Workshop Instruction Manual-Version5

Instruction Manual
GENERAL
WORKSHOP INSTRUCTION MANUAL
03-2006 / Version 5
HAZEMAG & EPR GmbH
Brokweg 75 D 48249 Dlmen
Contents
1
General Notes .............................................................................................................. 4
Tolerances.................................................................................................................... 5
2.1
Tolerance symbols in general ................................................................................ 5
2.2
General permissible deviations .............................................................................. 5
2.3
Geometrical tolerancing ......................................................................................... 7
2.3.1
Kinds of tolerances and symbols as well as included tolerances.................................. 7
2.3.2
Important geometrical tolerance symbols for HAZEMAG & EPR GmbH products ....... 8
Tolerances of raw material.........................................................................................12

3.1
Tolerances of channel steel according DIN 1026 ..................................................13
3.2
Tolerances of - and H- beams according DIN EN 10034......................................14
3.3
Tolerances of autogenes cutting according DIN EN ISO 9013 ..............................16
Surface Roughness ....................................................................................................18

4.1
Surfaces without finishing symbols........................................................................18
4.2
Surfaces with finishing symbols ............................................................................18
4.3
Surfaces with finishing symbols on old drawings...................................................19
4.4
Centre line average height Ra acc. to DIN 4768 ....................................................19
Welding .......................................................................................................................20
5.1
Manufacturing company........................................................................................20
5.2
Welders.................................................................................................................20
5.3
Filler metals ..........................................................................................................20
5.4
Hard-facing ...........................................................................................................20
5.5
Production plan .....................................................................................................23
5.6
Welding processes................................................................................................23
5.7
Weld symbols, technical drawing ..........................................................................24
5.7.1
Main symbols and supplementary symbols................................................................. 24
5.7.2
Position of symbols...................................................................................................... 26
5.7.3
Complementary indications ......................................................................................... 26
5.7.4
Dimensioning of welds................................................................................................. 27
5.8
Welding guidelines for customers..........................................................................29
5.9
Quality ..................................................................................................................39
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5.10
Testing..................................................................................................................45
5.10.1
Extent and methods of testing..................................................................................... 45
5.10.2
Acceptance criteria ...................................................................................................... 46
5.10.3
Time of inspection ....................................................................................................... 47
5.10.4
Practical and non-destructive Testing of Welding Seams according to HAZEMAG &
EPR GmbH ................................................................................................................................... 47
Thread .........................................................................................................................48
Trial Mounting in Workshop.......................................................................................50
Corrosion-Proofing in general ...................................................................................51

8.1
Corrosion-Proofing of machined surfaces .............................................................51
8.2
Stock qualities.......................................................................................................52
8.3
Corrosion-Proofing by painting..............................................................................52
8.3.1
Detail of painting procedures....................................................................................... 52
8.3.2
Description of painting specification ............................................................................ 52
8.3.3
Colouring schedule...................................................................................................... 52
03-2006 / Version 5
1 General Notes
Sphere of applications
This instruction manual shall be a help for customers to build HAZEMAG & EPR GmbH
products in their own manufactures. But the customer is responsible for the fault-free
production of equipment-components according to the HAZEMAG & EPR GmbH
drawings.
Field of application
The instruction manual contains tolerancing specifications, welding guidelines, quality
requirements, etc.
Limitations
Consequently, if a situation should arise, the occurrence of which is not foreseen in the
instruction manual, and which the supplier is/feels unable to handle, we would
recommend that HAZEMAG & EPR GmbH be contacted without undue delay for advice
on appropriate action.
03-2006 / Version 5
2 Tolerances
2.1
Tolerance symbols in general

The tolerance symbols used on drawings and in parts lists referred to in this
instruction manual are in accordance with the ISO system of tolerances.
Note!
Tolerance figures specified after the tolerance symbol refer to the permissible
dimensional deviations at 20C.
All our tolerances are based on manually operated machine tools. If numerically
controlled machine tools or other mass-producing types of machines are used, a
central position in the tolerance area should be aimed at.
2.2
General permissible deviations

In the technical drawings of HAZEMAG & EPR GmbH, the permissible deviations for
dimensions without tolerances are according to DIN ISO 2768 with the tolerance
class mK (see following tables).
Table 1: Worst deviations for length dimensions except from broken edges
Tolerance class
Worst deviations for nominal size area (in mm)
Short
symbol
Description
from 0,5
to 3
over 3
to 6
over 6
to 30
over 30
to 120
over 120
to 400
over 400
to 1000
over 1000
to 2000
over 2000
to 4000
fine
0,05
0,05
0,1
0,15
0,2
0,3
0,5
middle
0,1
0,1
0,2
0,3
0,5
0,8
1,2
coarse
0,2
0,3
0,5
0,8
1,2
very
coarse
0,5
1,5
2,5
Table 2: Worst deviations for angular dimensions

Tolerance class
Short
symbol
Description
fine
middle
c
v
Worst deviations for length areas, in mm, for the short angle leg of the
relevant angle
over 10
over 50
over 120
over 400
to 10
to 50
to 120
to 400
1
0 30
0 20
0 10
0 5
coarse
130
0 30
0 15
0 10
very coarse
0 30
0 20
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Table 3: General tolerance for straightness and flatness

General tolerance for straightness and flatness for nominal size area (in mm)
Tolerance
class
bis 10
ber 10
bis 30
ber 30
bis 100
ber 100
bis 300
ber 300
bis 1000
ber 1000
bis 3000
0,02
0,05
0,1
0,2
0,3
0,4
0,05
0,1
0,2
0,4
0,6
0,8
0,1
0,2
0,4
0,8
1,2
1,6
Table 4: General tolerance for perpendicularity

Tolerance
class
Tolerance of perpendicularity for nominal size area

of the short angle leg (in mm)
bis 100
ber 100
bis 300
ber 300
bis 1000
ber 1000
bis 3000
0,2
0,3
0,4
0,5
0,4
0,6
0,8
0,6
1,5
Table 5: General tolerance for symmetry

Symmetry tolerance for nominal size area (in mm)
Tolerance
class
bis 100
H
K
L
0,6
ber 100
bis 300
0,6
1
ber 300
bis 1000
0,5
0,8
1,5
ber 1000
bis 3000
1
2
Table 6: General tolerance for run

Tolerance class
Run tolerances (in mm)
0,1
0,2
0,5
It also applies that:
Inside radii of curvature of machined parts with no marked dimensions must

always be R 0,4.
All external edges of machined parts must be chamfered (0,5x45) unless

otherwise specified.
For handling purposes, sharp edges of plates and steel sections must be broken
(chamfered) unless otherwise specified on the drawings.
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2.3
Geometrical tolerancing
Where necessary, our drawings contain symbols of form, orientation, location and
runout (see table 7). These symbols comply with DIN ISO 1101.
2.3.1
Kinds of tolerances and symbols as well as included tolerances

Table 7:
Tolerances
Toleranced
characteristics
Included tolerances
Straightness
Flatness
Straightness
Circularity
(Roundness)
Cylindricity
Straightness,
Parallelism,
Circularity
Parallelism
Flatness
Perpendicularity
Flatness
Angularity
Flatness
Position
Concentricity,
Coaxiality
Symmetry
Straightness,
Flatness,
Parallelism
Circular runout,
Axial runout
Circularity,
Coaxiality
Symbols
Form tolerances
Orientation
tolerances
Tolerances
of
position 1)
Location
tolerances
Runout
tolerances
1) Tolerances of position always refer to a datum feature or theoretically exact

dimensions.
Additional symbols
Description
Toleranced feature
indications
Symbols
direct
direct
Datum indications
by capital letter
03-2006 / Version 5
2.3.2
Important geometrical tolerance symbols for HAZEMAG & EPR GmbH products
For further description and explanation you find in table 8 the geometrical tolerances
which you find in our technical drawings.
Table 8: Geometrical Tolerance
Symbol
Definition of the tolerance zone
Indication and interpretation
Straightness tolerance
The tolerance zone when
projected in a plane is limited by
two parallel straight lines a
distance t apart.
Any line on the upper surface parallel to

the plane of projection in which the
indication is shown shall be contained
between two parallel straight lines 0.1
apart.
Any line on the upper surface parallel to

the plane of projection in which the
indication is shown shall be contained
between two parallel straight lines 0.1
apart.
The tolerance zone is limited by

a parallelepiped of section t1t2
if the tolerance is specified in
two directions perpendicular to
each other.
The axis of the bar shall be contained

within a parallelepipedic zone of width
0.1 in the vertical and 0.2 in the
horizontal direction.

a cylinder of diameter t if the
tolerance value is preceded by
the sign .
The axis of the cylinder to which the

tolerance frame is connected shall be
contained in a cylindrical zone of
diameter 0.08.
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Table 8: Geometrical Tolerance (continue)
Symbol
Parallelism tolerance
Parallelism tolerance of a line with reference to a datum line
The toleranced axis shall be
a parallelepiped of section t1 t2 contained in a parallelepipedic
tolerance zone having a width of
and parallel to the datum line if
0.2 in the horizontal and 0.1 in the
the tolerance is specified in two
vertical direction and which is
planes perpendicular to each
parallel to the datum axis A.
other.

a cylinder of diameter t parallel
to the datum line if the tolerance
value is preceded by the sign .
The toleranced axis shall be

contained in a cylindrical zone of
diameter 0.03 parallel to the
datum axis A (datum line).
Parallelism tolerance of a line with reference to a datum surface

The toleranced axis of the hole
two parallel planes a distance t
shall be contained between two
apart and parallel
planes 0.01 apart and parallel to
to the datum surface.
the datum surface B.
03-2006 / Version 5
Symbol
Definition of the tolerance

zone
Parallelism tolerance
Parallelism tolerance of a line with reference to a datum line
The tolerance zone is limited
The toleranced surface shall be
by two parallel planes a
contained between two planes 0.1
distance t apart and parallel
apart and parallel to the datum
axis C of the hole.
to the datum line.
Flatness tolerance
distance t apart.
The surface shall be contained

between two parallel planes 0.08
apart.
Symmetry tolerance
Symmetry tolerance of a median plane
The median plane of the slot shall
be contained between two parallel
distance t apart and disposed planes, which are 0.08 apart and
symmetrically to the median
symmetrically disposed about
the median plane with respect to
plane with respect to the
the datum feature A.
datum axis or datum plane.
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10
Symbol

Perpendicularity tolerance
Perpendicularity tolerance of a line with reference to a datum line

The toleranced axis of the inclined
The tolerance zone when projected
hole shall be contained between
in a plane is limited by two parallel
two parallel planes 0.06 apart and
straight lines a distance t apart and
perpendicular to the axis of the
perpendicular to the datum line.
horizontal hole A (datum line).
Perpendicularity tolerance of a line with reference to a datum surface

The tolerance zone when projected
in a plane is limited by two parallel
straight lines a distance t apart and
perpendicular to the datum plane if
the tolerance is specified
only in one direction.
The toleranced axis of the

cylinder, to which the tolerance
frame is connected, shall be
contained between two parallel
planes 0.1 apart, perpendicular to
the datum surface.
The tolerance zone is limited by a

cylinder of diameter t perpendicular
to the datum surface if the tolerance
value is preceded by the sign .
The toleranced axis of the cylinder

to which the tolerance frame is
connected shall be contained in a
cylindrical zone of diameter 0.01
perpendicular to the datum
surface A.
Perpendicularity tolerance of a surface with reference to a datum line

The tolerance zone is limited by two The toleranced face of the
workpiece shall be contained
parallel planes a distance t apart
and perpendicular to the datum line. between two parallel planes 0.08
apart and perpendicular to the
axis A (datum line).
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11
3 Tolerances of raw material

The quality / operability of the specific machines, e.g. impact crusher or apron feeder is
also depending on the quality of the selected raw-material, e.g. I-beams, Channel steel,
etc.
HAZEMAG & EPR GmbH points out that the local manufacturer of our client has to
choose a raw material with the sufficient quality and tolerance (according the technical
drawings and part lists of HAZEMAG & EPR GmbH). The quality and tolerances of the
raw material is defined in norms. Some extracts of the important norms are shown here.
Please note, that for the side beams of the apron feeders, more narrow tolerances are
required than in the norms are defined in general. Therefore see the fabrication drawings
of the apron conveyor.
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12
3.1
Tolerances of channel steel according DIN 1026
Flange parallelism and web ex curvature:
Table 9:
Width b
over
to
No flange parallelism
k, max.
100
1,0
100
110
1% from b
Table 10:
High h
over
to
Web ex curvature f
max.
100
0,5
100
200
1,0
200
400
1,5
Straightness and length:
Table 11:
Section height h in mm
Max. deviation q
0 < h 400
0.0015 x length
400 < h 600
0.0010 x length
600 < h 1200
0.0007 x length
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13
3.2
Tolerances of - and H- beams according DIN EN 10034
Worst deviations:
Table 12:
Profile height h
Flange width b
Web thickness s
Flange thickness t
Nominal size
Worst
deviation
Nominal size
Worst
deviation
Nominal
size
Worst
deviation
Nominal
size
Worst
deviation
h 180
+3,0
-2,0
b 110
+3,0
-1,0
s<7
0,7
t < 6,5
+1,5
-0,5
180< h 400
+4,0
-2,0
110< b 210
+4,0
-2,0
7 s < 10
1,0
6,5 t < 10
+2,0
-1,0
400< h 700
+5,0
-3,0
210< b 325
+4,0
-4,0
10 s < 20
1,5
10 t < 20
+2,5
-1,5
h > 700
+5,0
-5,0
b > 325
+6,0
-5,0
20 s < 40
2,0
20 t < 30
+2,5
-2,0
40 s < 60
2,5
30 t < 40
2,5
s 60
3,0
40 t < 60
3,0
t 60
4,0
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14
Flange parallelism and web eccentricity:
Table 13:
No flange parallelism
Web eccentricity
k0 = k + k1
e = ((b1 b2)/2)
at flange width b
mm
limiting deviation k0
mm
at flange width b
mm
limiting deviation e
mm
at t < 40 mm
b 110
1,5
b > 110
2% from b
(max. 6,5 mm)
03-2006 / Version 5
b 110
110< b 325
b > 325
2,5
3,5
5,0
at t < 40 mm
110< b 325
b > 325
5,0
8,0
15
Straightness (qxx and qyy)

Table 14:
3.3
Profile height h
mm
Straightness
tolerance qxx and qyy
80< h 180
0,30 % from L
180< h 360
0,15 % from L
h > 360
0,10 % from L
Tolerances of autogenes cutting according DIN EN ISO 9013

In our technical drawings, the tolerance class II B is required .
Worst deviations for nominal size
Table 15:
Tolerance
class
03-2006 / Version 5
Workpiece
thickness t
mm
Worst deviations for nominal size (mm)

35 up to
315
315 up to
1000
1000 up to
2000
2000 up to
4000
3< t 12
1,0
1,5
2,0
3,0
12< t 50
0,5
1,0
1,5
2,0
50< t 100
1,0
2,0
2,5
3,0
100< t 150
2,0
2,5
3,0
4,0
150< t 200
2,5
3,0
3,5
4,5
200< t 250
3,0
3,5
4,5
250< t 300
4,0
5,0
6,0
3< t 12
2,0
3,5
4,5
5,0
12< t 50
1,5
2,5
3,0
3,5
50< t 100
2,5
3,5
4,0
4,5
100< t 150
3,0
4,0
5,0
6,0
150< t 200
3,0
4,5
6,0
7,0
200< t 250
4,5
6,0
7,0
250< t 300
5,0
7,0
8,0
16
Goodness of cutting faces
Table 16:
Goodness of
cutting faces
Perpendicularity- and incline

tolerance, u, according
picture 1
Permissible
medium surface roughness,
R y5, according picture 2
Fields 1 and 2
Fields 1 and 3
Fields 1 and 2
Fields 1 and 3
Perpendicularity- and incline tolerance u (mm)
Picture 1: Perpendicularity- and incline tolerance
Cut thickness a (mm)

Field 1
Field 2
Field 3
Medium surface roughness R y5
Picture 2: Permissible medium surface roughness
Cut thickness a (mm)
Field 1
03-2006 / Version 5
Field 2
Field 3
17
4 Surface Roughness
The surface roughness symbols on drawings are shown in compliance with ISO 1302.
The most common symbols are shown in sub-section 2.2. As regards more specific
symbols, reference is made to the standard.
4.1
Surfaces without finishing symbols

Surfaces without finishing symbols must be made with a natural rough surface,
cleaned of loose oxide scales, burrs, etc., originating from casting, forging, rolling,
drawing, pressing, flame cutting, etc.
4.2
Surfaces with finishing symbols

For surfaces with finishing symbols according to ISO 1302, the Ra- roughness values
are measured in m unless otherwise specified.
indicates optional production method as well as maximum permissible surface

roughness.
indicates machining as well as maximum permissible surface roughness.
shown over drawing head indicates that the requirement applies to all
surfaces of workpiece.
shown over the drawing head indicates that all other surfaces
than those marked
and
must be made according to
indicates the maximum permissible roughness to be obtained without removal

of material.
indicates that the surface roughness must be obtained by means of the

processing method stated in the text space of the drawing.
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18
4.3
Surfaces with finishing symbols on old drawings
indicates a surface produced by casting, forging or with

mechanically propelled flame cutter. If necessary, the surface must be smoothed to
remove and large projections.
indicates roughness Ra: 5 < Ra 25 m
indicates roughness Ra: 1,6 < Ra 5 m
indicates roughness Ra: 0,25 < Ra 1,6 m
indicates roughness Ra: 0 < Ra 0,25 m
corresponds to the symbols
4.4
and
Centre line average height Ra acc. to DIN 4768

The centre line average height Ra is the arithmetic average of the absolute values of
the distances y between the profile heights and the centreline within the measuring
length. This is equivalent to the height of a rectangle (Ag) with a length equal to the
evaluation length lm and with an area equal to the sum of the areas enclosed between
the roughness profile and the centre line (Aoi and Aui) (see figure 1).
03-2006 / Version 5
19
5 Welding
Welding must be done and inspected on the lines described in the following subsections.
5.1
Manufacturing company
The manufacturing company and any sub-suppliers must be able to draw on adequate
production facilities and competent personnel for planning, execution and supervision
of the welding production to meet the requirements specified.
5.2
Welders
All welders and welding operators must be qualified and approved as concerns the job
the person is to carry out. This applies also tack-welding and handling of material and
to the tools required for carrying out the job.
All welders and welding operators must be familiar with the welding norms, welding
process, type of joint, material group, welding position and dimensions, etc. for the
welding job to be carried out.
Welders performing welding in areas making specified demands on certified welders
must be approved in compliance with EN 287-1 or a similar standard.
In case of doubt, the HAZEMAG & EPR GmbH representative on side/workshop is the
ultimate authority for judging a welders qualifications and the welding job that is carried
out.
5.3
Filler metals
Filler metals must be stored, handled and used in accordance with the suppliers
instructions. The filler metal must be correct for the parent metal and secure that the
weld will have the same physical properties as the parent metal.
5.4
Hard-facing
Following hard-facing materials are used by HAZEMAG & EPR GmbH.
03-2006 / Version 5
20
Supplier Bhler Thyssen Welding Germany
SK 258 TIC-O
DIN 8555: MF 6-GF-60-GP
Description:
Martensitic Chromium-Titanium alloy designed to resist high stress abrasion with heavy
impact. Deposits usually do not relief check.
Suitable for:
Crusher rolls, crusher hammers, asphalt mixer blades, agricultural tools, shovel bucket
teeth and lips, bulldozer blades, cane knives and shredders, bed knives in the wood
pulp industry
Table 17: Typical all-weld metal analysis (weight %)
C
1.8
Mn
0.9
Si
0.2
Cr
6.1
Mo
1.4
Ti
5.5
Fe
Balance
Table 18: Typical all-weld metal mechanical properties
Hardness
58 HRc
Wear Index
2
General characteristics:
Microstructure
Finely dispersed Titanium carbides in a hard

Chromium martensitic matrix
Machinability
Grinding only
Oxy-acetylene cutting
Cannot be flame cut
Deposit Thickness
15 to18 mm in 5 to 6 layers
Flux-cored
Table 19: Welding parameters and economical datas
SAP
N
[mm]
Currant
[A]
Voltage
[V]
Stick out
[mm]
29357
29359
31722
29231
25197
31725
29363
1.2
1.6
2.4
2.4
2.8
2.8
2.8
120 - 150
180 - 200
250 - 300
250 - 300
300 - 350
300 - 350
300 - 350
26 - 30
26 - 30
26 - 30
26 - 30
26 - 30
26 - 30
26 - 30
35 - 40
35 - 40
35 - 40
35 - 40
35 - 40
35 - 40
35 - 40
X : Standard
03-2006 / Version 5
* : On request
Spool
15 kg
X
X
X
X
-
Reel
25 kg 50 kg
X
-
Auto-Pak
150 kg
250 kg
X
*
-
- : Not available
21
Supplier Bhler Thyssen Welding Germany
SK AP-O
DIN 8555: MF 7-GF-200-KP

ASME IIC SFA 5.21: FeMn-Cr
Description:
All purpose alloy, rebuilding and joining of carbon and 14 % Manganese steels, buffer
layer prior to deposit hard overlay.
Suitable for:
Railway rails and crossovers, mill shaft drive ends, gyrator crusher mantles, repointing
of shovel teeth, buffer layer for inter-particles crushers
Table 20: Typical all-weld metal analysis (weight %)
C
0.37
Mn
16.0
Si
0.35
Cr
12.8
Fe
Balance
Table 21: Typical all-weld metal mechanical properties
Hardness
As welded 205 HB
After work hardening: 50 55 HRc
General characteristics:
Microstructure
Austenite
Machinability
Good with metallic carbides tipped tools
Oxy-acetylene cutting
Cannot be flame cut
Deposit Thickness
As required
Flux-cored
Table 22: Welding parameters and economical datas
SAP
N
[mm]
Currant
[A]
Voltage
[V]
Stick out
[mm]
29445
1.2
120 - 150
26 - 30
41309
1.6
180 - 200
26 - 30
29446
1.6
180 - 200
24979
2.4
29448
31713
29450
Spool
Reel
Auto-Pak
13 kg
15 kg
25 kg
50 kg
150 kg
250 kg
35 - 40
35 - 40
26 - 30
35 - 40
250 - 300
26 - 30
35 - 40
2.8
300 - 350
26 - 30
35 - 40
2.8
300 - 350
26 - 30
35 - 40
2.8
300 - 350
26 - 30
35 - 40
X : Standard
03-2006 / Version 5
* : On request
- : Not available
22
5.5
Production plan
The manufacturing company must carry out suitable production planning including at
least:
Specification of the production sequence of the workpiece, e.g. as single parts or

part workpieces and then the sequence of the final assembly.
Identification of the welding processes and associated processes (e.g.

preheating, straightening, stress-relieving annealing, etc.) which are required to.
The produce the workpiece according to the specified requirements with

reference to relevant standards and procedure specifications.
Note!
HAZEMAG & EPR GmbH drawings normally show the final workpiece and so do not
allow for weld shrinkage. When materials are cut to size by the supplier, allowance
must, therefore, be made for such shrinkage.
5.6
Welding processes
The welding process and weld parameters must be selected with allowance for
production conditions (joint design, wind and weather, ambient temperature, heat
supply, etc.) and quality requirements including undercuts and surface nature. The
table below indicates welding processes normally used. Other processes must not be
used unless approved by HAZEMAG & EPR GmbH.
Table 23: Used welding processes
Welding process
Process code acc. to DIN/ ISO 4063
Coated electrodes
111
MIG/ MAG welding
131/ 135
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23
5.7
5.7.1
Weld symbols, technical drawing

Main symbols and supplementary symbols
The main symbols for welds are indicated according to DIN ISO 22553: 1994. The
symbols do not indicate the joining methods. In table 24 are shown main symbols
used by HAZEMAG & EPR GmbH. Examples of combined symmetrical main symbols
are shown in table 25.
Examples of the use of supplementary symbols are shown in table 26. Reference is
made to the standard in cases where the symbols shown are not exhaustive.
Table 24: Main symbols
No.
Designation
Illustration
Symbol
Square butt weld
Single-V butt weld
Single-bevel butt weld
Single-V butt weld with

broad root face
Single-bevel butt weld

with broad root face
Filled weld
Surfacing
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24
Table 25: Examples of combined for symmetrical welds
Designation
Illustration
Symbol
Double-V butt weld
Double-bevel butt weld
Double-V butt weld with

broad root face
Double-bevel butt weld with

broad root face
Table 26: Examples of applications of supplementary symbols
Designation
Illustration
Symbol
Flat single-V butt weld
Convex double-V weld
Concave fillet weld

Flat single-V butt weld with flat
backing run
Single-V butt weld with broad
root face and backing run
Flush finished single-V butt
weld
Filled weld with smooth
blended face
03-2006 / Version 5
25
5.7.2
Position of symbols
Besides main symbols and supplementary symbols, a complete indication also
consists of (see fig. 2):
an arrow line (1)
a double reference line consisting of a real reference line (2a continuous line)
and an identification line (2b dashed line) which are parallel. The identification
line is not required for symmetrical welds and any, therefore, be omitted.
a number of dimensions and supplementary details.
1 = arrow line
2a= reference line (continuous line)
2b = identification line (dashed line)
3 = welding symbol
Fig. 2: Method of representation
5.7.3
Complementary indications
Peripheral welds all round the part are indicated by a circular symbol as shown in Fig.
3. To indicate field or site welds, a flag is used as shown in Fig. 4.
Fig. 3: Indication of peripheral weld.
03-2006 / Version 5
Fig. 4: Indication of field or site weld.
26
5.7.4
Dimensioning of welds
All welds symbols can be supplemented by indication of dimension. Dimensions are
placed as shown in Fig. 5 on the following lines:
a) main dimension of cross section is written before the symbol
b) length dimension is written after the symbol
Indication of main, cross and length dimensions as well as their position is given in
table 27.
On HAZEMAG & EPR GmbH welding drawings the dimensions of fillet welds are
indicated always the throat depth (a-dimension). On the welding drawings is mostly a
sentence, called: e.g. All welding seams a = 4 mm, this means that all welding
seams dimensions on this drawing are 4 mm unless otherwise specified.
If the weld is shown in one place only on the drawing (the main symbol), it implies that
all welds must comply with the symbol.
If length dimensions are not indicated to the right of the symbol, it means that the
weld continues over the total length of workpiece.
Fig. 5: Method of indicating fillet weld dimension
03-2006 / Version 5
27
Table 27: Main dimensions

No.
Designation
Butt weld
Illustration
Definition
s: min. distance
from the surface
of the part to the
bottom of the
penetration;
which cannot be
greater than the
thick-ness of the
thinner part
Inscription
Continuous
filled weld
a: height of the
largest isosceles
triangle that can
be inscribed in
the section.
z: side of the
largest isosceles
that can be
inscribed in the
section.
Staggered
intermittent
fillet weld
Intermittent
fillet weld
03-2006 / Version 5
l: length of weld
(excluding seam
welds).
(e): distance
between adjacent
weld elements.
n: number of weld
elements.
L:
(e):
n:
a:
z:
a: (see No. 2)
z: (see No. 2)
(see No. 3)
(see No. 3)
(see No. 3)
(see No. 2)
(see No. 2)
28
5.8
Welding guidelines for customers

The following welding procedure specifications represent a general guideline. This
guideline describes exemplary current welding joints. The given data are based on the
welding machines and tools, HAZEMAG & EPR is using in their workshop. Please
note, that the manufacturing company is still responsible for the correct welding
procedure.
The data (like thickness of welding) shown in the fabrication drawings, do have
precedence over the data given in the General Instruction Manual.
Table 28:
Welding Procedure Specification
Welding process: 111 (Coated electrodes)
Material S355J2G3, S235JRG2 thickness 10 - 15 mm
Weld type: Double fillet weld
Numbers of welding seams: 1 - 2
Ampacity: 190 - 230 A
Diameter of filler material: 5 mm
Filler material after EN 499 (and see section 5.3)
Weld design in drawings
03-2006 / Version 5
Weld order
29
Table 29:
Welding process: 135 (MAG welding)

Numbers of welding seams: 1-2
Voltage: 28 - 32 V
Diameter of filler material: 1,2 mm
Wire speed: 9 - 11
Filler material after EN 440 G3 Si1 (and see section 5.3)
Gas shield: EN 439-M21; 10 - 12 l/min
Weld order
Table 30:

Filler material after EN 499 (and see section 5.3)
03-2006 / Version 5
Weld order
30
Table 31:

Material S355J2G3, S235JRG2, thickness 10 - 15 mm
Voltage: 28 - 32 V
Wire speed: 9 - 11
Filler material after EN 440 G3 Si1 (see section 5.3)
Weld order
Table 32:

Filler material after EN 499 (see section 5.3)
03-2006 / Version 5
Weld order
31
Table 33:

Weld type: Single-V butt joint with backing run
Voltage: 28 - 32 V
Wire speed: 9 - 11
Vertical up position
Weld order
Table 34:

03-2006 / Version 5
Weld order
32
Table 35:

Voltage: 28 - 32 V
Wire speed: 9 - 11
Weld order
Table 36:

Voltage: 28 - 32 V
Wire speed: 9 - 11
Preheating: 110 - 130C, ex 30 mm
03-2006 / Version 5
Weld order
33
Table 37:

Voltage: 28 - 32 V
Wire speed: 9 - 11
Weld order
Table 38:

03-2006 / Version 5
Weld order
34
Table 39:

Voltage: 28 - 32 V
Wire speed: 9 - 11
Preheating: 110 - 130C
Weld order
Table 40:

Voltage: 28 - 32 V
Wire speed: 9 - 11
03-2006 / Version 5
Weld order
35
Table 41:

Voltage: 28 - 32 V
Wire speed: 9 - 11
Weld order
Table 42:

Voltage: 28 - 32 V
Wire speed: 9 - 11
03-2006 / Version 5
Weld order
36
Table 43:

Material S355J2G3, S235JRG2 thickness 20 mm
Weld type: Double-V butt weld
Voltage: 28 - 32 V
Wire speed: 9 - 11
Weld order
Table 44:

Material S355J2G3, S235JRG2 thickness 30 mm
Voltage: 28 - 32 V
Wire speed: 9 - 11
03-2006 / Version 5
Weld order
37
Table 45:

Weld type: Double J butt weld
Voltage: 28 - 32 V
Wire speed: 9 - 11
03-2006 / Version 5
Weld order
38
5.9
Quality
HAZEMAG & EPR GmbH requires the welding quality D Moderate acc. to DIN EN
25817. In order to achieve this quality, the welders of our customers manufacturing
company have to have the correct and sufficient qualification. The welding classes are
indicated in table 46.
Length of imperfection
The distance from an imperfection in a longitudinal seam to the next imperfection of the
same type must be equal to or longer than the mean length of the two imperfections in
order that the two lengths may be regarded as separated from each other.
If so, the length of imperfections is equal to the length of the individual imperfection.
If this condition is not satisfied, the seam is regarded as imperfect over a length
corresponding to the distance between the two outer limits of the areas of imperfection.
Short imperfections
One or more imperfections of a total length not exceeding 25 mm taken from any 100
mm of a weld or max. 25% of a weld length shorter than 100 mm. (Such imperfections
were previously denoted local imperfections).
Long imperfections
One or more imperfections of a total length exceeding 25 mm taken from any 100 mm
of a weld or max. 25% of a weld length shorter than 100 mm. (Such imperfections were
previously denoted local imperfections).
03-2006 / Version 5
39
Table 46: Limits for imperfections (acc. to DIN EN 25817)
No.
Imperfection
designation
ISO 6520
reference
Remarks
Limits for imperfections for

quality levels
Moderate
InterStringent
D
mediate C
B
Cracks
100
All types of cracks except

2
micro cracks (h x l < 1 mm )
For crater cracks, see No. 2
Not permitted
Crater cracks
104
Porosity and
pas pores
2011
2012
2014
2017
Permitted
The following conditions
and limits must be fulfilled:
a) max. dimension of the
projected or surface
crack area of the
imperfection
b) max. dimension of a
single pore for:
butt welds
fillet welds
c) max. dimension for a
single pore
The total pore area within
the cluster should be
summed and calculated as
a percentage of the greater
of the two areas; an
envelope surrounding all
the pores or a circle with
diameter corresponding to
the weld width.
The permitted porous area
should be local.
The possibility of masking
other imperfections should
be taken into consideration.
Localized
(clustered)
porosity
03-2006 / Version 5
2013
The following conditions

and limits for imperfections
must be fulfilled:
a) max. dimension of the
summation of the
projected or surface
crack area of the
imperfections
b) max. dimension of a
single pore for:
butt welds
filled welds
c) max. dimensions for
localized clustered
porosity
4%
d 0,5 s
d 0,5 a
Not permitted
2%
d 0,4 s
d 0,4 a
1%
d 0,3 s
d 0,3 a
5 mm
4 mm
3 mm
16 %
8%
8%
d 0,5 s
d 0,5 a
d 0,4 s
d 0,4 a
d 0,3 s
d 0,3 a
4 mm
3 mm
2 mm
40
Table 46: Limits for imperfections (continued)
No.
Imperfection
designation
ISO 6520
reference
Remarks
Long imperfections for
butt welds
filled welds
Elongated
cavities,
wormholes
2015
2016
In any case, max.

dimension for elongated
cavities, wormholes
Short imperfections for
butt welds
filled welds
In any case, max.
dimension for elongated
cavities, wormholes
butt welds
filled welds
Solid
inclusions
(other than
copper)
300
In any case, max.

dimension for solid
inclusions
butt welds
filled welds
In any case, max.
dimension for solid
inclusions
Copper
inclusions
Lack of
fusion
(incomplete
fusion)

quality levels
Moderate
InterStringent
D
mediate C
B
h 0,5 s
h 0,5 a
Not
permitted
Not
permitted
h 0,4 s
h 0,4 a
h 0,3 s
h 0,3 a
4 mm
or not lager
than
thickness
3 mm
or not
lager
than
thickness
2 mm
or not
lager
than
thickness
h 0,5 s
h 0,5 a
Not
permitted
Not
permitted
h 0,5 s
h 0,5 a
h 0,4 s
h 0,4 a
h 0,3 s
h 0,3 a
4 mm
or not
lager
than
thickness
3 mm
or not
lager
than
thickness
2 mm
or not
lager
than
thickness
2 mm
h 0,5 s
h 0,5 a
2 mm
3042
401
Not permitted
Only intermittently
and not
breaking
the surface
Not permitted
Long imperfections:
Not permitted
Lack of
penetration
(incomplete
penetration)
402
Short imperfections
h 0,2 s
max. 2 mm
03-2006 / Version 5
Not
permitted
h 0,1 s
max.1,5mm
41
No.
Imperfection
designation
ISO 6520
reference
Remarks

quality levels
Moderate
InterStringent B
D
mediate C
An excessive or
insufficient gap between
the parts to be jointed.
10
Bad fit-up
filled welds
Undercut
5011
5012
Smooth transition is
required
12
13
14
Excess weld
metal
Excessive
convexity
Fillet weld
having a
throat
thickness
greater than
the nominal
value
03-2006 / Version 5
h 0,5 mm
+ 0,2 a
h 0,5 mm
+ 0,1 a
max.
4 mm
max.
3 mm
max.
2 mm
h 1,0 mm
h 0,6 mm
h 0,4 mm
h 1,0 mm
+ 0,25 b
h 1,0 mm
+ 0,15 b
h 1,0 mm
+ 0,1 b
max.
10 mm
max.
7 mm
max.
5 mm
h 1,0 mm
+ 0,25 b
h 1,0 mm
+ 0,15 b
h 1,0 mm
+ 0,1 b
max.
5 mm
max.
4 mm
max.
3 mm
h 1,0 mm
+ 0,2 a
h 1,0 mm
+ 0,15 a
h 1,0 mm
+ 0,1 a
max.
5 mm
max.
4 mm
max.
3 mm
Gaps exceeding the

appropriate limit may in
certain cases be
compensated for by a
corresponding increase in
the throat
required
11
h 1,0 mm
+ 0,3 a
502
503
For many applications a

throat thickness greater
than the nominal one may
be a reason for rejection.
42
No.
15
16
17
Imperfection
designation
Fillet weld
having a
throat
thickness
smaller than
the nominal
value
ISO 6520
reference
Excessive
penetration
504
Local
protrusion
5041
Remarks
A filled weld with an
apparent throat thickness
smaller should not be
regarded as imperfect if
the actual throat depth
thickness with a
compensating greater
depth of penetration
complies with the nominal
value.

quality levels
Moderate
InterStringent B
D
mediate C
Long imperfections:
Not permitted
Short imperfections:
h 0,3 mm + 0,1 a
max. 2 mm max. 1 mm
h 1,0 mm
+ 1,2 b
h 1,0 mm
+ 0,6 b
h 1,0 mm
+ 0,3 b
max.
5 mm
max.
4 mm
max.
3 mm
Permitted
The limits to deviations
from the correct position.
Not
permitted
Occasional local excess

permitted
Fig. A
Plates and longitudinal imperfections
Unless otherwise
specified, the correct
position is when the
centrelines coincide.
Fig. A
18
Linear
misalignment
max. 5 mm
max. 4 mm
max. 3 mm
507
Fig. B Circumferential welds

Fig. B
max. 4 mm
03-2006 / Version 5
h 0,5 t
max.
3 mm
max. 2 mm
43
No.
19
Imperfection
designation
Incompletely
filled groove
ISO
6520
reference
511
Remarks
required.
509
20
512
Root
concavity
515
21
Moderate
InterStringent B
D
mediate C
Long imperfections:
not permitted
Short imperfections:
Sagging
Excessive
asymmetry
fillet weld

quality levels
It is assumed that an
asymmetric fillet weld
has not been expressly
prescribed.
required.
h 0,2 t
h 0,1 t
h 0,05 t
max.
2 mm
max.
0,1 mm
max.
0,5 mm
h 2,0 mm +
0,2 a
h 2,0 mm
+ 0,15 a
h 1,5 mm
+ 0,15 a
h 1,5 mm
h 1,0 mm
h 0,5 mm
Shrinkage
groove
5013
22
Poor restart
517
Not permitted
23
Stray flash or
arc strike
601
Acceptance may depend on posttreatment. Acceptance depends on

parent metal type, with special ref. to
crack sensitivity
24
Spatter
602
Acceptance depends on applications.
25
Overlap
506
03-2006 / Version 5
Permitted
Not permitted
44
5.10 Testing
HAZEMAG & EPR GmbH requires the welding quality D Moderate acc. to DIN EN
25817. In the fabrication drawings of HAZEMAG & EPR GmbH, in connection with the
weld symbol, no reference is made to specific quality class. The extent of testing can
be reduced to include Visual Test (VT) and Dimension Test (DT).
In case of doubt non destructive test must be carried out in accordance with an
international recognised standard.
Non-destructive testing must be carried out in accordance with an international
recognised standard. The test equipment must be suitable for the purpose.
The test personnel must be qualified to carry out inspection jobs in accordance with
DIN EN 473 or a corresponding internationally recognised standard.
Table 47: Test methods and abbreviations
Method
Abbreviation
Visual test
VT
Dimension test
DT
Magnetoflux test
MT
Liquid penetrant test
PT
Radiographic test
RT
Ultrasonic test
UT
A determination of external imperfections should precede testing of internal

imperfections (UT and RT).
5.10.1 Extent and methods of testing
Welded seams must be examined by the use of suitable test methods to such an
extent that a realistic evaluation is achieved of the quality, shape and dimensions of
the welded seams.
Quality level and extent of testing are defined by the quality class (D, C, B) as it is be
seen in table 48.
03-2006 / Version 5
45
Table 48: Extent of testing
Quality
class
D
C
B
Quality level
Testing
VT
DT
MT/ PT
UT/ RT
Intermediate (C)
normal
100%
5%
5%
5%
Moderate (D)
stringent
100%
20%
20%
20%
Moderate (D)
compete
100%
100%
100%
100%
Intermediate (C)
normal
100%
20%
20%
20%
Intermediate (C)
compete
100%
100%
100%
100%
Stringent (B)
compete
100%
100%
100%
100%
If imperfections are found causing non-compliance with the quality requirements, the
extent of testing must be increased to 100%. As it can be seen from table 48, it will,
however, suffice to test only 5% to obtain quality class D if at least quality level
Intermediate C is obtained. The extent of testing must be extended to 20% if during
the original 5% extent of testing a quality inferior to Intermediate C is found. If
Moderate D is not obtained at 20% testing, repairs will be required. At the same
time, the extent of testing must be increased to 100%. Repaired sections of welded
seams must be examined 100%.
5.10.2 Acceptance criteria

It is a main rule that acceptance levels for imperfections in any welded joint are
specified by the quality levels defined in DIN EN 25817.
Detection and determination of sizes of imperfections are greatly dependent on
inspection methods and the methodology used which must be chosen and carried out
according to an internationally recognised standard to enable the methods to supply
the detection, characterization and indication of size which are required to determine
the types of imperfections mentioned in DIN EN 25817.
DIN EN 12062 Non-destructive testing of weld seams General rules is an
example of an internationally recognised standard which gives guidance on choice of
inspection methods and links standard concerning acceptance level for nondestructive testing with DIN EN 25817.
03-2006 / Version 5
46
5.10.3 Time of inspection

Inspections of welds must only be started after termination of any Thermal
straightening or heat treatment.
5.10.4 Practical and non-destructive Testing of Welding Seams according to
HAZEMAG & EPR GmbH
Welding works are to be exclusively executed by welders, certified according to DIN
EN 287-11 or a similar standard. A welder certified according DIN EN 25817 to
welding grade quality B must achieve the required welding quality D. It is thereby
ensured that the required welding seam quality will be met and that the inspection of
the welding seams will not be compulsory.
In case of doubt, the below mentioned practical and economically justifiable nondestructive examination can be applied following a visual inspection of the welding
seams (VT and DT) on a random basis:
About up to 5 % - 10 % of the butt welds should be subjected to ultrasonic testing/
radiographic testing (irrespective of the plate- respectively welding seam thickness).
To this end we would recommend, if necessary, to level the welding seam to be
inspected using a grinder, in order to obtain a satisfactory inspection result. The
welding seam moreover should be examined from the final and root run.
As far as fillet welds are concerned, we would recommend, taking account of the
required plate- and welding seam thickness, to exclusively apply the magnetic power
testing method (MT) for examination of 5 % - 10 % of the welds.
Furthermore, for inspection of the inner condition, the fillet welds could be free-cutted
on a random basis, in order to get an impression of the inner weld condition.
The welding seam is to be rated according to DIN EN 25817 which stipulates the
admissible number of "faults" (please refer to General Instruction Manual, chapter
5.8).
A heat treatment of the welds by applying stress-relieve annealing is not planned.
Preheating prior to the welding of plates, having a higher thickness, (kindly refer to
the General Instruction Manual, chapter 5.7), is, however, necessary.
03-2006 / Version 5
47
6 Thread
Metric coarse thread (ISO M) is the thread normally used by HAZEMAG & EPR GmbH
for screws and nuts.
Metric coarse thread is indicated on drawings and parts lists by capital M followed by the
diameter, e.g. M16.
Metric fine thread is indicated on drawings and parts lists by capital M followed by the
diameter multiplied by the pitch, e.g. M16 x 1,5.
The correct dimension and profile of threads on shafts, special-type bolts and similar
parts as well as internal threads in nuts to match must be checked by the use of a thread
gauge.
For the tightening forces and torques for metric bolts look at table 35. This table is
normally used by all screw connections unless otherwise specifies.
Note!
Loose bolts, screws, and keys may give rise to serious break-downs.
Examine therefore all bolted, screwed, and keyed joints some time after a new or
repaired machine has been put into use. Any slackened nuts or screws must be
tightened up immediately, and loose keys driven home.
03-2006 / Version 5
48
Table 49: Tightening forces and torques for Metric Bolts
Tightening forces and torques for Metric Bolts

(applies only to connections where no details are given)
Coefficient of Friction ges = 0.14 applies to bolts and nuts untreated, non-lubricated.
Table 1:
Bolt size
4.6
kN
Tightening force F
Torque M
Strength category
Strength category
5.6
kp
kN
8.8
10.9
kp
kN
kp
kN
4.6
kp
Nm
5.6
kpm
Nm
8.8
kpm
Nm
10.9
kpm
Nm
kpm
M5
2.1
210
2.79
279
6.35
635
8.95
895
2.0
0.2
2.7
0.27
6.0
0.6
8.5
0.85
M6
2.96
296
3.94
394
9.0
900
12.6
1260
3.5
0.35
4.6
0.46
10.0
1.0
14.0
1.4
M8
5.42
542
7.23
723
16.5
1650
23.2
2320
8.4
0.84
11.0
1.1
25.0
2.5
35.0
3.5
M10
8.64
864
11.5
1150
26.2
2620
36.9
3690
17.0
1.7
22.0
2.2
49.0
4.9
69.0
6.9
M12
12.6
1260
16.8
1680
38.3
3830
54.0
5400
29.0
2.9
39.0
3.9
86.0
8.6
120.0
12.0
M14
17.3
1730
23.1
2310
52.5
5250
74.0
7400
46.0
4.6
62.0
6.2
135.0
13.5
190.0
19.0
M16
23.8
2380
31.7
3170
71.0
7.1
95.0
9.5
M16x1.5
M18x1.5
73.0
7300
102.0
10200
210.0
21.0
295.0
29.5
79.0
7900
111.0
11100
225.0
22.5
315.0
31.5
103.0 10300
145.0
14500
325.0
32.5
460.0
46.0
M20
37.2
3720
49.6
4960
114.0 11400
160.0
16000
138.0
13.8
184.0
18.4
410.0
41.0
580.0
58.0
M24
53.6
5360
71.4
7140
164.0 16400
230.0
23000
235.0
23.5
315.0
31.5
710.0
71.0 1000.0
100.0
183.0 18300
257.0
25700
780.0
78.0 1100.0
110.0
85.7
8570
114.5
11450
262.0 26200
368.0
36800
475.0
47.5
635.0
63.5 1450.0
145.0 2000.0
200.0
141.0
14100
300.0 30000
422.0
42200
740.0
74.0 1600.0
160.0 2250.0
225.0
125.5
12550
167.5
16750
382.0 38200
538.0
53800
830.0
83.0
1110.
0
111.0 2450.0
245.0 3560.0
356.0
172.5
17250
230.0
23000
526.0 52600
740.0
74000 1330.0
133.0
1780.
0
178.0 4070.0
407.0 5720.0
572.0
227.0
22700
303.0
30300
693.0 69300
975.0
97500 2020.0
202.0
2690.
0
269.0 6140.0
614.0 8640.0
864.0
M24x2
M30
M30x2
M36
M36x3
M42
415.0 41500
2650.0
265.0
M42x3
M48
M48x3
725.85 72585
6213.0
621.3
Values for Table 1 acc. to "Bauer & Schaurte".
Table 2:
Tightening forces F and torques M for high-tightened bolts as per DIN 6914 - 6918 Strength category 10.9
Bolt size
M 12
M 16
M 20
M 22
M 24
M 27
Tightening with torque wrench

Tightening force F
Torque M
kN
kp
Nm
kpm
52
5200
120
12.0
99
9900
305
30.5
155
15500
597
59.7
192
19200
815
81.5
221
22100
1025
102.5
292
29200
1520
152.0
with hammer wrench

Tightening force F
kN
kp
56
5600
107
10700
168
16800
208
20800
239
23900
316
31600
Values for Table 2 as per "Preliminary Guidelines for HV Connections" from German Commitee for Steel Construction, 1963.
03-2006 / Version 5
49
7 Trial Mounting in Workshop

The function of all moving parts must be tested to the extent which is possible in
practice.
Dismantling
If the specifications, e.g. packing instructions or shipment sketch de not prescribe
specific dismantling of the trial-mounted machines or parts, dismantling should generally
only be made to the extent which is expedient for shipment all the way to the plant.
Match-marking in workshop
To ensure that the parts are remounted on site in locations to those of shop-mounting,
the parts must be match-marked by punching numbers in them and marking these
numbers with a frame of white weather-proof paint.
03-2006 / Version 5
50
8 Corrosion-Proofing in general
Corrosion-Proof includes protection of parts, machines and goods by the use of special
oil products and paint.
Generally, the quality of corrosion-proofing must be so good as to permit sea transport
as well as storage of the goods on wharfs and factory sites under unfavourable
conditions.
8.1
Corrosion-Proofing of machined surfaces

One of the below-mentioned proven rust-proofing products can be used for protection
of e.g. threads, turned, planed or ground surfaces if painting is not specifies:
1) Tectyl 506 WD
Producer: Valvoline Oil Company (USA)
Thickness: 30-50 m (dry film)
Teyctyl forms a brownish film which remains slightly adhesive even after a long
time.
2) Chesterton, Heavy Duty Rust Guard
Producer: A.W. Chesterton Co. (USA)
Thickness: 40-50 m (dry film)
Chesterton Heavy Duty Rust Guard forms a brownish film which is dry to touch
within 4 hours and completely dry after approx. 14 hours.
3) Esguard Pipe Coating
Producer: Esguard Inc.(USA)
Thickness: Min. 100 m (dry film)
Esguard Pipe Coating forms a wax-like greyish film which remains soft and sticky
for a long time (one or two years). The agent must be sprayed on because of the
large layer thickness of wet film (approx. 200 m).
The above three rust-proofing agents can be washed off relatively easily with aliphatic
solvents are derived from mineral oil and have a low dissolving power. Best know is
turpentine. Water-base cleaning agents, also called emulsion degreasers, can also be
used.
03-2006 / Version 5
51
Surfaces to be protected must be cleaned of visible remains of drilling and cutting oils
with a rag and, if required, turpentine, after which the proofing agent is applied by
dipping, spraying, brushing or rolling.
8.2
Stock qualities
Stock qualities like e.g. bolts and screws which are shipped in the manufacturers
original cartons and packing normally require no additional rust-proofing.
8.3
8.3.1
Corrosion-Proofing by painting
Detail of painting procedures
The customer shall submit to local manufacturer the painting specification describing
the customers painting procedures in detail to verify that they conform to this
specification and other instructions specified in the specifications and drawings, etc.
8.3.2
Description of painting specification

Dry film thickness per coat
The figure of dry film thickness per coat shows the average.
8.3.3
Colouring schedule
The final colour shall be informed after contract.
03-2006 / Version 5
52

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Instruction Manual

General Notes .............................................................................................................. 4

Tolerance symbols in general ................................................................................ 5

General permissible deviations .............................................................................. 5

Geometrical tolerancing ......................................................................................... 7

Kinds of tolerances and symbols as well as included tolerances.................................. 7

Tolerances of raw material.........................................................................................12

Tolerances of channel steel according DIN 1026 ..................................................13

Tolerances of - and H- beams according DIN EN 10034......................................14

Tolerances of autogenes cutting according DIN EN ISO 9013 ..............................16

Surface Roughness ....................................................................................................18

Surfaces without finishing symbols........................................................................18

Surfaces with finishing symbols ............................................................................18

Surfaces with finishing symbols on old drawings...................................................19

Centre line average height Ra acc. to DIN 4768 ....................................................19

Filler metals ..........................................................................................................20

Production plan .....................................................................................................23

Weld symbols, technical drawing ..........................................................................24

Main symbols and supplementary symbols................................................................. 24

Complementary indications ......................................................................................... 26

Welding guidelines for customers..........................................................................29

Extent and methods of testing..................................................................................... 45

Acceptance criteria ...................................................................................................... 46

Time of inspection ....................................................................................................... 47

Practical and non-destructive Testing of Welding Seams according to HAZEMAG &

EPR GmbH ................................................................................................................................... 47

Trial Mounting in Workshop.......................................................................................50

Corrosion-Proofing in general ...................................................................................51

Corrosion-Proofing of machined surfaces .............................................................51

Detail of painting procedures....................................................................................... 52

Description of painting specification ............................................................................ 52

Tolerance symbols in general

General permissible deviations

Worst deviations for nominal size area (in mm)

Table 2: Worst deviations for angular dimensions

Table 3: General tolerance for straightness and flatness

Table 4: General tolerance for perpendicularity

Tolerance of perpendicularity for nominal size area

Table 5: General tolerance for symmetry

Table 6: General tolerance for run

Run tolerances (in mm)

It also applies that:

Inside radii of curvature of machined parts with no marked dimensions must

All external edges of machined parts must be chamfered (0,5x45) unless

Kinds of tolerances and symbols as well as included tolerances

1) Tolerances of position always refer to a datum feature or theoretically exact

Definition of the tolerance zone

Indication and interpretation

Any line on the upper surface parallel to

Any line on the upper surface parallel to

The tolerance zone is limited by

The axis of the bar shall be contained

The tolerance zone is limited by

The axis of the cylinder to which the

Table 8: Geometrical Tolerance (continue)

Definition of the tolerance zone

Indication and interpretation

The tolerance zone is limited by

The toleranced axis shall be

Parallelism tolerance of a line with reference to a datum surface

Table 8: Geometrical Tolerance (continue)

Definition of the tolerance

Indication and interpretation

The surface shall be contained