DIN 19704 HYDRAULIC STEEL STRUCTURES e DIN 19704— MAY 1998 — HYDRAULIC STEEL STRUCTURES — PART 1 — DESIGN ANALYSIS e DIN 19704 — MAY 1998 —- HYDRAULIC STEEL STRUCTURES — PART 2 — DETAILING AND FABRICATION e DIN 19704— MAY 1998 - HYDRAULIC STEEL STRUCTURES — PART 3 — ELECTRICAL EQUIPMENT e DIN 19704 — SEPTEMBER 1976 — HYDRAULIC STEEL STRUCTURES EREN NUVEYRE MORELMANUSCRIPT TRANSLATION May 1998 Hydraulic steel structures Part 4: Design analysis So z | wk o x ° 4-1 Ics 98.140; 13.160 Descriptors: Hydraulic steel structures, water engineering, design analysis. Stzhiwasserbauten ~ Toll 1: Berechnungsgrundlagen in keeping with current practice in standards published by the International Organiration for Standardization ('S0), a. comma has been used throughout as the decimal marker. Contents 7 Foreword +1 83. Accidental actions ...... 53.1 Leaking of air chambore 4 Bropesss- *2 53.2. Tranopor, erection end repair 2 Normative references +8 54 Other action ee 54.1 Gates with double-acting drive 3 Documentation: «<< & $.4.2 Blockage by foreign bodies 2 3.1 Stee! structures a8 ig Accidental action of a drive in the case 32 Machinery .... “5 of a malfunotion 2... 3 4 Materiate +8 6 Friction... 441° Steol structures 8 81 General ras 42 Seals . 8 82 Sliding friction | 42.1 Elastomers . 6 6.3 Stotic fiction... 422 Plastics o +8 64 Rolling triton 423 Timber 2.2. 8 64.1 Rolling bearings 42.4 Nonferrous metals 7 642 Wheels on rails 43° Machinery ...... 7 64.3 Wheel flange friction 14 5 Characteristic values of actions for T Analysis of steel structures .. n steel structures. 7 7 7.1 Scope of analyses coe waa 5.1. Permanent actions 7 7.2. Analysis of oifeots of actions sss... Ee! Venu ceuees 7 7.8 Analysis of resistances a 5.2.1 Hydrostatic actions 7 4 PfOcedure 5... secrseee ed? 5.22 Hydrodynamic actions 7 7:8 Utimate limit siate analysis) 12 5.2.8 Water load . 4 AaE Botealssrne zi 1 Be Nae ead « } 752 Stability analysis Dieuncle 4 7.5.3 Analysis of positional stabilly |...) 12 See PE RCEONE eecsusterscnnzaeuieers FGA Rateneanteme tt oy 213 2:26 Imposed loads... 2.2... 2 LS. Serviceabilty limit state analysis 21 “18 5.2.7 Forces due to inertia ot Tet aene 2 5.2.8 Changes in aupport conditions § ye Boome 3 5.2.8 Thermal effects § 763 Closing pressure v2 licesssscicsssi8 5.2.10 Ship friction £ 7.7. Further provisions CNTs 5.2.11 Ship impact . + $ 7.7.1 Beams with wide flanges 13 $2.48 Wind load. soveiesseevssecessseee 8 77.2 Design of plates in bending 13 5.2.19 Tow-rope pulling forces on bollards ... © 7.73 Cutouts in plato. 8 5.2.14 Pressure of fresh concrete seseees © 7.74 Rails... 4 ‘Translation by DIN-Sprachendienst Incase of doubt the German-anguagocrigira shoud bo corauited as the authontatve tex, ‘This standard, together with DIN 19704-2 ang DIN 19704-3, May 1998 editions, supersedes DIN 19704 and DIN 19708, Septem- ber 1976 editions. Continued on pages 2 to 28. Rel, No. DIN 19704-1: 1998-05,Page2 DIN 19704-1 2000-00 8 Characteristic values for actions 10.9.2 Interference fits . on machinery . 14, 10.9.3 Involute spline joints . % 8.1 General mae 14 10.9.4 Ring cone locking assemblies . 82. Determining drive forcae 2.21211 i244 10.10 Tosthed gearing 88 Dive power .....essvsessessesecsseest8 1011 Worm gesring snieygaves 8.4 Charactertstic values of maximum 10.12 Plain bearings made from nonferrous transmitted forces ses eecee cee ee esos 18 casting allot esesesesesr ene es ou 22 8.5 Hydraulic drives ssssssee16 10.13 Plain bearings made from composite 85.1 Basie of ealoulaion |. 2.2.2 os LAG material with sot lubricant 23 8.5.2 Determining design operating 10.14 Spherical plain radial bearings 23, POSSESS, on-sueneeevsrnnersvsccrand® 10:18- Eve bara; cham piston and ove Glos oa 8.53 Determining static prossure in the 10.18 Chain joints .- voller aed hydraulic cylinder or motor . 10.17 Rod ends gowns elu 25 85.4. Oil prossure limit valuea 40.18. Pinion racks, pinion chains and ooar 85.5 Provoure limiter ~~ racks sviisesvenes rts gH BB anche 10.19 Rolling becrings seer) Ser ee ge RRR res 1020 Rope drives NTs 2 ee 1021 Rope wheels, rope dius and 2.3 Analysis of effects of actions Gomponsating tONes onsen. 25 a Cae cee 1022 Wheels, gue roles, rire gat dogs and rails... BSH Araijun al sroseee dor sid” 10.28 Axes and hingo beite Ga 19 10.24 Holealeprings 25.2 Stability analysis 0000. lag 10.28. Oise springs 9.5.3 Fatloue assessment O20" TEBETOTE: xe 9.5.4 Serviceabilty limit state analysis 19 (0 Abalysis of special machine ep aEN Atal seam 29 Basie critotia for fatigue assessment ......,...27 tot General BB aa Gates inintandwaters scence sar 10.2 Hycreulic éylineiaes sn29 Alt Lock gates 10.2.1 Standardized oylinders ...0200..)1.1120 AL2 Ship Ift gatos = ts 10.2.2 Siress enalysis for static loading ......20 1-8 Ship lift troughs . soreness BT 10.2.8 Analysis of buckling strength ....).21.20 -Al.4 Welr gates... cee PB 102° Hydraulic pipes vs... ses 21 A1.6 Floodgates and safety gates og8 10.4 Hydraulic components 1.21 ALG Gates of pumping stations ..... 2)... 28 10:8 Electric motors ......-.scstlosiesse21 A2 Gates in coastal waters... 28 10.6 Brakes... .. 21 2A Tidal range : venom e 10.7 Couplings oe et A22 Leck gates |)” pene 10.8 Shafts 0.120! s.21 A28 Flocd gates and barrage gaies |... 28 10.9 Shatt-to-hub ‘connections 21 -A& Gates of dams end hydroelectric power 10.9.1 Keyad shefts and splinos net plants . Mee kau senaesne 28 Foreword This standard has been prepared by Technical Committee Stahhvesserbau of the Normeneusschud Wesser- wesen (Water Practice Standards Committee). Amendments This standard differs from DIN 18704 and DIN 19705, September 1976 editions, in that these standards have boon completely revised and combined into one standard which includes a neWv safety concert besed on ultimate limit state, Provious editions DIN 19704: 1958-06, 1963-12, 1976-09; DIN 19708: 1963-12, 1976-08. 1 Scope ‘This standard contains specifications for the design of hydraulic steal structures comprising the sttuctures as such and their assaciated machinary and electrical equipment, The structures comprise gate bodies with seals and bearings, drives and linkaga sloments (connecting gates and drives).Page 3 DIN 19704-1 :2000-00 This stancard covers inspection gates and equipment such as intake trashracks, floating bollards and impact protection facilities, and canal bridges. it may also be applied by analogy to pressure pipes and their fittings. |tdoes not apply to dolphins, lead-in jottioe, waterfront structures, landing stages andotf-shore structures (ea, off-shore platforms and lifting platforms). When designing small gates subject to minor loads fe. less than 0,5 bar/m? for water pressure acting on the skin plate), the requirements of this standard need not be complied with if the client so agrees. The specifications relating to steel structures shall apply to structures subject to loads due to stil or flowing waters. They cover both the movable elements and the fixed parts (Le. parts that are firmly connected to the Solid structure), such es sleepers and contact facos. Structural staclwork erected in conjunction with hydrauite Steel structures, but not subject to loading due to water pressure, shall be designed and constructed as specified in the relevant regulations or codes of practice. The specifications relating to machinery cover the machinery required for moving or supporting gates. They comprise mechanical and hydraulic drives (i.e. drives using oil as the ‘luid fer powar transmission), manual avg aundliary drives, machine housings and frames, covers of gate shafis under pressure, wheels and guide rollers and their rails, dogs, plain beatings and locking mechanisms tor gates, chains, ropes, pinion racks, tooth racks and linkage elements. Pins for connecting machine components to steel structures and axlos (including the associated bores) shall be regarced as machine components for the purposes of this standard. NOTE 1: See DIN 4048-1, DIN 4045-2 and DIN 4084 for terminology relating to water engineesing in general Further specifications relating to dams are given in DIN18700-10, DIN 19700-11. DIN 1970012, BIN 18700-13, and DIN 1700-14. 2 Normative references This standard incorporates, by dated or undated reference, provisions from other publications. These norma- tive references are cited at the approoriaie places in the text and the titlas of the publications are iisied below, For dated references, subsequent amendment to or revisions of any of these publications apply to this standard only when incorporated in it by amendment or revision. For undated references, ihe latest edition of the publication referred to applies, DIN 115-1 Power transmission olements ~ Clamp couplings ~ Dimensions, torques and speeds DIN 116 Power transmission elements ~ Flange couplings - Dimensions, tarques and speeds DIN 732-1 Rolling bearings - Thermal reference epeed ~ Design and coeticients"| DIN 722-2 Rolling bearings ~ Thermally parmissible operating speed — Design and coefficients") DIN 740-2 Powar transmission engineering — Flexible couplings - Concepts end design principles DIN748-1 Cylindrical shaft ends ~ Dimensions and nominal torques DIN 748-3 Gylindrical shaft ends for rotating electric machinery DIN 7056-4 Design loads for structures ~ Impesed loads ~ Wind loads on structures not susceptible to vibration DIN 1072 Road and foot bridges ~ Design loads DIN 2089-1 Holical compression springs made form found wire or rod ~ Design DIN2092 Designing conical disc springs DIN 2093 Dimensions and quality of ccnical disc springs DIN 2413-1 Design of steel pressure pipes DIN 2413-2 Design of steel bonds used in pressure pipes BIN 6980 Concepts and parameters relating to cylindrical gears and cylindsical gear paies Supplement | Concepts and parameters relating to cylindrical gears and cylindrical gear pars ~ List of to DIN 3960 equations DIN 3981 Tolerances tor cylindrical gears ~ Principles DIN 9962-1 Tolerances for cylindrical gears ~ Tolerances for specified errors DIN 9902-2 Tolerances for cylindrical gears ~ Tolerances for helix errors DIN 8962-3 Tolerances for oyfindrical goars — Tolerances for pitch range deviations DIN 9969 Tolerances for cylindrical gears ~ Tolerances for composite errors DINS964 Axle distances and axle bearing tolerances for oylindrical gear teansiission cases DIN 9965-1 Accuracy of bevel gears ~ Principles DIN 3965-2 Accuracy of bevel gears ~ Tolerancas for individual errors DIN 9965-8 Accuracy of bevel gears ~ Tolerances for composite errors DIN 3965-4 Accuracy of bevel gears ~ Tolerances for shaft angle errors andl commen apex errors *) Currenily at draft stage.Page 4 DIN 19704-1: 2000-00 DIN 3967 DIN 3990-1 DIN 3e90.2 DIN 3390-3 DIN 3990-4 DIN 3990-5 DIN 3990-8 DIN 3990-11 DIN 3990-12 DIN 3290-21 DIN 3991-4 DIN 3991-2 DIN 391-3 Din 901-4 DIN 4048-1 DIN 4048-2 DIN 4054 DIN 4768 DIN 5480 series DIN 7190 DIN 15020-1 DIN 15431 DIN 1844-1 DIN 15434-3 DIN 18218 DIN 1880-1 DIN 18800-2 DIN 18800-3 DIN 18800-4 DIN 18809 DIN 1970-10 IN 13700-11 DIN 19700-12 DIN 19700-13, BIN 19700-14 BIN 19703 DIN 19704-2 DIN 19704-8 DIN 24333 DIN V ENV 4992-14 DIN V ENY 1998-1-1 DIN VENY 1995-1-1 DIN EN 10003-1 DIN EN 1088-1 DIN EN 10088-2 *) Gur Systom of fits for transmissions ~ Backlash, thickness deviations, and tooth thickness tolerances ~ Principles Designing the load capacity of cyindrical gears —Intreduction and general parameters Designing the load capacity of oylindiical gears ~ Catcutation of pitting resistance Designing the load capacity of cylindrical gears ~ Caloulation of roct strength Dosigning the load capacity of cylindrical gears — Calculation of scuffing load capacity Designing the load capacity of oylindrical gears —Fatique strength and material quaitios Designing the load capacity of cylindrical gears ~ Calculation of service strength Designing the load capacity of cylincrical gears — Application standard for industrial transmissions - Detailed method Dosigning the load capacity of cylindrical gears ~ Application standerd for industrial transmissions ~ Simplified method Designing the load capacity of cylindrical gears ~ Application standard for high-speed transmissions and transmissions subject to similar requirements Designing the load capacity of bevel gears without shaft offset —Introcuction and gen- etal factors Designing the load capacity of bevel gears without shaft offset ~ Calculation of pitting resistance Designing the load capacity of bevel gears without shaft offset ~ Calculation of root strenath Designing the load capacity of bevel goars without axle offset — Calculation of scuting resistance Water engineering ~ Tarminology ~ Dam plants Water engincering ~ Terminglagy ~ Water power plants Navigation structures ~ Terminology Determination of surface roughness parameters Ryy Ry, Raa Using electne stylus in- struments ~ Concepts and measuring conditions Involute spline joints interference fits ~ Principles and design Rope drives - Design prineiples Power transmiscion engineering ~ Main dimensions of brake drums Power transmission engineering ~ Design principles for drum and dlise brakes Power transmission engineering ~ Emorgoney atop brakes — Safely requirements") Pressure of fresh concrete on vertical formwork Structural steelwork ~ Design and construction Struotural steelwork ~ Safety agains! buckling of finear members and frames Structural steelwork ~ Safety against buckling af plates Structural steelwork ~ Safety against buckling of shells Stoel road and foot bridges ~ Dimensioning, design and construction Dam plants ~ Genoral specifications Dam plants ~ Dams Dam plants ~ Flow control reservoirs Dam plants ~ Weirs Dam plants ~ Pumped storage reservoirs Looks for inland waterways ~ Design and equipment Hydraulic stee! structures ~ Detailing and fabrication Hydraulic stec! structures ~ Elecirical equipment Fluid power ~ 20 bar hydraulic cylinders - Mounting dimensions Design of concrete structures ~ General cules and tules for buildings Design of steel structures ~ General sules and rules for buildings Design of timbor structures - General rules and nules for buildings Metallic materiats ~ Brinell hardness test — Test method Stainless steels ~ Part 1: List of stainless stools Steinless steels ~ Part 2: Technical delivery conditions for general purpose sheet/plate and strip. nily at drafl stage,Page 5 DIN 19704-1 :2000-00 DIN EN 1088-3 Stainless stoels ~ Part 3: Technical delivery conditions for general purpose se: products, bars, rods and sections DINEN 10204 Inspection documents for metallic products (includes Amandment A 1 : 1995} DINEN 60204-1 Safety of machinery ~ Electrical equipment of machines ~ General requirements (mocified version of IEG 204-1 : 1992) 180 76:1987 Rolling beatings - Static load ratings '$0 281: 1990 Rolling beatings ~ Dynamic load ratings and rating lite 1SO 3505-1: 1997 Mechanical properties of corrosion-resistant stainloss steel fastencre ~ Part 1: Bolte, screws and siuds 180 3508-2: 1997 Mechanical properties of corrosion-resistant stainless steel fasteners — Pari 2: Nuts 'S0 3505-3 ; 1987 Mechanical properties of corrosion-resistant stainless steal factonors — Part &: Set screws and similar fastensrs aot under tensile strose 180.4008: 1991 Mezsurement of fluid flow in closed conduits ~ Vocabulary and symbols 180 4384-1: 1982 Plain bearings ~ Hardness testing of bearing motals — Part !: Compound materials 180 4964-2 | 1982 _ Plain bearings: Hardness testing of bearing metals ~ Part 2: Solid materials DASt-Richtlinie (DASt Code of practice) 17 Beulsicherheitsnachweis for Schalen; Spozielle Féile (Buckling of shells ~ Special cases)" Anpassungsiichttinie Stahlbau ~ Anpassungsrichttinie zu DIN, 18800 Tell 1 bis 4 (Goce of practice covering the use of DIN 18B00-1 to DIN 16800-4)"") EAU 1996, Empfohlungen dos Arbeitsausschusses Ufereintassungen (Recommendations of the Technical Committee Ufereinfassungem), 1986") References to DIN 19704-2 and DIN 19704-3 are to the May 1998 editions, and, references to the standards of the DIN 18800 sories sre to the November 1990 editions, inished 3 Documentation 3.1 Steel structures Documentation as stated in clause 2 of DIN 1880-1 shall be submitted. Drawings shall include information on form and position tolerancas, The client shall specify whether weld Inspection plans are required. ‘Any erection aids to be permanently attached to the steel structures (2.9. for fixing rope shackios] challbe shown in the drawings. 3.2 Machinery The documentation specified in DIN 16800-1 shall be supplemented by the folowing: a) a descriptive and performance specification’ b) diagrams showing opening and closing procedures (e.g. foree/distance diagrams, and, for hydraulic transmission, the volume flow); ©} calculations of drive outputs stating motion times, speeds, etficienctes and, for hycraulic transmission, Pressures; ) a structural analysis; €) assembly and detail drawings, and parts lists with details of materials and surface roughness parameters; f)_ material data sheets issued by the manufacturer, or DIN EN 10204 inspection documents if non-stan- dardized materials are used; @) technical data sheats or DIN EN 10204 inspection documents for machine compenerits or machinery supplied as standard products (e.g. gears, actuator drives, pumps}; h) ciroult diagrams of hydraulic drives anc associated parts lists with designations and details of manufac- ture i) documentation as in DIN EN 60204-1 for the electiical equipment; operating instructions, maintenance schediula, instructions ralating to inspection. Iehall bo the client's reaponsioility to specify the types of inspection documents. “4 Obtainable from Stahtbaw-Verlagsgeselischalt mbH, Sohnstiafe 68, 40237 Dusseldor!, Germany. *") Obtainable trom Vedag Emst & Soha, Mithlenstiae 33-34, 13187 Bedin, Germany.Page o DIN 19704-1 :2000-00 4 Materials 4A Steel structures The characteristic material values for unalloyed structural otcel, cast steel and fasteners shall be taken from DIN 1880-1 ‘The characteristic values for common stainless steels are given in tables 1 and 2. When intended to ha used in sea or brackich water, stainless steels shall coniain at least 2 % molybdenum. 42 Seals 4.24 Elastomers The material cheracterstics of elastomers on the basis of natural rubber (NA), styrone-butadiene rubber (SER) and chloroprene rubber (CR) shall be taken from table 8 of DIN 19704-2, and those of other elastomers. rom manufacturers’ data sheets. 42.2 Plastics Thematerial characteristics of polymer materials {¢.g, polyamide (PA) and polysthylene (PE)) shall be taken from manutacturers’ data sheets. 4.2.3 Timber - In the case of frictionally connected solid timber seals, the stresses occurring under the desian actions shall not exceed two-thirds of the reduced design resistances specified for utilization class 3 in DIN VENV 1998.1 1 NOTE: this reduction takes into account the lower resistance of timber when exposed to water permanently or over prolonged perieds ‘Table 1: Characteristic values for stainless steels von xian) 0296 2% | rane stew loxheted Derigntonscin | angi scouee| Saeed | Ts ss ; No] ontetocs:r'y | Mati RGU | Bt | street ade ees seer omen sca alee a Pe wir [indienne] Has nnn ne se = 7] 207 | 520) | an 1] omnes | racer [55253] 209 | 07 ey 160 = 75!) | 2001) 500) a A a - 2 | xeonmis-0 cet [E08] ae | 50) Tey 160 3 | xocrNiMeTH7-12-2 | tas | = ,78) | 2209 | 8209 | orem | sooa09 5260) | 200) | 500% Rrate:| HR = 759 | 600%) | 2209 4 4408 | 2509 | 5505 | zo0q | 229 1033 enti = 75) | 400) | 40H | 8 | monmencess | wate |S iey | ait | od | ae 130 i KAT GRAB] 4.40574 | = 1605 | 6004 | 900% | 2959 | 215000 | e000 | too ») For hot-rolieé steel sheet, plate and stein 2) For semictinished products, bare and sections ®) For quenched and tempered steel sheet and plate (27 84) 2 Fer quenched anc tempered semicfinished products. bars and sections (QT 760). 8) For quenched and tempered semi-finished products, bare and sections (QT 600), §) For annealed semi-finished products, bers and sections. Table 2: Characteristic values of etainleas steel bolts a Yield stress, Tensile strength Steel groups asin 180.9806 | Strength class | Maximum | fais Sasa in Nénm? in Némm? - i so | Maa 210 500 A2and Ad 7 M20 450 700 80 M20 00 800Page 7 DIN 19704-1 = 2000-00 4.2.4 Nonferrous metals The material characteristics of nonferrous metals shall be taken from the relevant standards or manufacturers’ data sheets, 43 Machinery The material constants (e.g. the modulus of elasticity) and the characteristic strengths of values for materials used for machine componenis shall be taken from the relevant matarial standards (ese tables 1 and 2 for stainless steels) or, in the case of non-standardized materiale, they shell be taken from manufacturers’ data sheets of be covered by incpection documents, ‘The yield stress, f,, 0,2 % proof stress, fo, and tensile strength. f, specified shall be assumed tobe charaé- teristic values, The dapondance of the material characteristics on the component thickness and, where appiicable, on heat ‘treatment or ambient temperatures prevalling ai the location of use shall be taken into account 5 Characteristic values for actions on steel structures 5. Permanent actions The following densities shall be used to determino sel-weight: steel, cast steel, copper alloys: +10? kg/m; aluminium alloys: 2.65 - 108 kof: plastics = 1445 105 ka/m®s timber (= 1,00 10° kg/m’. Unless a more accurate analysis is made, coatings, any adhering water, adhering ive, vegetation and dirt shall be taken into account by acing an allowance of 10% of the self-weight of the gate, 5.2. Variable actions 5.2.1 Hydrostatic actions When determining the rated water level (to be specified by the client), wind set-up may need to be taken into account, The following densities of freshwater and seawater shall be applied: freshwater: 2 = 1,00 - 10° kgims seawater: @= 1,04 - 102 kgim?, Uplift shall be taken into account for all parts submerged in the water, $.2.2 Hydrodynamic actions The following actions shall be taken into account, details of which shall be provided by the client: 2) overflow or undertiow at the gate; b) swell and suction; ©) pressure surge ) wave prossure on gates in inland waters; ©] Wave pressure on gates in coastal wate'S') (due to ratlecting, breaking or broken waves\: 4} ellect of propelior wash from ships Items b), ) and) may be taken into account by assuming « ciflerent hydrostatic water pressure The actions may be determined by means of model tests 6.2.9 Water load [he water load resulting from the displacemant of water caused bya moving gate or water loads in action during lifting of a gata shall be taken into account. 5.2.4 leo load ‘The exposed part of an ice block on or within the gate shall be treated as acting vertically. The magnitude and frequency of occurrence shall be specified by the clisnt. The donsity of ioe, @, may be taken as 0,70 107 kg/m. 6.2.8 lee pres: Unless more detailed data are available, ice pressure, inclucing ice impact, shall bs assumed to act in addition to the static water pressure. This pressure shall bo taken to bs an aroa load, pg, acting in horizonial direction, and shall be taken to be 150 ktl/m? in inland areas and 250 kN/m? in coastal Stoas, | For the purposes of this standard, coastal waters cover the entire German North Gea and Dallic Sea coast, including the islands, mouths of rivore and firths,Page 8 DIN 19704-1 : 2000-00 Ininland areas, 2 minimum ico thickness, fig, equal to 0,3 m shall be assumed. In coastal areas, ice thicknesses can vary botween 0,6 m (moderate) and 0,6 m (substantil) The ice thickness to be assumed shall be specified by the client. The ice pressure shall be assumed to act in relation to the ice thickness balow the water level as shown in figure 1. The ice pressure zcting on a sloping skin plate shall be dotermined in accordance with figure 2, using atiction coofficiont, p, of 0,1 On no account shall these loads be reduced. even where anti-icing facilities such as heaters or similar equip- ment are provided. Fer the sake of convenience when calculating the steel structure forming the gate, the ice pressure may bataken as aline load, py ° fig, acting at water |eve! When desigring the skin platos anc thoir stiffeners, the surface load due to ice pressure may be reduced byhalf if twice the ice thickness is aseumed, in the case of inspection gates, it shall be the responsibility of the client to specify whother ice pressure needs to be taken into account, and if so, its magnitude When checking the skin plate of gates with underflow for adequate local stiffness, a horizontal line load of 90 kN/m shall be assumed to act at the bottom edge, irrespective of the water pressure. 5.2.6 Imposed loads For walkways, a load of 2.5 kN/m? and for handrails a load of 0,5 kN/mat raitheightshall be assumed, Imposed loads shall be taken from DIN 1072 where traffic over the gate Is to be taken into Consideration (e.9, where the gate is of the sliding type). Imposed loads for covers of pits, channels etc. shall be specified by the client. 5.2.7, Forces due to inertia Where accoloration rates referred to the centioid of the gate are less than 0,5 m/s2, forces due to inertia of the gate may be neglected, This does not apply to slevable gates with rigidly connected count rwoights. Figure 1: Application of ico proscure on a vertical skin plate Pers Pesin a Per =H Py Cosa Figure 2: Ice pressure acting on a sloping skin platePage 9 DIN 19704-1 : 2000-00 8.2.8 Changes in support conditions Where the support conditions for gates ars staticelly indeterminate, the influence of fabrication and erection inaccuracies shall be taken into account (see substause 5.2 of DIN 19704-2), Changes in the support conditions shall be taken into account by considering the sottloment and deformation likely to occur in the foundations, the appropriate valuies for which are to be spocifiod by the eliont, Uneven settlement and deformation shall be minimized by selecting a suitable system for the solid structure and its foundation. The gate system shall be selected with the anticipated deformations in mind. 5.2.9 Thermal effects ‘The following temperature fluctuations (uniformly present over the surface of the gate) shall be assumed: a) gates temporarily lifted out of water in their entirety or substantially: 435K: b) gates in contact with water on one side: +20 K; ©) gates partially in contact with water on both sides: d) completely submerged gates: +10 K {hn addition, for eases s) and b) a temperature gradient of 20K across the thickness of the gate leaf shall be ascumod, Uniform temperature fluctuations shall only be considered together with temperature gradionte if this would have an unfavourable effect on the gate. 2.10. Ship friction Provided local conditions do not impose different assumptions, a horizontal load of 100 KN shall be used to take into account ship friction (e.g. on epened mitre gates and ship basins) at the water line, perpencicular to the direction of travel and, simuftaneously, a horizontal load of 5D kN in the direction of travel Inthe case of other hydraulic steel structures, it shall be the responsibility of the client 1o specily whether loads are to include ship friction, anc if so, in what magnituds. 20K: 5.2.11 Ship impact Wohip impact needs to be taken into account at lock and ship lift gates, impact protection facilities, which are not to be attached to the gate, shall be provided for absorbing this impact. Load assumptions for impact protection facilities shall be taken from DIN 19703. 5.2.12 Wind toad Wind load need not be considered when caloulating gate structures. To determine the driving forces and enable docign of the appropriate machinery (see clause 6), the assumptions from DIN 1055-4 shall be used for wird load acting on the gate The wind toad, WW, shall be the product of the aerodynamic force coofticient, op the hydrodynamis pressure, ¢, and the projection surface of the gate normal to the wind dirostion, A (Le. W = c,-q-A). Whore gates arp exposed to wind above the level of the ground), ¢,chall bo taken te be as specified in subclause 1.3. For gates which are protected against wind beneath the level of the ground (e.g. lock chambers), ¢ shall be taken to bs 0.5. It shall be the responsiaiity of the client to specity the relevant hydrodynamic pressure Wind effects on portals or similar structures shall be determined using the load ascumptione from DIN 1056-4. 82.18 Tow-rope pulling forces on bollards Tow-rope pulling forces on bollarcsforintend waterway vessels sia be taken from DIN 18703. For sea vessols, the tow-rope pulling forces on bollards shail be taken from Recommendation E12 of EAU 1996, 5.2.14 Pressure of fresh concrete The pressure of fresh concrete on embedded parts shall be taken into account as spocifiod in DIN 16018 5.3 Accidental actions $3.1 Leaking of air chambers Any leaking of air chambers shall be taken into account. Where there is more than one air chamber, leeking of two adjacent air chambers at the most unfavourable places shall be assumed, It shall be the responsibilty of the clisnt to specity whether the operation ofthe lock is tobe continued in the case ofleakage or whather a single ‘movement of the gate to a repair position is to be assumed. 5.3.2 Transport, erection and repair Any actions due to transport, erection and repair shall be considered (this also includes pressure testing of hollow bodies at z test pressure of at least 0,3 bar) 5.4 Other action 5.4.1. Gates with double-acting drive 'tshall be the responsibility af the client to spacify the load situation to be assumed (see table'6) for cases when a gate with double-acting drive fails and the gate requires still o be moved, and which of the following modes applies:Page 10 DIN 19704-1 : 2000-00 2) gate movernont is to be stopped, followed by a movement of the gate to repair posit 1) the gate is temporanly driven from one side only. 5.4.2 Blockage by foreign bodies If blockage of the gate by foreign bodies (a.g. entrapped flotsam, bedioad, freezing up) Is to be taken into account, it shall be the responsibility of the client to specify the load case as in table 5. NOTE: The design does not in all cases preclude local damage to the gate 5.5 Accidental action of a drive in the case of a malfunction When the drive operates in abnormal conditions (e.g. when the gate is blocked as aresultof jamming or treszing up), the maximum drive forces or torques acting On the gate shallbe basedon the assumptions made in clause & and subclause 9.8 and using load case 3 as in table 5. 6 Friction 0.1 General ‘Tha frictional forces and moments a friction coefficients below. If other fict be subject to agreement. In subclauses 6.2 to 6.4.3, the maximum values shall bo applied if frictional forces or moments fave an adverse effact, and the minimum values if their effect is favourable, Intermediate values shall not be usec, Where gates are to be lowered for closing without the aid of a mechanical drive, it shall be ensured that this can be done safely by increasing by 25 % the frictional forces determined using th maximum friction costiicieats, 1g on the steel structures and machinery shall be determined using the " coefficients are tobe use«, these shall be of proven suitability or shall 6.2. Sliding friction Tables and 4 specity fiction coofficients for spoods up to approximately 50 min/s, table3 gives hose forstee! strictures (2.9. sliding gates and slide tracks) with a high surface roughness (.e. where the arithmetical mean deviation of the profile, R,, (6. 80 4006) is between 3 ym and 15 pm), and table 4 gives the friction coefficients {or machine components (e.g. spherical plain radial beerings, pivot bearings, pivot bearings and sprocket chains) of low surface rouchness (ie, with an R, value betwaen 0,1 pm and 0,8 pl, and for mitre brackets Tho offoct of sliding ttiction (or rolling friction, ef. subclause 6.4) on shaft beatings, gears, etc. may be estab- lished by using their efficiencies, Le. without applying table 4. 6.3. Static friction Static tretion shall be taken into account it has an adverse effect. The static friction cootficients, yy, may be calculated by muttiplying the 17 values wih the 1/1 ratios from tables $ and 4 6.4 Rolling ‘riction 644 Rolling bearings A triction coefficient, 4, equal to 0,003 shall be applied for relling bearings. NOTE: This (notional) friction caefficient can be used to calculate the rolling friction moment referred to the moan radius of tho pitch cirole, ry by means of the equation M = Fp, "Tq (E being the whoel load) Table 8: Friction coefficients for steel structures ; Sliding fiction eoetficiont, (wet) Material combination yylrratio Minimum | Maximum Hel Steol/tee! | 020 0,98 i Steel/eopper alloy : 00 0,30) i Stainless stee/polyamide (PAGG + PE) ots 12 Stainless steevpolyethylene (PE-UHMM) oro | 12 SteeV/elastomer 0,0 1.0 [ot hardiness about 60 to 70 Shore A) Stocl/elastomer with PTFE costing 0.10 010 10 {he Hy Value for stesliconcrata is equal to 0.4Page 11 DIN 19704-1 : 2000-00 Table 4: Friction cootficients for machinery Sliding fiction ooetfcient, p Material combination by Wet Lubricated were Minimum | Maximum | Minimum | Maximum | Minimum | Maximum Steolistee! oto | oss 0,10 0.15 002 0,05 4 Stealecpperaty| aio [ois [oro | os | 002 | aos WW Stainless steel? ‘self-lubricating G12 O15 0,03 0,10 - 10 copper alloy 6.4.2. Wheels on rai jhe oling friction coefficient. 1.5., shall be obtained by calculating j/R (where R is the radius of the wheol and fis the lever arm of the ralting friction), with # equal to 0,5 mm for steel with a Brinell harcness of not more then USLHES anc 0.2 mm for oteel with a Brinell harcness of not less than 300 HBS. Intermodiate values may fe cotermined by linear interpolation 6.4.3, Wheel flange friction For wheels with a flange, a flange friction equal'te 1/100 of the wheel load shall be taken into Account when it has an adverse effect. 7 Analysis of steel structures 7.1 Scope of analyses Analyses of the steal structures at ultimate and serviceability mit stato, and an onalysis of their positional stability Including safely acainst uplift and eapsizing) shall be provided. the serviceability lit state anayen mainly deals with deformations with a view to ensuring the movablity and sealing function of gales ard ha reliability of crivos, 7.2 Analysis of effects of actions [The design values of effects of actions shall be determined using the characteristic values of actions as set out in clause 5 for the load cases to be specified by the client. Design shail tako inte account friction os set erin Clause 6, by Using partial safety factors % and, where mere than one variable action occurs, cootficlents Partial cafoty factors and coefficients shall be taken from 8) table 8 for ultimate limit state analyses (with the exception of fatigue assesaments} b) subclause 7.5.4 for fatigue aesessments (cl. table 8): ¢) subclause 7.6 for serviceability limit state analyses, Mt specitied by the clfent, accidental hydrostatic and hycrodynamie actions may also be classified as load case 2 I" hydrostatic and hydrodynamic actions that make a load contribution are present at the same time as such that result in toed reduction, both shall be multiplied by tho came y or vale {he dasign vaiuos of actions from drives on the steel structure in the case of a malfunction shall be muitiptied BY fesrom fable 6. For permanent actions resulting in load reduction (e.g. from counterweights), both yr an weshall be taken as equal to unity. To take into account impact from ships on impact protestion jacilties as set out in subvclause 5.2.11 and for {ov Tepe pulling forces on bollards as sel out in subclause 9.2.13, 7, shall be taken as equal to 1,6 and yequal to unity, NOTE: y; can be derived from tho following equation: Ye= Yee Yiays. (See item (808) of DIN 18600-1}, 1.3. Analysis of resistances Resistances shall be obtained using resistance values and the partial safaty factor yas sel outin subclause 7.3 of DIN 18800-1Page 12 DIN 19704-1 : 2000-00 Table 5: Partial safety factors and coefficients for ultimate limit state analysis of steel structures {excluding fatigue assessment) Buisasa ; Basicload cases | Accidental No] Getegory Type of action Asin load cases'y99) 1 2 3 1 | Permanent | Permanent actions sa | % o 2 ~~ [Hydrostatic actions 52.4 [3 Hydrodynamic actions 522 4 Water foad 5.2.3 3 ice load 5.2.4 "He “6 | Variable [imposedtoad Be] Po | yas 7 Forces due to inertia 52.7 veg | yp=135 8 Changes in support conditions 5.2.8 3 icepressure 525 | 10 | Thermal effects 528 . Ship friction 52.40 Leaking of air chambers 5a 19 | Accidental | Actions under vansport, erection) 5.8.2 and repelr conditions i [Moods dentin | as] 7a eee | ofa maltunetion et 1) Variable actions epecified by the client as occurring simultaneously shall only be taken into account f they are likely to coincide 2) Accidental actions shall be considered separately. 3) Other actions may be specified by the olient (see subolause 5.4) 7.4 Procedure Steel siructures comprising the gates shall be dasigned by elastic theory, using tho olastic-olastic method specified in DIN 1880-1 To enable continuous skin plates to resist edge moments, a higher loadbearing capacity may be assumed making use of Uie plastic reserves, if bending due to local leading (apart from that occurring in skin plates as aresultof concurrent action of stresses in the steel structure forming the gate), istakan into account, and there are only pulsating stresses. The equivalent stress cue to multi-axial loading, o, may in thia oage exceed the design yield strass, f,4, by 20 % on the surface of tho ekin plate NOTE: It should be noted that in some cases (e.9. where gates operate both ways), the stresses oscurring at skin plates may be alternating instead of pusating. 7.5 Ultimate limit state analysis 7.54 General In gonoral, subclauses 7.5 and 7.6 of DIN 18600-1 shall apply unless other provisions are made below. Reference shall be made to DIN 18809 where gates ar2 to bear the load of vehicular traffic passing over thom, 7.5.2. Stability analysis A stability analysis shall be carried out as specified in DIN 18800-2, DIN 18800-3, DIN 18B00-4 and DAST- Fichtinie 017 for the load cases specified in subclause 72. The stability of plates subject to concurrent compression from the steal structure forming tho gate anc! bending due to local loads (e.g. skin plates) shall be verified as spocifiad in item (802) of DIN 18800-5. 7.5.3 Analysis of positional stability Positional stability shall be verified for all load cases specified in subclause 7.2. Positional stability shall be at least 1,5 when the characte‘istic values of actions are applied. A partial safety factor equal to unity shall be used for permanant actions reeulting in @ load reduction Verification of safety against uplift shall be made. I shall be ensured that floating gates will not capsize or sink It shal be the responsibility of the cient to spacity the maximum angle at which the gate will be permitted to tilt in the longitudinal and trancverse directionsPage 13, DIN 19704-1 : 2000-00 7.5.4 Fatigue assessment 7.5.4.1 General Fatigue assessment shall be to clause 9 of DIN V ENV 1993-1-1 for load case 1 from table 5, Dut taking into ccount the partial safety factors from subclause 7.5.4.2. Other specifications may be used for detail categories ‘not dealt with in that standard, Appendix A shall be taken as a basis for determining collective stresses, Dynamic effects shall only be taken into account if they result in a change in collective stresses. Unless otherwise stated by the client, a service life of 70 years shall b= assumed. 7.5.4.2 Partial safety factors A partial safety factor, q. oqual to unity shell be applied to take into account fatigue action. ‘A partial safety factor, 744, equal to 7,85 shall be applied to take into account fatigue resistance. This may be reduced to 1,15 when calculating the design value of fatigue strength for pulsating compressive strooses in skin plates. 7.0. Serviceability limit state analysis 7.6.1 General Serviceabiity kimit state analyses shall be made using partial safely factors yp and yay and coofficiont, yall equial to unity. 7.6.2 Deformations Where the sealing perfomance, movability and support conditions of stustures are liable to be affected by deformations wf the structure, it shail be ventiad that such deformations are within the permissinla limits to maintain the sealing performance aad movability ofthe structure and ensure the proper operation oi machinery Analysis of deformations may be based on the eross-cectianal values of gross cross sections 7.6.3 Closing pressure The closing pressure on flat bottom seals shall be obtained from the resultant of all vertical foreas, with the sealing line being the underflow edge of the seal. The closing pressure along the seal shall be atleast § kN/in 7.7 Further provisions 7.7.1 Beams with wide flanges When determining the stresses in wide flanges of straight or circular arched plate beams, shear lag shall ba taken into account using elastic theory, When introducing normal force, it may be asoumed thatthe flenge makes @ full contiibution outside the area of load tranamission. Within the area of load transmission, the stress may be determined assuming the toad tO bo transmitted at an angle of 45° to both sides of the line of action (ct. figure 3). NOTE: Large normal forces are withstood by elements such as the thrust bars of mitre gates. Such elements need to be designed separately for normat loads and bending, 7.7.2 Design of plates in bending Tne internal forces and moments occurring in plates as a result of bending due to water pressure shall bo calculated by elastic theory, assuming rigid support (ct. subclauses 7.4 and 7.5.2) 7.7.8 Cut-outs in plates Fatigue assossmont shall take into consideration the higher stresses al the edges of cut-outs (e.g. manholes, drainage holes}. Figure 3: Effective flange area under normal leadingPage 14 DIN 19704-1: 2000-00 T.4 Ralls stress analysis shal be made of rails and rail supports (sleepers) (see figure 4), based on the assumption that these make a major loadbearing contiibution. To this end, calculations shall assume a beam on an elastic foundation, using a bedding modulus, C, of 250 N/mm®, Subclause 10.22 shall be used when verifying Hertzian proscuros. Unless verified otherwise, the minimum thickness of block rails (rails of rectanguler cross section), fy, shall be equal to 86 i! the rails direatly supported on concrete, and 36 il the railis supported on stool embedded in the conerete, with b as in subclause 10.22. With the exception of guide rails, the minimum distance of the rail or the sleeper trom the conorete side face, &, shall be 120 mm (ee figuie 4). it may be reduced if a stael cladding is fitted on the concrete surface, are if this is sufficiently anchored by reinforcing bers in the y cirection The maximum conerete compression under a rail or under the flange of the sleaper shall be calculated as follows: MAX Pooncacte = Pal sey a K shal then be compared with the resistance of the conerate eo set out in subclause 5.4.8.1. of DIN V ENV 1992-1-1. The following notation is used: Fy design whee! load (cf. subclause 9.3) Ae =4:(640')(b + 64, notional concrete area in comprossion, as in figure 4 4, somiaxes of the elliptic contact face between the crowned roller and the rail surface, as specified in subclause 10.22; a 26, witha’ < ih: Bony ho shyt hy ¢ smallest distance of oliptic contact face from rail edge, In he calculation, A may bereplaced bya cicularareact the samesizeitits ratio of side length than2t ‘The concrete used shall nocmally be of strength class ©25/30 to DIN V ENV 1992-1-1 \Wh duo regard to pulsating compressive loading, the design value of the eyindor compressive strength of 2) on rn onan (2-52) os concrete shalt bowutitzed with (11°88). 490 96 for 108 anc with F5— SAX} - 100 9% for n> 108, 1 being tho number of rolling contacts isnot greater 6 Characteristic values for actions on machinery 841 General Forthedesian of machine components, gates shallbe assumodito bo in their most unfavourable position, tekng into account the same load cases as for the otoa! structure (cf. table 5). Gates can be assumed to be at resto moving (at constent, accelerating or decelerating speed) {shall be verified that, assuming the highest possible loads transmitted on the drive side (see subclauses 5.4.2 and 5.5), the values of actions donot exceed the rosistances of the machine components ane thested! stricture forming the gate. 82. Determining drive forces The charecteristic values of loads or moments 2s a result of the following shall be determined 2) actions on the steel structure as set out in subclauses 5,1, 5.2.1 to 5.2.5, 8.2.42, and (where ppticable) subclauses 5.9 and §.4; 5) s2lF weight of the connecting etements between drive and gate and self-weight of the rollers and guido. ways, ¢) friction from roting equipment and guideways, as set out in clause 6; 4) fiction as in table 3; ®) friction of sprocket chains, pinion drives, rope drives and hinges; ) forces due to inertia (see subclause 5.2.7); 9) any non-uniform distribution of loads in the casa of gates with double-acting drives, and in particular gates of high torsional stiffness with a horizontal axie of rotation, In the cass of electromechanical drives, determination of mass forces shell be based on the assumption of motor and braking torques as in service. I required, the effects of auxiiary equipment that may limit torques (2g start-up couplings, frequency converters, thyristor controllers and overload protection devices), and the efiects of emergency cut-offs and power loss shall also be taken into accountPage 15, DIN 19704-1 : 2000-00, Block rail Sleeper Hertzian contact face Notional concrete area in compression Figure 4: Raile (notetion) Inthe case of hydraulic drives, the forces due to inoria may be ignored when designing machine components igiven the presence of pressurs-rolict valves). t shall be the responsibility of the clieat to specify any braking distances or braking times to be considered 8.3 Drive power [fe drive power required shall be determined on the basis of the motion times ofthe gate as specitied by the clien! and the characteristic values of actions taken fromsubslause 8.2. Generally accepted valves shalloe ised {or efficiencies and frictional losses of machine components (references to the relevant iterature heing pro- vided), On the basis of the values required for tho drive power, torque and force, the nominal motor torque of electro- mechanical drives of, for hydraulic drives (hydraulic cylinders, hydraulic pumas, hydraulic motors). design operating pressures as in subciause 5.5, shall De used. In the case of electric motors controlled by frequency converters, the nominal motor torque selected shall be at least 5 % greater than the required drive torque, Inte case of hycraulic dives, the design aperating pressure in the system, py, a, (cf. subslause 8.5.2.2) ahell be increased by at least § % when determining the electiie motors to bo eelsciaelPage 16 DIN 19704-1 : 2000-00 Manually opeiated crives shall be designed so that the continuaus power does notexceed 80 Nm/s. The manual force should not exceed 80N to 100N per person, and 250 N over the short term, 8.4 Characteristic values of maximum transmitted forces The actions of drives such as the stalling torque of the motor, the braking torque or the set values of pressure~ relief valves (to be secured by sealing) in hydraulic systems shall be considered as controlled variable actons. These shall be inctuded in the design calculations as charactar'stic values of the maximum forces transmitted The reaction to these forces shall be analysed for all essential machine compononte requiring ultimate state atalysis (excluding fatigue assessment), comprising the connection with the steel structure forming the gate or, if required, up to its supports (eee clause 8). Where electromechanical drives with overload protection or electric motors controlled by frequency converters are used, the highest torque that can be set (.e. the maximum drive torque) may be used instoad of the stalling torque in the ultrmate state analysis (excluding fatique assesement) of the machine components, Instead of the highest theoretical torque, the torque actually set may also be used in the ultimate state analysis if Ws is maintained by seating and cannot be exceeded during installation, repair or maintonance wore The torque set should be at least 25 % higher than the required drive torque as in subsiause 8.3, In cases where the drives of gates with double-acting drive are electrically or mechanically synchronized, the maximum possible imbalance of drive forces shall be taken into account 8.5 Hydraulic drives 8.5.1 Basis of esleulation The following provisions apply to drive systems using hydraulic cylinders or hydraulic motors, When considering service conditions (movement or halting of the gate), the determination of the design oper ating pressures, py, shall be based on the characteristic values of permanent and variable actions 23 in subslause 6.2. The drive system shall shut down automatically if accidental actions as set out in subclause 5.9 or 5.5 occur whila the gate is maving, (Fit is necessary to take into account accidental actions as in subclause 5.4, or other actions as in eubclause 9.4 (lo be specified by the client), as aresult of which the hydraulic cyinder or motorie oubjoct to sireases higher than those occurring during operation, the associated static prosoure, p,,, (see subclause €.6.3) shall be determined to supplement the ultimate state finit analysis (excluding fatigue assessment) for the ‘haliing of the gate’ load case. 8.5.2 Determining design operating pressures A distinction shall be mace between the dasian operating pressures in the hydraulic evindar er moter and those elsewhere in the system (se subclauses 8.5.2.1 and 8.5.2.2), 8.5.2.1 Design operating pressure in the hydraulic eylinder or motor Pressure in hydraulic cylinders or motors is composed of the following componen a] Pressure component 1, 1. the oll pressure acting on the effective area of the piston, obtained from tho characteristic values of actions and, whereapplicable, the sol-weight of tho cylinder barrel or the pistonrad., If in the case of doubie-acting hydraulic cylinders, both piotone are subjected alteinately to pressure, the dasign operating pressure chall be determined for both pistons, bj Pressure component 2, Le. any existing loading or supply pressures acting on the rear effective area of the piston (pressure increase or reduction). I the direction of action changes during = movement, the pistons shall be hydraulically pressurized on either sido. ©) Pressure component3, j.e.losses due to friction caused by seals and guideways in the hydraulic cylinder. ) Pressure component 4, Le. pressure lossesin the pipework and manifolds, caused by cil returning to the reservoir, The sum of pressure components 1 to 4 gives the design operating pressure in the hydraulic eylinder or motor, Pp, and the corresponding value at which the pressure-relief valve DV1 (see figure 5) is recuired to be vet (the actual pressure setting, max pp, being 10 % higher, Le. max py = 1.1 +p, (2)) ands to be sealed), The design operating pressure in the hycrauic motor shall be determined as the ratio! therequired drive torque {0 tho torque of the hydraulic motor related to the pressure. 8.6.2.2 Design operating pressure elsewhere in the systom ‘In addition to pressure components 1 to 4, the following shall be taken into account. a) Pressure component 5, i.e. pressure losses in the pipework on the pressure side. ) Pressure component 6, 1-2, pressure losses in open and closed loop contral equipment, and in control blocks. Pressure components 4, § and 6 shall be datermined with an oll viscosity at the lowest anticipated ambient tomparatura, which, in the open, will generally be 25 “C.Page 17 DIN 19704-1: 2000-00 The cum of pressure components + to 6 gives the design operating pressure elsewhere In the System, Pa, ng end the corresponding value al which pressure-reliet valve DV2 is required to be set ithe actual setting sik 10% higher, Le. maz Py gy = 111 “Pp, ap (3)) and is to be sealed]. 5.3 Determining static pressure in the hydraulic cylinder or motor When considering the ‘halting of the gate! load cose, static pressure in the hydraulic cylinder, up of prosoure component 1 end, insome cases, pressure component2 (ci. subclause 8.5.2.1) components may be ignored, The pressure inctease in tha hydraulic eylinder or motor in the accidental load case shall be limited by insta tation of a prossure-ratiof valvo (DV3}, sot at a value, maa peu, oy) QUAI 10 141° Pag, on (4) Pega cg IS made Othe! pressure 2.5.4 Oil proscure limit values 8.5.4.1 Limit values in normal operation Hydraulic crives shall be designed so that the values at which pressure-reliof valves DV1 and OV2 are set, max py, and max py, Fespectively, do not exceed 260 bar. The proof pressure, Ppieop shall be not less than 1,3 max py, a. (5), with a maximum of 326 bar. 8.5.4.2 Limit values in the caco of a malfunction The value at which valve DV3, to be mounted to the hydraulic cylinder or motor, is to be sot shall not oxcoed 300 bar. For accidental load cases, valve DV1 does not become operative. 8558 Pressure limiter Whore a pressure limiter with electrical pressure release is provided, it shall be setat aresponse value, p,, equal t0 0,95. maz pr (0), where mas pp Is the Set value ot valve DVI asin subciause 8.5.2.1 v3 bys Piston chamber, unpressurized Piston chamber, prossurized Electrical pressure limiter Pressure side To reservoir pews Figure 5: Location of pressure-relief valves on a single-acting single rod eylinder (example)Page 18 DIN 19704-1 : 2000-00 9 Analysis of machinery 94 General The design of machinery shall bear in mind the need for adequate loadbearing capacity, fatigue strength, reliability and low woar, taking into account the requirements relating to design and fabrication as in DIN 19704-2 and electiical equipment as in DIN 19704-3, Machine components shall be designed by elastic theory. 9.2 Scope of analyses Ultimate limit state analysis (including otros analysis for static loading, stability analysis and fatigue assess- ‘ment is required for loadbearing machine components andtheir fasteners. Asa rue, utimate limit state analysis is also to include serviceability limit state analysis. Special machine components (2.9. gear whcols and chain joints) may need to be designed taking Into account wear, dimensional ctobilty (e.g. for long shafts), resistance to fracture (e.g. for rope drives) or stability (a. for slender hydraulic cylinders, pinions anc linkage) 93 Analysis of effects of actions in ultimate limit state analysis (excluding fatigue assessment) of the machine components contained in me- chanical, hydraulic, emergency and manval crives, stresses shall be determined on the basis of the design values of actions, The characteristic values of the maximum forces transmitted (cf. subclause 8.4} multiplied by the partial safoty factors, yp, from table 6 design values shall be taken as the design valuas, Each of the abtions listed in table 6 chall be considered separately assuming y aqulal to untiy. For all machine components net subject to direct loading from the dives (@.9. wheels, quide rollers, dogs, hinges, pivot bearings and locking mechanisms). ultimate lit stata analysis shall bo eartied out based on tre design values of the same actions and load cases as are requited in the analysis of steel structures, Since the most unfavourable values thus obtained already include factor yp and coelfcient y trom table 5. they canbe used as the dasign offecte of actions. ‘The design values of the actions on lateral guides (wheels, rollers, skids and their springs) specified in sub- Clause 2.1 of DIN 19704-2 resull fom the requirement that lateral guides have to Fold or reset the gate a specified position fin which case hydrostatic and hydrodynamic actions on the skin plate and friction on totter sills may be neglected), For each wheel, roller or skid, at least 5 % of the design value of the permanent load fon the gate, but not less than 10 kN, should be assumed, 9.4 Calculation of resistances Caloulation of resistances of machine components shall be based an the data from subelause 4.9, Thedesign valies atthe yelé stress f, 4,01 the0,2 % proof stres3,/4 4 Sill Detaken asthe resistance, whore faas= hyd 4 (2 274 fog a= foalg (0) Sosumming a valuo of 18 fori With the exception of high-strength bolts, the yield stress or 0,2 9% proof stress used in the calculations shall Act exceed 70 % of the tensile strongth. Table 6: Partial safety factors, yp, for actions of drives no. | Type of action tk 1_| Drive torque of mechanical drives, limited by auxiliary equipment’) 1.98 2 | Btling tetgue-bvig aborts 138 3. [Design operating prossure in tho hydraulic system for Service conditions, lated tothe sat] 1.36 values of valves DV1 and DV2 - | 4 | Drive torques of emergency and manual drives _ 8_| Motor stalling toraue _ - 1.10 9 _| Braking torque in an emergenoy stop or eccidental action (e.g. power loss) 1.10 7] Maximum operating pressure inthe hydraulie cylinder or motor in the caso ofan accidental | 1.10 action, related to the set value of valve DVS ) See subclause 8.2.Page 19 DIN 19704-1 : 2000-00 9.5 Ultimate limit state analysis 9.5. Analysis of stresses under static loading Astress analysis of machine components under stating loading conditions chall bo provided, It shall be verified that the stresses, essuming the design values of the actions specified in subclause 9.3, do not exceed f, 40° fy», 4 8 In Subclause 8.4, ‘gnoring local peak strasses as a result of impact Inthe analysis of mechanical and hydraulic drives, the product of 7p and yy (of. subclauses 9.9 and 9.4) may bbe reduced by 10 % for static loads when considering accidental load cases. 9.5.2 Stability analysis Vihen analysing the stability of machine components, DIN 1600-2, DIN 12800-3 and DIN 1€800-4 shall apply by analogy, using partial safety factors, 1, as in subclause 9.3 and calculating the resistence capacity using 8 yy valuo of 1,6 9.5.2 Fotigue assessment 9.53.1 General For machine compenents made of stee!, it shall bo verified that the fatigue strength is sufficient to accommo- date loads from the actions specified in subciause 8.2, that are anticipated to occur during nomal operation. The service liie of machine components and their electrical equipment, with the exception of parts cubject to wear le.g. ropes and bushes of sprockat chains), shall be assumed to be 86 jears, and the anticipated collective stress shall bo taken into account for the fatigue assessment. ‘The service life of parts subject to wear may be specified by the client. The collective stress for rotating machine componente shall bo determined taking into account the number of sirese cycles (number of revolutions). A fatigue assessment is not required where the total number of stress cycles is 10 or loss, ‘The fatigue assessment shall include the amplitudes of longitudinal stress, Ag’ and of shear Sires, 4, to be calculated from tha nominal stesses as in subclause 9.5.3.5 or from the notch stresses asin subclause &.5,3,4. When calculating stress amplitudes, the reactions toloads or moments (as in subclause 8.2) shall bo determined for allessential machine components, starting with the motor, and their connections, and theas taken es design values In the calculation, a damage-equivalent constant stress amplitude may be substituted for variable stress amplitudes. For fatiguo assessment, actions of the drives shall be assigned a partial safety factor, yy, equal to untty. The came factor chall be used in the fatigue assessment Of machine components that are fot Subject to direct loading from the drives (see subciause 9.3). 9.5.8.2. Fallgue strength The design values of fatigue strength (1.6. the acceptable stress amplitucles) shall be obtained as follows og 4 = 80K, he °) Ata = te Me (10) where dog, pand Asp j.are the characteristic velues of fatigue strength and y4q shall be taken to be equal to 135" 9.5.3.3 Analysis based on nominal stress amplitudes The difference betwocn the maximum and minimum nominal stresses shall be taken as stress amplitudes Ao ond Ar [calculated according to elastic theory, ignoring any notch effect) at the celevant point of the cross section under consideration. Fatigue assessment may be omitted if eithor Aa S 26/ yy aNd AT S 36/4 (nt) N £ 5-108. [26/(yyy-Aal}® or N = 104-[O0Ayyy Aa), i) with Ag and Ar in Niro. Otherwise, it shall be verified that Avand At do not exceed the Agg g and Ary q values as in subslause 9.5.3.2. Tho dag , and Arg y values shall be used taking into account the relevant detall category and making reference to the lligrature used (e.g, the detall category tables in DIN V ENV 1993-1-1). NOTE: In the analysis considering nominal stress amplitudas, the influence of poak streases a8 a result of the local geometry (notches) of the structural member is inoluded in the detail category lables. 8.5.9.4 Analysis based on noteh stress amplitudes It the local geometry of components is not allowed for in detail category tables, the maximum and minimumPage 20, DIN 19704-1 : 2000-00 Notch stresses {peak stresses) shall be determined, and Ag and Ax shall be established 2s the difference between these, using concentration factors a, where relevant, patigue assessment ofnon-welded machine components made from unalloyed or low. alloy structural steel may be dispensed with if: Bo S TT yg 2nd Ae < 46% py (19) N 2 8-109. (197i: Adlp or AF 10°» 146A y ye AQP, ny with Aoand Ar in Nimm?, Otherwise. an approximate method may be used to verify that the amplitudes Acand Ar of the notch stresses do not exceed the Avg, 4 and Az 4 values as in subolause 9.5.3.2, 2. AOS Adg g ANG ATS Arty g (15) As an altemative, fatigue assessment may be made substituting for the full amplitudes of the notch stresses, these amplitudes reduced by the ratio of the fatiguettector, A, to the stress concentration factoryay, 26 follows: Ao- Bla, S Ao, and At Bila, < Atm (16) The faluzs of hetunnotched material shall be used as characteisis values of fatiguo-strenath, Adp and tay 4, ANG fi, (which shall not be greater than «,) shall bo uced making reference to tho relevant lnvatac "+ Serviceabilty limit state analysis Ifa sorviceabilty limit state analysis is required for machine components (e.g. in cases where there arerestie- fons on deformations or when determining wear rates}, analysis shall be based on tho charactodatle values (sing 7% equal to unity) of the loads or moments as in subclause 8.2, and the resistances snl be calculated with Yo equal to 1,0 10 Analysis of special machine components 10.1 General When determining the stresses and resistance capacities of the special machine components covarsd in Subciauses 10.2 to 10.26, clause 9 shall be applicable unless otherwise specified in the following, l'special machine componente ars designed cn the basis of global safety factors, Shall bo used instead of the product of yp and 7y as in clause 8. In ths case, the stresses resulting from ihe characteristic values trom clause 5 end subclause 8.4 (cf.tables § and6) shallbe compared with the parmivelbla Nalucs (i. the characteristic values of the resistances divided by ). ignoring partial eafaly factors end cone bination factors. instead of a strass analysis, a comparison of other physioal parameters (e.g, of outputs, torques or oparating hours) may be made. {1 crive assemblies as specified in subclause 10.7 of DIN 19704-2 are used for small gates subject to minor loads, an inspection douement as undor itom g) of subclause 9.2 may be provided instead of carrying out an 10.2 Hydraulic cylinders 10.2.4 Stendardized cylinders Analysis is not required for hydraulic cylinders sonforming to DIN 24339, which have no influence on the motion of the gate and are with pistons 126 mm or less in diarrwter, 10.2.2 Stros analysis for static loading Design of the cylinder barrel shall be based on DIN 2418-1 The analysis assuming service conditions shall use safety factors, S, taken trom table 3 of DIN 241-1, load Case | increased by 40 96. These factors shall also be used instead of the product of yy and ry to takeaccount 97 abnormal load cases as a result of a malfunction, 10.2.3 Analysis of buekting strength For slander hydraulic eylindors, the buckling strength shall be verfied by second order theory as set ou DIN 18600-2 F the safety factor of the notional buckling load (see DIN 18B00-2), ie not greater than 10. When calculating the smallest notional bucking load, N,,, by elastic theory, the system corsisting of the gylinder barrel and piston rod may, for convenience, bo azcumed to consist of two camponents of different cross sections. The analysis shalt take the following into account:Page 21 DIN 19704-1 : 2050-00 a) an equivalent initial bow imperfaction in the form of one sinusoidal half-wave witha maximum deviation, Hig, equal to L/300 (where Lis the distance between the joint axes), to cover the cleatance of the piston and piston rod guide and the manufacturing tolerances (e.g, including cylinder wall thicknesses): ) bending as a result of bearing friction in the rod ends; ©} the design self-weight in the case of a non-vertical axis. ‘The piston and piston rod guide shall be analysed for comprassion. 10.3 Hydraulic pipes For the design of hydraulic pipes, DIN 2419-1 end DIN 2415-2 shall be used, with the same safety factors ag subslause 10.2.2. ‘Analysis is not required for pipes designed for a maximum operating pressure, maz pyy of 26 bat. 10.4 Hydraulic components Hydraulic components such as hydraulic pumps, hydraulic motors, standardized hydraulic cyinders, and open and closed loop contrel devices, shall be selected so that the nominal operating pressure according to the manufacturer's data sheeisisat least 25 % higher than the design operating pressure, maspy ,..te subelaure 85.2. 105 Electric motors Drive motors shall be selected s0 that. within the range from etandetil to nominal speed, the motor torque Is higher than the relevant characteristic valuo of the momentas in subclause 8.2, in order to ensure tat the motes starts up and runs at constant speed when the gate Is at any position, 10.5 Brakes Brakes shall be designed in accordance with DIN 15431 and DIN 15434-1, The required braking toraue, erf M,, is obtained from the characteristic values of the moment (including any braking torques of rotated or linearly moved masses; cf. subclause 8.2), referred to the brake shart. Forservice brakes, the braking torque of the moved mass may usually be taken to be 10 % of tho moment due toaload at rest. Itmay vary asa function of the braking distancos or times specified by the client, ot depending on the dynamics of the braking process, Holding brakes shall be selected so t hhigher then the design braking torque, Constant deceleration during the braking time may be essumed. at minimum friction, the actual braking torque is at least 2,5 times 10.7 Couplings DIN 115-4, DIN 116 and DIN 740-2 shall apply with respect to clamping, flange and flexibie couplings. 10.8 Shatts DIN 746-1 and DIN 748-3 shall apply with respect to grooved shalt ends. For shafts with a ratio of span to diamoter of §0 or mora, the angle of torsion shall be calculated, with 20 angular minutes par metre permitted under the characteristic values of actions, Inthe case of fast rotating shatts, the critical speed and, if required, the effect of the speed on the supporting structure, shall be taken inte account. The deflection of shafts under the characteristic values of actions shall be not greater than §/1000 times the modulus at a gear wheel, and not greater than 2/1000 times the chain pin diameter for a flying chain pinion. 10.8 Shaft-to-hub connections 10.9.1 Keyed shatts and splines Surface pressure shall be verified for keyed shafts and spline combinations with shaft and hub, [ispiattalse be veritiod that, assuming the design vaives of actions, p, 4, compression is not greater than f, / ne (17) for shafts or splines with one key and not greater than 0,75 f, yyy (16) for shelts or splines with twolkeys Assuming constant surfece pressure, an effective length equal to nol more than 1,2+d may be used (d being the shaft diameter). 10.92 Interference tits DIN 7190 shall be applicable to intorforonce fits. 10.9.3 Involute eplino joints ‘The DIN 5480 series shall be applicable to involute spline joints.10.9.4 Ring cone locking assemblies The resistances of ring cone locking assemblies shall be ve manufacturer. of design values provided by the 10.10 Toothed gearing Fortoothed gears and racks, the root strength, piting resistance, scutting resistance and fatigue strength shall be veriffed as specified in DIN 3300-1 to DIN 3990-6, DIN 3990-11, DIN 3990-12, DIN 3990-21 and DIN 3991-1 to DIN3991-4, Proot shall bo provided for torques derived from the characteristic value of the nominal motor torque as in subciause 8.8, The following parameters shall be used: a) en application factor, Ky, of 1,5; b) @ service lite of 26 years; ©) a pressure angle, dq, of 20°; 9) safety factors allowing for: breakage of tooth (rcot strength):S, = 3,0; pitting, Seat scuffing; S, > 2,0; 2) toothing quality as in DIN 9960 to DIN 3965 and DIN 3967; tor closed gears: hardened and ground tooth: grade 7; milled or shaped teeth: grade & for open gears: where v = 0,8 més: grade 9; where » < 0,8 m/s: grade 10, v being the circumferential speed at the pitch circle. These parameters do not apply to cast toathing. ‘The material data applicable to grade MQ from DIN 3990-5 shall be applied. Instead of calcuiating the root strength and pilting using K,, fatigue assessments to DIN990.6may be carried out using safety factors S, and S,, to take into account tho cellective iad, 10.11 Worm gearing Worm gesring shall be designed for torques dorived from the characteristic value of the nominal motor torque as in subclause 8.3, ‘The toliowing parameters shall be used! a) an application facter, Ka, of 1,5; ) a service life of 40.000 operating hours, unless a shorter serve life is specified by the clients 6) safety factors allowing for breakage of tooth? 5,2 2,0; pitting: Sy 21.8; weer: Sy = 1,0; Deflection of the worm shaft assuming the characteristic values a the actions shall not exceed 1/100 of the ‘modulus, NOTE: The specified service life includes a margin to cover short-time operation. 10.12 Plain bearings made from nonferrous casting alloys The following requirements apply assuming a short-term low epeed typical of components used in hydraulic steel structures (e.g, plain bearings ef whels and rollers, gudgean bearings and pintle bearings of mitre gates, chain joints and journal bearings of radial gates}. For plain bearings with the contact faces made of a combination of steel and nonferrous casting alloy, the steel shall have a Brinall hardness ofat least 220 HAS (asin DIN EN 10008-1) and the nonferrous material s hardness lower by af least 80 HBS. The design values of the contact pressures shall be veritied for centric loads using the following: F an gt Sone (19)Page 23 DIN 19704-1 : 2000-00, where Fis the design value of the force in the joint (or 7¢-fold loading}; die the bearing diameter; {isthe effective length: %1,_ IS the design value of the bearing resistance. {P2 ta. values given balow shall be applicable unless the manufacturer of tha nonferrous material recommends smaller values for specific applications. For pin Bearings with extemal lubrication, the oj, , valuo (in N/mm) a function ofthe Btinell hardness of the nonferrous material. For slewing movemonte, apy, ~ 0,90 “HBS (20). sing scabricating plain bearings made from nonferrous meterial with sold lubricant packing, the effective sting eurtace area shall be calculated with that of the non-motal components deducted! In ths cass, 0118 3 function of the Brinell hardness and the distance covored por year, » For slewing movarmente: aff oar = 4.9 Hes YE #1) ‘whore + ie tho distance covered per year in m, with a minimum of 8 m, to be calculated as follows: 4 © 2) where is the number of slowing movements of the loaded gate per year: £ is the gate swivel angle, in radians; dis the plain bearing diameter. Teo aga hardness numbers te be used in equations (20) and (21) for nonferrous materials shall be taken from 1s0 4384-2, For plain bearing bushes which rotate under load (except for bush: resistances shall be reduced by hall in sprocket chains), the design values of 10.13 Plain bearings made from composite material with solid lubricant ir epetling requirements apply, assuming a short-term low speed typical of joints, wheels and rollers used in hyorautc steel structures or plain Bearings mede trem a combination of steel and composite material, the steot shall have a Binet hardness of at least 220 HBS (as in DIN EN 1003-1) ‘he design surface pressure shall ba vorifiod for centio leading using equation (19), Thee ales listed below shall apply uniess the manutacturer of the compesite matotia’ recommends @ ‘mallet value for specific applications ralreg Ubticating plain beatings (made of sintered copper alloy, with integrated sold lubricant) and for thine alld, toled bushes consisting of a metal case with a sintered Copper alloy raceway at onat Ton Mele nd For slewing ceaent ci. i function ofthe aistancecovered per year and the Brinellhardneos of theraceuray For slewing movements acaa-nes. VE ey Where s is the distance from eubslause 10.12, being not less than $m for thin-walled, rolled bushes, and otherwiso not loss than 20 m. ‘The Brinethardness number to be used in equation (23) for composite material shall e taken trom ISO 4984-1 For Pian Bearing bushos that rotate under load (except for bushes in sprocket chains), the design resistances shall be reduced by half. 10.14 Spherical plain bearings: Eo Spherical plain beatings, the contact pressure shall be calculated forthe slicing surface and the resistance objained compared with that given by the manufacturer Moreover, the servic life shall be veied 2s a function of the number of fl slewing movements of the gate ‘The rato of the axial load to the radial load, #/P, shall generaly be not greater than 0.25,Page 24 DIN 18704-1 ; 2000-00 Figure 6: Eye bar, chain linkptate and eye plate 10.15 Eye bars, chain link plates and oye plates For eye bars, chain Ink plates and eye plates, analysis for static loading and fatigue assecement shall be Provided on the basis of the assumption that the design width of the smallest cross section (‘web' ross Section), ¢ (movement from one end position to the other and back) is not greater than height a (see figure 6): {In the analysis for static loading, the nominal tensile stresses in the web cross section shall be calculated assuming the design values of actions and to allow for friction in the joint increased by a factor, f, obtaned as follows: Pal +pdiia +o) e4 where p is the friction coefficient taken from table 4, {shall be verified that the nominal stress increased by factor # is net greater than the design yield stress, Le. Oy = Be Pell2et) = fy, tag 5) where Fy is the design tensile force to be transmitted; £ is the eye plate thickness. Moreover, it shall be varified that the peak stress characteristic value of the yield stress, ie. in the web cross section, max a does nol exceed the MAE T= Ay * Oy < fy (26) Ifthe clearance in the holeis not greater than that forthe H9/e8 fit, nd ¢ more detailed analysis is not provided, the stress concentration factor, a,, may be obtained as follows: we (od) (eH on where b=ze+d and c< este, The governing factor in the fatigue assessment shall be the difference batween the peak stresses in the wols at the edge of the hole; however, this shall be caloulated on tha basis of the characteristic valuo of the tensile force, Fi 10.16 Chain joints {shall bo verified for sprockot chains thet the contact pressure in the joints, o,, deriving from the chain design tensile force, 7y is not greater than the design resistance, oa ,, e= Feld 15 on (28) where @ Is the chain pin diameter; 1 is the centre distance of pins (pitch) The length of bushes mada trom composite material shauld be not shorter than 1/4 of the pin diameter It shall be assumed that only one pin transmits the force to the wheel.The cosign resistances of plain bearings, a, oF dy ., shall be determined as specified in subclauses 10.12 and. 10.13, For the design of guides for chains, a force not ess than 5 % of the chain tensile force shall be assumed to act normal to the auides. ltmay be assumed that adjacent plates of a chain link have the same loadbearing capacity. 10.17 Red ends ‘The provisions for plain bearings as in subclause 10.14 and eye bars as in subclause 10.15. shall apply by analogy to rod ends. 10.18 Pinion racks, pinion chains and gear racks ‘The design of pinion chain pins and teath shall be based on the bending stress and the contact pressure botwoon the pins and teeth. The characteristic tensile strength, f,, ,. of the pin material shall be not less than 500 N/m, ‘The provisions for plain bearings as in subclause 10.12, composite material bearings as In subclause 10.13 and ‘wheels as in subclause 10.22 shall apply by analogy to guided pinion chains deflected under load. Guides shall be designed to accommodate thelateral forces which result trom the geomotry, taking into account apartial safety factor, 7, of2,0. The design lateral forces shall, however, be assumed to be at leas! 5 % of the dosign comprosaive forse of the pinion, even if the guide is designed to be straight. Moreover, at the point where the wheel and the pinion mesh, the guide shall be designed to accommodate a force equal toatleast 30 % of the tensile or compressive force from tho chain, acting porpendicular to the guide. 410.19 Rolliag bearings The design of rolling bearings shall be a6 specified in DIN.732-1, DIN 792-2, ISO 76 and ISO 261. 10.20 Rope drives The design of rope drives, including the ropes for counterweights, shell be based on the specifications of DIN 15620-1. Load case 3 ‘heavy’ shall be assumed when designing the drive assembly and normal trananor’ shall be assumed when designing the rope diameter as in table 2 from DIN 15020-1, February 1974 edition. I shall be the responsibility of the client to specify the class for sorvice lifo, For accidental load cases, the characteristic tensile force of the rope shall be given a threefold factorof safety against its reaching the minimum breaking force (which is the product from the stranding factor. cross section 07 the rope, and nominal tensile strength of wires! 10.21 Rope wheels, rope drums and compensating rollers Forrope crives, as a deparature from the spocificatione of DIN 1020-1, the ratio of the wheel or drum diameter, D, to the nominal rope diameter, d, should not be less than the values given in table 7. 10.22 Wheels, guide rollers, ‘e gate dogs and rails It shall be verified tha the maximum Hertzian pressure, mas p, for wheels, guide rollers and rails subjected te 2 design wheel pressure, F,, calculated in accordance with subslause 8. is not greater than the design resistance, pp, g Le. max Py Pp, « (29), This analysis isto cover the ultimate limit state andinclude an analysis of fatigue strength. A sorviceability limit state analysis is not required. Table 7: Diameter ratios for rope drives with counterweight suspensions Dave components na, Tope whess “ Lok gates Rope auns oa [" Compensating rire | 16 Rope wheels: 32 Weir gates Tepe cms 25 Compensating roles 4Page 26 DIN 19704-1 : 2000-00 Inthe ease of crowned wheels or rollers and fa all surfaces, the maximum Hortzian pressure, max pis given by the following equation: _ 15 Fy 15 2 14)? MOEA ab amy YR TOR lea ¥ 0) where Eis the elastic modulus of the wheeV/roller or rail material; Fs ts the design wheel/roller load; R is the wheel/roller radius; R, ie tha crown radius (R, = R), 2 Is the Poissons’s ratio of the wheel/roller or rail material. For the major semiaxis of the resulting elliptic contact face, the following shall apply: face 6 ITT lta ny y ans for he mina seman pefs 8 Coefficients g, and shall be taken from table 8: Tabie 8: Coefficients for Hertzian pressures 10 28 5.0 76 | 10 | 10 | 200 | a0 1 - 1,838 2,890 3,749 4,499 5,800, 6,929 8,876 ay 4 xaese | 129 | 2,1902 | 23904 26132 | 31571 | 3.7118 ve | 1 | oasis | oeare | aes | asora | o 210°: pag =P _ hhas to be applied —_ iat brackets dogs “| Table7, tow Ne.2.5 [pulleys wheels 0.23 16 inser’ afier shear: and torsion due to | friction, - | [i028 inser! afigrEOOE i, [factor fr yield creep ‘Appendix A: insert: (normative) A133 Supporting siee ‘Steel “| AIS it Barrier Flood A2i_ 2B the siress ranges: ‘iflerential stiessos A222 AD Sea lock LockMANUSCRIPT TRANSLATION May 1998 | Ee Zz Hydraulic steel structures Part 2: Detailing and fabrication | = o QI ° & oe ICS 93.140; 93.160 This standard, together with DIN 197041 and DIN 19704-3, May 1998 editions, suporsedes DIN 19704 and ‘Stahlwasserbauten ~ Tell 2: Bauliche Durchbildung und Herstetlung DIN 19705, Septem ber 1976 editions. Desoriplors: Hydraulic steel structures, water engineering. Contents 668 eae Foreword . 1 8.28 Toloranees for embedded elements... & # Beope. 2 b24 ‘Tolerances for gates . . 10 PO wi wise serssessese ess Be Tasting of wolds - sas 10 2 Normative roforences ...........2:22+++ 2 5:4 Testing of hollow structures. 10 . 5.8 Stainless steals»... 110 & Donalal abratieratens (6 alton, gS Combined use of Structural sos! and” 3.1 General requirements .. 3 stainless steel 10 32 5.7 Corrosion protection 10 82 Accessibilty . aa 3) ET PUTER N Piste coe 1G jachining of edges and welds -.....-. 33 Rooms for drive systems |... vo 8 Bre Coating iv 3.4 Locking mechanisms gs EES Coating vi oS ee ee 35.78. Cathodke protection 2.2 "1 3.6 Trash racks . 3 6 Seals . 37 Covers 38.1 Materiale- 88. Protection against ship impact 82 Design .... “ Se: pete a iretehip impact 3 5.3 Seal sliding ‘faces and stp facos 4_ Detailing of steel structures 5 14 Rubber seals 4 44 Gonoral 5 6.5. Sealing timber»... 4 42 Minimurn thicknesses... © 20. Lelteee: ab 43. Bolted connections 5 teu Geen 3 7 Prevention of foing ....cccsesceresscos st? 43.2 Minimum diameter of bolts end rivets 6 T.1 Heating of sealing faces... oe 12 433 Hole pitchos for bolls and rivets 8 7.2 Water cinculation 2... sees ses eecT® 494 Scouring of batts 8 6 Embedded elements .......0.ceeeer ceed 44 Welded connections S 8.4 Installetion « Q TS 4.4.1 Fill welds © 8.2 Gonoreting 12202000203 442 Butt welds 8 Ba Joints 13. 443 Flange plates 8 G4 Rails and guide mils « 18 4AA Welding of ocld worked components .. 7 445 Welding of loadbearing components .., 7 9 Design principles for machinory 14 4.4.6 Special precautions . 7 9.4 Supporting end guidance of gates ..,....19 45. Axle supports . .7 92 Drives seeeees ste aee pees Se Cutouts 7 921 Accessitilty 2 13 47 Fillor plates so... 7 9.2.2 Speed of gate... we 44 7 92'3 Suitch-off at end position’ 14 5 Fabrication of steel structures: 7 9.2.4 Synchronization monitoring and 8.1. Manufacturer's approval ...... 7 closed loop control .......2ee0se+see-14 52 Tolerances : 7 9.2.5 Position sensing systems - i 14 624 General . 7 9.2.8 Overload protection . 44 522 Tolerance classes 8 92.7 Manual drives 14 Continued on pages 2 to 22, Translation by DIN-Sprachendienst Ineaxe of doubt, two Gorman tongeagn erga shouks be consulted asthe utostaiv ext Rof. No. DIN (9704-2 - 196-05Page 2 DIN 19704-2 : 2090-00 10. Design principles for special machine 10.5 Cylindrical and bevel gears 18 components 14 108 Worm gears -..... + eee tot Hydraulic drives 200002020. 14 10.7 Drive assemblies... oe 19 0.1.1 General requirements for hydeaulic 10.8. Plain bearings 118 cylinders fievuteessssesecl4 10-9. Spherical plain bearings : 19 10.1.2 Design and fabrication of hydraulic 10.19 Rolling bearings. 19 eylinders 15 10.41 Bearings fer slewing movements ‘9 10.1.4 Passagos of piston rods and linkages «15 10.12 lotary shalt ip so 20 10.1.4 Further components of hydraulic 1018 Bearing housings ....220020 200.0011 20 SySteMs eevee Sivtesciess18 1014 Sprocket chains voceteeree 20 10.1.5 Hydraulic fluids aot 16 40.15 Pinion racks and pinion 20 10.1.6 Hydraulic station sc 16 10.18 Rope crivos ee n 40.1.7 Pipework 47 40.17 Wools and guide roliors <2. css 000021 10.1.8 Changes in gats position 48 10.18 Sliding quideways ...... wall 10.1.9 Manual and emergency dives 18 10.19 Axles and hinge pins... poiweed 10.110 Marking “oe 1:18 1020 Springs ra 101-71 Corrosion protection «<1. 18 1021. Threads : vei 22 10.2 Brakes 48 1022 Connoetions . 1.2.1... vee 40.3 Couplings 2.21... vicrereres18 1022.1 Bolts and bolied Gonnestions |)!!! z2 104 Shaft-to-hub connections .2....0.1.L118 1022.2 Welds 122 Foreword This standard has been prepared by Technical Gommittee Stahivesserbau of the Normenausschul Wasser wesen (Water Practice Standards Committee), Amendments This standard differs from DIN 19704 and DIN 19705, September 1976 editions, in that these standards have bean completely revised and combinad into one slandard which includes a new safely concept based cn ultimate limit state, Provious editions DIN 19704: 1988-06, 1963-12, 1976-09; DIN 19705: 1983-12, 1976-09. All dimensions are-in millimetros, 1 Scope This standard covers the detailing and fabrication of hydraulic steel structures as specified in clause 7 of DIN 19704-1, May 1998 edition, 2 Normative references This Standard incorporates by dated or undated raference, provisions fram other publications. These normative references are cited al the appropriate places in tha text and tha fillae of the publications are fisted bolow. For dated references, subsequent amendments to or rovisions of any of these publicetions apply to this Standard ‘only when incorporated in it by amendment or revision, For undated references, the latest edition of the publication referred to applies. DIN18-1 General purpose ISO metric screw threads — Nominal sizes for 1 mi to.68 mm diameter corse pitch DIN 3092-1 Socketing of wire ropes ~ Metal sockating ~ Safety requiroments and testing DIN 15020-1 Rope drives ~ Design principles DIN 1880-1 tural steelwork — Design and construction DIN 18800-7 Structural steelwork ~ Fabrication end vesdfication of suitability for welding DIN 19703 Locks for inland navigation waterways ~ Dimensianing and equipment prinoiplos DIN (9704-1 Hydraulic steel structures - Design analysis DIN 1974-3 Hydrautic steel structures ~ Electrical equipment DIN 20086 Hose assomblics for uso in fluid power systems ~ Dimensions and require nents DIN 2006-4 Hose assemblies for use in fluid power systems — InstallationPage 3 DIN 19704-2 : 2000-00, DIN 24346 Fluid power systems ~ Design principles for hydraulic equipment DIN 24559 Fluid power systems ~ Accumulators in hydraulic eystoms ~ Concepts and general requirements Supplement 1 Fluid power systems ~ Accumulators in hydraulic systems — Configuration exam- to DIN 24552 ples: Supplement 2 Fluid power systems— Accumulator in hydraulic systems~Comparisan of DIN 24552 to DIN 24552 with the Druckbefiierverordnung (Geman pressure vessels regulation) and the rel evant Technische Regain tir Druckbehilter (Codes of practice for pressure vesssls) DIN 50021 Corrosion testing ~ Spray tosts with different sodium chiorice solutions DIN 50969 Testing of high-strength steel building elements for resistance to hydrogen-indused brittie fracture and advice on the prevention of such fracture DIN 53504 Determination of tonsile streas/strain properties of rubber DIN 53505 Shore A and U hardness testing of rubber and plastics DIN 3509-1 Determination of the resistance of rubber to ozone cracking under static load DIN 53518 Determination of abrasion of rubber DIN 53517 Testing of compression set of rubber at constant strain DIN Sat34-1 Non-destructive testing - Radiographic examination of metallic materials by X-rays or gamma rays — Radiographic techniques for fusion welded joints DIN 86076 Seawater and oil-resistant olastomor sealing sheets ~ Dimensiens, requirements and testing Dine EN 462-3 Non-destructive testing ~ Image quality of radiographs ~ Image quality classes for ferrous metals DIN EN 1495 Non-destructive examination of welds ~ Radiographic examination of welded joints DIN V ENV 1995-1-1 Design of timber structures ~ General rules for buildings Din EN 10025 Hot ralled products of unalloyod strustural steele ~ Technical delivery conditions finclucing Amendment At; 1933) bint EN 10226-1 Pipe threads where pressure-tight joints are made on the thread — Designetion of dimensions and tolerances") DIN EN 24032 Hexagon nuts, style 1 - Product grades A and 6 DIN EN 24034 Hexagon nuts, style 1 ~ Product grade C DIN EN 24035 Hexagon thin nuts (chamfered) ~ Product grades A and B DIN EN 28817 Aro-welded joints in steel ~ Guidance on quality levels for imperfeotians DIN EN 180 12944-1 rrosion protection of stool structures by protective paint systems ~ Part 1; General introduction (I80 12944-1 : 1998) DIN EN 1S0 12944-2 Corrosion protection of steel siructures by protective paint systems — Part 2: Classi fication of environments (ISO 1294-2: 1998) DIN EN 180 12944-3 Corrosion protection of steel siructuses by protective paint sysiems ~ Part 3: Design considerations (ISO 12944-3: 1998) DIN EN 1S0 12344-4 Corrosion protection of steel structures by protective paint syctoms ~ Part 4: Types of surface and surface proparetion (ISO 1294-4; 1996) DIN EN ISO 1294-5 Gorrosion protection of stee! structures by protective paint systems ~Part 5! Prot tive paint systems (ISO 1294-5: 1998) DIN ISO 3202-4 : 1999 Rubber ~ Tolerances for products ~ Part 1; Dimensional tolerances ISO 228-1: 1994 Pipe threads where pressure-tight joints are not made on the threads - Cimensions, tolerances and designations ISO 1629: 1987 Rubber and latices - Symbols Technische Liefarbedingung der Deutschen Bahn AG (Technical delivery condition of the German Railways) TL.91843 ~ Elastomere fir technische Zwecke, fir Gummi und gummiclastische Hochpotymer (Rubber for Industrial use, suber and elastomeric high polymers)"*) AD-Merkblatt (AD Gade of practice) HP 5/3 Herstetiung und Priifung von Verbindungen ~ Zerstérunastieie Prisfung von Schweifverbincungen (Fabric an¢ tasting of joints in pressure vessels ~ Non-destructive testing of welds) *) Currantly at draft stage. *) Obtalnable trom the Drucksachenzentrate der Deutschen Bahn AG (Publications Centre of Deulsche Behn AG), Kerlsruhe,Page 4 DIN 19704-2 : 2000-00 DVS-Merkblait (DVS Code of practice) 704 Emptehlungen 2ur Heweriung von Ultraschallbefunden an SchmeleschweiBverbindungen (Recommendations for assessment of results of Ultrasonic testing of fusion welds to DIN 8563-3)"") References to DIN 19704-1 and DIN 19704-8 are to the May 1998 editions, and references to th the DIN 18800 series are to the November 1990 editions. standards of 3 General considerations for design, operation and maintenance 3.1 General requirements To ensure their reliability, hydraulic steel structures shall be designed to be simple, robust and safe. For steel structures, a service life of 70 years shall be assumed, for machine components and their elecicical equipment, 35 years. This dozs not apply to parts subject to wear. When designing the stect structure and the seals, due attention shall be paid to hydrodynamic effect ‘Any cavitation shall be prevented by taking suitable measures with regard to design features, venting, ete To facilitate control of the headwator lovol and for easy removal of ice and floating debris, these should be able te pass over the top of the gates, whenever possible. 3.2 Accessibility The design shal take into consideration the need for simple and efficient maintenance, alse with regard te the civil engineering aspects. This applies especially {0 ease of access, inspection and replacement of elements and components, Gates siiould be accessible. For this purpose, ladders, menholes, gratings and walkways may be provided, It Shall be possible to vent closed, accessibie gates, end they shall be fitted with a sufficient number of access openings of adequate size. Laddors shall bo designed to confarm te DIN 19703, 3.3 Rooms for drive systems Rooms for drive systems shall be kept free of water, vented and, where necessary, protected aga sation. If the driving machinery ts rot located above the maximum water level, the rooms for drive systems and penetrations for cables and pipes shall be made proof against water exerting hydrostatic prossure. Drive motors and controls for gates which are used for flood water discharge ot flood protection shall remain accessible even at the design flood water level. Rooms for drive systems shall be designad to prevent environmentally hazardous fluids from escaping inte the environment, Auxiliary equipment for repair purposes shall be provided for all drives and each room, Drives should be installed and removed as assemblies and be able 10 be conveyed ta the surface: 3.4 Locking mechanisms Gatos shall ba capable of being mochanically locked in tho required positions as gverned by the locking system and operational safety requirements, and to facilitate erection and maintenance work, 3.5. Inspection gates It shall be possible to inspect any submerged parts, usually by means of inspection gates. Inspection gates should be clasigned for quick and simple installation and removal, even in flowing water, if required. 3.6 Trash racks Intake trash racks shall be capable of baing cleaned. It shalt be possible jolt! trash racks installed at alow level. Trash racks should not be installed in front of deep sluices unless thoy ean ba cleaned, The absence af trash racks shall bo takon into account by e eultable dasign of gate and sluice. 3.7 Covers Pits and channels shall have sip-proo! covers. They shall be installed in tied frames, {rom which they shall be easily removable. They shall be fixed if there 18 a risk of uplit ) Obtainable Irom the Deutscher Verband fir Schweiftechnik (German Welding Association}, DlsselcortPage 5 DIN 19704-2 : 2000-00 3.8 Protection against ship impact Gates koly to be subjected to ship impact shall be protected by suitable means In the case of mitre gates, protective bars should be located approximately 100 mien behind the chamber wall fine when the gate is in the open position, See DIN 19708 for tho installation of impact protaction facilities. 4 Detailing of steel structures 4.4, General In general, the structural detalling of steel structures shall be as specified in clause 5 of DIN 18600-1, except where the following supplementary or deviating provisions apply. Except for other parts firmly connected to the solid structure, stool structures and rails shall be classed as elements that, according to DIN 1800-7, are noi subjected to predominantly static loading. This remains the case when fatigue assessment to DIN 19704-1 Is lirelevant or not required. If inspection gates are also to be considered not subjected to predominantly static loading, this shall be specified accordingly by the client, The design of steol structures shall aim to koop mochanical stressos (0.9, duo to ice, flotsam or floating debris) loa minimum: The support conditions for gates shall not sianificently change as a result-of settling, deformation or weer. NOTE 1; Minor mechanical stresses and corrosion tond to occur mith avon surlaces and loss complex designs. ‘See DIN EN ISO 12944-2 far design principles that take Into account corrosion protection. NOTE 2: Design features to ensure constant support conditions for the gate include the selection of agate of low torsional stiffness, and means of adjusting bearings, rails anc soals. 4.2 Minimum thicknesses With the exception of filer plates and equipment such as heating pipes, air bubbler system pipos and lubricant pipes, the faklowing minimurn thicknesses shall be observed for elements made from unalloyed structural ste. =. skin plates for lock gates, barrage gates and safely gates: 12 mm; = skin plates for other gates and inspection gates: 10 mm ~ steel plate, flats and wide flats: 8 om, — steal bars and sections, and walls of hollow sections and tube: = embedded steal elements: 10 mm. Minimum thicknesses of elements made from stainless steel shall be specified by the client. mm; 43 Bolted connections 43.1 General Bolted connections intended to withstand shear and bearing pressure or ensure positional stability stall be designed as fitted shear bolt connections. ‘There shall be no bolted joints on skin plates unless they are required, for example, to enable the subsequent removal of such plates or the assembly and disassembly of getes consisting of several parts. Friction-grip conneetions are nat pormitted owing to tho risk of corrosion on submorgad friction interfaces. Iftusting-in of the thread in bolted connections of removable, adjustable or replaceable parisis tobe precluded, all pats of the connections shall be made from staintess steel The tightening torques and prostrossing loads of preatroseod bolts mado from stainlase cteol of property class 70 shell be not greater than those given in table The prestressing loads and tightening torques of bolts of other property classes shall be converted in the ralaticnship of their yield strasses to that of steel of proporty class 70. Table 1: Maximum permissible prestressing loads and tightening torques for stainless steel bolts of property class 70 Thread sizo | Prosiressing load, [Tightening torquo] inkN inNm M16 150 [Meo | __2r5 Moa 285 M27 400 M90 850Page 6 DIN 19704-2: 2600-00 Table 2: Maximum edge distances and hole pitches Type of connection —_ [Maximum edge distance] Maximum pitch Sealing joints 25d, ors! Other joint Mountings of elastomer seals - and connections ad or Be 4.3.2. Minimum ciameter of bolts and rivets ‘The nominal diameter of bolis and rivets shall be at locst 18 mm, 4.8.8 Hole pitches for bolts and rivets The following table partially replaces DIN 8800-1, table 7, with ¢ being the thickness of the thinnest of the extemal parts of the connection and d,, being the hole diameter. “The smaller value shall be Laken in each case. 4.8.4 Securing of bolts Onlyadhesive orhexagonal nuts to DIN EN 2403 for securing bolts, Prestressed bolts do not require additional securing, DINEN 24034 and DIN EN 24935 may be used as counternuts 4.4 Welded connections 4.4.1 Fillet welds Interrupted welds are only permitted on elements embedded in cancrata, with the distance of the free conerate surface to the fillot wold interruption boing ai loast 100 mm (soe tiguro 1) As a departure from DIN 18800-1, item (619), the minimum throat thickness shall be 3 mm, Single-sided fillet welds are only permitted for closed profiles (e.g. hollow stiffeners! in conerete. Slot welds on loadbearing members should be avoided wherever possible. 4.4.2. Bult welds ‘The dasign of butt welds for plates differing in thicknaee perpendicular te the line of force shall diffor somewhat {ror that specified in DIN 8800-1, element (515), in that edges abutting by more than 3 min are fo be bevelled toaslope of 1: 4 or less, and backing strips made from steel on ihe rat side of butt welds are to be welded on botit sides unloss they are located in sealed hollow structures, and elements embedded 4.4.3. Flange plates In tho case of flange plates, tho slope of the face fillet weld shall be bavalled to 1 +2 or loss, and the slope of additional flange plates to 1:4 er less, 4) Values anply to both sides, Figure 1: Interrupted fillet weldsPage 7 DIN 19704 Figure 2: Welding of reinforcement plates 4.4.4 Welding of cold worked components Welding of cold worked components that are mada fram unalloyed structural eteel to DIN EN 10928 and are net subjected to predominantly static loading shall be cubject to the client's consent in each particular cast 4.4.5 Welding of loadbearing membore Welds in loadbearing members, whether subjected to predominantly static loading or noi, shall meet at least the requirements of quality level B and C to DIN EN 25817, respectively. 4.4.6 Special precautions Welding at low temperatures shall be permitted only with the consent of the elient and or: condition that special precautions are taken. 4.5 Axle supports Axle support plates and hubs shall consist of a single unit, considered in the direction of their depth. If. for the support of axles, etc, reinforcement plates are used instead of hube, they shall be of circular form and welded on along their external and internal diameter (see figure 2), 4.6 Cut-outs ‘The radius of cut-outs should be as great as possible, but not less than 40 mm, 4.7. Filler plates ‘Submerged filler plates shall be provided as a single layer to fit exactly and finish flush with the edgos, unless otherwise agreed with the client, 5 Fabrication of steel structures 5.1 Manufacturer's approval Gompanies which fabricate hydraulic steel structures shall be in possession of the comprehensive certificate of approval to DIN 18360-7 with an adjunct covering the fabrication of weldadstesl etructures subjected to non predominantly static loading, 5.2. Tolerances 1 General For embedded elements of fixed wheel ates and sliding gates, radial lack gates, flap gates and mitre gates, fabrication and erection inaccuracies should not exceed the toicrances givan below. For inspection and other gates, as well as for special cases (e.g, Instaltation of fixed elements under water), the magnitude of the tolerances shall be specified by the client.Page 8 DIN 19704-2 : 2000-00 The tolerances given are applicable for casos whore water prossure is not to bo takon into account, 6.22 Tolerance classes See tables 3 to 6 for tolerance classes 1 and 2. As a rule tolerance class 1 shall apply, with lolerance class 2 covering any special requirements specified by the client, 5.23 Tolerances for embedded elements [All the dimensions in tables 2 to 6 refer to the nominal position of the elements concemed, Tolerances covering the distance of rails positioned opposite each ather in the direction of flow shall be specified as a function of the type of rear guide roller. Table 3: Tolerances for embedded elements for fixed wheel gates and sliding gates x x 3 % a a —leydl | No. Elements / toleranced feature [Tolerance class 1 [Tolerance class 2 1 | Rails / straightness at right 1< 5000 mm Ay=2mm | ay=1mm | anales to ditection of flow, for “eee aT Oe El L<5000mm | ALy=L2mm ‘a 4 1. > 25000 mm AE, =£4mm | Ab, - £2 mm Inlermediate values to be obtained by linear interpolation 5 | Rails /siraightness in direction of flow Be=2mm | Ae=1mm | 6 | Rails /siraightness over length of 2000 mm | ax=tmm | ax= 0.5mm [7 | Machined rails /cross fall 77 “| tan = 0,002 | tan e = 0,002 | & | Sealing faces Function of rails [8 | Ground sil /straightne: L = 5000 mm | destmm | ae-tmm Fo Over ents length; far 1. 25000 mm z=3mm Ag =2 mm Iniermadiaté values to be btained by linear interpolation, 71 | Groona o 7 ralariness ver tength ot 1000 mm Aes nt inn] ") Clearance.DING! Table 4; Tolerances for embedded elements for radial lock gates Page 9 9704-2 = 2000-00 yi a = No. Elements / toleranced feature Toterance class 1 [Tolerance class 1_| Laterat guide rotlars ancl seats / £6000 men Ay=2mm | ay 2. | Steaightness for 1. > 25000 mm Ay=4mm Intermediate values to be obtained by lnk 1mm 2mm ear interpolation, Lateral guide rollors and seals / ay=t mm straightness over length of 1000 m 4_| Pivot bearings / anal misalignment for 1 < 5000 mm Ax = Az = 1mm] 5 1 > 25000 mm Ax = az =2irm| Intermediate values to bo obtained by linear interpolation. | 6 | Pivot bearings / parallelism of axes I tan @ = 0,002" 7_| Ground sili straightness 1. < 5000 mam Agstmm | Az=1mm B [Set entielensth. fer 1 > 25000 mm Ag=3mm | Ag=2mm Intormediate values to be oblained by linear interpolation. | Ground si /stiaightnoss over iongth of 1000 mm Beni fim 4 1mm ®I Ax or Az. 3) Notional axis, Table 5: Tolerances tor embedded oloments for flap gates. No. Elemonts / toleranced feature [Tolerance class 1 [Tolerance class 2| 1 | Sido plating / flatness evar entire suriace ay=4mm | ay=2mm Side plating / flatness over length of 1000 mr Ay=3mm_ | Ay= 1.5mm 3 | Fivot bearing / axial misalignment where there are more than [Ax-Az=0,6mm|Ax=A2=0.5mm| two bearingsPage 10 DIN 19704-2 : 2000-00 ‘Table 6: Tolerances for embedded elements for mitre gates No. Elements / toleranced feature Tolerance class 1] Tolerance clase?) -1_| Gudgeons and pintle bearings / ae ay 2mm | ax =ay= 1 me 2. | Wall plates and holow quoin pasts / misalignment Ay=2mm | Ay= 1mm 2. | Mitre brackets of hollow quoin and mitre posts / maximum saaeo* | s-a-10" ‘gap width (with gate in closed posttion) where a is the shorter distance between two adjacent brackels, in mam 5.2.4 Tolerances for gates Tolerances for gates shall bo harmonized with these for embedded olomante, if this is requited for funetional reasons. ‘Tne deviation from parallelism of the axles of gates with fixed wheels, tan a, shall be not greater than 0,005. Ifthe gates are not fully assembled or preassembled in the production shop, suitaéle means for their adjustment during erection shall be provided in their design. If sealing faces are situated on the gate body, the tolerances from subclause 5.2.2 shall apply by analogy. 5.3 Testing of welds Radiographic examination of welded connactions by Xorgammarays shall beas epscified in DIN EN 1435, with, the requirements complying with those for class B from the same standard. Radiographic film images shall comply with image quality class I to DIN EN 462-3. Ultrasonic testing shall he carried out by a qualified test house in line with AD-Merkbfatt HP 5/9. The require- monte rolating to class 8 (as above} chall be applicable. The results shall ba converted! into quality levels as in DIN EN 25817 using the procedure spectiied in DVS-Merkblatt 0704, 5.4 Testing of hollow structures The tightness of hollow structures such as flotation chambers or heating pockets shall be venifled by means of pressure testing using a proof pressure of 0,3 bar over a minimum duration of six hours, 5.5 St Elemants and camponents made from stainloss stect shall he hancled carefully at the location of their fabrica- tion and onsito. In particular, they shall be protected against soiling and damage (e.g. from grinding and welding spatter). After completion of all work, stainless steel surfaces shall be cleaned using rotating stainless sie! brushes or fine sanders or polishers made from a suitatile material, or by equivalent means. They shall then be rin theroughly in clean water. Any tarnish on tho wator side shall be romoved from surfaces exposed to water. less steels: 5.6 Combined use of structural steel and stainless steel ‘The tisk of electrolytic corrosion shall be taken inte account when stainless steel is used in conjunction with unalloyed structural stecl, the degree of such corrosion being a function of the potential cifference, the ratio cof areas of the conducting metals in contact with each other, and the conductivity of the electrolyte (see DIN EN ISO 12944.) Irelements made from stainless steel are grouted, the ties and stiffeners embedded in the concrete may be of unalloyed structural steel provided the concrete cover is 60 mm thick or more. 5.7 Corrosion protection 5.7.1. Machining of edges and welds ‘To ensure corrosion protection, all external machined edges shall be chamfered, and any he removed by grinding ale-on welds shall 5.7.2 Coating Since hydraulic steel structures ars exposedte savera corrosion attack, frequently in conjunctian with mecha cal and biological straases, importance shall be attached to passive corrosion protection in the form of thick layer, abrasion-resistant paint systems (see table A.5 of DIN EN 180 12944-5), Surfaces of bolted and riveted connections in direct contact shall be provided with the recuired ceating prior to assembly,Paget DIN 19704-2 : 2000-00 5.2.8 Cathodic protection To prevont corrosion of gatos and othar structuras which are permanently in contact with water (2.9. canal bridge troughs), the ackitional installation of eathodia protsction systems can be useful (active protection) “These can take the form of elactraplating or inpressed-current systoms. Thorough prelinihary investigations (water analyses, supply measurements, etc) are required prior to their raling and installation, Adequate prepa ration for cathodic protection systems (ie. for accommodation of anodes, cables and guard circuits) shall slroady be made at the design stage. 6 Seals 6.1 Materials Seals may consist of the following material combinations: a) elastomer and metal; B} plastics oa. PAPE) and mete 6) wood and motal; 4) metal and metal. 6.2 Design Seats shall be easily replaceable and accessible Deformation of the gate shall be taken into account whien engineering the sealing system, Adjustable seals shall be selected if the deformation ot the gate and the wear of the seals ara likely to equal the seal clearance, In the case of bottom seals, the rubber elements (uncompressed) should protrude by about § mm in orderte compensate for unevenness in the sealing face. If the tightness is nevertheless unsatisfactory, adcitional adjustments will be required (6.a. by retightening seal bolls}. Welc-on steel stud bolts are not permitted for fixing seals. The use of weld-on nuts, cap nuts and sorews Is not recommended 6.3 Seal sliding faces and stop faces Sliding faces in contact with rubber seals shall be made from either stainless steel ar coated structural steal Where there are large sliding faces (e.g. for lateral seats of radial or lap gatas) and high water conductivity (as in the case of seawater, brackish water and heavily contaminated river wate’), theuse of coated structural steel Is 10 be given preference. Goatings shall mee! stringent requirements with regard to adhesion, hardness, evenness, smoothness and resistance to elevated temperatures. As regards the surface roughness of seals, the arithmetic mean deviation of the profile, R,, shall be not greater than 3.2 im. The costing shall be dacigned to withstand severe mechanical strose 2s dfinod in subclause B.2.2 of DIN EN ISO 1294-2, It seals are designed to lose contact with the sliding face while the gate is in motion, transitions shall be flattened. Taking into ascount the deformation and the play when the gate isin motion, the width of stop faces or sliding faces shall be designed so that the faces protrude by at least 25 mm on either side. 6.4 Rubber seals It shall be possible to adjust adjustable seals within small rangas, even after any coating has been applied, Adjusting devices shall ba made from stainless steel. Seals shall compensate for any unevenness of the sliding faces by belng appropriately prestressed and of Suitable elasticity, even In the absence of water pressure, and shall retain their sealing function throughout Moulded corner pieces shall be used for perimeter seals having the samo or similar crocs sections. Jointing of seais shall be by vuicanizing using @ joint mould or an equally effective method 150 3302-1 shall apply with regard to seal tolerances. For extnided seals, accuraey grade E2 shall apply, and for compression-maulded seals, grace M3. ‘The Shore harchess shall be selected as a function of the intended use, (65 + §) Shore A harcness béing used in the most common applications. The seal materials shall comply with at least the specifications of tablo 7 Clamping and spacer strips shall be rounded ot chamfered on the seal side. 6.5 Sealing timber Solid oak timber of grade A to DIN V ENV 1995.1-1 chall be used as sealing timber,Page 12 DIN 19704-2: 2000-00 Table 7: Material characteristics for rubber seals Characteristics and test orteria Unit Testing to | Requiremenis for rubber of types [ NA‘) and SBR’ | CR) Terai srengih wimar | om saso0 a0) 27 Compression set % DIN 83517 S25 520 An 70°C) % | | Riesiatance to ozone 3 DIN S9509-1 | Gracks, class 0 | Gracks, class 0 (241i, 50 pphm) _ i Abrasion DIN $3518 5120 S100 Water absorption (25 °©) % - ss =5 Resistance to seawater ') DIN 86075 - (28 days, 95 °C) Change in hardness DIN 54505 5 Change in volum: % - 55 Resistance to oil 9) = | Th 9i8as = | ail *} Symbols taken from ISO. 1628. NA: natural rubber; SBR: styrene-butadiene rubber; CR: chloroprens. 1) For seals exposed to sea or brackish water. 2) For soals in contact with oil and grease & 6.6 Leakage It shall be the responsibility of tho client to spectly the permissible rate of leakage of water through gates. 7 Prevention of icing 7.4 Heating of sealing faces It shall be the resporisiailty of the ctlent to specity the surfaces to be heated. Seal heaters shall be designed to prevent the formation of ice at air temperatures down to -20 °C, Heated surfaces should be warmed just enough to keop thoir tomporature above freezing point. Surfaces are to be conventionally warmed: a) by heating elements positioned in cavities: b) by electrical heating elements (strip of guid) fixed to the surfaces. Heating elements shall be installed with adequate protection against envircnmental influences, and shall be removable. Thermal conctetion may be improved by filling oxiating cavities with an appropriate frost-proot heat transfor fluid whose level shall be capable of being moniioved and maintained, Temperature-telated fuctua: tions in the volume of the fluid shall be Laken Into account. in general, the temperature of th heating system should be adjustable. 7.2 Water circulation Water circulation enables the heat stared in deeper water to beused to prevent the formation of ice on the gate. For this purpose, the following sysiome may bo used: a) pressurized water systems, b) air bubbler systen ©) mechanical circulating systems (e.g. mixer pant). Pipes for pressurized water and air bubblar systems shall be made from stainless stool. It shall bo possible to flush oF blow air through them for cleaning purposes. The outlets should be located as deep as possible in the water and fitied with screw nozzles. Compressors far air bubbler systems shall be equipped with @ downsircam filer system that provents the cancantration of resichial al exceading 0,07 mg/m? at 20 °C ‘The output of te system should be at least 1 Us per metre of pipe length in the air outlet zone. Ii there are several gates, il should be possible to oparate air bubble pipes separately,Page 19 DIN 19704-2: 2000-00, 8 Embedded elements 8.1. Installation Embedded elements whose accuracy to gauge is a major factor, such as bottom seal contact faces, quite rails, seal sliding faces and stop frames, should generally be installed in duly prenared recesses, afterwhich they shall be alignest and grouted, The recesses shall be large enough to enable the trouble-free placing of second-stage concrete and compaction by intemal vibrators. Steel ties should be fitted in the recesses to which the elements to be embedded can be fastened for alignment purposes, Ingress of water in joints between concrete and steal elements shall be preventad. Care shall be taken to ensure proper adhesion between first-stage and second-stage conerate (2.9. by the use of ties or projecting reinforce. ent, application of tack costs, sandblasting of the first-stage conerets, or other suitable measures). Embedded elements shall be fixed so as to enable their proper installation and grouting, and to ensure setis- factory transmission of loads. Any ties affecting the loadbearing function shall grip into both the second-stage and first-stage conereto, However, it elements are to be embedded without being tled., suitable measures shall be taken to keep them in the correct form and position during the concreting operations and until the concrsta has sufficiently set IF a cathodis protection system is forescan, tho gate, including any embedded steel element ve parts of the solid structure (ie. reinforcement and sheet piles) shall be kept isolated and the conduc 82 Conereting Loads occurting as a result of concrete pressure on the formwork shall not be transmitted to the embedded elements. These shall be checked for their correct position before and.after grouting 8.3 Joints Wf embedded elements cross construction or movement jeints in the concrete, epecial structural measures are gonoraily required (o.g. interruption of bettom seal contact face). 8.4 Rails and guide rails Ralls, including guide rails, of frequently operated gates (@.g. luck gates) shall be replaceabie on the basis ot the anticipated wear. Countersunk bolts shall nat be fitted in the crown of rats ‘There shall be no joints in rails at points of high whaet pressure. Where unavoidable, joints shauld be mitred at an angle of 45° Any differences in height of rails shall be levelled out. Rails and sleepers shall be frictionally connected to enable alrect load transmission. For rails mada from unalloyed structural steel as thease material and with a stainless etee! crown (6.9. appliod by doposit wolding or explosive cladding), the minimum thickness of the crown should still be G mm after mechanical machining. Gubciauses 7.7.4 and 10.22 of DIN 19704-1 shall be observed. Deposit welding shell be with at least three runs. 9 Design principles for machinery 9.1 Support and guidance of gates Fixed whoo! gatos shall bo provided with lateral guide rollers. In the case of fixed axles, this shall be by means of single flanged wheels or by means of lateral guide rollers, and in the case of roller trains, by means of double flange wheels and lateral guide rollers. Lateral guide rollar rollers or skids shall either be spring-mounted or have reasonable clearance. Care shall be taken to ensure the unhindered interaction of lateral seals and lateral guide rollers. If the gate is centially suspended, each side shall be guided al a minimum of two points, Radial lock gates should a'so be equipped with lateral guide rollers. For gates with double-acting drive, whose wheels will altemately contacttwo rails on opposite sides, additional spiing:preloaded rear guide rollers siiauld be provided. 9.2 Drives 8.2.1 Accessibility Mechanical or hydraulic drives shall be easily accessible. Components that require adjustment or regular servicing (e.g. limit switches, lubrication points, hydraulic flters) shall be easily accessible. Hydraulic compo: nents should be clearly positioned on the power units,Page 14 DIN 19704-2 : 2000-00 9.2.2 Speed of gato Gates shall be accelerated and decelerated within a reasonable time as a function of the design type, mass and travel time. Gates shall approach the end position ala speed not exceeding 0,1 m/min to 1,0 m/min, depending on their type and m: 9.2.8 Switeh-off at end position Preferably, drives should be switched off at their end pasition by limit switches that aro automatically actuated when the gate reaches a certain position. If, for oporating roascns (e.g. closing prossurc), drives are to be switched off as a function of load or pressure, position-actuated limit switches shall be used to control tho movernent of the gate to end position (see subclauses 4.6 and 5.1 of DIN 19704-3), 9.2.4 Synchronization monitoring and closed loop control Tha synchronous operation of gates with double-acting drives shall be monitored, except for drives of gates of largo torsional stiffiees such as radial or flap gatos, or crivos with a shait. In order to ensure the synchronous operation of drives, meckanical/elecirical, mechanical/hydrautic or hydiau- lclelectrical synchronization closed loop control systems may be used, Synchronization monitoring and closed loop control systema shall oporate as @ function of the position, A position sensing system is required on either drive side. Thelocal control cabinet shalt be fitted with a digital position indicator. 9.2.5 Position sensing systems Gates which can be operated to stop at any pio-solooted position in addition to the end positions shall be fitted with a position sensing system. It shall be the responsibil of the cientto specify the type oi cksplay (2. digital analogue, or mechanical) to be used. Position sensing systems shall be designed fo rule out any risk of icing or blocking. For hydraulic drives, position sensing systems located in the cylinder shall be removable without the cylinder having to be emptied 2.2.6 Overload protection Drives shall normally be fitted with an elsctrical ovarioad protection device, which shall be designed in tine with the epecifications of substause 4.7 of DIN 19704-3, Protective equipment in the form of couplings with an electrical switch-off device shall be arranged so that they do not hold the load while the drive is at rest Seals of overload protection devices shall nat ba broken when the gate is in operation, 8.2.7 Manual drives Mechanical drives shall be equipped with manual drives for adjustment and maintenance work. Once tha manua driveis activated, the main drive shall be automatically disconnectad from power or d’songaged. In the case of gates with doubla-acting drive, this applies to both drive unite, Manual drives shall be automatically made inoperative when the gate Is operated electrically main drive shall be capable ot being released only atter the manual drive has been engaged, be applied again before the manual drive can become disengaged, Manual drives shall be fitted with an automatic friction dise brake (which shell act in both directions, where required) oF be designed with ¢ self-locking mechanism. See substause 10.1.9. for manuel hydraulic drives. he brake of the \d 80 that it must 10 Design principles for special machine components 40.1 Hydraulic drives 10.1.1 General requirements for hydraulic eyiinders Hydraulic eyindars chould be positioned to prevent the piston rod being submeiged in flowing water, thus preventing damage from flotsam and ice, If this is nol possible, guards shall be provided. The use of bellows is not permitted. Hydraulte cylinders shall be hinged at both ends on bearings to allow thom to move freely to all sides, unless bending is precluded owing to restraint. Flanged cylinders (except for locking cylinders) mey be used in cases whore the oytinders are arranged vertically and their correct guidance is ensured, and the play in the gale movement can be minimized. Any additional support of hydraulic cylinders (Lo. thrae-point support) may only become elective when the cylinder is depresaurized, At the end positicns of gates, hydraulic cylinders shall have sufficient intemal clearance between the piston and the covers, unless a stap is provided in the design For cylinders in compression, the piston rod and front Beating head of the cylinder barrel shall havean overlap equal to at least 1,5 Das tne centre distance between guides (L) being the intexnal barrel diameter).Page 15 DIN (9704-2 : 2000-p0 Sylinders which are temporarily or permanently pressurized at system pressure shail be isolated so as to be leaktightin the ditection of loading by being flanged-maunted on shut-off or control manifolds. Control mani- folds shall be equipped with manually operated stop valves between the cylinder and the shut-off valve. It shall be the reaponsibilty of the client to specify details of monitoring leakage where cylinders are submerged temporavily or over prolonged periods. Both cylinder chambers shall be permanently filled with oll the gato is lowored without the pumps running, it shall bo ensured that the unprassurized chamber is flee with oil. To enable proper bleeding of cylinders, pressure tapings shall be provided at suitable locations. If requires, suitable procedures shall be specified for assembly and filling of cylinders. 10.1.2 Design and fabrication of hydraulic cylinders 10.1.2.1 Cylinder barre's Cylinder barrels shall ba fabricated Irom seamless steel tubes, where possible without joints, and'shall normally be designed to enable flanges to be connecied at both ends. The eylindor bore shall bo finished to a surface roughness corresponding to an adttunetic mean deviatlonof the profile, 2, of less than 0,4 pi, bracing rings are welded to the barrel, t 10.1.2.2 Piston rods Piston rads, including those for hydraulic cylinders designed as specified in subctause 10.2 of DIN 19704-1, shall be fabricated either {rom stainless steel with @ chromium content of not less than 15, Plating with an overal thickness of nat lees than 50 jm bj unalioyed steel with an oxide ceramic coating. It shall be the responsibility of the cent to specify constructional details, Surfaces should be finished so that in both cases the R, value is less than 0,3 jim Coramic coatings shall be designad to rule out corrosion of the substrate. It should be homogeneous, scratch: resistant, free of cracks and non-conductive, and shall /tave a thickness of at leas! 150 ulm and a surface hacdness of 800 HY to 1000 HY, Subsequent sealing of pores is not permitted The corrosion resistance of oxide ceramic coatings shall meet the requirements forthe DIN 50021. an exposure period of 1000 hours, Piston rods shall ba fabricated as single units unless othonwise justifiod, jis shall be finished after welding 6 % (n/m) and a multilayor hard chromium ESS test over 404.2.3 Mountings and connections Piston rode with piston tod heads, which are fitted with sphetical plain radial bearings, shall generally be connected to the gale or the supporting structure. ‘The connection of the rod to the rod head should be casigned with male thread on the rod, Tho thread of the rod heads shall be sealed against te ingress of water. Any holes for securing safety equipment shall not be dried into the thread, and shail be sealed IF cylinders ace mounted by means of clevises, these should be fabricated as single units. Welds tension shall bo butt watd. Where there js journal or carcanic bearing of the cylinder cf beating pins shall be made from stainless steel. 10.2.4 Guides and seals Guides for pistons and piston cods shall gonorally be made from copper alloys. The use of plastic guides is els poimitied. Only multtip systems shall be used for sealing. Any build-up af drag flaw pressure shall bo proctuded. Tho soale used between components without counter-movements (such as between cylinder head and barre) shall be O-ring seals with clametars of not less than 125 mm, fitted with additional back-up rings. Where piston rods pass through the cylinder head, the latter shall be fitted with dirt wipers, and with serrated ice serapers i thors is a risk of iee formation ‘Where cylinders are dasignedto be usedunder water, aduitional seals within a corresion-resistant housing shall be provided to prevent water being sucked in. il bearings shall be self-lubricating. Contact faces 10.1.3, Passages of piston rods and linkages Soale for sealing the piston rods and linkages against the water pressure present in the gate shatt shall be accommodated in housings mounted on the cover, These shall be equipped with guide bushes, dirt wipers and at least one multi-lip seal. A lubrication acint shall be provided for frequently moved rods. There shall be sufficient clearance between seal housing and cylinder head to ensurs adequate accossibilty for servicing,