater
than thickness


h 0,3 s
h 0,3 a
2 mm or
not greater
than thickness

6 Solid inclusions
(except copper)
300 Long imperfections for
- butt welds
- fillet welds
Max. dimension for solid inclusions

h 0,5 s
h 0,5 a
2 mm


Not permitted



Not permitted


Short imperfections for
- butt welds
- fillet welds
Max. dimension for solid inclusions

h 0,5 s
h 0,5 a
4 mm or
not greater
than thickness

h 0,4 s
h 0,4 a
3 mm or
not greater
than thickness

h 0,3 s
h 0,3 a
2 mm or
not greater
than thickness
7 Copper
inclusions
3042
Not permitted
8 Lack of fusion 401

Permitted, but
only when
interrupted and
not reaching to
surface
Not permitted

continued overleaf
Page 18
SN 200 Part 4 : 2003-09
Table 16 (continued)
Limits for the imperfections for quality levels
No.
Imperfection
designation
Reference
No. as in
DIN EN ISO
6520-1
Remarks moderate
D
intermediate
C
stringent
B
9 Lack of
penetration
402
Long imperfections:
Not permitted
Not permitted

Short imperfections:

h 0,2 s,
max. 2 mm
h 0,1 s,
max. 1,5 mm

10 Bad fit-up,
fillet welds
__ Excessive or insufficient gap between
the parts to be joined.







Gaps exceeding the permitted limit may be
compensated in certain cases by a weld of
corresponding additional thickness.
h 1 mm + 0,3 a,
max. 4 mm
h 0,5 mm + 0,2 a,
max. 3 mm
h 0,5 mm + 0,1 a,
max. 2 mm
11 Weld undercut 5011
5012
Smooth transition is required.

h 1,5 mm h 1,0 mm h 0,5 mm
12 Excess weld
metal
502 Smooth transition is required.

h 1 mm + 0,25 b,
max. 10 mm
h 1 mm + 0,15 b,
max. 7 mm
h 1 mm + 0,1 b,
max. 5 mm
13 Excess
convexity
503 h 1 mm + 0,25 b,
max. 5 mm
h 1 mm + 0,15 b,
max. 4 mm
h 1 mm + 0,1 b,
max. 3 mm
continued overleaf
nominal penetration
actual
penetration
Fig. A
Fig. B
Fig. C
nom. penetration
actual penetration
actual penetration
nom. penetration
nominal weld thickness
actual weld thickness
Page 19
SN 200 Part 4 : 2003-09
Table 16 (continued)
Limits for the imperfections for quality levels
No.
Imperfection
designation
Reference
No. as in
DIN EN ISO
6520-1
Remarks
moderate
D
intermediate
C
stringent
B
14 Fillet weld
having a throat
thickness
greater than
the nominal
value
__ For many applications a throat thickness
greater than the nominal one may not be a
reason for rejection.

h 1mm + 0,3a,
max. 5 mm
h 1mm + 0,2a,
max. 4 mm
h 1mm + 0,15a,
max. 3 mm
Long imperfections:
Not permitted

Not permitted
Short imperfections:
h 0,3 mm + 0,1 a

15 Fillet weld
having a throat
thickness
smaller than
the nominal
value











__ A fillet weld with an apparent throat thickness
smaller than that prescribed should not be
regarded as being imperfect if the actual throat
thickness with a compensating greater depth of
penetration complies with the nominal value.



max. 2 mm max. 1 mm
16 Excessive
penetration
504 h 1mm + 1,2b,
max. 5 mm
h 1mm + 0,6b,
max. 4 mm
h 1mm + 0,3b,
max. 3 mm
17 Local
protrusion
5041 Permitted Occasional local excess permitted
18 Linear
misalignment
507 The limits relate to deviations from the correct
position. Unless otherwise specified, the
position is correct when the centerlines of the
parts coincide.
t refers to the smaller thickness.


Fig. A Plates and longitudinal welds
h 0,25 t,
max. 5 mm
h 0,15 t,
max. 4 mm
h 0,1 t,
max. 3 mm

Fig. B - Circumferential welds
h 0,5 t
max. 4 mm max. 3 mm max. 2 mm







continued overleaf
Fig. A
Fig. B
nominal weld
actual weld
nominal weld
actual weld
Page 20
SN 200 Part 4 : 2003-09

Table 16 (continued)
Limits for the imperfections for quality levels
No.
Imperfection
designation
Reference
No. as in
DIN EN ISO
6520-1
Remarks
moderate
D
intermediate
C
stringent
B
Smooth transition is required.

Long imperfections:
Not permitted

Short imperfections:
19 Incompletely
filled groove

Sagging
511


509
h 0,2 t,
max. 2 mm
h 0,1 t,
max. 1 mm
h 0,05 t,
max. 0,5 mm
20 Excessive
asymmetry of
fillet welds
512 It is assumed that an asymmetric fillet weld has
not been expressly prescribed.

h 2mm+0,2a h 2mm+0,15a h1,5mm+0,15a
21 Root concavity

Shrinkage
groove
515

5013
Smooth transition is required.

h 1,5 mm h 1,0 mm h 0,5 mm
22 Overlap 506

Short imperfections
permitted
Not permitted
23 Poor restart 517
Permitted Not permitted
24 Stray flash
or arc strike
601 Acceptance may be influenced by post treatment.
Acceptance depends on type of parent material with
particular reference to crack sensitivity.
25 Welding spatter 602
Acceptance depends upon applications.
Maximum total height of short imperfections h
For thicknesses s or a 10 mm special
consideration may be necessary.









26

Multiple
imperfections in
any cross-
section
1)

__



0,25s or 0,25a,
max. 10 mm

0,2s or 0,2a,
max. 10 mm

0,15s or ,15a,
max. 10 mm
h1 + h2 + h3 + h4 + h5 = h

h1 + h2 + h3 + h4 + h5 + h6 = h

2 a z =
Page 21
SN 200 Part 4 : 2003-09

Explanations on Table 16:
Fillet weld thickness, a; desired weld thickness: Height of the biggest isosceles triangle which can be inscribed in the
weld section (see DIN EN 22553/ISO 2553).
NOTE 1: For countries in which the leg length z is used for dimensioning a fillet weld, the limits for the imperfections should be
changed such that they refer to the leg length.
Butt weld thickness, s: Shortest distance from the top side of the part to the bottom of the penetration, this distance cannot
be greater than the thickness of the thinner part (see DIN EN 22553/ISO 2553).
Short imperfections: One or more imperfections of a total length of max. 25 mm, related to each 100 mm of weld length, or
of a max. length of 25% of the total length of a weld seam which is shorter than 100 mm.
Long imperfections: One or more imperfections of a total length above 25 mm, related to 100 mm of weld length, or of a
min. length of 25 % of the total length of a weld seam which is shorter than 100 mm.
Short designations
a desired fillet-weld thickness
b width of weld reinforcement
d pore diameter
h dimension of the imperfection (height and width)
l length of the imperfection
s nominal butt-weld thickness or, in the case of partial penetration, the specified depth of penetration
t pipe-wall or plate thickness
z desired leg length of fillet welds (with isosceles-rectangular section)



Referenced standards

AD Merkblatt HP 5.3 (AD Reference Sheet HP 5.3) Manufacture and testing of joints Non-destructive testing of welded
joints
DIN 2559 Parts 1-4 Preparation of welds
DIN 15018 Cranes; principles relating to steel structures; verification and analyses
DIN 17456 General purpose seamless circular stainless steel tubes
DIN 17457 Welded circular austenitic stainless steel tubes subject to special requirements
DIN 17458 Seamless circular austenitic stainless steel tubes subject to special requirements
DIN 18800 Part 1 Structural steelwork, design and construction
DIN 18800 Part 7 Steel structures, fabrication, verification of qualification for welding
DIN 50930 Part 4 Corrosion of metals; corrosion of metallic materials inside of tubes, tanks and apparatus under corrosion
load by water
DIN EN 287-1 Approval testing of welders, fusion welding
DIN EN 288 Specification and approval of welding procedures for metallic materials
Parts 1 to 9

DIN EN 440 Wire electrodes and deposits for gas-shielded metal arc welding of non-alloy and fine-grain steels
DIN EN 473 Qualification and certification of NDT personnel; general principles
DIN EN 499 Covered electrodes for manual metal arc welding of non-alloy and fine grain steels
DIN EN 719 Welding coordination - tasks and responsibilities
DIN EN 729 Quality requirements for welding, fusion welding of metallic materials
DIN EN 970 Non-destructive examination of fusion welds Visual examination
DIN EN 1011-1 Welding; Recommendations for welding of metallic materials General guidance for arc welding
DIN EN 1011-2 Welding; Recommendations for welding of metallic materials Arc welding of ferritic steels
DIN EN 1289 Non-destructive examination of welds, penetrant testing of welds
DIN EN 1290 Non-destructive examination of welds, magnetic particle examination of welds
DIN EN 1291 Non-destructive examination of welds - Magnetic particle examination of welds Acceptance levels
DIN EN 1435 Non-destructive testing of welds - Radiographic testing of welded joints
Page 22
SN 200 Part 4: 2003-09


DIN EN 1600 Welding consumables, covered electrodes for manual metal arc welding of stainless and heat-resisting
steels
DIN EN 1712 Non-destructive examination of welds - Ultrasonic examination of welded joints Acceptance levels
DIN EN 1713 Non-destructive examination of welds - Ultrasonic examination Characterization of indications in
welds
DIN EN 1714 Non-destructive examination of welds - Ultrasonic examination of welded joints
DIN EN 10204 Metallic products; types of inspection documents
DIN EN 12062 Non-destructive examination of welds General rules for metallic materials
DIN EN 12517 Non-destructive examination of welds - Radiographic examination of welded joints Acceptance levels
DIN EN 12536 Welding consumables; Rods for gas welding of non alloy and creep-resisting steels; Classification
DIN EN 22553 Welded, brazed and soldered joints; symbolic representation on drawings
(ISO 2553)
DIN EN 25817 Arc-welded joints in steel; guideline for the quality levels of imperfections.
(ISO 5817)

DIN EN ISO 4063 Welding and allied processes; Nomenclature of processes and reference numbers
DIN EN ISO 6520-1 Welding and allied processes, classification of geometric imperfections in metallic materials
DIN EN ISO 9001 Quality management systems; Requirements
DIN EN ISO 9692-1 Metal-arc welding with covered electrode, gas-shielded metal-arc welding and gas welding; joint
preparations for steel
DIN EN ISO 9692-2 Welding and allied processes; Joint preparation; Submerged arc welding of steel
DIN EN ISO 9692-3 Welding and allied processes; Recommendations for joint preparation; Metal inert gas welding and
tungsten inert gas welding of aluminium and its alloys
DIN EN ISO 13920 Welding, general tolerances for welded constructions Dimensions for lengths and angles, shape and
position00

SN 402 Deposit welding

SEW 086 on non-alloy and alloy high-temperature ferritic steels, preheating for welding
SEW 088 on weldable fine-grained structural steels, guidelines for processing, in particular for fusion welding
September 2003

Manufacturing instructions

MACHINING
SN 200
Part 5

Dimensions in mm
Field of application
The manufacturing instructions laid down in this standard apply to all workpieces produced by machining on the basis of SMS
Demag drawings unless other instructions are given in drawings or other manufacturing documentation.


Table of contents Page
1 Surface condition.....................................................................................................................................................2
1.1 General .............................................................................................................................................................2
1.2 Selection of measured variables of surface roughness comparative table .........................................................2
1.3 Symbols for indication of surface roughness .......................................................................................................2
1.4 Positions of surface indications at the symbol .....................................................................................................3
1.5 SMS Demag stipulations....................................................................................................................................3
1.6 Indication of surface lay......................................................................................................................................3
2 General tolerances as in DIN ISO 2768 Parts 1 and 2..............................................................................................4
2.1 Lengths, angles, radii of curvature and chamfer heights .....................................................................................4
2.1.1 Field of application.............................................................................................................................................4
2.1.2 Degree of accuracy............................................................................................................................................4
2.1.3 Linear dimensions..............................................................................................................................................4
2.1.4 Radii of curvature and chamfer heights (bevels)..................................................................................................4
2.1.5 Angle dimensions (inclination) ............................................................................................................................5
2.2 Form and location tolerances .............................................................................................................................5
2.2.1 Field of application.............................................................................................................................................5
2.2.2 Degree of accuracy............................................................................................................................................5
2.2.3 Tolerances on shape..........................................................................................................................................5
2.2.3.1 Flatness and straightness...................................................................................................................................5
2.2.3.2 Roundness, cylindricity, line and surface tolerances............................................................................................5
2.2.4 Tolerances of location........................................................................................................................................5
2.2.4.1 Parallelism.........................................................................................................................................................5
2.2.4.2 Perpendicularity.................................................................................................................................................5
2.2.4.3 Inclination (angularity) ........................................................................................................................................5
2.2.4.4 Symmetry..........................................................................................................................................................5
2.2.4.5 Coaxiality...........................................................................................................................................................5
2.2.4.6 Run ...................................................................................................................................................................5
2.2.4.7 Tolerances for hole-center distances and hole-circle diameters ...........................................................................6
3 General manufacturing instructions........................................................................................................................7
3.1 Free choice of tool .............................................................................................................................................7
3.2 Surface finish.....................................................................................................................................................8
3.3 Workpiece edge.................................................................................................................................................8
3.4 Thread...............................................................................................................................................................8
3.4.1 Thread tolerance for metric ISO thread (selection series SN 152) ......................................................................8
3.4.2 Thread runout/thread undercut ...........................................................................................................................8
3.5 Roller burnishing and deep-rolling ......................................................................................................................8
4 Inspection.................................................................................................................................................................9
4.1 Inspection of surface condition, measuring conditions .........................................................................................9
4.2 Inspection of dimensions, requirements on measuring devices ............................................................................9
5 Tolerancing of form and location (abridged version) ..............................................................................................10
5.1 General ...........................................................................................................................................................10
5.2 Entries in drawings...........................................................................................................................................10
5.3 Symbols with detailed definitions ......................................................................................................................12
6 Tolerances and limit deviations for linear dimensions from 1 to 10,000 mm.......................................................14
6.1 Field of application and purpose.......................................................................................................................14
6.2 General ...........................................................................................................................................................14
6.3 Designation of tolerance series.........................................................................................................................14
6.4 Fundamental tolerances...................................................................................................................................14
6.5 Limit deviations for shafts (nominal dimension range up to 3150 mm).............................................................15
6.6 Limit deviations for holes (nominal dimension range up to 3150 mm).............................................................16
6.7 Limit deviations for shafts (nominal dimension range over 3150 mm to 10,000 mm)........................................17
6.8 Limit deviations for holes (nominal dimension range over 3150 mm to 10,000 mm)........................................17
Referenced standards................................................................................................................... 17




Continued on pages 2 to 17
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Page 2
SN 200 Part 5 : 2003-09

1 Surface condition
1.1 General
Indication of surface condition in drawings is made as specified in DIN EN ISO 1302 (see item 1.4), but with certain
restrictions. The preferred measured variable indicated in the drawing is the arithmetical average peak-to-valley height Ra,
but only the roughness value itself (see tables 1 and 2).
All other measured roughness variables are indicated in the drawing.

1.2 Selection of measured variables of surface roughness comparative table
Table 1
Selection of measured variables of surface roughness comparative table
DIN EN ISO 1302
Ra m Ra inch Rz m Roughness class
50 2000 160 N 12
25 1000 100 N 11
12,5 500 63 N 10
6,3 250 40 N 9
3,2 125 25 N 8
2,5 100 16 --
1,6 63 12,5 N 7
0,8 32 6,3 N 6
0,4 16 2,5 N 5
0,2 8 1,6 N 4
0,1 4 1 N 3
The shaded boxes show SMS Demag standard values.

1.3 Symbols for indication of surface roughness
Table 2
Symbol Meaning


Basic symbol. Supplementary information required for definition


Surface produced by any process within the average peak-to-valley height of
Ra 3,2 m


Surface must be produced by metal-cutting process (machining), no specification of
average peak-to-valley height.

Surface must be produced by metal-cutting process (machining) within the average
peak-to-valley height of Ra 3,2 m

No working, surface remains in the as-delivered condition.

1.4 Positions of surface indications at the symbol
Table 3
a = roughness value Ra in m
SMS Demag standard
indication, contrary to
DIN EN ISO 1302
b = manufacturing process, surface treatment
c = reference length
d = groove direction
e = machining allowance

f = other measured roughness variables, e.g. Rz, Rmax

indications only if
indispensable for
functional reasons.

Page 3
SN 200 Part 5 : 2003-09

1.5 Indication of surface lay
Table 4
Symbol Meaning Illustration

Grooves parallel to plane of projection of view
in which symbol is used.


Grooves perpendicular to plane of projection of view
in which symbol is used.


Grooves crossed in two oblique relative to plane of projection
of view in which symbol is used.


Multidirectional grooves.




Grooves approximately circular relative to center of
surface to which the symbol applies.




Grooves approximately radial to center of
surface to which symbol applies.




1.6 SMS Demag stipulations
Table 5
Symbol Meaning Example of drawing indication





Machining after welding-in or welding-on.
(Machining allowance required.)
Note: Use only for detailed torch-cut parts.








Machining before welding-in or welding-on.
(Machining allowance required.)




a = roughness value Ra in m





Free choice of tool (see 3.1).
___





a
direction of lay
direction of lay
direction of lay
Page 4
SN 200 Part 5 : 2003-09

2 General tolerances
The general tolerances specified in DIN ISO 2768, Parts 1 and 2, are based on international stipulations. This DIN ISO
standard does not fully cover the national regulations in force so far, for this reason, all differing data have been
taken from DIN 7168 and are shown against shaded background.
2.1 Lengths, angles, radii of curvature and chamfer heights
2.1.1 Field of application
General tolerances as in DIN ISO 2768-1 and DIN 7168 for lengths, angles, radii of curvature and chamfer heights are
applied to parts manufactured by machining. They apply to dimensions without tolerance indication between two machined
surfaces of a part made of any metallic material, provided that no material-specifically required general tolerances are
stipulated in other specifications or standards.
For dimensions between an unmachined surface and a machined surface of a part, for which no individual tolerance
is indicated, half the general tolerances specified in the corresponding standard for cast, torch-cut and forged parts
are applicable.
Dimension shown in brackets are not required for the geometrical determination (manufacture) of a part.
General tolerances apply to the following:
- linear dimensions such as outside, inside, stepped dimensions, diameters, distances (see table 6),
- radii of curvature and chamfer heights (bevels; see table 7);
- angles, whether indicated or not normally indicated like angles of equal-sided polygons (see table 8);
- Length and angle dimensions resulting from machining of jointed parts.
General tolerances do not apply to the following:
- auxiliary dimensions shown in brackets as in DIN 406 Part 11;
- theoretical dimensions enclosed in rectangles according to DIN ISO 1101;
- hole-center distances, hole-circle diameters (see table 13);
- non-indicated right angles between lines that form axes of coordinates;
- length and angle dimensions resulting from jointing/assembling.
2.1.2 Degree of accuracy
General tolerances are subject to degree of accuracy

DIN ISO 2768 - m
2.1.3 Linear dimensions
Upper and lower deviations for linear dimensions. Indications relating to sawing are SMS Demag specific stipulations.
Table 6
Limit deviations for nominal dimension ranges Degree of accuracy

0,5
1)

to
6
> 6
to
30
> 30
to
120
> 120
to
400
> 400
to
1000
> 1000
to
2000
> 2000
to
4000
> 4000
to
8000
> 8000
to
12000
> 12000
to
16000
> 16000
to
20000
m (medium) 0,1 0,2 0,3 0,5 0,8 1,2 2 3 4 5 6
Sawing 1 2 3
2.1.4 Radii of curvature and chamfer heights (bevels)
Upper and lower limits for radii of curvature and chamfer heights (bevels)
Table 7
Limit deviations for nominal dimension ranges
> 6
to
Degree of accuracy
0,5
1)

to
3
> 3
to
6 30
> 30
to
120
> 120
to
400
m (medium) 0,2 0,5 1 2 4

Values in shaded boxes correspond to those of DIN 7168.






1)
Permissible deviations for nominal dimensions smaller than 0,5 mm are shown at the nominal dimension.
Page 5
SN 200 Part 5 : 2003-09

2.1.5 Angle dimensions (inclination)
Table 8
Limit deviations in angle units for nominal dimension ranges of the shorter leg Degree of accuracy


up to 10
> 10
to 50
> 50
to 120
> 120
to 400
> 400
m (medium) 1 0 30' 0 20' 0 10' 0 5'
Tangent values 0,0175 0,0087 0,0058 0,0029 0,0015
for lubrication holes
c (coarse)
1 30' 1 0 30' 0 15' 0 10'
Tangent values 0,0262 0,0175 0,0087 0,0044 0,0029
The maximum permissible deviation in mm follows from tangent value multiplied by length of shorter leg. Any smaller angular
tolerance required must be indicated in the drawing.
2.2 Form and location tolerances
2.2.1 Field of application
General tolerances for form and location as in DIN ISO 2768-2 are applicable to parts manufactured by machining. They are
also applied to individually toleranced dimensions or dimensions toleranced in accordance with ISO tolerance system, unless
they are overruled by drawing indication as specified in DIN ISO 1101.
2.2.2 Degree of accuracy
Tolerances of form and location are subject to degree of accuracy

DIN ISO 2768 - H
2.2.3 Tolerances on shape
2.2.3.1 Flatness and straightness
General tolerances of flatness and straightness are given
in Table 9.
2.3.3.2 Roundness, cylindricity, line and surface tolerances
The tolerances of shape are limited by the dimensional
tolerance areas defined by the dimensional tolerances
including the general tolerances of the workpiece shape
elements in question.
2.2.4 Tolerances of location
2.2.4.1 Parallelism
The permissible position tolerances with respect to
parallelism are limited by the tolerance assigned to the
distance between the parallel lines or surfaces.
2.2.4.2 Perpendicularity
General tolerances with respect to perpendicularity are
stated in Table 10.
2.2.4.3 Inclination (angularity)
General tolerances for iclination (angularity are stated in
Table 8.
2.2.4.4 Symmetry
The general tolerance for shape elements without
rotational symmetry is given in Table 11. The general
tolerance also applies if one of the symmetrical shape
elements possesses rotational symmetry and the other
does not (e.g. cardan-shaft heads and sockets).
2.2.4.5 Coaxiality
General tolerances relating to coaxiality have not been
specified.
In the extreme case they are allowed to be as high as the
radial and axial runout tolerances given in Table 12.
2.2.4.6 Run
General tolerances for radial runout and axial runout are
limited by the permissible tolerance specified in Table 12.



Table 9
General tolerances for straightness and flatness
for nominal dimension ranges
Tole-
rance
class

up to
10
> 10
to
30
> 30
to
100
> 100
to
300
> 300
to
1000
> 1000
to
3000
H 0,02 0,05 0,1 0,2 0,3 0,4

Table 10
Perpendicularity tolerance for nominal dimension
ranges for the shorter angle leg
Tolerance
class
up to 100
> 100
to 300
> 300
to 1000
> 1000
to 3000
H 0,2 0,3 0,4 0,5

Table 11
Tolerance class Symmetry tolerances
H 0,5

Table 12
Tolerance class Runout tolerance
H 0,1

Page 6
SN 200 Part 5 : 2003-09


2.2.4.7 Tolerances for hole-center distances and hole-circle diameters
The tolerances shown in Table 13 are to be understood as position tolerances as in DIN ISO 1101 and are applicable to non-
toleranced hole-center distances and hole-circle diameters.
The indication of position tolerances preclude the summation of tolerances resulting from production. This means that the
distances between individual holes represent theoretically precise coordinate dimensions without deviations, the intersections
of which define tolerance cylinders corresponding to the tolerances shown in Table 13.

Table 13
Thread size M4 M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 M42 M48 M56 M64 M72 M80 M90 M100
Through-hole for
mechanical
engineering
4,5 5,5 6,6 9 11 13,5 17,5 22 26 33 39 45 52 62 70 78 86 96 107
Through-hole for
sturctural steel
engineering
- - 7 10 12 14,5 18,5 24 28 35 42 48 56 - - - - - -
0,25 0,3 0,5 0,75 1,0 1,5 2,0 3,0 3,5
Location tolerance



for through-hole for tap hole
Page 7
SN 200 Part 5 : 2003-09

3 General manufacturing instructions
3.1 Free choice of tool
Rounded or oblique surfaces, keyways, bore mouths and end faces for recesses are produced as required for the tool
contour. The necessary drawing indication is made as shown in the following examples.
Table 14
Situation Drawing indication required
Curvatures and chamfers on turned and milled parts
Possible tool contours:






Fig. 1 Fig. 2 Fig. 3 Fig. 4






Fig. 5 Fig. 6 Fig. 7 Fig. 8






or



or




or

Drilling tool runout
Examples of drilling tool runouts:







Fig. 9 Fig. 10 Fig. 11
.
End faces of countersinks
Milling of one joint countersink area for several individual countersinks is
allowed.
Below are some examples of end faces:










Choice of drilling tool for stepped holes
Unless otherwise detailed in drawings, it is left to the manufacturer's
discretion to produce stepped (or, as an alternative, smooth) holes
depending upon the drilling tool available.












(with indication of functional dimensions)
or
Fig. 12
G 3/4x16 / 11-22x1200
or

G 3/4x16/
11-22x1200

Page 8
SN 200 Part 5 : 2003-09

3.2 Surface finish
SMS Demag standard surface finish without drawing indication. Indications shown in Table 15 are also valid when the
summarising symbol is shown.
Table 15
Linear dimensions referring to surfaces without indication of
roughness variables (e.g. surfaces produced by sawing)

Holes up to dia 40, oblong holes, keeper plate slots
Premachined parts, weld-in parts

Screw contact faces
- on rolled plate
- on other surfaces of blanks
- on countersinks for screws

Undercuts, chamfers, threads, thread undercuts, keyseats,
keyways and oil grooves, end faces of stationary sealing
surfaces, grooves for retaining rings

Radii or curvatures and chamfers on:
inner curvatures of the finer adjoining surface,
outer curvatures of the coarser adjoining surface.
chamfers of the coarser adjoining surface.




3.3 Workpiece edge
All workpiece edges which are inevitably produced by metal-cutting working must be deburred in accordance with DIN ISO
13715.
for outer edges: for inner edges:




free from burrs up to 0.3 transition up to 0.3

3.4 Threads
3.4.1 Thread tolerance for metric ISO thread (selection series SN 152)
Thread tolerance class as in DIN ISO 965-1: medium (m)
Tolerance zone as in DIN ISO 965-1: 6g for pin
Tolerance zone as in DIN ISO 965-1: 6h for nut
From thread size M64, drawing indication is required.
3.4.2 Thread runout/thread undercut
The normal cases as in DIN 76 Parts 1 and 2 are applicable to all thread runouts and thread undercuts.
3.5 Roller burnishing and deep-rolling
The difference between the two processes consists mainly in their purposes.
The purpose of roller burnishing is the producing of the prescribed surface roughness.
Deep-rolling is a proven process for surface hardening by mechanical treatment. It makes use of the combination of three
physical effects that take place at the same time.
Residual compressive stress
Increase of strength by shaping
Smoothing by removal of roughness
Premachining: - preferably by turning, boring, inside turning or reaming with angular reamer,
- less suitable procedures are grinding, honing, reaming with multiple-edged reamers, and milling.
Deep-rolling requires permanent control of the working parameters in the process. (rolling force, feed rate, speed and
geometry).
Table 16
It is recommended peforming
roller burnishing or deep-rolling at
the end of metal-cutting shaping
in one setup on the machine.
Roller burnishing and deep-rolling
Drawing indication
required
Roller burnishing roller burnish
Deep rolling (surface smoothing)
Hardening of surface
(increase of local surface strength by approx. 30%)
deep-rolled
Page 9
SN 200 Part 5 : 2003-09
4 Inspection
All features created during the manufacturing process (dimensions, surface roughness etc.) shall be inspected by the
manufacturer. Surface flaw detection specified in drawings shall be carried out by the manufacturer of the surface after finish-
machining.
Manufacturer records the results of the inspections using the criteria set out below indicating the associated desired and
actual values in an inspection certificate as in DIN EN 10204 - 3.1B.
- Dimensional tolerances with IT tolerance class IT9
- Dimensional tolerances without IT tolerance class as set out below:
Dimensions below 180 mm with tolerance ranges 0,1 mm
Dimensions > 180 to 800 mm with tolerance ranges 0,2 mm
Dimensions > 800 to 2.000 mm with tolerance ranges 0,4 mm
Dimensions > 2.000 to 5.000 mm with tolerance ranges 0,8 mm
Dimensions > 5.000 mm with tolerance ranges 1,0 mm
- tolerances of shape and position of small tolerance class H according to DIN ISO 2768-2.
- for angles, curves and radii, small degree of accuracy m according to DIN ISO 2768-1.
- surface roughnesses Ra 0,8 m as in DIN EN ISO 1302.
- pressure tests for operating pressures > 25 bar stating type of test, test pressure, test time and pressure media.
- threads, with exception of metrical (normal) vee thread and pipe thread with indication of testing method/means
- toothings, stating base tangent lengths, tooth form, tooth alignment, pitch
- surface treatments and coatings with indication of hardness and of coating thickness.
- external condition, e.g. surface crack detection using dye penetrant and magnetic particle testing, with indication of
recording and acceptability limits and with sketches if necessary


4.1 Inspection of surface condition, measuring conditions
To avoid mesuring errors, dependence as shown in the table below exists according to DIN 4768 between the roughness-
trace length or sampling length and the cutoff wavelength.
Table 17
Regularly repeating profiles
(geometrically defined
cutting edge)
Non-repeating profiles
(geometrically undefined cutting edge)
Cutoff wavelength Sampling length
Roughn.
trace
length

Groove spacing
S m
Mean height
of profile
R z
Arithmetic average
peak-to-valley height
R a


c

l e
(R z)

l m
(R z u. R a)
l t
mm m m mm mm mm mm
> 0,01 to 0,04 to 0,1 to 0,02 0,08 0,08 0,4 0,56
> 0,04 to 0,13 > 0,1 to 0,5 > 0,02 to 0,1 0,25 0,25 1,25 1,75
> 0,13 to 0,4 > 0,5 to 10 > 0,1 to 2 0,8 0,8 4 5,6
> 0,4 to 1,3 > 0 to 50 > 2 to 10 2,5 2,5 12,5 17,5
> 1,3 to 4 > 50 > 10 8 8 40 56
Regularly repeating profile: turned, milled, planed; non-repating profile: ground, honed, lapped.
Overall sampling length l m = 5 x individual sampling length le.
Roughness trace length l t = run-up distance l v + overall sampling length l m + run-off distance l n
Groove pitch S m = mean spacing of profile irregularities within the overall sampling length l m

Cutoff wavelength: wave filters as in DIN EN ISO 11562 are named according to their cutoff wavelengths. They are profile
filters which, depending upon their characteristics, have the effect that the long-wave portions of the actual profile are entered
in the roughness profile/measuring result only in part or not at all.


4.2 Inspection of dimensions, requirements on measuring devices
Each manufacturer shall make available sufficient measuring devices for verification of the features produced. Measuring and
inspection devices should be selected and used as appropriate for the respective measuring requirements; the measuring
inaccuracies of the devices used must be known.
When necessary, proof shall be furnished of fulfilment of the requirements concerning control of measuring and test
equipment as in DIN EN ISO 9001, 7.6: "Control of monitoring and measuring devices" and in DIN ISO 10012-1.
Shape and position tolerances should be examined on calibrated 3-coordinate measuring machines. If the manufacturer
possesses neither a three-coordinate measuring machine nor any other measuring and testing equipment, SMS Demag
reserve the right to demand inspection performed by scanning of the workpiece on a machine tool in unclamped condition.
This inspection must be performed on a machine not involved in the production of the workpiece and with known accuracy. In
case of need, this accuracy shall be proved. Whenever possible, machine errors shall be eliminated, if not, they shall be taken
into account. Deviations from these requirements must be approved by the SMS Demag quality assurance department.



Page 10
SN 200 Part 5 : 2003-09

5 Tolerancing of form and location (abridged version)
5.1 General
DIN ISO 1101 shall be applied when using tolerances other than the admissible tolerances of shape and position specified in
Tables 9 to 12.
Contrary to the stipulations made in DIN ISO 8015, the principle of independency is not applicable, instead, the principle of
envelope requirements continues to apply at SMS Demag.

All dimensions are subject to the envelope requirements as specified in DIN 7167.

This means that all tolerances of shape and parallelism must always be within the specified general or ISO tolerances.
Tolerances of form and position can be stated in addition to dimensional tolerances to ensure function and replaceability.
Shape tolerances limit the extent to which an individual element may deviate from its geometrically ideal shape.
Position tolerances limit the extent of deviation from the relative positions of two or more elements one of which is, for
functional reasons or for the purpose of clear definition, usually used as a reference element for the tolerance indications. If
necessary, more than one element can be specified as reference element. The reference element must be of sufficient
accuracy (if necessary, a shape tolerance is specified).



5.2 Entries in drawings






















The tolerance refers to the overall dimension of the element concerned. If the tolerance applies only
to part lengths in any position, a linear dimension must be indicated near the tolerance value,
separated from it by a stroke; for example:



If the tolerance indication applies only to a defined area, this area shall be marked with a wide
dash-dot line and its dimension shown; for example:









1)
Theoretically accurate dimensions are the bases for the locations of the shape and position tolerance areas. The general
tolerances do not apply to these dimensions.

theoretically exact
dimension (in a box)
1)
,
valid only in conjunction
with position tolerance.
reference letter

reference triangle
reference element

reference letter
(if required)

tolerance value (t)
tolerance type symbol
indication
arrow

toleranced
element

Reference triangles with reference letter R shown in a circle are reference surfaces for starting dimensioning
and shall be taken into account when defining the manufacturing sequence.
SMS Demag stipulation

Page 11
SN 200 Part 5 : 2003-09


When the indication refers to the axis of the workpiece, the indication arrow or reference triangle is placed to meet the arrow of
the dimension line. If the indication arrow is placed on the centerline, the tolerance zone applies to all axes represented by this
centerline. An indication referring to the surface line is made by indication arrow or reference triangle placed at a distance of
min. 4 mm to one side of the dimension line.


Reference to the axis Reference to all Reference to surface line
axes represented by centerline










The tolerance zone is cylindrical when the symbol precedes the tolerance value. When this sign is not indicated, the
tolerance zone is delimited by two lines or surfaces whose distance in the direction of the indication arrow is equal to the
tolerance value.









When a common tolerance zone shall apply to several individual elements, this requirement is shown by addition of CZ (for
common zone).

These stipulations can be applied by analogy to other types of tolerances.

In the example shown all three surfaces must be parallel to the reference surface. As a result, they are also symmetric to each
other within the tolerance of 0,1 mm.
































Page 12
SN 200 Part 5 : 2003-09

5.3 Symbols with detailed definitions
Table 18 Form and location tolerances
Detailed definitions of tolerances

Symbol
and toleranced
feature Tolerance area
Drawing indication
as in DIN ISO 1101
Meaning
Straightness

The axis of the cylinder to which the tolerance indication refers must lie
within a cylindrical tolerance zone of dia. 0,08
Flatness
The surface must lie between two parallel planes which are 0,08 apart
Level surface



SMS Demag
stipulation

The toleranced horizontal line must lie between two horizontal lines which
are t = 0,2 mm apart. Without reference length indication, reference is always
made to the respective overall length.

Roundness


The circumferential line of each cross-section must lie between two
concentric circles which are in the same plane and 0,1 apart.
I
n
d
i
v
i
d
u
a
l

e
l
e
m
e
n
t
s

Cylindrical
shape

The toleranced outside cylinder surface must lie between two coaxial
cylinders which are 0,1 apart.
Line shape

In every section parallel to the drawing plane the toleranced profile must lie
between two lines which envelope circles of 0,04 dia. whose centers lie on a
line of geometrically ideal shape.

S
h
a
p
e


I
n
d
i
v
i
d
u
a
l

o
r

r
e
l
a
t
e
d

e
l
e
m
e
n
t
s

Surface
shape


The toleranced surface must lie between two surfaces which envelope
spheres of 0,02 dia. whose centers lie on a surface of geometrically ideal
shape.

The toleranced axis must lie within a cylinder of 0,03 dia. which is parallel to
reference axis A.
Parallelism

On a partial length of 100 in any position and any direction on the toleranced
surface, all points must lie between two planes which are parallel to the
reference surface A and 0,01 apart.
Perpendi-
cularity

The toleranced axis of the cylinder must lie between two parallel planes
which are perpendicular to the reference surface and 0,1 apart.
T
o
l
e
r
a
n
c
e
s

(
r
e
l
a
t
e
d

e
l
e
m
e
n
t
s
)

D
i
r
e
c
t
i
o
n

Inclination
(angularity)

The toleranced surface must lie between two parallel planes which are 0,08
apart and at an angle of 40 to reference surface A.
continued on following page


ball
Page 13
SN 200 Part 5 : 2003-09
Table 18 (continued)
Detailed definitions of tolerances Symbol
and toleranced
feature
Tolerance area
Drawing indication
as in DIN ISO 1101
Meaning
Position

The axis of the hole must lie within a cylinder of 0,08 dia. whose axis is
located in the theoretically exact place.
Symmetry

The central plane of the groove must lie between two parallel planes which
are 0,08 apart and which are symmetrical to the central plane of reference
element A.
Coaxiality

The axis of the cylinder to which the tolerance indication refers must lie
within a cylinder which is coaxial to reference axis AB and has a dia. of
0,08.
2)
L
o
c
a
t
i
o
n

Concentri-
city

The center of the toleranced circle must lie within a circle which is 0,01 in
dia. and concentric to the center of reference circle A.
Axial runout

In one rotation around reference axis D the axial runout in any measuring
position shall not exceed 0,1.
Radial
runout




In one rotation around reference axis AB the radial runout must not exceed
0,1 in any measuring plane.
Overall axial
runout

In repeated rotation around reference axis D and radial shifting between
workpiece and measuring unit, all surface points of the toleranced element
must lie within the overall axial runout of t = 0,1.
3)

T
o
l
e
r
a
n
c
e
s

(
r
e
l
a
t
e
d

e
l
e
m
e
n
t
s
)

R
u
n

Overall axial
runout

In repeated rotation around reference axis A-B and axial shifting between
workpiece and measuring unit, all surface points of the toleranced element
must lie within the overall radial runout of t = 0,1.
3)




1)
Theoretically accurate dimensions are the bases for the locations of the shape and position tolerance areas. The general
tolerances do not apply to these dimensions.
2)
As axes are difficult to determine from the measuring viewpoint, runout should be preferred to coaxiality.
3)
In shifting either measuring unit or workpiece shall be moved along a line which is of theoretically exact shape and in
correct location relative to the reference axis.

Page 14
SN 200 Part 5 : 2003-09

6 Tolerances and limit deviations for linear dimensions from 1 to 10,000 mm
6.1 Field of application and purpose
This standard is applicable to the determination of tolerances for all linear dimensions such as lengths, widths, heights,
depths, diameters etc. It defines tolerances subdivided into 12 different tolerance classes (to be selected and agreed upon as
required for the application) for linear dimensions over 1 up to 10,000 mm.
Note 1: For nominal dimensions up to 3150 mm, the tolerances are identical to ISO standard tolerances of DIN ISO 286.
Fundamental tolerances for nominal dimensions over 3150 mm are, however, not stated in DIN ISO 286.
Note 2: For ISO fundamental tolerances for nominal dimensions over 3150 mm, see DIN 7172.
Note 3: It is underlined that in case of dimensions over 500 mm special care is required during manufacture to ensure
fulfilment of tolerances of tolerance classes finer than 8, in particular with respect to temperature fluctuations and temperature
gradients in the workpiece.


6.2 General
The fundamental tolerances stated in Table 19 are assigned to the respective tolerance series and classes. For all values
indicated the reference temperature of 20 C as in DIN EN ISO 1 is valid.


6.3 Designation of tolerance series


Tolerance
series
DIN ISO 286- IT ... (up to 3150 mm)
Tolerance
series
DIN 7172- IT ... (above 3150 mm)

Designation

Main DIN No.

IT symbol and tolerance class
(IT = international tolerance grade)

6.4 Fundamental tolerances
Table 19 Fundamental tolerances
IT
Nominal dimension
range
mm
5 6 7 8 9 10 11 12 13 14 15 16
from 1 to 3 4 6 10 14 25 40 60 100 140 250 400 600
> 3 to 6 5 8 12 18 30 48 75 120 180 300 480 750
> 6 to 10 6 9 15 22 36 58 90 150 220 360 580 900
> 10 to 18 8 11 18 27 43 70 110 180 270 430 700 1100
> 18 to 30 9 13 21 33 52 84 130 210 330 520 840 1300
> 30 to 50 11 16 25 39 62 100 160 250 390 620 1000 1600
> 50 to 80 13 19 30 46 74 120 190 300 460 740 1200 1900
> 80 to 120 15 22 35 54 87 140 220 350 540 870 1400 2200
> 120 to 180 18 25 40 63 100 160 250 400 630 1000 1600 2500
> 180 to 250 20 29 46 72 115 185 290 460 720 1150 1850 2900
> 250 to 315 23 32 52 81 130 210 320 520 810 1300 2100 3200
> 315 to 400 25 36 57 89 140 230 360 570 890 1400 2300 3600
> 400 to 500 27 40 63 97 155 250 400 630 970 1550 2500 4000
> 500 to 630 32 44 70 110 175 280 440 700 1100 1750 2800 4400
> 630 to 800 36 50 80 125 200 320 500 800 1250 2000 3200 5000
> 800 to 1000 40 56 90 140 230 360 560 900 1400 2300 3600 5600
> 1000 to 1250 47 66 105 165 260 420 660 1050 1650 2600 4200 6600
> 1250 to 1600 55 78 125 195 310 500 780 1250 1950 3100 5000 7800
> 1600 to 2000 65 92 150 230 370 600 920 1500 2300 3700 6000 9200
> 2000 to 2500 78 110 175 280 440 700 1100 1750 2800 4400 7000 11000
> 2500 to 3150 96 135 210 330 540 860 1350 2100 3300 5400 8600 13500
> 3150 to 4000 105 165 260 410 660 1050 1650 2600 4100 6600 10500 16500
> 4000 to 5000 130 200 320 500 800 1300 2000 3200 5000 8000 13000 20000
> 5000 to 6300 160 250 400 620 980 1600 2500 4000 6200 9800 16000 25000
> 6300 to 8000 195 310 490 760 1200 1950 3100 4900 7600 12000 19500 31000
> 8000 to 10000 240 380 600 940 1500 2400 3800 6000 9400 15000 24000 38000

Page 15
SN 200 Part 5 : 2003-09
6.5 Limit deviations for shafts (nominal dimension range up to 3150 mm)
Table 20
Tolerance zones for outside dim. of shafts as in DIN ISO 286-2 (SMS Demag selection). Deviations in terms of m
Nominal
dimension range
mm
e7 e8 e9 f7 g6 h6 h9 h11 j6 / js6
1)
k6 m6 n6 p6 r6 s6
> 1 to 3
- 14
- 24
- 14
- 28
- 14
- 39
- 6
- 16
- 2
- 8
0
- 6
0
- 25
0
- 60
+ 4
- 2
+ 6
0
+ 8
+ 2
+ 10
+ 4
+ 12
+ 6
+ 16
+ 10
+ 20
+ 14
> 3 to 6
- 20
- 32
- 20
- 38
- 20
- 50
- 10
- 22
- 4
- 12
0
- 8
0
- 30
0
- 75
+ 6
- 2
+ 9
+ 1
+ 12
+ 4
+ 16
+ 8
+ 20
+ 12
+ 23
+ 15
+ 27
+ 19
> 6 to 10
- 25
- 40
- 25
- 47
- 25
- 61
- 13
- 28
- 5
- 14
0
- 9
0
- 36
0
- 90
+ 7
- 2
+ 10
+ 1
+ 15
+ 6
+ 19
+ 10
+ 24
+ 15
+ 28
+ 19
+ 32
+ 23
> 10 to 18
- 32
- 50
- 32
- 59
- 32
- 75
- 16
- 34
- 6
- 17
0
- 11
0
- 43
0
- 110
+ 8
- 3
+ 12
+ 1
+ 18
+ 7
+ 23
+ 12
+ 29
+ 18
+ 34
+ 23
+ 39
+ 28
> 18 to 30
- 40
- 61
- 40
- 73
- 40
- 92
- 20
- 41
- 7
- 20
0
- 13
0
- 52
0
- 130
+ 9
- 4
+ 15
+ 2
+ 21
+ 8
+ 28
+ 15
+ 35
+ 22
+ 41
+ 28
+ 48
+ 35
> 30 to 50
- 50
- 75
- 50
- 89
- 50
- 112
- 25
- 50
- 9
- 25
0
- 16
0
- 62
0
- 160
+ 11
- 5
+ 18
+ 2
+ 25
+ 9
+ 33
+ 17
+ 42
+ 26
+ 50
+ 34
+ 59
+ 43
> 50 to 65
+ 60
+ 41
+ 72
+ 53
> 65 to 80
- 60
- 90
- 60
- 106
- 60
- 134
- 30
- 60
- 10
- 29
0
- 19
0
- 74
0
- 190
+ 12
- 7
+ 21
+ 2
+ 30
+ 11
+ 39
+ 20
+ 51
+ 32
+ 62
+ 43
+ 78
+ 59
> 80 to 100
+ 73
+ 51
+ 93
+ 71
> 100 to 120
- 72
- 107
- 72
- 126
- 72
- 159
- 36
- 71
- 12
- 34
0
- 22
0
- 87
0
- 220
+ 13
- 9
+ 25
+ 3
+ 35
+ 13
+ 45
+ 23
+ 59
+ 37
+ 76
+ 54
+ 101
+ 79
> 120 to 140
+ 88
+ 63
+ 117
+ 92
> 140 to 160
+ 90
+ 65
+ 125
+ 100
> 160 to 180
- 85
- 125
- 85
- 148
- 85
- 185
- 43
- 83
- 14
- 39
0
- 25
0
- 100
0
- 250
+ 14
- 11
+ 28
+ 3
+ 40
+ 15
+ 52
+ 27
+ 68
+ 43
+ 93
+ 68
+ 133
+ 108
> 180 to 200
+ 106
+ 77
+ 151
+ 122
> 200 to 225
+ 109
+ 80
+ 159
+ 130
> 225 to 250
- 100
- 146
- 100
- 172
- 100
- 215
- 50
- 96
- 15
- 44
0
- 29
0
- 115
0
- 290
+ 16
- 13
+ 33
+ 4
+ 46
+ 17
+ 60
+ 31
+ 79
+ 50
+ 113
+ 84
+ 169
+ 140
> 250 to 280
+ 126
+ 94
+ 190
+ 158
> 280 to 315
- 110
- 162
- 110
- 191
- 110
- 240
- 56
- 108
- 17
- 49
0
- 32
0
- 130
0
- 320
+ 16
- 16
+ 36
+ 4
+ 52
+ 20
+ 66
+ 34
+ 88
+ 56
+ 130
+ 98
+ 202
+ 170
> 315 to 355
+ 144
+ 108
+ 226
+ 190
> 355 to 400
- 125
- 182
- 125
- 214
- 125
- 265
- 62
- 119
- 18
- 54
0
- 36
0
- 140
0
- 360
+ 18
- 18
+ 40
+ 4
+ 57
+ 21
+ 73
+ 37
+ 98
+ 62
+ 150
+ 114
+ 244
+ 208
> 400 to 450
+ 166
+ 126
+ 272
+ 232
> 450 to 500
- 135
- 198
- 135
- 232
- 135
- 290
- 68
- 131
- 20
- 60
0
- 40
0
- 155
0
- 400
+ 20
- 20
+ 45
+ 5
+ 63
+ 23
+ 80
+ 40
+ 108
+ 68
+ 172
+ 132
+ 292
+ 252
> 500 to 560
+ 194
+ 150
+ 324
+ 280
> 560 to 630
- 145
- 215
- 145
- 255
- 145
- 320
- 76
- 146
- 22
- 66
0
- 44
0
- 175
0
- 440
+ 22
- 22
+ 44
0
+ 70
+ 26
+ 88
+ 44
+ 122
+ 78
+ 199
+ 155
+ 354
+ 310
> 630 to 710
+ 225
+ 175
+ 390
+ 340
> 710 to 800
- 160
- 240
- 160
- 285
- 160
- 360
- 80
- 160
- 24
- 74
0
- 50
0
- 200
0
- 500
+ 25
- 25
+ 50
0
+ 80
+ 30
+ 100
+ 50
+ 138
+ 88
+ 235
+ 185
+ 430
+ 380
> 800 to 900
+ 266
+ 210
+ 486
+ 430
> 900 to 1000
- 170
- 260
- 170
- 310
- 170
- 400
- 86
- 176
- 26
- 82
0
- 56
0
- 230
0
- 560
+ 28
- 28
+ 56
0
+ 90
+ 34
+ 112
+ 56
+ 156
+ 100
+ 276
+ 220
+ 526
+ 470
> 1000 to 1120
+ 316
+ 250
+ 586
+ 520
> 1120 to 1250
- 195
- 300
- 195
- 360
- 195
- 455
- 98
- 203
- 28
- 94
0
- 66
0
- 260
0
- 660
+ 33
- 33
+ 66
0
+ 106
+ 40
+ 132
+ 66
+ 186
+ 120
+ 326
+ 260
+ 646
+ 580
> 1250 to 1400
+ 378
+ 300
+ 718
+ 640
> 1400 to 1600
- 220
- 345
- 220
- 415
- 220
- 530
- 110
- 235
- 30
- 108
0
- 78
0
- 310
0
- 780
+ 39
- 39
+ 78
0
+ 126
+ 48
+ 156
+ 78
+ 218
+ 140
+ 408
+ 330
+ 798
+ 720
> 1600 to 1800
+ 462
+ 370
+ 912
+ 820
> 1800 to 2000
- 240
- 390
- 240
- 470
- 240
- 610
- 120
- 270
- 32
- 124
0
- 92
0
- 370
0
- 920
+ 46
- 46
+ 92
0
+ 150
+ 58
+ 184
+ 92
+ 262
+ 170
+ 492
+ 400
+1012
+ 920
> 2000 to 2240
+ 550
+ 440
+1110
+1000
> 2240 to 2500
- 260
- 435
- 260
- 540
- 260
- 700
- 130
- 305
- 34
- 144
0
- 110
0
- 440
0
-1100
+ 55
- 55
+ 110
0
+ 178
+ 68
+ 220
+ 110
+ 305
+ 195
+ 570
+ 460
+1210
+1100
> 2500 to 2800
+ 685
+ 550
+1385
+1250
> 2800 to 3150
- 290
- 500
- 290
- 620
- 290
- 830
- 145
- 355
- 38
- 173
0
- 135
0
- 540
0
-1350
+ 67
- 67
+ 135
0
+ 211
+ 76
+ 270
+ 135
+ 375
+ 240
+ 715
+ 580
+1535
+1400
Tolerance zones for nominal dimension range above 3150 mm are subject to DIN 7172 (see page 17).




1)
above nominal dimension range 500: js6 or JS7
Page 16
SN 200 Page 5 : 2003-09
6.6 Limit deviations for holes (nominal dimension range up to 3150 mm)
Table 21 Tolerance zones for inside dim. of holes as in DIN ISO 286-2 (SMS Demag selection). Deviations in terms of m
Nominal
dimension range
mm
D7 D10 E9 F7 F8 G7 G8 H7 H8 H9 H12 H13 J7/JS7
1)
K7 M7 P9
> 1 to 3
+ 30
+ 20
+ 60
+ 20
+ 39
+ 14
+ 16
+ 6
+ 20
+ 6
+ 12
+ 2
+ 16
+ 2
+ 10
0
+ 14
0
+ 25
0
+ 100
0
+ 140
0
+ 4
- 6
0
- 10
- 2
- 12
- 6
- 31
> 3 to 6
+ 42
+ 30
+ 78
+ 30
+ 50
+ 20
+ 22
+ 10
+ 28
+ 10
+ 16
+ 4
+ 22
+ 4
+ 12
0
+ 18
0
+ 30
0
+ 120
0
+ 180
0
+ 6
- 6
+ 3
- 9
0
- 12
- 12
- 42
> 6 to 10
+ 55
+ 40
+ 98
+ 40
+ 61
+ 25
+ 28
+ 13
+ 35
+ 13
+ 20
+ 5
+ 27
+ 5
+ 15
0
+ 22
0
+ 36
0
+ 150
0
+ 220
0
+ 8
- 7
+ 5
- 10
0
- 15
- 15
- 51
> 10 to 18
+ 68
+ 50
+ 120
+ 50
+ 75
+ 32
+ 34
+ 16
+ 43
+ 16
+ 24
+ 6
+ 33
+ 6
+ 18
0
+ 27
0
+ 43
0
+ 180
0
+ 270
0
+ 10
- 8
+ 6
- 12
0
- 18
- 18
- 61
> 18 to 30
+ 86
+ 65
+ 149
+ 65
+ 92
+ 40
+ 41
+ 20
+ 53
+ 20
+ 28
+ 7
+ 40
+ 7
+ 21
0
+ 33
0
+ 52
0
+ 210
0
+ 330
0
+ 12
- 9
+ 6
- 15
0
- 21
- 22
- 74
> 30 to 50
+ 105
+ 80
+ 180
+ 80
+ 112
+ 50
+ 50
+ 25
+ 64
+ 25
+ 34
+ 9
+ 48
+ 9
+ 25
0
+ 39
0
+ 62
0
+ 250
0
+ 390
0
+ 14
- 11
+ 7
- 18
0
- 25
- 26
- 88
> 50 to 65
> 65 to 80
+ 130
+ 100
+ 220
+ 100
+ 134
+ 60
+ 60
+ 30
+ 76
+ 30
+ 40
+ 10
+ 56
+ 10
+ 30
0
+ 46
0
+ 74
0
+ 300
0
+ 460
0
+ 18
- 12
+ 9
- 21
0
- 30
- 32
- 106
> 80 to 100
> 100 to 120
+ 155
+ 120
+ 260
+ 120
+ 159
+ 72
+ 71
+ 36
+ 90
+ 36
+ 47
+ 12
+ 66
+ 12
+ 35
0
+ 54
0
+ 87
0
+ 350
0
+ 540
0
+ 22
- 13
+ 10
- 25
0
- 35
- 37
- 124
> 120 to 140
> 140 to 160
> 160 to 180
+ 185
+ 145
+ 305
+ 145
+ 185
+ 85
+ 83
+ 43
+ 106
+ 43
+ 54
+ 14
+ 77
+ 14
+ 40
0
+ 63
0
+ 100
0
+ 400
0
+ 630
0
+ 26
- 14
+ 12
- 28
0
- 40
- 43
- 143
> 180 to 200
> 200 to 225
> 225 to 250
+ 216
+ 170
+ 355
+ 170
+ 215
+ 100
+ 96
+ 50
+ 122
+ 50
+ 61
+ 15
+ 87
+ 15
+ 46
0
+ 72
0
+ 115
0
+ 460
0
+ 720
0
+ 30
- 16
+ 13
- 33
0
- 46
- 50
- 165
> 250 to 280
> 280 to 315
+ 242
+ 190
+ 400
+ 190
+ 240
+ 110
+ 108
+ 56
+ 137
+ 56
+ 69
+ 17
+ 98
+ 17
+ 52
0
+ 81
0
+ 130
0
+ 520
0
+ 810
0
+ 36
- 16
+ 16
- 36
0
- 52
- 56
- 186
> 315 to 355
> 355 to 400
+ 267
+ 210
+ 440
+ 210
+ 265
+ 125
+ 119
+ 62
+ 151
+ 62
+ 75
+ 18
+ 107
+ 18
+ 57
0
+ 89
0
+ 140
0
+ 570
0
+ 890
0
+ 39
- 18
+ 17
- 40
0
- 57
- 62
- 202
> 400 to 450
> 450 to 500
+ 293
+ 230
+ 480
+ 230
+ 290
+ 135
+ 131
+ 68
+ 165
+ 68
+ 83
+ 20
+ 117
+ 20
+ 63
0
+ 97
0
+ 155
0
+ 630
0
+ 970
0
+ 43
- 20
+ 18
- 45
0
- 63
- 68
- 223
> 500 to 560
> 560 to 630
+ 330
+ 260
+ 540
+ 260
+ 320
+ 145
+ 146
+ 76
+ 186
+ 76
+ 92
+ 22
+ 132
+ 22
+ 70
0
+ 110
0
+ 175
0
+ 700
0
+1100
0
+ 35
- 35
0
- 70
- 26
- 96
- 78
- 253
> 630 to 710
> 710 to 800
+ 370
+ 290
+ 610
+ 290
+ 360
+ 160
+ 160
+ 80
+ 205
+ 80
+ 104
+ 24
+ 149
+ 24
+ 80
0
+ 125
0
+ 200
0
+ 800
0
+1250
0
+ 40
- 40
0
- 80
- 30
- 110
- 88
- 288
> 800 to 900
> 900 to 1000
+ 410
+ 320
+ 680
+ 320
+ 400
+ 170
+ 176
+ 86
+ 226
+ 86
+ 116
+ 26
+ 166
+ 26
+ 90
0
+ 140
0
+ 230
0
+ 900
0
+1400
0
+ 45
- 45
0
- 90
- 34
- 124
- 100
- 330
> 1000 to 1120
> 1120 to 1250
+ 455
+ 350
+ 770
+ 350
+ 455
+ 195
+ 203
+ 98
+ 263
+ 98
+ 133
+ 28
+ 193
+ 28
+ 105
0
+ 165
0
+ 260
0
+1050
0
+1650
0
+ 52
- 52
0
- 105
- 40
- 145
- 120
- 380
> 1250 to 1400
> 1400 to 1600
+ 515
+ 390
+ 890
+ 390
+ 530
+ 220
+ 235
+ 110
+ 305
+ 110
+ 155
+ 30
+ 225
+ 30
+ 125
0
+ 195
0
+ 310
0
+1250
0
+1950
0
+ 62
- 62
0
- 125
- 48
- 173
- 140
- 450
> 1600 to 1800
> 1800 to 2000
+ 580
+ 430
+ 1030
+ 430
+ 610
+ 240
+ 270
+ 120
+ 350
+ 120
+ 182
+ 32
+ 262
+ 32
+ 150
0
+ 230
0
+ 370
0
+1500
0
+2300
0
+ 75
- 75
0
- 150
- 58
- 208
- 170
- 540
> 2000 to 2240
> 2240 to 2500
+ 655
+ 480
+ 1180
+ 480
+ 700
+ 260
+ 305
+ 130
+ 410
+ 130
+ 209
+ 34
+ 314
+ 34
+ 175
0
+ 280
0
+ 440
0
+1750
0
+2800
0
+ 87
- 87
0
- 175
- 68
- 243
- 195
- 635
> 2500 to 2800
> 2800 to 3150
+ 730
+ 520
+ 1380
+ 520
+ 830
+ 290
+ 355
+ 145
+ 475
+ 145
+ 248
+ 38
+ 368
+ 38
+ 210
0
+ 330
0
+ 540
0
+2100
0
+3300
0
+ 105
- 105
0
- 210
- 76
- 286
- 240
- 780
Tolerance zones for nominal dimension range above 3150 mm are subject to DIN 7172 (see page 17).




1)
above nominal dimension range 500: js6 or JS7
Page 17
SN 200 Part 5 : 2003-09

6.7 Limit deviations for shafts (nominal dimension range from 3150 mm to 10,000 mm)
Table 22 Tolerance zones for outside dim. of shafts as in DIN 7172 (SMS Demag selection). Deviations in terms of m
Nominal dimension
range
mm
e7 e8 e9 f7 g6 h6 h9 h11 js6 k6 m6 n6 p6
> 3150 to 4000
- 320
- 580
- 320
- 730
- 320
- 980
- 160
- 420
- 40
- 205
0
- 165
0
- 660
0
-1650
+ 83
- 83
+ 165
0
+ 263
+ 98
+ 330
+ 165
+ 455
+ 290
> 4000 to 5000
- 350
- 670
- 350
- 850
- 350
-1150
- 175
- 495
- 43
- 243
0
- 200
0
- 800
0
-2000
+ 100
- 100
+ 200
0
+ 320
+ 120
+ 400
+ 200
+ 560
+ 360
> 5000 to 6300
- 380
- 780
- 380
-1000
- 380
-1360
- 190
- 590
- 47
- 297
0
- 250
0
- 980
0
-2500
+ 125
- 125
+ 250
0
+ 395
+ 145
+ 500
+ 250
+ 690
+ 440
> 6300 to 8000
- 420
- 910
- 420
-1180
- 420
-1620
- 210
- 700
- 51
- 361
0
- 310
0
-1200
0
-3100
+ 155
- 155
+ 310
0
+ 495
+ 185
+ 610
+ 300
+ 850
+ 540
> 8000 to 10000
- 460
-1060
- 460
-1400
- 460
-1960
- 230
- 830
- 55
- 435
0
- 380
0
-1500
0
-3800
+ 190
- 190
+ 380
0
+ 610
+ 230
+ 760
+ 380
+1060
+ 680


6.8 Limit deviations for holes (nominal dimension range from 3150 mm to 10,000 mm)
Table 23 Tolerance zones for inside dim. of holes as in DIN 7172 (SMS Demag selection). Deviations in terms of m
Nominal dimension
range
mm
D7 D10 E9 F7 F8 G7 H7 H8 H9 H12 H13 JS7 K7 M7
> 3150 to 4000
+ 840
+ 580
+1630
+ 580
+ 980
+ 320
+ 420
+ 160
+ 570
+ 160
+ 300
+ 40
+ 260
0
+ 410
0
+ 660
0
+2600
0
+4100
0
+ 130
- 130
0
- 260
- 98
- 358
> 4000 to 5000
+ 960
+ 640
+1940
+ 640
+1150
+ 350
+ 495
+ 175
+ 675
+ 175
+ 363
+ 43
+ 320
0
+ 500
0
+ 800
0
+3200
0
+5000
0
+ 160
- 160
0
- 320
- 120
- 440
> 5000 to 6300
+1120
+ 720
+2320
+ 720
+1360
+ 380
+ 590
+ 190
+ 810
+ 190
+ 447
+ 47
+ 400
0
+ 620
0
+ 980
0
+4000
0
+6200
0
+ 200
- 200
0
- 400
- 145
- 545
> 6300 to 8000
+1290
+ 800
+2750
+ 800
+1620
+ 420
+ 700
+ 210
+ 970
+ 210
+ 541
+ 51
+ 490
0
+ 760
0
+1200
0
+4900
0
+7600
0
+ 245
- 245
0
- 490
- 185
- 675
> 8000 to 10000
+1480
+ 880
+3280
+ 880
+1960
+ 460
+ 830
+ 230
+1170
+ 230
+ 655
+ 55
+ 600
0
+ 940
0
+1500
0
+6000
0
+9400
0
+ 300
- 300
0
- 600
- 230
- 830


Referenced standards
DIN 76 Run out and undercut for metric ISO threads according to DIN 13
DIN 7167 Relationship between dimensional tolerances and form and parallelism tolerances; Envelope principle
without drawing indication
DIN 7168 General tolerances of linear and angular dimensions and general geometrical tolerances
DIN 7172 Tolerances and limit deviations for sizes above 3150 up to 10 000 mm; principles, standard tolerances,
limit deviations
DIN EN 10204 Types of inspection documents
DIN EN ISO 1302 Geometrical Product Specifications (GPS); Indication of surface texture in technical product
documentation
DIN EN ISO 11562 Surface texture: Profile method, metrological characteristics of phase correct filters
DIN ISO 286-1 ISO system of limits and fits; Bases of tolerances, deviations and fits
DIN ISO 286-2 ISO system of limits and fits; Tables of standard tolerance grades and limit deviations for holes and
shafts
DIN ISO 1101 Technical drawings; Geometrical tolerancing; tolerances of form, orientation, location and runout
DIN ISO 2768-1 General tolerances; Tolerances for linear and angular dimensions without individual tolerance
indications
DIN ISO 2768-2 General tolerances; Geometrical tolerances for features without individual tolerances indications
DIN ISO 8015 Technical drawings; Fundamental tolerancing principle
DIN ISO 10012-1 Quality assurance requirements for measuring equipment; Metrological confirmation system for
measuring equipment
DIN ISO 13715 Edges of undefined shape; Vocabulary and indications
DIN EN ISO 9001 Quality management systems; Requirements



September 2003

Manufacturing instructions

ASSEMBLING
SN 200
Part 6

Dimensions in mm
Field of application
The manufacturing instructions laid down in this standard apply to all components to be assembled and assembled units, unless
otherwise specified in drawings or other manufacturing documentation.

Assembling is the permanent connecting or other joining of two or more workpieces of geometrically defined shape, it includes all
handling and auxiliary procedures inclusive of measuring and inspection.
Table of contents Page
1 Safety instruction................................................................................................................................................................... 1
2 Preparation............................................................................................................................................................................... 1
3 Execution.................................................................................................................................................................................. 2
3.1 Assembling of machines........................................................................................................................................................ 2
3.1.1 Tolerances of shape and position for assembled equipment components .......................................................................... 2
3.1.2 Permissible loads on screws of strength category 8.8 .......................................................................................................... 3
3.2 Assembling of pipe lines ........................................................................................................................................................ 3
3.2.1 Locations of pipelines and piping components ..................................................................................................................... 3
3.2.2 General tolerances for pipelines ............................................................................................................................................ 3
3.2.3 Assembling of pipe couplings and flanges ............................................................................................................................ 4
3.2.4 Sealing of pipe couplings and threaded fittings..................................................................................................................... 4
3.2.5 Arrangement of fastening elements....................................................................................................................................... 4
3.2.6 Cleanliness of pipelines and fluid-carrying components........................................................................................................ 4
3.2.7 Positions of screw holes ........................................................................................................................................................ 4
3.2.8 Connection bores................................................................................................................................................................... 5
4 Inspection................................................................................................................................................................................. 5

Referenced standards................................................................................................................................................................ 5


1 Safety instruction
- The data and safety sheets relating to all chemical substances used (glues, lubricants, sealing agents etc) must be
available and the instructions given must be followed. The data and safety sheets shall be included in the supply to SMS
Demag.
- The use of asbestos and substances containing asbestos is always prohibited.
- Pipe couplings and flanged elements for oxygen pipelines must be absolutely free of grease.
- Couplings requiring introduction of heat (flame) for disconnecting must not be used on pipelines which carry inflammable
fluids.


2 Preparation
- All parts shall be deburred (free from burrs acc. to DIN ISO 13715) and cleaned, all surfaces shall be properly dressed before
assembling.
- Holes used for the feeding of fluids should be illuminated and checked for correct passage (for example with compressed air).
- Assembling of parts shall take place on a base surface that corresponds to the later supporting surface and complies with the
accuracy necessary for the inspections to be performed. The static and dynamic loads shall be taken into account in the
process.
- Assembling of the components shall take place only upon inspection of the individual parts, complete inspection records of all
individual parts shall have been submitted.



Continued on pages 2 to 5

T
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i
s

c
o
p
y

w
i
l
l

n
o
t

b
e

u
p
d
a
t
e
d

i
n

c
a
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e

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f

c
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a
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e
s
!

Page 2
SN 200 Part 6 : 2003-09

3 Execution
3.1 Assembling of machines
- For assembling (e.g. of wear plates, couplings, bushings etc.) the bonding, lubricating and sealing instructions given by the
makers shall be observed.
- When shrink fitting or removing bearings, couplings and other parts, the installation instructions given by the makers and the
maximum permissible heating and undercooling temperatures must be observed (in particular for quenched and tempered and
for hardened gear wheels).
- Areas that are no more accessible after assembling shall be provided with priming and top coats before assembling.
(see Part 7)
- Grease bearing points and grease lines shall be delivered with initial fill.
- Required setting of fitting clearances and contact patterns shall be followed.
- For assembled parts and machined surfaces max. surface contact percentage shall be achieved.
- Prior to assembling, all exposed worked contact faces, with the exception of shrink connections, shall be provided with anti-
corrosion compound Tectyl 511-M or equivalent products.
- All components which require lubrication shall be provided with sufficient quantities of one of the lubricants standardised in
SN 180.
- Tightening torques indicated in drawings must also be observed when partial assembling takes place for the purpose of final
machining.
- Standard securing of screwed connections is with Loctite 243 (SN 507). Drawing indication is not required.
- Dismantling shall be only to the necessary extent, screws and shims shall be left on the equipment provided this does not cause
shipping problems.
- Prior to disassembling, parts likely to be mixed up (e.g. pipe supports, split covers, split housings) shall additionally be provided
with permanent and well visible marking using steel stamping letters/figures.
- If movements are effected by means of hydraulic power package, the required purity of the hydraulic fluid shall be ensured, but
at least degree of purity 17/13 acc. to ISO 4406.



3.1.1 Tolerances of shape and position for assembled equipment components
These tolerances are referred to the respective overall lengths of the parts.


Table 1 Tolerances of shape and position
Tolerance class Feature

very fine (sf) fine (f) medium
(m)
coarse (g)
Straightness 0,05 0,1 0,2 0,5
Flatness 0,05 0,1 0,2 0,5
Parallelism 0,03 0,1 0,2 0,5
Perpendicularity 0,05 0,1 0,2 0,5
Inclination 0,03 0,1 0,2 0,5
Level surface 0,05 0,1 0,2 0,5
Vertical line 0,05 0,1 0,2 0,5
Axial alignment 0,03 0,1 0,2 0,5

SMS Demag standard use is tolerance class medium. Deviations are indicated in the associated drawings or testing schedules.





Page 3
SN 200 Part 6 : 2003-09

3.1.2 Permissible loads on screws of strength category 8.8

Table 2 Permissible screw loads
Screw size
Stressed
cross-section
Tightening method
Turning Stretching
Pretensioning force

Tightening torque Pretensioning force

d1 P
As
[mm]
2
FV [kN] [Nm] FV [kN]
M 6 1 20,1 7 7 -
M 8 1,25 36,6 13 18 -
M 10 1,5 58 20 35 -
M 12 1,75 84,3 29 61 -
M 16 2 157 55 149 -
M 20 2,5 245 86 290 -
M 24 3 353 124 500 158
M 30 3,5 561 199 1004 251
M 36 4 817 291 1749 366
M 42 4,5 1121 401 2806 502
M 48 5 1473 529 4236 660
M 56 5,5 2030 732 6791 909
M 64 6 2676 969 10147 1199
M 72x6 3463 1265 14689 1551
M 80x6 4344 1597 20368 1946
M 90x6 5590 2069 29492 2504
M 100 x 6 7000 2605 41122 3136
M 125 x 6 11800 4205 80284 5018
M 140 x 6 14200 5352 113326 6362
M 160 x 6 18700 7073 171027 8378


When other screw materials are used, the factors below are used for converting pretensioning forces and tightening torques:
Screw material: 5.6 = 0,47; 10.9 = 1,41; 12.9 = 1,69; A 2-70 = 0,71; A 2-8 = 0,94.

3.2 Assembling of pipe lines
3.2.1 Locations of pipelines and piping components
The locations of pipelines, piping components and pipe supports is shown in drawings. Deviations are allowed only in coordination
with the design department.
When pipework is not fully dimensioned and must be fitted on site, the manufacturing department must take into account the
following:
- functional laying of pipework acc. to general arrangement, pipework or P & l diagram;
- functional installation of fittings taking their accessibility into account;
- appropriate pipework routing for ease of assembling and disassembling.


3.2.2 General tolerances for pipelines
For pipework which is not fully dimensioned and freely laid, ensuring of proper functioning has priority. All untoleranced
dimensions are subject to accuracy classes C and F acc. to Tables 3 to 5 in DIN EN ISO 13920.
For fully dimensioned pipework (e.g. pipe detail drawings, isometric drawings), accuracy classes B and F according to Tables 3
to 5 in DIN EN ISO 13920 apply to all untoleranced dimensions.

Table 3 Linear dimensions (outside, inside and stepped dimensions)
Nominal dimension range
Tolerance
class
2
to
30
> 30
to
120
> 120
to
400
> 400
to
1000
>
1000
to
2000
>
2000
to
4000
>
4000
to
8000
>
8000
to
12000
>
12000
to
16000
>
16000
to
20000
>
20000


B 1 2 2 3 4 6 8 10 12 14 16
C 1 3 4 6 8 11 14 18 21 24 27





Page 4
SN 200 Part 6 : 2003-09

Table 4 Angular dimensions
Nominal dimension range
(length of shorter leg)
Permissible deviations in degrees and minutes Permissible deviations in terms of tangent values
Tolerance
class

to 400
> 400
to 1000
> 1000
to 400
> 400
to 1000
> 1000

B 45' 30' 20' 0,013 0,009 0,006
C 1 45' 30' 0,018 0,013 0,009


Table 5 Straightness, flatness and parallelism tolerances
Nominal dimension range (length of longer side of surface)
Tolerance
class
> 30
to
120
> 120
to
400
> 400
to
1000
> 1000
to
2000
> 2000
to
4000
> 4000
to
8000
> 8000
to
12000
> 12000
to
16000
> 16000
to
20000
> 20000


F 1 1,5 3 4,5 6 8 10 12 14 16


3.2.3 Assembling of pipe couplings and flanges
When assembling pipe couplings, cleanliness and greasing of the thread shall be ensured and assembling instructions of the suppliers
followed.
In the case of pipe couplings in stainless steel the threads and contact surfaces of the union nuts on the welding cones shall be
sufficiently lubricated with lubricant (for example "Gleitmo 805" of Messrs. Gleitmolybdn or other lubricants approved by SMS
Demag) to avoid seizing of the couplings.

When flanges made of two different materials are used, the parts remaining on the pipe (flanges and welding collar) must always be
made of equivalent pipe material for reasons of pickling. All piping components (such as split flanges etc.) which can be removed
before pickling can be made of surface-treated (galvanized, chromalised or nickel-plated) steel.


3.2.4 Sealing of pipe couplings and threaded fittings
When use is made of male stud couplings with front-side elastic seal, no additional sealing agents shall be applied.
In exceptional cases couplings and threaded fittings without front-side elastic seal shall be sealed in the low-pressure range <16
bar with Omnifit 50H (Messrs. Henkel), in the high-pressure range > 16 bar with AVX No. 586 (Messrs. Loctite) or equivalent sealing
compounds.
Couplings in grease pipelines shall not be provided with additional sealing compound.
As couplings sealed with AVX can be disconnected only by introduction of heat (flame), this sealing compound shall not be used for
pipelines carrying inflammable fluids.


3.2.5 Arrangement of fastening elements
Unless otherwise specified in drawings, pipework shall be installed in such a way that
the distance between two fastenings does not exceed the value stated in table 6.
Fastenings shall also be installed immediately near detachable connections and
elbows.
Weld-on pipe fasteners are welded on with a fillet weld of a = 0.3 x smallest plate
thickness.
Grease pipelines of outside diameters up to and including 10 mm are fastened with
appropriate pipe clamps on the machine without spacing.


3.2.6 Cleanliness of pipelines and fluid-carrying components
Prior to final assembling, pipework and fluid-carrying components shall be cleaned, i.e. all impurities (dirt, chips, welding spatters,
paint, etc.) which stick to the inside surface must be removed. Then the pipeline shall be closed in such a way that ingress of new
impurities is safely avoided.


3.2.7 Positions of screw holes
Screw holes in pipelines and fittings shall be arranged in such a way that they are symmetrical to the two
main axes and that no holes are located on the axes themselves (refer to DIN 2501-1).









Pipe outside
dia.
Max. distance in m
10 0,6
> 10 38 1,5
> 38 88,9 2,5
> 88,9 3,0

Table 6
Page 5
SN 200 Part 6 : 2003-09



3.2.8 Connection bores
To avoid contamination of control elements, all connection bores (fittings, measuring instruments, cylinder ports, valve block
connections etc.) must be kept appropriately sealed (with disks, caps, adhesive tape etc.) until final assembling. Connecting bores
opened for reasons of assembling/installation shall be closed again immediately upon termination of this activity.


4 Inspection
The scope of inspection/testing of assembled units shall be agreed upon with the SMS Demag Department of Quality Inspection.
(refer to Part 10, Section 2)
The minimum requirements are, as far as applicable and feasible, inspections of
- tolerances of shape and position for assembled units,
- supporting and seating surfaces, connecting and takeover points,
- clearances and contact patterns to be adjusted,
- surface contact percentages (with 0,05 mm feeler gauge),
- movements and travelling distances (with auxiliary drives if necessary),
- cylinder strokes (with suitable hydraulic packages),
- corrosion protection and coat of paint
Manufacturer shall draw up reports of all tests/inspections that have been performed.



Referenced standards
DIN 2501-1 Flanges, mating dimensions
DIN EN ISO 13920 General tolerances for welded constructions
DIN ISO 13715 Technical drawings; edges of undefined shape; vocabulary and indications
ISO 4406 Hydraulic fluids, method for coding the level of contamination by solid particles
SN 180 Lubricant recommendations
SN 403 Permissible bolt loads
SN 507 Metal bonding
September 2003

Manufacturing instructions

PRESERVING
SN 200
Part 7

Dimensions in mm

Field of application
The manufacturing instructions in this part of SN 200 define our standard for corrosion protection of machines, pipes and
pipelines, vessels and structural steel components unless otherwise specified in drawings or other manufacturing
documents. It is recommended passing the coating instructions to the contracting workshop immediately upon starting the
project.




Table of contents Page
1 Principles.................................................................................................................................................................... 2
1.1 Fundamental definitions............................................................................................................................................ 2
1.2 Indication in drawings and other manufacturing documents........................................................................................ 2

2 Surface condition......................................................................................................................................................... 2
2.1 Surface preparation .................................................................................................................................................. 2
2.2 Standard preparation grade of steel surfaces prepared by blasting............................................................................. 2
2.3 Standard preparation grade of steel surfaces prepared by manual derusting .............................................................. 2
2.4 Standard preparation grade of steel surfaces prepared by pickling ............................................................................. 2
2.5 Derusting by blasting ................................................................................................................................................ 2

3 Coating......................................................................................................................................................................... 3
3.1 Prime coat ................................................................................................................................................................ 3
3.1.1 Basic specifications .................................................................................................................................................. 3
3.1.2 Prime coats and their properties................................................................................................................................ 3
3.2 Delivery and intermediate coats ................................................................................................................................ 4
3.2.1 Basic specifications .................................................................................................................................................. 4
3.2.2 Delivery and intermediate coats and their properties .................................................................................................. 4
3.3 Cover coat................................................................................................................................................................ 4
3.3.1 Basic specifications .................................................................................................................................................. 4
3.3.2 Cover coats and their properties................................................................................................................................ 5
3.4 Standard colours for special cover coats.................................................................................................................... 5
3.5 Coating of follow-up and Morgoil spare parts ............................................................................................................. 5
3.6 Emulsion-resistant coating........................................................................................................................................ 5

4 Preservation................................................................................................................................................................. 6
4.1 Basic specifications .................................................................................................................................................. 6
4.2 Preserving agents and their properties ...................................................................................................................... 6

5 Coating and preservation of pipelines, pipes and vessels ......................................................................................... 7
5.1 Pipe lines ................................................................................................................................................................. 7
5.1.1 Pipelines in steel ....................................................................................................................................................... 7
5.1.2 Pipelines in stainless and acid-resistant steel............................................................................................................. 7
5.2 Pipes........................................................................................................................................................................ 8
5.2.1 Steel pipes ............................................................................................................................................................... 8
5.2.2 Pipes in stainless and acid-resistant steel .................................................................................................................. 8
5.3 Pipe fasteners .......................................................................................................................................................... 8
5.3.1 Pipe fasteners in steel ............................................................................................................................................... 8
5.3.2 Pipe fasteners in stainless and acid-resistant steel..................................................................................................... 8
5.4 Vessels .................................................................................................................................................................... 9
5.4.1 Vessels in steel ........................................................................................................................................................ 9
5.4.2 Vessels in stainless and acid-resistant steel .............................................................................................................. 9

6 Inspection..................................................................................................................................................................... 9

Referenced standards................................................................................................................................................... 9


Continued on pages 2 to 9
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Page 2
SN 200 Part 7 : 2003-09

1 Principles

1.1 Fundamental definitions
All surfaces in steel (except high-grade steel) of machine or structural steel elements shall be provided with a coat
of paint. This does not apply to contact surfaces for other components. All other unpainted components in steel (except
high-grade steel) shall be provided with preserving agent.
All colours shall be the glossy type.
All parts which have to remain without coat shall be preserved with Tectyl 502-C or equivalent products after shot-blasting
and/or pickling; drawing indication is required.
Exceptions:
Anchor plates as in SN 227 for casting in concrete are blasted only to remove rolling skin and annealing scale from the
surface. These parts are neither coated nor preserved to achieve better adhesion to the foundation. Indoor storage of
the parts is required to avoid new formation of rust.
All parts in stainless and acid-resistant steels are neither coated nor preserved.
1.2 Indication in drawings and other manufacturing documents
Apart from the basic exceptions described under item 1.1, indications in drawings and other manufacturing documents are
required when deviations from the standard specifications given in Tables 1 to 3, Sections 3.1, 3.2 or 3.3, are required for
functional reasons.
Only the top coating is indicated, for example
- oil-resistant coating: SN 200 Part 7 - 3.3.4.1
- heat-resistant coating: SN 200 Part 7 - 3.3.2.
- no coating, only preservation: SN 200 Part 7 - 4


2 Surface condition
2.1 Surface preparation
All surfaces to be provided with coat or preserving agent shall be cleared of annealing colours, rust, slag, rolling skin, mill
scale, dirt, dust, oil, grease, old paint, cooling lubricants etc.
2.2 Standard preparation grades of steel surfaces prepared by blasting
Preparation grade Sa 2 is required for parts which are subject to normal corrosion attack, in case of very heavy corrosion
attack, when functioning of the machine, e.g. gear unit or vessel, can be hampered by corrosion, preparation grade Sa 3 is
required.
The following conditions are required according to DIN EN ISO 12944-4:
Sa 2 = scale, rust and coats have been removed to such an extent that remainders on the steel surface are visible only
as spots of slight shading due to discolouring of pores.
Sa 3 = scale, rust and coats have been completely removed (viewed without magnification).
2.3 Standard preparation grade of steel surfaces prepared by manual derusting
Preparation grade St 3 is required for machine components which cannot be blasted due to their sizes or weights, for example
mill housings.
The following conditions are required according to DIN EN ISO 12944-4:
St 3 = loose coats or scale have been removed; rust has been removed to such an extent that the steel surface after
subsequent cleaning shows a clear lustre given by the metal itself.
2.4 Standard preparation grade of steel surfaces prepared by pickling
Instead of by blasting and when a pickling tank is available, the surfaces of small parts can be derusted and prepared by
pickling, e.g. in hydrochloric acid bath with subsequent passivation. In this case, preparation grade Be is required.
Requirement as in DIN EN ISO 12944-4:
Be = coating residues, scale and rust shall have been completely removed.
Preparation grade Be corresponds to preparation grade Sa 3.
2.5 Derusting by blasting
To achieve preparation grade Sa 2 or Sa 3, the following metallic chilled-cast blast-cleaning abrasive with sharp-edged
grain is used:
blast-cleaning abrasive ISO 11124 M/CI/G70
When using this type of blast-cleaning abrasive taking into account impact energy and angle, the actual average roughness
must not be markedly higher than the specified average roughness of Ra = 12.5 m.

Page 3
SN 200 Part 7 : 2003-09

3 Coating
3.1 Prime coat
Basic specifications
Upon preparation of the steel substrate, the prime coat shall be applied within 6 hours to prevent new formation of rust.

When surface preparation is made by pickling in a phosphoric acid bath, the prime coat shall be applied only after 48 hours
to avoid chemical change of the prime coat.

This prime coat prevents penetration of cooling lubricants during machining.

Depending on the degree of damage to the primer by finish-machining or welding, the prime coat is either touched up or
newly applied.

The weld seam area shall be cleaned with particular care to remove the alkaline or acid filler metal constituents and to avoid
their destructive effects.

Areas which are not accessible after assembling shall be provided with prime and top coats prior to the final assembling.

Prime coats and their properties
The following prime coats shall be applied:
Table 1

Durability max.
2)

(in months)
Type of prime coat
1)

Standard
preparation
grade
Layer
thickness
(m)
Temp.
max.
(C)
Indoor storage
Outdoor
storage
Note
Drawing
indication
3.1.1SMS Demag standard
All-purpose primer on Pu-alkyd basis with
zinc phosphate (lead- and chromate-
free)
grey appr. RAL 7005
Sa 2
or
Be.
40-50 120 21 9
All machinery and struc-
tural steel components,
pipelines and vessels in
steel. Follow-up and
Morgoil spare parts
No
3.1.2Heat-resistant
Silicate zinc dust primer,
moisture-hardening
grey appr. RAL 7037
Sa 2
or
Be.
70-75 400 24 12
Machines or parts thereof
which are exposed to
elevated temperatures
Yes
Sa 2
or Be.
40-50 150 21 9
Machines or parts thereof
which are exposed to
acid fumes and splashes
3.1.3Acid-resistant
Two-component epoxy-resin primer with
zinc phosphate
reddish brown appr. RAL 3009 It is recommended making vessels in stainless and acid-resistant steel
Yes
3.1.4
3.1.4.1
Oil-resistant
External coat
like 3.1.1 SMS Demag
standard
Sa 2
or
Be.
40-50 120 21 9 All machines No
3.1.4.2 Internal coat
two-component epoxy-resin
primer,
reddish brown appr. RAL 3011
Sa 3
or
Be.
40-50 150 21 9
e.g. gear housings and
gear internals such as
welded gear wheels
Yes







For footnotes see page 6


Page 4
SN 200 Part 7 : 2003-09
3.2 Delivery and intermediate coats
Basic specifications
The delivery coat is required only if the cover coat shall be applied after site installation.
Intermediate coating is required only for machines or machine components which are exposed to acid fumes or splashes.
Drawing indication is necessary.
The intermediate coat is applied upon completion of workshop assembly or functional or acceptance testing, immediately
before application of the final coat.

Delivery and intermediate coats and their properties
The following delivery and intermediate coats shall be applied:
Table 2

Durability max.
2)

(in months)
Types of
delivery and intermediate
coats
Layer
thickness
(m)
Temp.
max.
(C)
Indoor
storage
Outdoor
storage
Note
Drawing
indication
3.2.1Delivery coat
as under 3.1.1 SMS Demag standard,
but olive grey appr. RAL 7002
40-50 120 36 18
Cover coat after site erection. Specifi
cation required through shop order or
interoffice letter.
No
3.2.3Intermediate coat
Two-component epoxy-resin with zinc
phosphate and iron mica reddish brown
appr. RAL 3009
40-50 150 36 18
Machines or parts thereof which are
exposed to acid fumes and splashes
Yes



3.3 Cover coat

Basic specifications
As a rule, the cover coat is applied only upon proper application of the coats stated in Tables 1 and 2 and on completion of
assembling or functional or acceptance testing of the machine.
It shall be ensured that the surfaces to be coated are free of grease, oil, dirt and dust.
Areas which are not accessible after assembling shall be provided with prime and top coats prior to the final assembling.


























For footnotes see page 6

Page 5
SN 200 Part 7 : 2003-09


Cover coats and their properties
The following cover coats shall be applied:
Table 3
Durability max.
2)

(in months)
Type of cover coat
Layer
thickness
(m)
Temp.
max.
(C)
Indoor
storage
Outboard
bearing
assembly
Note
Drawing
indication
3.3.1SMS Demag standard
All-purpose cover coat on alkyd resin
basis (lead and chromate-free
green approx. RAL 6011
3)

40-50 120 36 18
All machines and structural steel
components, pipelines and vessels
in steel.
No
3.3.2Heat-resistant
Silicone bronze varnish
white aluminium appr. RAL 9006
15-20 400 36 18
Machines or parts thereof which are
exposed to elevated temperatures.
Yes
3.3.3Acid-resistant
Two-component epoxy resin
coating compound
green approx. RAL 6011
40-50 150 39 24
Machinery or parts thereof which are
exposed to acid fumes and
splashes.
Yes
3.3.4
3.3.4.1
Oil-resistant
External coat
like 3.3.1 SMS Demag
standard
40-50 120 36 18 All machines No
3.3.4.2
Internal coat
Two-component epoxy resin
coating compound
ivory RAL 1014
40-50 150 36 18
e.g. gear housings and gear
internals such as welded gear
wheels.
Yes

3.4 Standard colours for special cover coat
Table 4
Application Colour Drawing indication
Rotating parts in danger zone
DIN 4844 yellow/black marking
RAL 1004 / RAL 9005
Yes
Cover plates (bulb or checker plate) medium black RAL 9005 No
Cover plates (smooth plates )
anti-slip coating, e.g. PUR 120,
crystallite grain 0,2 to 1,2 mm,
standard preparation grade Sa 2
matt black RAL approx. 9005 Yes
SMS Demag logo
- on bright machine cover coats
white RAL 9001
- black RAL 9005
Yes
Railings yellow RAL 1004 No
Bought-out items Standard -
Hydraulic cabinets, servo boxes or other hydraulic
units
with coated interior
white RAL 9001 No

3.5 Coating of follow-up and Morgoil spare parts
Follow-up spare parts are spare parts which are not part of the original equipment delivery.
As a rule, follow-up and Morgoil spare parts are provided only with standard base coating as specified under 3.1.1. Parts in
baremetal condition and machined surfaces are provided with preservation as under 1.1.
If customer requests deviate from the above, consultation with our specialist department AEW is required.

3.6 Emulsion-resistant coating
Data on prime and cover coats and their properties with regard to emulsion resistance depend on the respective emulsion.
Generally valid specifications cannot be given in this respect, the situation has to be examined and specifications given from
case to case. Drawing indication is required.





For footnotes see page 6

Page 6
SN 200 Part 7 : 2003-09

4 Preservation
Basic specifications
Preserving of surfaces not provided with prime, delivery or top coats takes place after applying the final coat upon termination
of assembling or functional/acceptance testing of the machine.
It shall be ensured that the surfaces to be covered with preserving agent are free of grease, oil, dust and film rust.

To avoid rust formation under the coat, preservative shall be applied only on absolutely dry surfaces.


Preserving agents and their properties

Preserving agents shall be used as specified in Table 5.

Table 5

Durability max.
2)

(in months)
Type of preservation
Standard
4)
preparation
grade
Layer
thickness
(m)
Indoor
storage
Outdoor
storage
Note
Drawing
indi-
cation
4.1 Preservation of external
surfaces
Tectyl 846
Sa 3 50 36 12
Metallically bright surfaces, can
be removed with solvent.
No
4.2
4.2.1
Preservation of
internal surfaces
Tectyl 502 C
Sa 3 40 24 3
Metallically bright surfaces, gear
internals. Dissolves during test
run.
4.2.2 Tectyl 511 M Sa 3 15 18 -
For intermediate storage and
dispatch within short time
No
4.2.3 Renolin MRX 46 Sa 3 - 24 -
Hydraulic power packages. Test
stand oil for functional testing.
No
4.3 Preservation of Morgoil
bearings
Tectyl 502 - C 95 %
Tectyl 511 - M 5 %
Sa 3
Immersing
70
36 6 Morgoil bearings No





1)
When other prime coats are used, they must be environmentally acceptable, i.e. no use of PVC coatings or primers
containing zinc chromate.

2)
Indoor storage = closed building without temperature control
Outdoor storage = storage under tarpaulin or roof

3)
Other colours, for example grey: RAL 7000, 7031, 7032, green: RAL 6010, 6021, blue: RAL 5010 are at choice, but
shall be specified in drawings or other manufacturing documents.

4)
Indication of Sa 3 for preservation purposes refers to the features of the preparation grades as in DIN EN ISO 12944-4
and not to the associated rust removal method Sa = blast cleaning.



















see SN 200 Part 9

Page 7
SN 200 Part 7 : 2003-09

5 Coating and preservation of pipelines, pipes and vessels
Pipe lines
Pipework means prefabricated lines laid on machinery and consisting of pipes and pipeline components. This includes
pipelines delivered to the site in prefabricated condition. Pipework is used to convey fluid (cooling water, air, oil, etc.) from the
point of provision (e.g. tank) to the point of consumption (e.g. cylinder).
Pipes
Pipes which have not undergone working and are delivered to site by the meter in the as-produced condition for further use to
form connecting conduits.
Vessels
Vessel which holds fluid ready for use and in which, due to operation, operating pressure exists or can be generated
which is 0,1 bar or minus 0,2 bar = pressureless vessel,
or > 0,1 bar or < minus 0,2 bar = pressure vessel.

5.1 Pipe lines

5.1.1 Pipelines in steel
- Pipework consisting of pipes according to DIN 2448 and 2458 are pickled, flushed and then passivated. Pickling resi
dues are removed by blowing off with compressed air. The required preparation grade is Be.
- Pipework consisting of pipes according to DIN 2391 with bite-ring or similar couplings, for example Walform, which do
not undergo welding or heat treatment, is neither pickled nor passivated if supplied with corrosion protection.
- Pipelines must be clean inside.
- External coating is made as specified in 3.1.1, internal coating is not applied.
- The durability period is max. 18 months in case of indoor storage.
- Internal preservation, if required, is made using Tectyl 511-M or equivalent products. Drawing indication or communica
tion through shop order is required. With internal preservation the durability period is max. 36 months in case of indoor
storage.


5.1.2 Pipelines in stainless and acid-resistant steel
- Pipework consisting of pipes according to DIN EN ISO 1127 is pickled, blast-cleaned or brushed to remove scale
layers or annealing colours.

Scale and slag shall be completely removed, annealing colours are acceptable up to colour scale brown.
(Refer to DIN 25410, page 9, Annex A, annealing colours 1 and 2.)
- Pipelines consisting of pipes according to DIN EN ISO 1127 with bite-ring or similar couplings (Walform) which do not
undergo welding or heat treatment remain without post-treatment.
- Pipelines shall be clean inside.
- Coating or preservation is not required.




























Page 8
SN 200 Part 7 : 2003-09


5.2 Pipes

5.2.1 Steel pipes
Treatment and delivery condition of steel pipes as stated in Table 6.
Table 6
Pipes
Treatment/delivery condition
blast-cleaned prime-coated
For the
media
inside outside
pickled,
flushed,
passivated
inside outside
closed with
caps
Water
Steam
Condensate
Gases /
compressed
air
no yes
1)
no no yes
1)
yes

Oil/emulsion
Hydr. fluid
Instrument
air
no no yes
1)
no yes
1)
yes

Oxygen no no yes

no yes

yes
Grease no no yes
1)
no yes
1)
yes



5.2.2 Pipes in stainless and acid-resistant steel

Pipes are supplied pickled or descaled (metallically bright) and delivered to place of use without further treatment. All pipes
are closed with caps.


5.3 Pipe fasteners

5.3.1 Pipe fasteners in steel
Depending upon their size and quality, prefabricated fasteners are pickled or sand-shot blasted to preparation grade Sa 2
and subsequently provided with 40 m base coat as in 3.1.1. The durability period is max. 21 months in case of indoor
storage.

5.3.2 Pipe fasteners in stainless and acid-resistant steel
Prefabricated fasteners which have undergone welding or heat-treatment are either pickled, blast-cleaned or brushed to
remove the scale layers and annealing colours and to ensure formation of the passivation layer.
Scale and slag shall be completely removed, annealing colours are acceptable up to colour scale brown (refer to DIN 25410,
annex A, annealing colours 1 and 2). Coating or preservation is not required.









1)
Not applicable to pipes as in DIN 2391, which remain in the treatment/delivery condition (bright annealed and oiled) in
which they are supplied by the manufacturer.









Page 9
SN 200 Part 7 : 2003-09
5.4 Vessels

5.4.1 Vessels in steel
- Vessels are steel-shot blasted, the required preparation grades are Sa 3 for hydraulic vessels and Sa 2 for centralised
and Morgoil lubrication, water and compressed-air systems.
- Vessels without manhole (small inspection opening) are pickled inside, flushed and passivated; the required preparation
grade is Be.
External coating is carried out as in 3.1.1 SMS Demag standard (universal coating on Pu alkyd basis with zinc phosphate,
free of lead and chromate, grey approx. RAL 7005).
- Internal coating shall be a hygroscopically hardening one or two-component coat or shall be applied with Tectyl 502-C or
equivalent products.

Table 7
Type of preservation
Layer thickness
(m)
Note Drawing indication
Tarponal
40 50
approx. 250 g/m
2 Use for hydraulic systems Yes
Copaphen
Aluminium
2 x 30
approx. 350 g/m
2

Use for centralised and
Morgoil lubrication systems
Yes
Intertol Poxitar
3 x 80
aprox. 1000 g/m
2
Use for water and
compressed-air systems
Yes

- All parts to be installed in vessels shall not be coated, but preserved with Tectyl 502-C or equivalent products.
- Vessels without manhole are swing-rinsed with Inertol.
- Vessels must be clean inside.
- All openings shall be safely closed for transport after surface treatment.
- The durability period is max. 24 months in case of indoor storage.

5.4.2 Vessels in stainless and acid-resistant steel
- Vessels are pickled, blast-cleaned (with quartz sand, glass beads) or brushed to remove scale layers and annealing colours
resulting from welding and to ensure the formation of the passivation layer.
- Scale and slag shall be completely removed, annealing colours are admissible up to colour scale brown; refer to
DIN 25410 (page 9, annex A, annealing colours 1 and 2).
- Vessels must be clean inside.
- Upon surface treatment, all openings shall be safely closed for transport.
- Coating or preservation is not required.

6 Inspection
- All contractors are bound to present the base coat on machines or components to SMS Demag before applying the top
coat.
- We reserve the right to check the compliance with the specified number of paint coats and layer thicknesses as well as
their proper application.
- The paints and related products, preservatives, adhesives and sealing materials used must be certified with safety data
sheets and technical specification.


Referenced standards
DIN 2391-1 Seamless precision steel tubes; dimensions
DIN 2391-2 Seamless precision steel tubes; technical delivery conditions
DIN 2440 Steel tubes; medium-weight suitable for screwing
DIN 2448 on seamless steel tubes; dimensions and conventional masses per unit length
DIN 2458 Plain end welded steel tubes; dimensions and conventional masses per unit length
DIN 4844 Part 1 Safety marking; concepts, principles and safety signs
DIN 25410 Nuclear facilities, surface cleanliness of components
DIN EN ISO 1127 Stainless steel tubes; dimensions, tolerances and conventional masses per unit length
DIN EN ISO 11124-2 Specifications for metallic blast-cleaning abrasives; chilled-iron grit
DIN EN ISO 12944-4 Corrosion protection of steel structures by protective paint systems; Types of surface and surface
preparation
SN 200 Part 9 Manufacturing Instructions; Packaging
SN 227 Part 1 Anchor plates for tee-head bolts, single anchor plates
SN 227 Part 2 Anchor plates for tee-head bolts, double anchor plates
SN 903 Delivery condition of pipes, fittings and pipe supporting material

September 2003

Manufacturing instructions

LABELING
SN 200
Part 8



Field of application
The manufacturing instructions laid down in this part of SN 200 apply to all parts intended for shipment (whether intermediate
or final), unless otherwise specified in drawings or other manufacturing documentation. Labeling is with stick-on labels
which shall be attached by supplier.

Table of contents Page
1 Definitions.................................................................................................................................................................. 1
1.1 Project No. ................................................................................................................................................................ 1
1.2 Identification No. ....................................................................................................................................................... 2
1.3 Designation .............................................................................................................................................................. 2
1.4 Quantity ................................................................................................................................................................... 2
1.5 Shipping unit (VE) ..................................................................................................................................................... 2
1.6 Shipment labels......................................................................................................................................................... 2
1.7 Preliminary package (VP) .......................................................................................................................................... 2
1.8 VP label .................................................................................................................................................................... 2
1.9 Final package............................................................................................................................................................ 2

2 Reporting of shipping units and packages containing SMS Demag designed items............................................... 3
2.1 General..................................................................................................................................................................... 3
2.2 Reporting of shipping units ........................................................................................................................................ 3
2.3 Reporting of package data......................................................................................................................................... 3
2.4 Labeling of shipping units ......................................................................................................................................... 3

3 Reporting of shipping units and packages containing items not designed by SMS Demag.................................... 3

4 Fixing of shipment labels........................................................................................................................................... 4

Examples on item 2.2 ................................................................................................................................................ 5
Examples on item 2.3................................................................................................................................................. 6



1 Definitions
1.1 Project No.
This number is used to subdivide a plant by functional aspects from equipment unit level (machine) to sub-item level.


Project structure Project No.

Equipment AE AB AU AP AUP
Example 54014 100 01 01 01 001

Equipment

Equipment unit

Assembly

Sub-assembly

Item

Sub-item






Continued on pages 2 to 6

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SN 200 Part 8 : 2003-09

1.2 Identification No.
Number which serves to identify parts (e.g. drawing No., material No.).

1.3 Designation
Name of the shipping unit.

1.4 Quantity
Numerical indication of the number of parts contained in the shipping unit.
Piece(s) as unit of quantity is not indicated, other units of quantity (e.g. sets, meters, kg) are expressly stated.

1.5 Shipping unit (VE)
Serial number of a unit of the SMS Demag scope of supply,
for example loose parts of an item or an assembled unit, cardbox with several identical parts.

1.6 Shipment labels
Stick-on label stating the specific data of the shipping unit. The shipment label gives the following information:

Example:






















1.7 Preliminary package (VP)
Package prepared for transport to packaging company. The preliminary package contains one or more shipping units and
shall be labelled with additional VP label.

1.8 VP label
This label is used to label a preliminary package (VP) for its shipment to the packaging company

Example:












Explanations on how to complete the VP label are given in our shipping instructions.


1.9 Final package
Package ready for shipment direct to the customer.


SMS Demag Aktiengesellschaft
PROJ EKT NR.:
PROJ ECT NO.:

IDENT NR.:
IDENT. NO.:

BENENNUNG:
DESIGNATION:

MENGE:
QUANTITY:

VERSANDEINHEIT NR.:
SHIPPING UNIT NO.:
Codeword: Lysteel
Order No.: 72023858
VP No.: BSME-SMS(2)-041 (88945)
Package No.: 88945
Packing type: case
Storage symbol: bay

Page 3
SN 200 Part 8 : 2003-09

2 Reporting of shipping units and packages
containing SMS Demag designed items

2.1 General
Reporting of the shipping units and packages by the supplier shall take place only with the table made available by SMS
Demag, as only this form can be processed by our EDP systems.
The shipment labels which are made available shall be attached to the respective shipping unit.

2.2 Reporting of shipping units
The reporting of the shipping units documents which project item is assigned to which shipping unit.
An example is shown on page 5.


2.3 Reporting of package data
The reporting of the package data documents which shipping units are assigned to which package. These data serve as basis
for drawing up the SMS Demag delivery note.

An example is shown on page 6.



2.4 Labeling of shipping units
The shipment labels made available by SMS Demag shall be attached to the respective shipping unit; they contain the
following information:
The first eight digits of the project No. are indicated when the assembled parts belong to the same equipment unit, but to
different assemblies.
The first ten digits of the project No. are indicated when the assembled parts belong to the same assembly, but to different
subassemblies.
The first twelve digits of the project No. are indicated when the assembled parts belong to the same assembly and the same
subassembly.
The first fourteen digits of the project No. are indicated when the parts belong to the same subassembly and the same item
(component identification).
The seventeen digits of the project No. are indicated when the parts belong to the same item and the same sub-item
(component identification).
Identification No.
Indication of the ident. No. which belongs to the project No.
Designation
Indication of the designation which belongs to the respective project No. and which is taken from the shipment processing
system (VAB).
Quantity
Refer to 1.4
Shipping unit (VE)
Consecutive Nos. of the SMS Demag shipping units.



3 Reporting of shipping units and packages
containing items not designed by SMS Demag

Reporting of the shipping units and packages containing assemblies and equipment units not designed by SMS Demag shall
be made by supplier only with the Excel table made available by SMS Demag as this form can be processed by our EDP
systems.
Further proceeding is as described under item 2. Contrary to the information given, only blank forms are made available as
drawing up the bill of materials is in the responsibility of the supplier. The supplier only reports the content of his packages;
component parts to be supplied shall be designated in detail.

Page 4
SN 200 Part 8 : 2003-09

4 Fixing of shipment labels

The shipment label is sticked on a perforated plastic support. Fastening to the shipping units is with non-rotting pack threads,
with zinc-coated or high-grade steel tying wire or with cable fasteners.

The labels shall not be sticked direct on the shipping units.



Referenced standards
None.


Annexes see pages 5 and 6.













































































Column:

1
2
3
4
5
6
7
7a
8
9
11 Here only the unassembled parts are indicated with their consecutive numbers, assembled units are entered in columns 13 to 19.
12 This column shows the pieces which are shipped loose.
13
14
15
16
17
18 P
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Example on 2.2 Reporting of the shipping units

Purchase order No. 1928888.001 K Reporting of the shipping units

1 2 3 4 5 6 7 7a 8 9 11 12 13 14 15 16 17 18

Project
No.

AB AU AP AUP
Identification
No.
Quantity
Unit of
quantity
Weight
in
kg
English designation
Unassembled
shipping units
Assembled shipping units


No.

Quantity 4
46015239 71 9 4 20405338 1 pieces 208 Caged ladder 1
46015239 71 9 4 1 M9052547 2 meter 72 Tube DIN 2448 48,3x3,6 mm 2
46015239 71 9 4 2 M9722894 31 meter 38 Square DIN 1014 20 31
46015239 71 9 4 3 M9021028 5 meter 17 Flats DIN 1017 50x5 5
46015239 71 9 4 4 M9021028 7 meter 79 Flats DIN 1017 50x5 7
46015239 71 9 4 5 M9040109 2 m 0 Plate EN 10029 5 2
46015239 71 9 5 M9030026 10 meter 27 Angle bar 50x 50x 5 1 10
46015239 71 9 6 20405337 2 pieces 3 Ladder foot 2 2
46015239 71 9 7 46015239710907 4 pieces 0 Upat-UKA3 anchor bolt M16 3 4



These columns are already completed in our form
The numbering of the assembled VE (shipping units) is entered as headings of these columns; below each heading, the quantity of parts assembled in this VE is filled
in.
A
n
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x
e
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Column:
1 Please indicate here the shipping unit number assigned by you to the item in the list of "Report of shipping units".
2 Column not relevant for suppliers.
3
4
5
6
7 These columns need not be filled in, data can be taken from report of shipping units.
8
9
9a
10 Please enter designation of shipping unit in this column. This is of particular importance for assembled units, as their designations may differ from those in our bill of materials.
13 Please enter consecutive package number here.
11 Please indicate packing type of package. (for example, B = bundle, CO = container, EP = Europallet, EW = disposable pallet, FA = barrel, GB = skeleton container
KA = cardbox, KH = timber structure, KI = case, U = unpacked, VS = crate)
15
16 Please enter here the sizes (in cm) and weights (in kg) of your packages.
17
Example on 2.3 Reporting of package data

Purchase order No. 1928888.001 K Reporting of package data

1 2 3 4 5 6 7 8 9 9a 10 13 14 15 16 17
Supplier
VE No.
SMS
Demag
VE No.
Project No. AB AU AP AUP Ident. No. Quantity
Unit of
quantity
English designation
Package
No.
Type
of
packing
Size
(l * w * h)
in cm
NET
weight in
kg

GROSS
weight in kg

1 46015239 71 9 5 M9030026 10 meter Angle bar 1 U 5x220x600 27 27
2 46015239 71 9 6 20405337 2 pieces Ladder foot 2 KA 20x20x2 4 6
3 46015239 71 9 7 M9030025 4 pieces Upat-UKA3 anchor bolt M16 2
4 46015239 71 9 4 20405338 1 pieces Caged ladder 3 U 913x71x68 208 208



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September 2003

Manufacturing instructions

PACKAGING
SN 200
Part 9
Dimensions in mm
Field of application
The manufacturing instructions specified in this part of SN 200 apply to equipment and components shipped on behalf of SMS Demag
unless otherwise specified in drawings or other manufacturing documents.
The packing designs described in these instructions shall be regarded as minimum requirement with special regard to the particular
merchandise structure of SMS Demag.
In specific cases, it may be impossible to comply with these instructions on account of the particular nature of the packages. In such
cases coordination with our Department of Quality Inspection is required and the packing measures to be taken must be of provable
adequacy to the instructions given herein.
The packing categories shall always be selected as required for the nature of the respective equipment, transport type and route and
duration of storage. The examples given refer to packaging of goods for sea transport. The shipping units shall be made up in an
appropriate way, i.e. space-saving, with due regard to a favourable ratio of size to weight.
If necessary, the present instructions will be extended with special, SMS Demag project-specific packaging and labeling instructions.

Table of contents Page
1 Packing categories ................................................................................................................................................................... 2
1.1 Category 1.............................................................................................................................................................................. 2
1.2 Category 2.............................................................................................................................................................................. 2
1.3 Category 3.............................................................................................................................................................................. 2
1.4 Category 4.............................................................................................................................................................................. 2
1.5 Category 5.............................................................................................................................................................................. 2
1.6 Category 6.............................................................................................................................................................................. 2
1.7 Category 7.............................................................................................................................................................................. 2
1.8 Category 8.............................................................................................................................................................................. 2
1.9 Category 9.............................................................................................................................................................................. 2
1.10 Category 10............................................................................................................................................................................ 2
1.11 Category 11............................................................................................................................................................................ 2
1.12 Category 12............................................................................................................................................................................ 2
1.13 Category 13............................................................................................................................................................................ 2
2 Quality and strength of materials............................................................................................................................................ 3
2.1 General................................................................................................................................................................................... 3
2.2 Packings of categories 1 to 8 and 11 to 13 .......................................................................................................................... 3
2.3 Packings of category 9 ......................................................................................................................................................... 3
3 Execution of packages............................................................................................................................................................. 3
3.1 General................................................................................................................................................................................... 3
3.2 Cases of packing categories 1 to 4 and 13........................................................................................................................... 4
3.3 Crates of packing category 5................................................................................................................................................. 4
3.4 Bundles of packing category 6 .............................................................................................................................................. 4
3.5 Sledges of packing category 7 .............................................................................................................................................. 4
3.6 Planking of packing category 8 ............................................................................................................................................. 4
3.7 Dangerous goods packing of packing category 9 ................................................................................................................ 5
3.8 Transport packing of packing category 11............................................................................................................................ 5
3.9 Container packing of packing category 12............................................................................................................................ 5
4 Fixation of goods ...................................................................................................................................................................... 5
4.1 Assumed loads ...................................................................................................................................................................... 5
4.2 Fixation of goods.................................................................................................................................................................... 5
5 Packing....................................................................................................................................................................................... 6
6 Marking....................................................................................................................................................................................... 6
6.1 Elements of marking.............................................................................................................................................................. 6
6.1.1 Inscription............................................................................................................................................................................... 6
6.1.2 Handling marking................................................................................................................................................................... 6
6.2 Execution of marking ............................................................................................................................................................. 6
6.3 Application of marking ........................................................................................................................................................... 7
6.4 Arrangement of marking........................................................................................................................................................ 7
6.5 Permitted storage classes...................................................................................................................................................... 7
6.6 Marking of dangerous goods................................................................................................................................................. 7
7 Inspection................................................................................................................................................................................... 8
Referenced standards, guidelines and ordinances ...........................................................................................................8
Annexes .......................................................................................................................................................................................... 9
Admissible stresses ........................................................................................................................................................................... 9
Construction of bottom...................................................................................................................................................................... 9
Construction of side part, end part and top..................................................................................................................................... 10
Dimensioning of mushroom head bolts........................................................................................................................................... 10
Construction examples .................................................................................................................................................................... 11

Continued on pages 2 to 13
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SN 200 Part 9 : 2003-09

1 Packing categories
1.1 Category 1 Packing in cases with protective jute paper, goods sealed in aluminium compound foil
(BWB TL 8135-0003 or equivalent foil) with addition of appropriate desiccant;
guaranteed durability of 24 months.
Goods corrosion-sensitive mechanical-engineering and electric materials, prefabricated pipe lines
1.2 Category 2 Like 1.1, but packing in double case with padding elements adapted to sensitivity of goods (g-values
to be specified), packing case-in-case.
Goods Highly sensitive electrical and control components.
1.3 Category 3 like 1.1, but sealed in 0.2 mm PE-foil (BWB TL 8135-0019 or equivalent foil);
guaranteed durability of 12 months.
Goods same as 1.1
1.4 Category 4 Like 1.1, without sealing of goods in plastic foils, but with gilled plates in upper section of case.
Goods shock and corrosion resistant units (simple machine components, pins, components for pipe lines such
as welding fittings, threaded fittings)
1.5 Category 5 Crate
Goods components insensitive to corrosion and to the usual mechanical transport effects; all types of vessels.
1.6 Category 6 Bundle
Goods pipes sold by the meter, structures/racks not requiring protection against usual mechanical effects and
combined only for the purpose of forming a loading unit
1.7 Category 7 Sledge
Goods robust corrosion-resistant components whose dimensions exceed the usual loading gauges.
1.8 Category 8 Planking (including cable drums)
Goods Components whose unit weights exceed 30 tonnes and/or exceed the usual loading gauges. Components
are insensitive to corrosion and mechanical influences from transport, only machined surfaces are protected
by planking.
1.9 Category 9 Dangerous goods packing
Goods Dangerous goods as in Dangerous Goods Ordinance Sea transport by sea
Dangerous Goods Ordinance Road and Rail transport by road and rail
IATA-DGR transport by air
1.10 Category 10 Unpacked goods
Goods Components not requiring specific protection during shipment.
1.11 Category 11 Transport packing (without durability guarantee for storage)
Goods Parts destined for intermediate shipment (to subsuppliers, machining workshops, central packers).
These parts shall be protected against climatic and mechanical influences during transport.
1.12 Category 12 Container package, packing on load-bearing transport bottoms, goods seald in aluminium
compound foil (BWB TL 8135-0003 or equivalent foil) with addition of
appropriate desiccant; guaranteed durability of 6 months.
Goods same as 1.1
1.13 Category 13 Tugged packing
Goods Components which are loaded with the loading gear attached to the goods.
Page 3
SN 200 Part 9 : 2003-09

2 Quality and strength of materials
2.1 General
Special requirements as to the type and nature of materials associated with a specific Buyer's Country are defined in the relevant
Consular and Standard Regulations of the Hamburg Chamber of Commerce.

2.2 Instructions applicable to packings of categories 1 to 8 and 11 to 13:
- For load-bearing structural parts only the use of coniferous timber as in DIN 4074 -1 - S 10 TA/FI (pine/fir) dry is
allowed.
- The use of timber as in DIN 4074 1 - S 7 TA/FI (pine/fir) - dry is allowed for non-load-bearing structural elements inside the barrier
sheathing of cases.

Supplements to DIN 4074-1 shall be observed:

Sorting class
S 10
Sorting class
S 7
Max.
rosing galls
l = 5,0 cm
b = 0,5 cm
l = 10 cm
b = 1 cm
Min. specific gravity 0,45 to 0,50 kg/dm
3
0,45 to 0,50 kg/dm
3


The following material can be used for surface planking:
- wood as in DIN 4074-S7-TA/FI - half-dry
- plywood as in DIN 68705-BFU 100, min. thickness 12 mm
- plywood of the types APA RATED SHEATHING and APA RATED STURD-I FLOOR, bonding method EXTERIOR, min. thickness
9 mm (use only for case types 1 to 3, see Table 3)
- boards as in DIN EN 300 OSB3, min. thickness 12 mm (use only for case types 1 to 3, see Table 3)
here it must be noted that only vertical bordering joints are admissible.

2.3 Instructions applicable to packings of category 9:
- Only type-tested cases and containers as in RM 001 are allowed.

3 Execution of packages
3.1 General
For packages exceeding the following dimensions:
Length = 1190 cm
Width = 240 cm
Height = 240 cm
Weight =20,000 kg
Packer shall, upon request, draw up transport/package sketches prior to packaging and hand these over to SMS Demag.
The maximum package dimensions admissible for air freight shall be agreed upon with SMS Demag from case to case.

The following conditions shall also be taken into account:
- Strength values and design features as in DIN 1052 (see Tables 1 and 2)
- Assumed loads, such as drop heights and acceleration during transport, as in strength calculations for wooden packings used in the
shipping of heavy-goods (RGV)
- Diagonal bracing of cleat frames (Page 11 and 12):
Connection: top - side - bottom (Fig. 1)
bottom - side wall (Fig. 2)
top - bottom - side wall (Fig. 3)
- Nailing as in DIN 1052: Nailing of wooden liners (Fig. 5)
- Wood quality categories according to section 2.2
- Nailing of end-grained wood is applied only for fixing of components of a case.
- Cleats are arranged inside the cases.

Page 4
SN 200 Part 9 : 2003-09

3.2 Cases of packing categories 1 to 4 and 13
Cases are assigned to type classes according to the weights to be packed (Table 3).
Details resulting from this classification are shown in Tables 4 to 10.
The cases must be designed in such a way that:
- it has at least two entries for the forklift,
- the cases and crates can be stacked in conventional loading up to a stacking impact pressure of 10 kN/m
2
.
- cases of 3 t and more are provided with heavy-lift corners at the rope sling points and with edge guards at the lids (min. metal
thickness: 3 mm).
- the packages withstand the tying-up forces when reloading,
- handling with hoisting gears and/or industrial trucks is possible.

All end headers shall be bolted up with the longitudinal skids.
Bolt details are shown in table 10. Double-bolting is required for cases of type 5.
When vertical side cleats are used, proof of twofold safety against buckling is required for these cleats. The vertical elements shall be
fixed in their positions.
The side and end faces shall be provided with vertical wooden sheathing.
Case tops shall be sealed against ingress of moisture with appropriate sealing elements at the bottom side of the top. The sealing
element shall be placed between wooden sheathing and cleat frame.
Holes/slots shall be provided in the case bottoms for draining condensation water and moisture. The holes/slots shall be protected
against entry of vermin.
Vertical openings of the package with diameters 500 mm shall be covered with 5 or 6 mm thick plywood panels. These panels shall
be fixed in their positions.

3.3 Crates of packing category 5
Above instructions given for the cases (3.2) equally apply to crates. The bottom of the crate is the load-carrying element and shall
always remain closed. Two thirds of the end, side and top faces shall be provided with wooden sheathing.

3.4 Bundles of packing category 6
A bundle shall be executed in such a way that:
- it has at least two entries for the forklift,
- it withstands the tying-up forces during reloading,
- handling with hoisting gears and/or industrial trucks is possible,
Bundling shall be carried out as follows:
- With square-timber clamps and clamping screws (threaded rods),
- With intermediate layers of wood, plywood or plastic material, dimensioned as required for the weight of the goods and secured
against slipping with clamping screws,
- with suitable screws/bolts whose projecting lengths shall be covered with strips provided with appropriate recesses. The cover strips
shall be fastened with nails.
- The screw connection shall be properly secured.
Instead of in square-timber, the clamps can be in the form of channels.

3.5 Sledges of packing category 7
The sledge must be designed in such a way that:
- it has at least two entries for the forklift,
- the rope sling points are provided with heavy-lift corners when the weight exceeds 3 t,
- it withstands the tying-up forces during reloading,
- handling with hoisting gear and/or industrial trucks is possible.
The sledge structure can be in timber or in steel.
Fastening of the goods is on the sledge and appropriate bands shall be used if direct bolting is not possible.
Length and width of the sledge structure shall not be smaller than the dimensions of the goods.
The ends of longitudinal bottom ledges shall be bevelled at an angle of 45 leaving at least 30 % of the ledge thickness.
If necessary, appropriate padding shall be provided between goods and supporting structure and between goods and fastening
means.

3.6 Planking of packing category 8
The planking must be designed in such a way that:
- it has at least two entries for the forklift,
- the rope sling points are provided with heavy-lift corners when the weight exceeds 3 t,
- it withstands the tying-up forces when reloading,
- handling with hoisting gear and/or industrial trucks is possible.
Protection by application of contact preservative and adhesive aluminium foil.
Wood planking of machined faces shall cover the entire surface.
Fittings, valves and projecting parts shall be fully wood-planked and padded if necessary.


Page 5
SN 200 Part 9 : 2003-09

3.7 Dangerous goods packing of packing category 9
When preparing packing units special attention must be paid to the regulations on the maximum quantities allowed for packing
together of dangerous goods.


3.8 Transport packing of packing category 11
The transport packing must be designed in such a way that:
- it has at least two entries for the forklift,
- it withstands the tying-up forces when reloading,
- handling with hoisting gear and/or industrial trucks is possible.
- the parts are protected against climatic and mechanical influences during transport.


3.9 Container packing of packing category 12
When goods are packed in containers, the internal dimensions of the containers must be observed.


4 Fixation of goods
4.1 Assumed loads
G values for the forces of gravity
The forces of gravity which are relevant for securing the goods result from the actually occurring acceleration and deceleration values.
The following table states acceleration factors for the different types of transport.
G values associated with the acceleration rates (max. rates occurring in regular operation)

Acceleration forces
Horizontal forces
Type of transport
Forward/backward Transverse
Vertical forces
Rail 4,0 g 0,5 g 0,3 g
Road 0,8 g 0,5 g 1,0 g
Sea 0,25 g 0,25 g 1,0 g
Air 1,5 g 1,5 g 3 g

(according to HPE Guidelines 2003/06)

In combined traffic, the highest value of each kind of acceleration force out of the types of transport used shall be taken into account.

4.2 Fixation of goods
- The merchandise shall be bolted to the case bottom structure through load-distributing transverse wooden members. Calculation of
the number of bolts and their dimensioning is made according to Table 11. The minimum bolt spacing and the minimum bolt
distance from the loaded edge in grain direction shall be 7 d, but at least 10 cm.
- Securing in place of movable parts of the merchandise shall be in the same quality as the fixation of the merchandise on the case
bottom structure.
- If screw-fastening/bolting of the merchandise to the case bottom structure is impossible or possible only to a limited extent, use of
appropriate intermediate layers, padding elements, supports or blocking elements shall be made to avoid slipping of the
merchandise in the case.

The following measures are appropriate:
- jamming of goods using wooden thrust blocks and threaded rods (min. bolt diameter see table 10),
- lashing of goods using prestretched wire and turnbuckle (proof of sufficient wire cross-section required)
- bracing with wooden members (direct wood-to-metal contact not permissible)








Page 6
SN 200 Part 9 : 2003-09


5 Packing
The preservative applied to the parts by the supplier shall be checked by packer for absence of damage on outer surfaces in the
scope of incoming and outgoing goods inspections and, if necessary, properly repaired with an agent as in
SN 200, Part 7.
Depending upon transport and storage times involved, corrosion protection is by the desiccant method by sealing the goods in plastic
film.
Following materials are used for the barrier layer:
- Polyethylene foil according to BWB TL 8135-0019 or equivalent foil,
- Aluminium compound foil according to BWB TL 8135-0003 or equivalent foil.

Preservation using the VCI method with appropriate carrier material (paper, film, foam pack, etc.) is an alternative possibility, but
requires previous consultation with SMS Demag regarding compatibility.
Barrier sheathings shall be designed to allow their proper opening and reclosing for two times.
The desiccant quantity required is calculated as in DIN 55474 for a maximum permissible ultimate humidity of 40%. Water vapour
permeability is established using the procedures specified in DIN 53122-2; the foils shall be checked both in as-delivered and in aged
condition.
The testing climates to be used depend upon the country of destination.If no climate data are available, use is made of
testing climate B as in DIN 53122. If no particular proof of water vapour permeability has been furnished, the max. permissible water
vapour permeability factor (mean value of as-delivered and aged condition) stated in the corresponding technical delivey condition shall
be used.
Proof of the test results shall be furnished in the form of an inspection certificate as in DIN EN 10204/3.1 B or 3.1 C.
Desiccant bags (low-dust type) shall be attached properly secured against dropping in the upper section of the packing. Fastening of
the desiccant bags shall be so as to permanently withstand loads due to transport, handling and weight increase by absorption of
humidity. Direct contact between merchandise and desiccant is not allowed.
Projecting parts and sharp edges shall be properly padded to prevent wearing through and piercing of the foil. Air inside the barrier
layer shall be sucked off.
Openings in the barrier sheathing such as spots pierced by fastening elements shall be sealed vapour-tight with seals and sealing
agent applied on both sides of the film (see Fig. 4).



6 Marking
6.1 Elements of marking
Marking is made up of inscription and handling marking.

6.1.1 Inscription
Inscription is project-related and part of our shipping instructions.
These shipping instructions will be made available to the contractor in due time.

6.1.2 Handling marking
In addition to the inscription, the packages shall be provided with the relevant internationally used handling marking as in
DIN EN 780.
All packages with weights exceeding 3 t require marking of the center of gravity and slinging point.
Storage-class marking is with the symbols shown under item 6.5.

6.2 Execution of marking
Unless otherwise specified, all marking shall be in Arabic figures and Latin capital letters.
The letter size depends on the sizes of the inscription surfaces.
Letter sizes of less than 2 cm shall not be used.
Handling marking shall be made according to DIN EN ISO 780 in the usual letter sizes specified in the standard.


50 C
15 C
Page 7
SN 200 Part 9 : 2003-09
6.3 Application of marking
Packages shall be marked either with labeling template using seawater-resistant, light-proof contrasting paint (preferably black RAL
9005) or using labeling plates approved by SMS Demag with regard to plate material, inscription, letter and plate sizes. When sledge
structures are used or the parts are unpacked, marking on the merchandise itself is allowed.
Handling marking is applied as specified in DIN EN ISO 780.


6.4 Arrangement of marking
Marking shall be applied on at least two faces of the package.
Cylindrical packages shall be provided with marking on two opposite faces.
Handling marking is applied as specified in DIN EN ISO 780.



6.5 Permitted storage classes Pictorial marking as in DIN EN ISO 780


- Open-air storage under tarpaulins or roofing
(outdoor storage)


- Closed building without temperature control
(indoor storage)




- Building protected from frost
Temperature range 5 C to 50 C
- Air-conditioned building
Temperature between 15 C and 25 C
Relative humidity from 40 % to 60 %



-Special storage area for dangerous goods Marking according to 6.6


Storage class shall be determined on the basis of the most sensitive component. If no specifications are given by SMS Demag,
storage class shall be determined by manufacturer or supplier of the goods. The determined storage class shall also be documented
in plain text in an appropriate part of the accompanying documentation of the merchandise (for example advice of delivery, delivery
note, packing list).


6.6 Marking of dangerous goods
Dangerous goods within the meaning of the Dangerous Goods Ordinance for the respective type of transport (GGVSee = Dangerous
Goods Ordinance for sea transport, GGVSE = DGO for road and rail transport, IATA-DGR = DGO for air transport) shall be provided
at least with the following additional marking:
- Inscription: UN number and technical designation of merchandise.
- Marking with danger class symbol and danger class figure, additional danger class symbols shall be applied in case of more than
one dangerous property of the merchandise. Size of marking at least 100 x 100 mm, on containers 250 x 250 mm.
When packages are combined to form loading units, marking and symbols of the individual packages must be fully and freely visible, if
not, the loading unit shall be provided with new marking.




5 C
25 C
Page 8
SN 200 Part 9 : 2003-09

7 Inspection
SMS Demag shall be informed by contractor in due time (at least two days) prior to beginning of packaging and has the right of
attendance during packaging. SMS Demag reserve the right to inspect the packing.

The contracting packaging company shall complete an inspection report (SMS Demag form No. 1325) for every package. In addition,
the calculation documents and a list of the materials used stating quantities, cross sections etc. shall be drawn up for each package.
These documents shall be submitted to SMS Demag for countersigning (company-specific records giving identical information will be
accepted by SMS Demag).

If, on the basis of the records or during inspection of the packages, there is reasonable doubt concerning proper preservation, marking
or packing, the authorized representative of SMS Demag will decide as to whether opening of the packages and possibly the barrier
sheathings is required.

If the opened packages are found to be unacceptable, the representative of SMS Demag will decide whether additional opening of
twice the number of packages opened for previous inspection shall take place.
Such additional inspection shall be repeated till all packages of an additional inspection are without complaint.
Contractor shall be liable to SMS Demag for correct packaging in compliance with these minimum requirements and for perfect quality
of the packing material. Any deviation from these conditions requires previous written approval by SMS Demag. Contractor shall be
liable to SMS Demag for any damage resulting from improper or faulty packing.

Package inspection does not relieve the packaging company from its warranty obligations and liability.


Referenced standards, guidelines and ordinances
DIN 603 Mushroom head square neck bolts
DIN 1052, sh. 1 Timber structures, design and construction
DIN 4074-1 Strength grading of wood, coniferous sawn timber
DIN 53122-2 Determination of water vapour transmission
DIN 55402-2 Marking for shipping of packages; directive for export packaging
DIN 55474 Desiccants in bag

DIN EN 300 Oriented strand boards (OSB)

DIN EN ISO 780 Pictorial marking for handling of goods (ISO 780)

- HPE Packaging Guidelines (The Registered Federal Association for Wooden Packages, Pallets and Export Packaging)
- Instruction Sheets covering Export Packing for Shipment to Overseas Countries (RGV)
- Provisions of the countries of destination
- Dangerous Goods Ordinance Road and Rail
- Dangerous Goods Ordinance Sea
- Dangerous Goods Ordinance Air Transport
- RM 001(Guidelines associated with the Dangerous Materials Handling Provisions/Refers to all Carriers of Goods)
- K and M, Consular and Standard Regulations of the Hamburg Chamber of Commerce
- BWB TL 8135-0003, Federal Office for Military Engineering and Procurement
- BWB TL 8135-0019, Federal Office for Military Engineering and Procurement
Page 9
SN 200 Part 9 : 2003-09

Annexes
Admissible stresses
Table 1 Strength data for wood used as packing material
Admissible stresses admiss and admiss in N/cm
2
for load case H
Sorting category S7 Sorting category S10
Kind of loading Coniferous
wood Hardwood
Coniferous
wood Hardwood
Bending badmiss 900 950 1250 1400
Bending of through beams without joints badmiss 950 1000 1250 1500
Tension in direction of grain z admiss 0 0 1100 1250
Pressure in direction of grain dadmiss 750 900 1100 1250
Pressure perpendicular to direction of grain dadmiss 250 400 250 400
Pressure perpendicular to direction of grain in components in which minor
indentations are harmless. dadmiss
300 500 300 500
Shearing off in direction of grain and glued joint admiss 120 130 120 130



Table 2 Admissible compressive stress in N/cm for angular application of force on wood of sorting category S10 for
load case H (main forces) dzul dzul - (dzul - dzul ) sin
Coniferous wood Oak and beech wood
Angle or between
connecting load and
direction of grain
__
for components for which minor
indentations are harmless
__
for components for which minor
indentations are harmless
0 1100 1100 1250 1250
10 950 1100 1100 1130
20 800 900 950 1000
30 650 700 820 900
40 550 600 700 770
50 450 500 600 680
60 400 450 500 600
70 300 370 430 550
80 270 330 400 530
90 250 320 390 500

For load case HZ (main and additional forces) shunting impact, crane transport, industrial-truck transport the
admissible stresses are multiplied by the factor 1.5.



Construction of bottom
Table 3 Construction of bottom
Type of
case
Net weight
in kg
Board thickness
in mm
Longitud. skid
Wx Hin cm
Rubbing skid
Wx Hin cm
End header
Wx Hin cm
1 < 1 000 24 8 x 10 10 x 10 8 x 8
2 > 1 000 - 5 000 24 10 x 12 10 x 10 8 x 10
3 > 5 000 - 10 000 24 12 x 14 10 x 10 10 x 12
4 > 10 000 - 25 000 24 14 x 16 12 x 12 12 x 14
5 > 25 000 24 > 16 x 18 > 12 x 12 > 16 x 18


Page 10
SN 200 Part 9 : 2003-09

Table 4 Number of squared timbers (longitudinal skids)
Bottomwidth (cm) 120 121 - 180 181 - 240 241 300 301 350
Number of
squared timbers
2 3 4 5 6



Construction of side part, end part and top
Table 5 Construction of side part, end part and top
Type of
case

Net weight
in kg
Boad thickness
in mm
Cleat frame,
diagonal, horizontal
in cm
1 < 1 000 24 10 x 2,4
2 > 1 000 - 5 000 24 10 x 2,4
3 > 5 000 - 10 000 24 12 x 3
4 > 10 000 - 25 000 24 12 x 3
5 > 25 000 24 12 x 5


Table 6 Number of side-part panels
Length of case (cm) 300 301 - 500 501 - 700 701 - 900 > 900
Number of panels 1 2 3 4 5


Table 7 Number of end-part panels
Length of case (cm) 200 > 200
Number of panels 1 2


Table 8 Number of longitudinal cleats of the top
Width of top (cm) 100 101 - 200 201 - 250 251 - 350
Number of cleats 3 4 5 7


Table 9 Dimensioning and quantities of top joists
(center distance from square timber to square timber max. 70 cm)
Width of top (cm) 100 101 - 150 151 - 200 201 - 250 251 - 300 301 -350
Squared timber
Wx H(cm)
6 x 8 8 x 10 10 x 12 12 x 14 14 x 16 14 x 18



Dimensioning of mushroom head bolts

Table 10 Dimensioning of mushroom head bolts, fixation of goods
Type of
case
Net weight
in kg
Diameter of
mushroomhead bolt
in mm
Max. hole dia. in mm
1 < 1 000 12 13
2 > 1 000 - 5 000 12 13
3 > 5 000 - 10 000 16 17
4 > 10 000 - 25 000 16 17
5 > 25 000 20 21

Use shall be made of mushroom head bolts as in DIN 603.


Page 11
SN 200 Part 9 : 2003-09

Table 11 Admissible loads on mushroom head bolt joints for application of force in direction of grain in N



Construction examples

Fig. 1: Connection
top - side - bottom



















To guarantee withstanding of the compressing stress on stack of 10 kN/m it may be necessary to prop the top joists with vertical
supports.
Pine wood
including
larch
Oak
and
beech wood
550 N/mm x a1 x d,
but not more than
2400 N/mm x d

700 N/mm x a1 x d,
but not more than
2800 N/mm x d

single-lap joint


d = bolt diameter in mm
end sheathing
top joists (3)
diagonal end
bracing
vertical center cleat
side sheathing
vertical corner
cleat
bottom board
main skid
diagonal side-
wall bracing
rubbing skid
end header
Page 12
SN 200 Part 9 : 2003-09



Fig. 2: Connection
Bottom side wall
































Fig. 3: Connection
top bottom side wall
longitudinal bottom
cleat
vertical cleat
bottom boards
end header
end header
diagonal cleat
side sheathing
boards
vertical support for
cross-timber
(top joist)
longitudinal
bottom cleat
vertical cleat
bottom boards
longitud. skid
stop cleat for rope
(sliding cleat)
side wall
end wall
rope stop
cleats
(sliding cleats)
longitudinal
skids
lower transverse cleat
upper transverse cleat
longitudinal
top cleat
Page 13
SN 200 Part 9 : 2003-09
Fig. 4:
Piercing of barrier films























Important: Hole-circle diameters in the rubber pads shall be smaller than the shank diameters
of the fastening screws



Fig. 5:
Nailing of wooden cleats
nut
rubber pad
sealing compound washer
machine base
barrier film
sealing compound
rubber pad
transverse
timber
padding film as protection
for barrier film
bottom board
longitudinal
skid
washer rubbing skid
bolt head
Shortest applicable nail distances:

10 d from loaded edge
5 d from unloaded edge
d = nail diameter

Cleats shall be fixed with at least
2 nails in each board.
diagonal
bracing 120
cleat
frame
sheathing
80-200

September 2003

Manufacturing Instructions

INSPECTION
SN 200
Part 10

Dimensions in mm

Field of application
The inspection instructions which are valid for SMS Demag are compiled in the standard SN 200. They are applied to all
components, assemblies and equipment units which are manufactured on the basis of SMS Demag drawings. This includes
all work and services which are performed by third parties on behalf of SMS Demag.
If the requirements stated in the drawings and associated technical documents differ from those specified in the inspection
instructions, these requirements have priority over the instructions of SN 200.


Table of contents Page
1 Warranty.................................................................................................................................................................... 1
2 General inspection instructions................................................................................................................................ 1
3 Inspection instructions for component parts ........................................................................................................... 1
4 Inspection instructions for assembled units ........................................................................................................... 2
5 Particular inspection instructions............................................................................................................................. 2
6 Inspections made by the end user ........................................................................................................................... 2
7 Inspection results...................................................................................................................................................... 2
8 Certificates ................................................................................................................................................................ 2
9 Types of inspection documents ............................................................................................................................... 3
Referenced standards...................................................................................................................................... 3


1 Warranty
The manufacturer has to warrant the proper execution of his supplies and services. He is responsible for material quality,
execution of welding, dimensional accuracy, surface condition, methods of processing and treatment etc. as required for his
scope of supply. Inspections made by SMS Demag quality inspectors do not relieve him of his warranties.



2 General inspection instructions
All features produced by the manufacturer must be inspected by the manufacturer himself. Recording of the inspection results
has to take place in accordance with the instructions given in the drawings and purchase orders and with the criteria stated in
the chapters of this SN. Inspection records and certificates have to be drawn up in German or English language. For the
purpose of clear identification, all documents etc. must state our project number, drawing number and, if applicable, our
purchase order number and the designation of the part.
Every manufacturer must ensure that residues from processing/machining (such as welding slag, loose burrs, chips, drilling
emulsion etc.) are removed from the product after completion. The cleanness must be ensured by visual inspection as in DIN
EN 13018 and guaranteed.
The members of the SMS Demag quality inspection department have the right, independently of maker's obligation to draw up
records, to demand proof that all features have been fulfilled or to check themselves the fulfillment of all features. If inevitable,
destructive testing is permitted within the scope of inspection and maker has to carry out destructive testing upon request by
the SMS Demag quality inspector.
All features tested/checked within the scope of intermediate or final inspection are recorded by the SMS Demag quality
inspector or put down in writing on the report drawn up by the manufacturer.



3 Inspection instructions for component parts
Component parts are parts which cannot be further disassembled and are identified by an at least 14-digit project number.
Inspection instructions for component parts are contained in the associated drawings, purchase orders and chapters of this
standard; the extent of inspection depends on the respective scope of supplies and services of the manufacturer.
The inspection instructions for high-quality components are stated in component-specific SN standards; the applicable
specific standard is indicated in the drawing of the respective component. In exceptional cases additional inspection
schedules for component parts will be drawn up by the SMS Demag quality inspection department and made available to the
manufacturer together with the drawings and ordering documents.


Continued on pages 2 and 3
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Page 2
SN 200 Part 10 : 2003-09

4 Inspection instructions for assembled units (assemblies and equipment units)
Given the wide range of products manufactured by SMS Demag, it is not possible to define standard inspection instructions
for assembled units within the scope of this SN 200.
Manufacturers of assembled units are therefore bound to contact our dept. of quality inspection to agree on the relevant
inspection procedures. For the most part, the scopes of assembly and inspection are listed in specific schedules, which will be
made available to the manufacturer and are considered to be constituent parts of this SN.
Within the scope of these inspections, functional and movement testing is the minimum inspection requirement on oscillating
and rotating parts.


5 Particular inspection instructions
Equipment such as lifting gears, pressure vessels etc. must be put through the acceptance tests and inspections stipulated in
the statutory regulations or other regulations having legal force (e.g. Accident Prevention Instructions, AD codes of practice).


6 Inspections made by the end user (acceptance by customer)
Inspections/testing which has been contractually agreed between SMS Demag and the customer will be notified to the
manufacturer in the respective documents (internally: shop order, externally: ordering document).


7 Inspection results
All inspections which are carried out in accordance with the inspection instructions given in the various chapters must be
documented showing the desired values and the actual values. Appropriate forms and certificates for the
reporting/documenting of inspection results are available at SMS Demag and will be supplied upon request. Company-specific
reports/certificates showing the same contents and drawn up by the supplier within the scope of his own quality assurance
system will be accepted by SMS Demag provided they can be assigned to the SMS Demag project number and to the
ordering and drawing numbers.

If the drawing stipulates identification marking of every single component part (eg by stamped figures or engraving), the
actual values of every such component part must be stated (one report for each component part).

In the case of parts which are manufactured in quantities greater than 1 and for which no identification marking is required,
it is sufficient to report the actual values of the respective maximum and minimum limits (i.e. one report per lot with values
ranging from ... to ...).

Inspections on assembled units must also be reported with indication of the desired and actual values.

The original reports are required to be handed over complete, in size A4, to the SMS Demag quality inspection representative
during his visit to the manufacturer's works. If no inspection by SMS Demag takes place at the manufacturer's works, the
original reports must be sent to the SMS Demag department of quality assurance. All reports required to be drawn up in this
SN 200 are constituent parts of the scopes of order/supply. If inspection reports are missing or not complete, payments will be
withheld by SMS Demag.


8 Inspection documents
In general, inspection documents are required to be drawn up on the basis of DIN EN 10204 according to the requirements
made in the drawings and/or ordering documents.
Unless otherwise specified in drawings or ordering documents, the inspection documents stated in the various sections of this
SN 200 are the minimum requirement of documents for component parts.
The minimum requirement for assembled units for which no particular specifications are made in the drawings and ordering
documents is a document drawn up on the basis of DIN EN 10204-2.1.
For further requirements in accordance with section 3, a inspection document based on DIN EN 10204-3.1B has to be drawn
up and the inspection documents of the component parts and the inspection document of the assembled unit have to be
joined to the certificate as annexes.
If the handover of the inspection documents is intended to induce payments by SMS Demag or their customers, an inspection
report as provided for in DIN EN 10204-3.2 is required to be drawn up by the manufacturer in mutual agreement with the SMS
Demag quality inspection representative in lieu of the inspection certificate as provided for in DIN EN 10204-3.1B.

Page 3
SN 200 Part 10 : 2003-09


9 Types of inspection documents (extract from DIN EN 10204)
Summary of inspection documents
Standard
designation
Document
Type of
control
Contents of document Delivery conditions Document validated by
2.1 Certificate of
compliance with
the order
Without mention of test
results
2.2 Test report
Non-specific
With mentionof test results
carried out on the basis of
non-specific inspection and
testing
2.3 Specific test
report

In accordance with the
requirements of the order, and if
required, also in accordance with
official regulations and the
corresponding technical rules
the manufacturer
3.1.A Inspection
certificate
3.1.A
In accordance with official
regulations and the corresponding
technical rules
the inspector designated in the
official regulations

3.1.B Inspection
certificate
3.1.B
In accordance with the
requirements of the order, and if
required, also in accordance with
official regulations and the
corresponding technical rules
the manufacturer's authorized
representative independent of the
manufacturing department
3.1.C Inspection
certificate
3.1.C
the purchaser's authorized
representative
3.2 Inspection
report
3.2
Specific
With mention of test results
carried out on the basis of
specific inspection and
testing
In accordance with the
specifications of the order
the manufacturer's authorized
representative independent of the
manufacturing department and
the purchaser's authorized
representative



Different language versions of inspectioin documents as defined in EN 10204

English French German
Certificate of compliance with the order
Attestation de conformit la
commande
Werksbescheinigung
Test report Relev de contrle Werkszeugnis
Specific test report Relev de contrle spcifique Werksprfzeugnis
Inspection certificate Certificat de rception Abnahmeprfzeugnis
Inspection report Procs-verbal de rception Abnahmeprfprotokoll



Referenced standards
DIN EN 10204 Metallic products; types of inspection documents
DIN EN 13018 Visual testing; general principles


Page 1
Revisions of September 2003

Part 1 General

Addition of passages on pipe classification and of hazardous materials/environmental protection.
Addition of passage on load-carrying attachments.


Part 2 Material

Section 1 - Casting

General tolerances for casting revised by revision of standard.
Addition of passage on inspection.

Section 2 - Forging

Quality classes revised by revision of standard.


Part 3 Thermal cutting and forming by bending

Revision of heading; addition of passages on plasma cutting and laser cutting.
Incorporation of DIN EN ISO 9013.


Part 4 Welding
Editorial revision.

Table 9 updated.
Addition of item 3.3 on filler metals.
Addition of item 3.4 on preheating.
Complete revision of Table 11.
Table 12: cancellation of shrink connection.
Addition of item 3.5.1.
Addition of item 3.5.2.
Addition of item 3.6
Table 13 completely revised on basis of DIN 2559.
Editorial revision of section 4.
Updating of standards in section 5.
Item 6.1: addition of passage on lifting devices.
Revision of Table 14.
Addition of new referenced standards.


Part 5 Machining
Editorial revision.

Table 5: new symbols.
Editorial revision of item 2.1
Table 6, indication of sawing tolerance up to max. nominal dimension range of 20,000 mm.
Table 14, revision of drilling tool runout
Addition of item 3.4.1
Item 3.5, addition of roller burnishing and deep-rolling
Section 5, addition of joint tolerance area cz
Section 6: editorial revision
Table 19: addition of new tolerance ranges (e7, e8, p6, D7, F8, G8, H12)
Addition of Tables 22 and 23


Part 6 Assembling

Section 1: addition of safety instruction
Section 2: DIN ISO 13715 substituted for DIN 6784
Editorial revision of section 2
Table 2: addition of permissible loads on screws



Page 2
Revisions of September 2003


Part 7 Preserving

Revision of field of application
Revision of section 1
Item 2.6 incorporated in item 2.4
Addition of Table 4
Addition of Table 6


Part 8 Labeling

Editorial revision of sections 2 and 3
Addition of examples on page 5 (reporting of shipping units) and page 6 (reporting of package data)


Part 9 Packaging

Updating of item 1.9
Item 4.1: revision of table


Part 10 Inspection

Editorial revision
Addition of section 1