www bzfxw com BS EN 12568 2010 ICS 13 340 50 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW BRITISH STANDARD Foot and leg protectors — Requirements and test methods for toecaps[.]
General
Table 1 — Summary of requirements for toecaps and number of tests
Property Subclause Metal toe cap
Number of tests for type approval
Finishing 4.2.1 X X 1 sample each size right and left
Internal length 4.2.2.1 X X 1 sample each size right and left
Width of flange 4.2.2.2 X X 1 sample each size right and left
Impact resistance 4.2.3 X X 1 sample each size right and left
Compression resistance 4.2.4 X X 1 sample each size right and left
Corrosion resistance 4.3 X - 3 samples of different sizes
Impact resistance after five environmental treatments 4.4 - X 2 samples for each treatment a
"X" means "Test shall be carried out"; "-" means "Test need not be carried out"
NOTE 1 For details, see 4.2 to 4.4
NOTE 2 "Worst performing" sample is where the smallest gap between required and measured clearance has been found a Select worst performing sample sizes of test 4.2.3
Each individual test result must meet the relevant requirements; otherwise, the entire lot is considered a failure If varying results are obtained from the same test on identical samples, the lowest value will be reported as the test result, adhering to the "worst case principle."
Requirements for all types of toe caps
Finishing
Toe caps must be completed without any surface marks or defects, ensuring they are free from burrs, sharp edges, and issues such as splitting or delaminating between material layers.
Dimensions
When measured in accordance with the method described in 5.2.1, the internal length of toe caps shall be not less than the appropriate value given in Table 2
Table 2 — Minimum internal length of toe caps
Toe cap number 5 and below
Minimum internal length in millimetres 34 36 38 39 40 42
NOTE The above numbering system for toecaps is not identical to any numbering system for footwear
If toe caps are formed with a flange, the inside width of the flange (e) shall be not greater than 10 mm, as shown in Figure 1 e
Key e Width of the toe cap flange
Figure 1 — Illustration of width " e " of the toe cap flange
Impact resistance
When toe caps are tested in accordance with the method described in 5.2.2 at an energy level of either
Toe caps designed for protective footwear must withstand an impact of (100 ± 2) J, while those for safety footwear should endure (200 ± 4) J At the moment of impact, the clearance beneath the cap must meet the specified values in Table 3 Furthermore, the toe cap must not exhibit sharp edges or cracks that penetrate the material, allowing light to pass through.
Compression resistance
Toe caps must be tested according to the method outlined in section 5.2.3, ensuring that the clearance under the toe cap at a compression load of (10 ± 0.1) kN for protective footwear or (15 ± 0.15) kN for safety footwear meets the minimum values specified in Table 3 Furthermore, the toe cap should not exhibit sharp edges or any cracks that penetrate the material, allowing light to pass through.
NOTE The provisions of 4.2, 4.3 and 4.4 do not exclude a toe cap design incorporating perforations
Table 3 — Minimum clearance under toe caps at impact and compression
Toe cap number 5 and below 6 7 8 9 10 and above
Internal toe cap minimum clearance
External toe cap minimum clearance
Special requirements for metal toe caps − Corrosion resistance
Metal toe caps must show no more than three areas of corrosion, with each area not exceeding 2 mm in any direction, both before and after testing as per the method outlined in section 5.3.
Special requirements for non-metal toe caps − Stability against ageing and environmental
Non-metal toe caps must undergo specific treatments and be tested according to established methods at energy levels of (100 ± 2) J for protective footwear and (200 ± 4) J for safety footwear During impact testing, the clearance under the cap should meet the minimum values specified in Table 3 Additionally, the toe cap must not exhibit sharp edges or cracks that penetrate the material, allowing light to pass through.
5 Test methods for toe caps
General
Each size will be tested with one pair of samples, with exceptions for certain properties outlined in Table 1 In cases where repeated tests yield varying results on identical samples, the lowest value will be reported as the test result.
If samples of only one size are available, two pairs shall be tested
Each one of the environmental treatments of 5.4 shall be applied to new samples.
Test methods for all types of toe caps
Determination of internal toe cap length
5.2.1.1 Determination of the test axis
Align the rear edge of the left toe cap with a designated baseline and trace its outline Next, position the right toe cap along the same baseline, ensuring that the outlines at the toe ends of both toe caps match.
A, B, C, D Points where the outlines of the right and left toe caps intersect on the base line
Figure 2 — Determination of test axis (schematic illustration)
Mark points A, B, C, and D at the intersections of the right and left toe caps on the baseline Next, draw a perpendicular line from the baseline at the midpoint of either AB or CD, establishing the test axis for both toe caps.
To measure the internal length \( l \) of the toe cap, place it open side down on a flat surface Use an appropriate gauge to measure from the front inside to the vertical projection of the back edge, ensuring the measurement is taken between 3 mm and 10 mm above the surface Record the longest distance as the length \( l \).
1 Test axis l Internal length of the toe cap
Figure 3 — Measurement of internal toe cap length
Determination of impact resistance
5.2.2.1.1 Impact apparatus, incorporating a steel striker of mass (20 ± 0,2) kg adapted to fall freely on vertical guides from a predetermined height to give the required impact energy calculated as potential energy
The striker must be constructed from steel with a minimum Rockwell hardness of 60 HRC It should feature a wedge that is at least 60 mm long, with rectangular faces measuring a minimum of 40 mm in height and forming an angle of (90 ± 1)° The apex where the faces converge must have a rounded radius of (3 ± 0.1) mm Additionally, during testing, the apex should remain parallel to the base of the clamping device within a tolerance of ± 2°.
The apparatus must feature a compact design with minimal elastic structures, ensuring a mass of no less than 600 kg Additionally, a metal block measuring at least 400 mm × 400 mm × 40 mm deep must be securely bolted to the base.
The apparatus must be positioned on a stable, flat floor that is adequately sized and sturdy to support the test equipment Additionally, a mechanism should be implemented to capture the striker after its initial impact, ensuring that the test specimen is struck only once.
The clamping device features a steel platen that is at least 19 mm thick and measures 150 mm × 150 mm, with a minimum hardness of 60 HRC It is designed to lightly clamp a toe cap, allowing for lateral deformation during impact testing without restriction.
An example of a suitable clamping device is shown in Figure 5
Figure 5 — Example of suitable design of toe cap clamp
The toe cap is secured at the front end using a forked clamp, which is fastened with a screw into one of the threaded holes, tailored to the size of the toe cap.
The toe cap is secured at the rear with a curved plate attached to a sliding rail, which exerts a force of 100 N to 200 N, pressing the cap against the forked clamp.
The sliding rail is designed with a spring mechanism that allows the toe cap to move backward along its axis when struck by the striker To replace the toe cap, simply retract the curved plate by releasing the clamping handle.
5.2.2.1.3 Cylinders of modelling clay, with a diameter (25 ± 2) mm; the height shall be (28 ± 2) mm for toe caps up to and including size 5, and (30 ± 2) mm for toe caps above size 5
The dial gauge features an accuracy of 0.1 mm and operates vertically, equipped with a flat base for supporting the clay cylinder It includes a hemispherical upper sensor with a radius of (3.0 ± 0.2) mm, applying a maximum vertical force of 250 mN.
Determine the test axis as described in 5.2.1.1
Use the toe cap as the test piece
Hold the test piece in the clamping device (5.2.2.1.2) so that when the striker hits it, the striker will project over the front and back of the toe cap
Position a cylinder under the rear upper edge of the test piece so that approximately two-thirds of its diameter is within the test piece and one-third is protruding behind the rear edge, ensuring the center of the cylinder aligns closely with the test axis The temperature of the modeling clay during the test must be maintained between 18 °C and 25 °C.
The striker should be released onto the test axis from a specified height to achieve an impact energy of (200 ± 4) J for toe caps intended for safety footwear, or (100 ± 2) J for toe caps designed for protective footwear.
Measure, to the nearest 0,5 mm, the lowest height to which the cylinder has been compressed, using the dial gauge (5.2.2.1.4) This value is the clearance at the moment of impact
The number of tests to be performed is stated in Table 1 If only one size is available (e.g prototype), two pairs of samples shall be tested
Figure 6 — Position of cylinder for impact or compression testing of toe caps
Determination of compression resistance
5.2.3.1.1 Compression testing machine, capable of subjecting the test piece to a force of at least 20 kN
(to a tolerance of ± 1 %) between two plain platens, by moving one of those at a speed of (5 ± 2) mm/min
Both platens must cover a minimum area with a diameter of 150 mm and possess a hardness of at least 60 HRC It is essential that they remain parallel while the load is applied, and any influence from eccentrically applied forces on the measurement should be minimized as much as possible.
5.2.3.1.2 Cylinders, as described for the impact test (see 5.2.2.1.3)
5.2.3.1.3 Dial gauge, as described for the impact test (see 5.2.2.1.4)
Determine the test axis as described previously (see 5.2.1.1)
Use the toe cap as the test piece
Position the test piece between the platens of the compression machine, ensuring that a cylinder is placed under the rear upper edge of the test piece, with approximately ⅔ of its diameter inside the test piece and ⅓ protruding behind the rear edge, aligning the center of the cylinder with the test axis The temperature of the modeling clay during the test must be maintained between 18 °C and 25 °C.
Compress the test specimen to a load of either (15 ± 0,1) kN for toe caps to be used for safety footwear or
(10 ± 0,1) kN for toe caps to be used for protective footwear (see Figure 7)
Reduce the load, remove the cylinder and measure, to the nearest 0,5 mm, the lowest height to which the cylinder has been compressed, using the dial gauge described in 5.2.3.1.3
NOTE This value is the compression clearance at the moment of highest compression
The number of tests to be performed is stated in Table 1 If only one size is available (e.g prototype), two pairs of samples shall be tested
Test method for metal toe caps − Determination of corrosion resistance
Preliminary examination
Examine the toe cap visually inside and outside for signs of corrosion under the coating and for corrosion occurring where the coating has broken down
Measure the longest distance across each area of corrosion and note the number of such areas.
Corrosion test procedure
Remove any grease, silicone, wax or similar material which might be present on the surface
To prepare a test solution, create at least 300 ml of a 1% (mass fraction) aqueous sodium chloride solution Pour this solution into a dish measuring at least 100 mm × 160 mm, ensuring the solution depth is ≥ 15 mm and the height from the glass plate is ≤ 10 mm Finally, cover the dish with a glass plate, leaving a small opening for ventilation.
To conduct the test, immerse two strips of white filter paper, each measuring at least 100 mm in width and 150 mm in length, into the test solution at one end until they are fully saturated, while positioning the other ends on a glass plate.
Position the toe cap with the flange facing down on a filter paper, ensuring complete contact with the wetted area Then, place another filter paper over the toe cap to maximize contact with the cap's nose and upper surface It is crucial to maintain the saturation of the filter paper throughout the testing process.
After 48 h remove the filter paper and examine the toe cap for signs of corrosion Measure the longest distance across each area of corrosion and note the number of such areas
Test methods for non-metal toe caps
General
New samples shall be used for each of the following five treatments.
Effect of high temperature
Place the toe cap in a forced air circulation oven at a temperature of (60 ± 2) °C for 4 hours ± 10 minutes After this, reduce the temperature to (45 ± 2) °C for an additional 18 to 20 hours Once the sample is removed, wait for 2 minutes ± 30 seconds before conducting the impact test as outlined in section 5.2.2.
Effect of low temperature
Place the toe cap in a chamber at a temperature of (-20 ± 2) °C for approximately 4 hours, then adjust the temperature to (-6 ± 2) °C for an additional 18 to 20 hours After removing the sample, wait for about 2 minutes before conducting the impact test as outlined in section 5.2.2.
Effect of acid
Immerse the toe cap completely in a 1 mol/l sulfuric acid solution at a temperature of (23 ± 2) °C for 24 hours, with a tolerance of ± 15 minutes After immersion, rinse off any excess acid with water and store the toe cap at (23 ± 2) °C for an additional 24 hours, allowing a variation of ± 1 hour, before conducting tests as outlined in section 5.2.2.
Effect of alkali
Immerse the toe cap in a 1 mol/l sodium hydroxide solution at a temperature of (23 ± 2) °C for 24 hours, with a tolerance of ± 15 minutes After immersion, rinse off any excess alkali with water and store the toe cap at (23 ± 2) °C for an additional 24 hours, allowing a variation of ± 1 hour, before conducting tests as outlined in section 5.2.2.
Effect of fuel oil
Immerse the toe cap completely in 2,2,4-trimethylpentane (iso-octane) at a temperature of (23 ± 2) °C for 24 hours, with a tolerance of ± 15 minutes After immersion, remove the toe cap, wash off any excess liquid, and store it at (23 ± 2) °C for an additional 24 hours, allowing a variation of ± 1 hour, before conducting the tests as outlined in section 5.2.2.
6 Requirements for penetration resistant inserts
General
Penetration resistant materials can be evaluated under this standard, even in their unshaped form, if they are meant to be cut or shaped by the footwear or sole manufacturer However, when shaped inserts are tested, their compatibility with specific footwear models is not guaranteed, as their fit depends on the unique dimensions of each shoe design.
Each individual test result must meet the relevant requirements; otherwise, the entire lot will be considered a failure If varying results are obtained from the same test on identical samples, the lowest value will be reported as the test result, adhering to the "worst case principle."
For number of samples and tests see also 7.1.
Requirements for all types of penetration resistant inserts
Resistance to nail penetration
Inserts must be tested according to method 7.2.1 with a minimum force of 1,100 N, ensuring that the test nail's tip does not penetrate the test piece A "pass" result is confirmed when the test nail's tip does not protrude from the rear side of the test piece, which can be verified through visual, cinematographic, or electrical detection methods.
Flexing resistance
In accordance with the testing method outlined in section 7.2.2, the inserts must demonstrate no visible signs of cracking, disintegration, or delamination after enduring one million flexion cycles.
Special requirements for metal penetration resistant inserts
Dimensions
Metal penetration resistant inserts can be designed as flat or bent to accommodate various boot styles To ensure proper placement within the footwear, each insert may feature up to three holes, with a maximum diameter of 3 mm However, it is important to note that no holes are permitted in the area that constitutes 10% of the insert.
52 % of the overall length of the insert, measured from its top (see Figure 9)
L overall length of the metal insert
Corrosion resistance
The inserts must show no more than three corrosion areas, with each area not exceeding 2 mm in any direction, both before and after testing as outlined in section 7.3.
Special requirements for non-metal penetration resistant inserts − Stability against
When subjected to each single one of the five treatments described in 7.4 and tested in accordance with the method described in 7.2.1, the inserts shall conform to the requirements of 6.2.1
NOTE The five treatments of 7.4.2 to 7.4.6 are basically the same as those of 5.4.2 to 5.4.6 for testing toe caps
7 Test methods for penetration resistant inserts
General
Each property must be tested a minimum of two to three times, as outlined in Table 4 For ready-shaped inserts, samples of various sizes should be utilized For unshaped materials, appropriate test pieces should be cut to resemble a typical insole, approximately sized 41 to 42 (Paris Point).
In cases where repeated tests yield varying results from identical samples, the lowest value will be reported as the test outcome Additionally, new test specimens must be utilized for each of the environmental treatments specified in section 7.4.
Table 4 — Summary of requirements for penetration resistant inserts a
Non-metal insert Number of tests
Nail penetration resistance 6.2.1 X X Not less than three
Multiple flex resistance 6.2.2 X X Not less than two
Corrosion resistance 6.3.2 X - Not less than three
Nail penetration resistance after five environmental treatments
6.4 - X Not less than two for each treatment a For all tests use samples of different sizes, if applicable.
All types of penetration resistant inserts
Determination of penetration resistance
7.2.1.1.1 Compression machine, capable of applying a uniform speed of (10 ± 3) mm/min and of measuring compressive forces up to at least 2 kN
7.2.1.1.2 Test nail, of diameter (4,5 ± 0,05) mm with a truncated end of the form and dimensions as shown in Figure 10
The test nail must be regularly inspected to ensure it aligns with Figure 10; if any discrepancies are found, the nail should be either corrected or replaced Steel with a hardness of HRc ≥ 60 has been demonstrated to be appropriate for use in the nail.
Figure 10 — Test nail for penetration resistance test 7.2.1.1.3 Clamping device
A proper clamping device features two rigid platens with central coaxial holes measuring (25 ± 0.2) mm, secured by screws or other appropriate methods to hold the test piece in place and prevent slipping during the puncture test This device is mounted on the upper traverse of the compression test machine, allowing for visual inspection of the test piece's upper surface opposite the puncture.
For effective visual inspection, the upper platen's thickness must not exceed 5 mm and should feature a conical shape around the center hole, as illustrated in Figure 11 During the compression test, the test nail is securely attached to the lower sample holder, ensuring that its tip applies perpendicular force to the center of the test piece when the machine operates.
To enhance grip and prevent slipping, it may be beneficial to prepare the clamping surfaces, such as by using emery paper Additionally, a tensile testing machine can be utilized when the clamping device is mounted within a compression cage.
Figure 11 — Schematic example of apparatus for the penetration resistance test of inserts 7.2.1.2 Preparation of test piece
To conduct the tests, either utilize the entire insert as a single test piece for three separate tests or prepare three individual test pieces, ensuring a minimum diameter of 50 mm for metal inserts and 75 mm for non-metal inserts, and test each piece independently.
Secure the test piece firmly between the two platens, ensuring adequate clamping force to prevent slipping Maintain a minimum distance of 25 mm for metal inserts and 35 mm for non-metal inserts from any previous puncture point or edge Operate the testing machine at a speed of (10 ± 3) mm/min until reaching a force of 1,100 N, then stop the machine Conduct a visual inspection within 10 seconds at an angle of (90 ± 15)° to the nail axis, or utilize electrical or cinematographic detection A test piece fails if the opposite surface is penetrated or if separation between layers occurs, known as the "tent effect."
The current method yields a pass/fail outcome without differentiating performance levels To gain further insights, a greater puncture force may be utilized, particularly for research purposes or when comparing different materials or solutions.
Determination of flexing resistance
The flexing apparatus includes a specialized flexing guide, such as a pair of bars, designed to move the free end of the insert over a specified distance at a defined rate It features a clamping device made up of two elastic interlayers, approximately 4 mm thick with a Shore A hardness of 75 ± 5, and is equipped with two metal clamping plates.
The guide operates at a distance of (70 ± 1) mm from the clamping plates, allowing for flexibility in accommodating various insert sizes by shifting the flexing line up to 10 mm towards the heel Additionally, the apparatus is designed to conduct the flex test at a frequency of (16 ± 1) Hz.
1 Flexing guide 2 Clamping plates 3 Elastic interlayer 4 Test piece
Figure 12 — Example of details of a suitable construction of a flexing apparatus for penetration resistant inserts
1 Flexing line 2 Base line 3 Flexing zone 4 Line of cut
Figure 13 — Flexing line for inserts 7.2.2.2 Determination of the flexing line
Position the insert so that its inner edge aligns with a straight line, ensuring that this line is tangent to the insert at the joint and heel areas From the tangent point at the joint, draw a perpendicular line; this line represents the flexing line where the insert is secured (refer to Figure 13).
If necessary, cut off the heel part of the insert at a distance of at least 90 mm from the flexing line (see Figure 13 and 7.2.2.2)
Deflect the test piece at a frequency of (16 ± 1) Hz by adjusting the guide bar to a height of 33 mm, measured vertically from the zero position Use a guide to ensure the test piece returns to the zero position after each deflection After 1 × 10^6 flexes, perform a visual inspection of the test piece.
Test method for metal penetration resistant inserts − Determination of corrosion
Preliminary examination
Examine the insert visually for signs of corrosion
Measure the longest distance across of each area of corrosion and note the number of such areas.
Test procedure
Ensure the surface is free from grease, silicone, wax, or similar substances Cut two rectangular specimens, each measuring approximately 30 mm × 40 mm, from the material or insert samples Test the specimens as outlined in section 5.3.2 by placing them between two papers moistened with the test solution on a glass plate.
After 48 h remove the filter paper and examine the specimens for signs of corrosion Measure the longest distance across each area of corrosion and note the number of such areas
When cutting, ensure that the test piece does not show any traces of tool metal that could rust later If uncertain, it is recommended to clean the edges using emery paper.
Test methods for non-metal penetration resistant inserts
General
New samples shall be used for each of the following five treatments.
Effect of high temperature
Clamp the specimen into the penetration device and place it in an oven with forced air circulation at a temperature of (60 ± 2) °C for a minimum of 4 hours ± 10 minutes Subsequently, lower the temperature to (45 ± 2) °C for an additional 18 to 20 hours After removing the assembly from the oven, initiate the penetration test within 2 minutes ± 30 seconds.
Effect of low temperature
Clamp the specimen into the penetration device and place it in a chamber maintained at (-20 ± 2) °C for a minimum of 4 hours, with a tolerance of ± 10 minutes Subsequently, adjust the temperature to (-6 ± 2) °C and maintain this condition for an additional 18 hours.
Remove the assembly from the chamber and, within 2 minutes ± 30 seconds, begin the penetration test as outlined in section 7.2.1.
Effect of acid
Totally immerse the penetration resistant insert in sulfuric acid solution, c(H2SO4) = 1 mol/l, at (23 ± 2) °C for
24 h ± 15 min Remove, wash off any excess acid with water and store at (23 ± 2) °C for (24 ± 1) h before testing it in accordance with the method described in 7.2.1.
Effect of alkali
Totally immerse the penetration resistant insert in sodium hydroxide solution, c(NaOH) = 1 mol/l, at
(23 ± 2) °C for 24 h ± 15 min Remove, wash off any excess alkali with water and store at (23 ± 2) °C for
(24 ± 1) h before testing it in accordance with the method described in 7.2.1.
Effect of fuel oil
Totally immerse the penetration resistant insert in 2,2,4-trimethylpentane (octane) at (23 ± 2) °C for
24 h ± 15 min Remove, wash off any excess liquid and store at (23 ± 2) °C for (24 ± 1) h before testing it in accordance with the method described in 7.2.1
Toe Caps
Toe caps must be distinctly and permanently labeled with essential information, including the toe cap number, designation for left or right foot, the manufacturer's identification mark, and the manufacturer's type designation Additionally, they should indicate whether they are designed for safety footwear, marked as either S or 200 J.
2) P or 100 J (toe caps designed for protective footwear); f) the number of this standard.
Penetration resistant inserts
Penetration resistant inserts shall be clearly and permanently marked with the following information: a) insert size (if applicable); b) manufacturer's identification mark; c) manufacturer's type designation; d) the number of this standard
Marking by embossing is permitted, and indicating the size is not mandatory when the material is distributed as a platen, especially if a third party is responsible for die-cutting or shaping.
Toe caps and penetration-resistant inserts specified by this standard do not qualify as personal protective equipment (PPE) Consequently, "CE" marking is not permitted as it contradicts the provisions of Directive 89/686/EEC.
[1] Council Directive 89/686/EEC of 21 December 1989 on the approximation of the laws of the Member States relating to personal protective equipment