Machines for the Part 6: Stationary and mobile equipment for the manufacture of precast reinforced products ICS 91.220... EUROPÄISCHE NORM September 2010 ICS 91.220 Supersedes EN 1262
General
Machinery must adhere to the safety requirements outlined in this clause and, unless stated otherwise, comply with the relevant standards of EN 12629-1:2000+A1:2010 Furthermore, the design of the machine should follow the principles of EN ISO 12100 for hazards that are relevant but not significant, which are not addressed in this document.
NOTE For hazards which are to be reduced by the application of an A or B-level standard such as EN 349, EN 547,
Manufacturers must conduct a risk assessment for machinery covered by standards such as EN 614-1, EN 894, EN 953, EN 1088, EN ISO 7731, EN ISO 13850, EN ISO 13857, and EN ISO 14122-1, including hydraulic and pneumatic systems This assessment is essential to determine the applicable A or B-level standards and should be integrated into the machine's overall risk assessment.
When the installation site includes existing risk reduction elements, the machine design can incorporate these features to enhance safety.
5.2 Layout - Circulation - Means of access """"
In addition to !5.3.7 of EN 12629-1:2000+A1:2010", at oil feeding points:
oil leakage shall be avoided or collected, or at least
walking surfaces shall be slip resistant (e g grids)
To minimize the risk of shearing and crushing zones between mobile machine parts and fixed elements, it is essential to position them carefully (refer to EN 349) If avoiding these danger zones is not feasible, access must be designed in accordance with EN 12629-1:2000+A1:2010, sections 5.2 and 5.3.
5.3 !!!! Control stations (see 4.11.8 of EN ISO 12100-2:2003 and 5.3.4, 5.3.5 of
The main control station of the stationary and mobile equipment for the manufacture of precast reinforced products shall be located near to the manufacturing module (module A)
The main control station features mode selector switches for each module—manufacturing, evacuation, storage, and packaging—that enable the selection of the appropriate control mode for current operations These switches are designed to prevent dangerous combinations, such as interlocking to ensure that automatic mode for one module cannot be combined with manual mode for another.
In addition to the primary control station, auxiliary control stations, remote control boxes, and specific manual controls may be required Sub clauses 5.3 to 5.5 outline the installation and operational conditions for this supplementary equipment.
When an auxiliary, mobile, or manual control station is activated, it will not affect the selected zone from any other control station The main control station must clearly display information regarding the operation mode.
The three modules can operate simultaneously in various working modes, ensuring automatic interactive safety and eliminating risks for operators both before and after each module's operation.
EXAMPLE Isolation and energy dissipation of module A requires isolation and energy dissipation of module B while module C can go on running.
Emergency stops
At least each module shall be fitted with one emergency stop device according to !5.6.2 of
EN 12629-1:2000+A1:2010" on the accessible length sides of the machine
Emergency stops must engage the entire machine, encompassing all modules Nevertheless, following a risk assessment, the manufacturer has the option to segment the machine into distinct emergency stop zones.
Operating mode
The equipment shall have, at least, two modes of operation as defined below for production, setting and maintenance operations
5.5.2 !!!!Semi-automatic and automatic operations (see 4.11.10 of EN ISO 12100-2:2003)""""
A specific mode for the stacking gantry with carried driver shall follow the requirements stated in 5.3.5, 5.12.1 and 5.2 of !EN 12629-1:2000+A1:2010"
In addition to 5.3.3 of !EN 12629-1:2000+A1:2010", the requirement of !4.11.9 of EN ISO 12100-2:2003" for a hold-to-run control shall be complied with.
Module A: Manufacturing
5.6.1 Concrete hopper (see also 5.3.7 and 7.5 of !!!!EN 12629-1:2000+A1:2010""") "
During manufacturing, operators may need to inspect the hopper Therefore, machines must be designed to keep operators safe from hazardous elements This can be achieved by incorporating visual aids like mirrors or cameras, or by setting up observation stations as outlined in section 5.3.7.
The design of the mould feeding hopper must prevent hand access to moving components, such as gates, wings, wheels, and drawers This can be achieved through a two-hand control system compliant with EN 574 or by implementing guards or trip devices that adhere to the relevant sections of EN 12629-1:2000+A1:2010.
5.6.2 Tool changing and adjustment (see Clause 7 and see also 5.3 and 7.1 of
The replacement of moulds, tampers, and the addition of new elements such as vibrators and accessories must utilize specialized handling equipment like hoists and forklifts It is essential that the machine design and installation guidelines consider these handling methods (refer to Clause 7 for more details).
Module B: storage-hardening
5.7.1 Transfer of green products and hardened products
5.7.1.1 Elevator/lowerator, pallet boards/moulds pusher
The two lateral sides of the elevator/lowerator shall be fitted with fixed guards (see
Access must be available near the elevator and lowerator, as well as to the pallet boards and moulds pusher This access should be equipped with an interlocking guard or a trip device, as specified in section 5.2.2 of EN 12629-1:2000+A1:2010, designed to halt the moving parts for safety.
For effective cleaning and maintenance, the elevator or lowerator, as well as the gantry leveling table, must be positioned at a minimum height of 2 meters to ensure safe passage for operators, in accordance with EN 614-1 and EN 547-1 to 3 standards.
It shall be possible to maintain this height, by means of:
mechanical locking of the moving elements; or
check valves fitted directly the cylinder with isolation and energy dissipation of control devices, see 5.2.3 and 5.2.4 of !EN 12629-1:2000+A1:2010"
In cases of the levelling table and/or staking, the height position shall be maintained under the same conditions
The danger zone of the gantry shall be entirely enclosed by an enclosure with an interlocked access gate (see 5.2.2 of !EN 12629-1:2000+A1:2010".)
The equipment for stacking pallet boards shall prevent them falling by:
mechanical centring devices (e g rollers, guides);
devices for checking the position (e g mechanical or electrical switches);
Storage/hardening zone: it shall be entirely equipped with safety devices as shown in 5.2.2, B.2 and B.3 of
Dynamic storage and warehouse rack: shall be fitted with guards conforming to Clause 5 of
!EN 12629-1:2000+A1:2010" and shall be continuous with those protecting the lifting/lowering equipment
On floor: see 5.12.2 of !EN 12629-1:2000+A1:2010".
Module C: Palletising and packaging of final products and defective products disposal station (see also 5.2 of !!!! EN 12629-1:2000+A1:2010 """" )
5.8.1.1 Automatic and semi-automatic operation
The area designated for palletising and packaging equipment must be safeguarded by a fixed guard that complies with Clause 5 of !EN 12629-1:2000+A1:2010, and this guard should be continuous with the one installed in the storage zone (refer to 5.4.2) Additionally, the access and exit points for product removal must be equipped with a trip device.
!EN 12629-1:2000+A1:2010", 5.2.2 and B.3) or, if a trip device is not suitable, with an interlocking guard (see
!EN 12629-1:2000+A1:2010", 5.2.2 and B.2) These devices shall stop the palletising equipment when activated
Mechanical disposal of the defective products (by providing gantries, cranes, conveyors or other lifting equipment) shall be considered to limit the physical efforts
An emergency stop actuation or unforeseen failure of energy supply shall not induce any fall hazard of elements lift by:
suction pads: safety device on vacuum;
lifting equipment and tightening tools: safety devices on actuators (pneumatic cylinder, overspeed anti-fall devices, “fail-safe brakes” ) (see 5.2.3 of !EN 12629-1:2000+A1:2010")
Emergency stop functions must be maintained for a sufficient duration to facilitate the evacuation of the danger zone An acoustic or visual warning signal will indicate when the emergency stop is activated or if there is a failure in the energy supply.
Gangways and platforms shall be provided conforming to !EN 12629-1:2000+A1:2010, 5.3.7" with safeguards to allow authorised operators to cross the roller conveyors
metallic floors on each side and level with the top of the rollers;
fixed infill between the rollers, under the upper part of the rollers;
Noise
In addition to !5.7 and 7.4 of EN 12629-1:2000+A1:2010", noise reduction at source shall be achieved by design features such as:
Interposition of rigid and absorbing material between the vibrating table and the mould (special hard plastic );
fixing of the moulds (hydraulic, pneumatic, mechanic);
use of the lowest frequency depending on the type of product;
to make the structures between the moulds and the vibrating table more rigid to avoid excessive resonance;
rubber stops for the hopper gates;
isolating materials on the vibrating beams, vibrating table
Polyurethane band on the rollers (gantry, stacking, pushing trucks, chains tensioners, pinions ).
Summary of the safety measures given in relation to the significant hazards listed in Clause 4
The tables in Clause 4 outline the risk-reducing requirements for various hazards, with the specific hazards listed in the third column and their corresponding requirements detailed in the fourth and fifth columns.
Table 5 — Safety measures required for tilting machine of mould/pallet boards, elevator/lowerator, warehouse rack storage and palletising gantry
Hazards zones Hazards Reference table 1
Requirements and measures Clauses of
Drawing-in or trapping hazards 1.5
1, 2 Oil inhalation and dust inhalation hazards 7.1 7.2.2
1, 8 Unhealthy postures, excessive efforts hazards 8.1 5.9
1, 5, 6, 7, 8 Essential equipment for safe maintenance and tool changing 10.6 5.3, 7.1, 7.3 5.6.2, 7.2.2
2, 4, 5, 8 Failure of energy supply hazards 13 5.8.1.2
Table 6 — Safety measures required for vibration on fixed beds, stacking/destacking gantry, overturning and palletising
Hazards zones Hazards Reference table 2
Requirements and measures Clauses of
4 Drawing-in or trapping hazards 1.5 5.2
1, 2 Oil inhalation and dust inhalation hazards 7.1 7.2.2
1, 3, 4 Unhealthy postures, excessive efforts hazards 8.1 5.9
Essential equipment for safe maintenance and tool changing 10.6 5.3, 7.1, 7.3 5.6.2, 7.2.2
4 Failure of energy supply hazards 13 5.8.1.2
Table 7 – Safety measures required for machines illustrated in Figure B.3
Hazards zones Hazards Reference table 3
Requirements and measures Clauses of
2, 3 Drawing-in or trapping hazards 1.5 7
1, 2 Oil inhalation and dust inhalation hazards 7.1 7.2.2
1 Unhealthy postures, excessive efforts hazards 8.1 5.9
1, 3, 8 Essential equipment for safe maintenance and tool changing
2, 3, 4, 8 Failure of energy supply hazards 13 5.8.1.2
Table 8 – Safety measures required for machines illustrated in Figure B.4
Hazards zones Hazards Reference table 4
Requirements and measures Clauses of
7 Drawing-in or trapping hazards 1.4 5.2
3 Unhealthy postures, excessive efforts hazards 8.1 5.9
1, 2, 3 Essential equipment for safe maintenance and tool changing
1, 2, 8 Failure of energy supply hazards 13 5.8.1.2
6 ! !Verification of safety requirements and/or protective measures" ! ! " " "
Verification of the requirements defined in Clause 5 can be made by means of inspection, calculation, or testing
For those requirements described in !EN 12629-1:2000+A1:2010", the verification means is described in that standard also
For the requirements given in this standard, the verification means are self-evident
The following procedures are to be implemented on a fully commissioned machine, although some partial dismantling may be required for specific checks This partial dismantling will not impact the verification results, and additional verification methods are provided below.
Table 9 — Checking conformity with these specific safety requirements given in Clause 5
Sub clause Safety system for Visual inspection
Test performance checking Measurement Remark
EN ISO 14122 series Access way
5.1.4 Control of the unit X X X 4.11.8 of EN ISO 12100-
5.2 Operating modes X X 4.11.10 of EN ISO 12100-
EN 349, EN 999, EN ISO 12100-1:2003, 3.26.5, EN ISO 13857 and EN 61496-1
13857 5.6 Palletising and packaging X X X 3.26.7 of EN ISO 12100-
5.6.1.1 Automatic and semi- automatic operation X
General
In addition to the general information in Clause 7 of !EN 12629-1:2000+A1:2010", the following shall be applied
A location for the storage of documents, which is easily accessible to the operators, shall be provided
The instruction handbook of the complete production machine and for each machine shall contain, when it applies, the following recommendations and intervention procedures:
Instruction handbook
7.2.1 Information shall be given about the reduction of vibration for module A (installation requirements, adjustments), see 5.7 of !EN 12629-1:2000+A1:2010", the corresponding noise levels and the safety measures to be taken
The designer shall provide in his handbook the technical characteristics of wear parts
The instruction handbook must provide essential information, including safe working procedures for the normal operation of machinery This encompasses guidelines for tool-setting, servicing, adjustments, and cleaning operations.
1) To restrict climbing on the pallet boards
2) Check the wear of the machine parts (e g guides and stops to prevent falls of boards)
3) To specify the type of personal protective equipment for the operator (e g gloves, hear protectors)
4) Training of the operator for the intended use of the equipment
5) programmed working procedures: i) preventative servicing (localisation of the service points and procedure to follow for the various cases: greasing, chains tensioning, changing of the spare parts ); ii) cleaning:
I) Module A cleaning (manufacturing station), released from energy supplies (but not isolated with energy dissipation, except the concrete hopper: concrete delivery with energy dissipation)
II) General cleaning of the installation, machine and hopper isolated with energy dissipation
III) Cleaning and/or putting absorbing materials on walking surfaces contaminated with oil b) the working procedures following malfunctions such as
1) pallet boards/mould jamming (in the boxes, on gantries, on stacking machine )
2) hardened products from the mould requiring providing the operator with the adequate tools for their removal
3) any intervention needed on the mould, tamper or drawer shall be carried out with these devices stopped c) the procedures for maintenance and similar operations, including:
1) disconnection of the energy supply/sources;
3) measures for neutralising the residual energy;
4) verification of the absence of energy.
Marking
In addition to Clause 8 of !EN 12629-1:2000+A1:2010", a plate shall be fitted on tanks containing oil for spraying, visible from the filling connection It shall specify:
the maximum authorised filling capacity;
Manufacturing process on machines with or without turnover
Main proceedings: — instantaneous demoulding (pallet boards);
— delayed demoulding (moulds) ẻ pallet board/moulds route with concrete products Å empty pallet boards/moulds return ề ẻ ễ Í ẻ Í ẻ Å
(machine with or without turnover)
(with carried vibrating mould, vibrating tables and frames fixed on the floor)
- Dynamic storage, on floor, warehouse rack, by stacking up – Stacking/destacking mobile gantry
*) Including the return of the empty pallet boards/moulds
Terminology and hazard zones relative to the various types of machines
2 Tilting machine of mould/pallet boards
Figure B.1 —Tilting machine of mould/pallet boards, elevator/lowerator, warehouse rack storage and palletising gantry
4 Pallet board handling and palletising gantry
6 Piling of pallet boards in storage/hardening area
This configuration offers multiple variants, including options for one or two gates, fixed module A, or packaging/overturning Additionally, it can accommodate processes with either immediate or delayed demoulding, as well as product outlets that are either in line or perpendicular.
Figure B.2 — Vibration on fixed beds, stacking/destacking gantry, overturning and palletising
4 Pallet board conveyor (going up and down)
6/7 Green products warehouse on rollers conveyer
Figure B.3 —Mobile manufacturing module with tilting with hardening warehouse and palletising
Figure B.4 — Lowerator, demoulder and manufacturing module with elevator (external storage)
! Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC
This European Standard was developed under a mandate from the European Commission and the European Free Trade Association to ensure compliance with the Essential Requirements of the New Approach Directive 2006/42/EC.
Citing this standard in the Official Journal of the European Union and implementing it as a national standard in at least one Member State grants a presumption of conformity with the relevant Essential Requirements of the Directive and associated EFTA regulations, as long as the compliance is within the scope of the standard.
WARNING — Other requirements and other EU Directives may be applicable to the product(s) falling within the scope of this standard."
[1] EN ISO 7731:2008, Ergonomics — Danger signals for public and work areas — Auditory danger signals
[2] EN ISO 13850:2008, Safety of machinery — Emergency stop — Principles for design (ISO 13850:2006)
[3] EN 61310-2:2008, Safety of machinery — Indication, marking and actuation — Part 2: Requirements for marking (IEC 61310- 2:2007)"