SERVICE INFORMATION
625/1586 E rev.: a 2003-07-02
How to Handle Damaged Jibs
General
This instruction is a guidance in how to handle
damaged jibs. It does not cover all types of damages
but gives only a general guidance.
Note: If there is any doubt in how the damage shall
be repaired, contact shall be done with Service
Department at MacGREGOR Cranes who can help
in this matter.
This Service Information describes
1. Repair of damage.
2. Repair of cracks.
3. Limits of corrosion.
4. Interchangeability of steel materials.
5. Welding Procedure Specification (WPS).
1. Repair of damage
In order to judge if the crane jib has got such a small
damage that it might be allowed for duty, compare
the actual figure on the damaged jib with the allowed
tolerances in accordance with the Quality Instruction.
If the figures of the actual crane jib are within the
tolerances, the crane jib might be allowed for duty.
The condition is, that the distorsion etc. is smooth
and not sharp, because a sharp flopper is dangerous
also if it has a reasonable depth. If the figures are not
within the tolerances, the jib has to be repaired.
Society of Classification
All repair should be done with approval by a
classification surveyor. If the surveyor so requires
an overload test must be done after the repair.
The Original Manufacturer of HÄGGLUNDS Cranes
Recommendation about the repair
So called dubblers, meaning that the damaged steel
plate will be hidden underneath a new plate, are not
accepted as a permanent repair. It might be accepted
as a temporary repair, if approved by a surveyor from
the Society of Classification. MacGREGOR Cranes'
recommendation is, that the damaged parts should
be changed. This can either be done by changing a
part of a steel plate, or changing a part of a profile.
New weld cannot be performed closer than 200 mm
from the existing weld.
Choice of steel material for repair
See page 4.
Steel from approved steel mill and certificate
according to DIN 50049-3.1C.
Repair company
The company shall have at its disposal appropriate
welding coordination personnel according to EN 719
(European Norms) or similar. This means that welding
personnel can be supplied with the necessary welding
procedure specifications or work instructions and that
the work can be properly performed and controlled.
Welding consumables
The consumables shall be according to requirement
in the drawing.
Performance of the joint
The joints shall be fully penetrated, if possible by
welding on both sides. If this is not possible, the
welding shall be performed from one side with steel
backing of permanent type.
Welding class B quality levels according to EN 25817.
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 SERVICE INFORMATION
Non-destructive testing and quality inspection,
dimension check
After welding a NDT (Non-Destructive Testing) has
to be performed by certified personnel and according
to EN 473 or similar.
The company responsible for the rapair has to make
the welding procedure WPS (Welding Procedure
Specification) according to EN 288-3 and record the
dimension of the crane jib. The dimension has to be
within the tolerances specified in MacGREGOR
Cranes' Quality Instruction. If the tolerance cannot
be fulfilled the misalignment has to be approved by
MacGREGOR Cranes in Sweden.
Quality inspection of the welds
All welds, that are new, repaired or are located close
to the damaged area, have to be visually inspected.
The quality class of the weld is specified in ISO 5817.
The repair has to be checked after tacking, where
the joint preparation is inspected. After welding all
new and repaired welds or welds close to the
damaged zone have to be tested with penetrant or
Min. 1.5 m
Damage
Min. 200 mm
Welds
Welds
Area to be replaced
Fig. 1. Damaged jib.
2 (6) The Original Manufacturer of HÄGGLUNDS Cranes
625/1586 E rev.: a 2003-07-02
Magnaflux. If no failure is observed during the
penetrant or the Magnaflux tests, only 20% of the
length of the jib has to be either ultrasonic or X-ray
tested. If failure is observed either during the crack
penetration, the ultrasonic or the X-ray tests, 100%
of the welds have to be X-ray or ultrasonic tested.
WPS guidelines
The company responsible for the repair shall make
the welding procedure (WPS).
The WPS enclosed is for guidance only.
Example of how the repair should be done
a) If a jib section has a dent on a corner a U-profile
must be replaced. See Fig. 1.
b) If a jib section has a damage on the complete profile
a complete box must be replaced. See Fig. 2.
c) If a longer section is to be replaced the section shall
be made so it fits into the existing welds.
Min. 1.5 m
Min. 200 mm
Welds
Damage
Welds
Area to be replaced
Fig. 2. Damaged jib.
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625/1586 E rev.: a 2003-07-02

Preparation of the new jib part

It is important that the new jib part as well as the
existing part is prepared so its stiffeners are supported
by a support. See Fig. 3.

Also the weld joints must be prepared according to

original drawing.

50 50

Stiffener

Support

Fig. 3. Preparation of jib.

2. Repair of cracks

1. The crack has to be ground in its bottom. The 4. Check the welds made. Methods to be used are
beginning and the end of the crack has to be 100% MPI, 100% ultrasonic test or 100% X-ray.
rounded off. Paint shall be removed near the crack.
Rounded off by grinding or drilling at both ends. 5. Approval by classification socitey if required.

2. The crack has to be filled with a weld bead if the

joint is wide and deep. Weaving is not allowed. 3. Limits of corrosion
Recommended electrodes are ESAB OK 48.00 or
similar. Dimension 2.5 - 3.25 mm. See Service Information 625/1568 E.

3. In order to improve the area where cracks have

arisen, there should be a smooth connection
between weld and parent metal. The best method
to reach better strength is to use the TIG-method
for the connection between weld and parent metal.
If this is impossible, grinding can be used.

The Original Manufacturer of HÄGGLUNDS Cranes 3 (6)

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625/1586 E rev.: a 2003-07-02

4. Interchangeability of steel materials

Steel plate
In order to achieve a correct level of quality when for some reason
the specified Swedish, DIN or other standard steel qualities have
to be substituted with steel of other standards, the following shall
apply:

Standard Steel grade

Swedish standard SS1312 SS1414 SS1415 SS2134 SS2135
ReL in Mpa 220 260 260 355 355
EN 10025 S235JRG2 S275 J2
DIN St44-3N* StE355** StE355**
JIS
EN 10113-2 S355N S355NL
Classification Societies
ABS B D27 E27 DH36 EH36
BV B D27 E27 DH36 EH36
DNV B D27 E27 D36 E36
GL B D32 E32 D36 E36
LRS B D27 E27 DH36 EH36
PRS B D27 E27 D36 E36
USSR B D27 E27 D36 E36
ZC B D27 E27 D36 E36
NKK KB HD32 KE32 KD36 KE36
o
* St44-3N is tested for impact value at -20 C, according to the
requirements of DIN 17100. When this steel is substituted for E27
or o
E36, it must be demonstrated by testing for impact value at -
40 C that the values as listed below have been obtained. Usage of
this steel must be approved by MacGREGOR Cranes.
**
According to DIN 17102 the requirements on impact value and
test temperature have to be specified by the buyer.

The carbon equivalent defined as Ce = C + Mn/6 + (Cr+Mo+V)/5 + (Cu+Ni)/

15 (ladle analysis) shall not exceed 0,41%. If the subcontractor not is able to
purchase steel plate with Ce ≤ 0,41%, MGC will accept acceptera Ce ≤ 0,44 provided
that:

‰ The welding take place in room temperature

‰ The combined plate thickness tcomb not exceed 40 mm (se next page)
‰ The weld deposite hydrogen contents is ≤ 10 ml/100. H10

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The Original Manufacturer of HÄGGLUNDS Cranes 5 (6)

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6 (6) The Original Manufacturer of HÄGGLUNDS Cranes