Managing the Welding of Lifting Lugs onto Manganese

Specialised welding requires detailed attention onsite – especially when you don’t know the exact metallurgical makeup of manganese, reports SARAH ANDREW, CMPA Project Manager.

WELDING lifting lugs onto manganese is a specialised task that requires the detailed attention of managers. This is considered a specialised stream of welding and there are certain requirements that a welder personally must meet, including being certified to AS 1554 “Structural Steel Welding” at minimum.

The welder should hold a welding qualification that complies with AS 1554:1 or alternatively to AS 1796 Cert. 3E, AS 3992, AS 2980 or ISO 9606-1. Their training must be current, they must have experience, they must be able to inspect welds (particular skills are necessary in magnetic particle or dye penetrate tests) and they must be able to document what they have done.

Last year, the CMPA commenced works with Quantec Solutions to develop a training program to provide welders with the required skills for welding onto manganese specifically in a crushing plant environment. Over the course of several months, the training resources were developed with the assistance of Boral, Crushing Equipment and Terex Jaques.

When welding lifting lugs onto wear parts, there are specific processes that must be followed to ensure the safety of all people onsite. This includes preparing equipment, testing the wear part, sourcing lifting lugs, and following an appropriate weld procedure.

PREPARING EQUIPMENT

Specific areas which must be considered include grinding equipment, oxy/fuel storage and welding equipment. For instance, does the welding machine comply to AS 1674.2 “Safety in Welding and Allied Processes – Electrical”?

ENSURING COMPLIANCE TO STANDARDS
Welding of lifting lugs is managed on a detailed level in a number of Australian Standards. Accordingly a site may require access to a number of standards for guidance and further information. The most relevant include:

• AS 1554:1 2004 Structural steel welding – Welding of steel structures
• AS 3992 1998 Pressure equipment – Welding and brazing qualification
• AS 1674.2 2007 Safety in welding and allied processes – Electrical
• AS 1988.1 2006 Welding of ferrous castings – Steel castings

TESTING THE WEAR PART

It is necessary to perform appropriate tests to confirm the manganese’s metallurgical composition to establish the pre-heating requirements. This can be checked by seeking a composition breakdown from the supplier; however it is suggested that this be confirmed onsite. Such tests include testing for magnetism, conducting a spark test or conducting a chip test.

SOURCING THE LIFTING LUG

Appropriate lifting lugs need to be sought. The lugs should be profile cut from plate from AS 3678 grade 350 plate and comply with the designed lifting specifications for the weight to be lifted. If in doubt, use a thicker lug. Rough lugs that have been hand cut from scrap plate and unequal in thickness should not be used.

Lugs must have a radius around the eye for the shackle to be able to rotate without being jammed which may cause the lug to break off . They will change between different wear items, and will be positioned accordingly.

USING WELD PROCEDURES

Once the previous criteria have been addressed, it is necessary to select a welding procedure (which has been prepared earlier – a standard one is provided to those trained) appropriate to the task. This will detail the welding rod to be used and the welding order.

This information is covered in more detail in the lifting lugs course which is available through Quantec Solutions.

For further information, contact Toby Corbett on 0425 768 060.

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