Table 1 cocluded Ref Hazard according to annex A of EN 1050:1996 Localisation/scenario See Figures A.1 and A.3 9 Hazards generated by temporary missing or incorrect positioning of s
Products
3.1.1 hollow core flooring slab pre-stressed slabs incorporating longitudinal hole used in the construction of floors They are considered as structural elements
3.1.2 beam pre-stressed concrete element used in building or bridge structures It has a supporting function; their section can be that of an I, T, Y, U, Π, a rectangle, a trapezium, etc
The joist is a pre-stressed concrete element that serves as a crucial support for complex flooring systems Its inverted T-shape design effectively supports infill blocks or slabs, as well as in-situ concrete screeds, also known as compression slabs.
A lintel is a pre-stressed concrete component with a prismatic shape and a rectangular cross-section It serves as the upper part of wall openings, providing essential support for the masonry positioned above.
3.1.7 lighting column rectilinear pre-stressed concrete post, designed to support public lighting (streets, parks, sports grounds, etc.)
3.1.8 railway sleeper trapezium-shaped element of pre-stressed concrete designed to support the rails and maintain them at the required gauge
Equipment
This standard addresses machines used in the production of pre-stressed hollow core flooring slabs While the term in the title is commonly used, various equivalent terms may also be found, combining phrases such as "production machines," "long line manufacture," and "manufacturing workshop for plain slabs."
In addition, annex H (informative) gives a trilingual list of terms relative to pre-stressing manufacturing products and equipment
The installation of a pre-stressing bed for flat products consists of two solid anchor blocks connected by a slab This bed may feature a steel plate soffit for casting concrete products such as pre-slabs, joists, and hollow slabs At each end, the anchor blocks are equipped with posts and anchor plates for abutment, while jacking devices facilitate the tensioning and detensioning of wires or strands.
NOTE 1 The length of the slab is generally between 40 m and 150 m and the width is between 1,20 m and 2,40 m
The pre-stressing bed for flat product manufacturing is typically equipped with rails on either side of the slab, which serve to guide mobile machines effectively.
The installation of a pre-stressing bed for beam-type products consists of two solid anchor blocks connected by a slab and flanked by two generally movable walls Each end of the bed features posts and anchor plates for support, while jacking devices facilitate the tensioning and detensioning of wires or strands.
NOTE 1 The length of the bed is generally between 80 m and 100 m and the width is between 0,50 m and 2 m
NOTE 2 The beds may be single or double (parallel casting of two beams).
The self-stressing bed structure is designed to enclose or support shutterings, resting directly on the ground or appropriate supports Its length varies from several meters, depending on the manufactured products, while ensuring a maximum size that maintains overall stability and accommodates the forces generated by the tension in the strands.
3.2.3 heating equipment equipment intended to harden the products
a type of energy sources from:
steam or hot fluids in a closed circuit;
3.2.4 tensioning and tension relieving equipment
Single strand tensioning equipment includes a mobile jacking device and a hydraulic machine that provides the necessary energy to tension wire or strands The jacking device is supported by an anchorage, utilizing a barrel and conical wedge to secure the pre-stressed reinforcement The strands are anchored at the anchorage abutment.
Multi-strand tensioning equipment enables the simultaneous tensioning of all strands on a single bed, utilizing anchor grips or button-heads for the transverse anchor points, which are created by cold forming the wire ends The pre-stressing bed features a fixed transverse anchor at one end and a mobile anchor at the other, which is adjusted using hydraulic cylinders, with a fixed hydraulic machine providing the required energy.
After tensioning, the cylinders are locked in position by a mechanical device (support, auger) so that they do not stay under pressure during the following operations
In the detensioning operation, jacking devices are initially pressurized slightly above the tensioning pressure to disengage the locking mechanism, such as screws or supports Subsequently, these devices function as brakes to gradually release the tension in the strands.
In the case of wide beds or asymmetry in the forces in the strands, a guiding and balancing device can be set up
The vibrodistributor is an independent mobile machine designed for the uniform distribution of concrete, primarily used in the production of plain slabs or joists It effectively compacts the concrete and regulates its thickness through vibration.
Generally, vibrodistributors incorporate auxiliary systems that allow to carry out the roughness of the upper face for plain slabs
The sheer compactor and extruder is a mobile automatic machine designed for the distribution of concrete while simultaneously forming products, typically used in the production of hollow core flooring slabs and joists This machine operates on the principles of vibrating and sliding cores to effectively compact and finish the concrete.
The machine can be moved under its own power (sheer compactor) or by reaction due to the thrust against the concrete applied during the feed (sheer compaction)
the spraying of release agents onto the soffit or moulds
In some cases, they locate the pre-stressing strands
Marking out machines are independent, self-propelled mobile carriages designed to accurately layout product dimensions and shapes They are primarily utilized in the manufacturing of floor shuttering slabs.
The machine for laying and removing block ends is a mobile carriage, either towed or self-propelled, designed to handle, store, install, and remove inserts, commonly referred to as combs These machines play a crucial role in the manufacturing of floor joists and plain slabs, ensuring efficient setup and withdrawal of materials.
Self-propelled carriages, or machines powered by alternative means, are designed to move laterally or across the bed while effectively pulling one or multiple strands to cut them to the desired length.
The strands are available in coils They are held in dispensers or turntables
The strand pushing machine is positioned alongside the beds, efficiently pushing each strand into a casing while automatically cutting them to the specified length Once the required number of strands is cut, the casing opens, allowing the strands to be released onto the side of the bed.
The strands are then pulled on the bed
3.2.6.6 strands setting up machine independent or towed mobile carriages used for positioning the pre-stressing strands on the bed
These strands are generally stored in coils or are pre-cut
Some similar machines can set down or fix the passive transverse reinforcement This equipment is more specifically used in the manufacture of plain slabs
The tarpaulin paying out machine is a mobile carriage, either independent or towed, that carries a tarpaulin payout drum It facilitates the rolling out of the tarpaulin over products to be heated and can wind it back in to uncover hardened products These operations can be performed either manually or through mechanization.
General
Machinery must adhere to the safety requirements outlined in this clause and, unless stated otherwise, comply with 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.
Manufacturers must conduct a risk assessment for hazards that need to be mitigated by A or B-level standards, such as EN 349, EN 547, and others This assessment is essential to determine the applicable requirements of these standards for hydraulic, pneumatic, or other machinery Furthermore, this specific risk assessment should be integrated into the overall risk assessment of the machine.
When the installation site includes existing risk reduction elements, the machine design can incorporate these features to enhance safety.
Layout - Circulation - Means of access
The design of access means to tensioning machinery pits and cleaning areas must adhere to the requirements outlined in section 5.3.7 of !EN 12629-1:2000+A1:2010.
Catwalks and access points to various controls and control stations must be installed, with horizontal surfaces made from materials that prevent the buildup of concrete waste or oil, such as gratings, in accordance with EN ISO 14122-2.
5.2.3 Tensioning or strands pits shall be covered with grids to avoid falls (see 4.2.4 of EN ISO 14122-2:2001)
To prevent falling hazards caused by condensation water accumulating under unwound tarpaulins, it is essential to implement effective evacuation or elimination devices, such as pipes and ventilation systems For further details, refer to clause 7.
Control of the machines, modes of operation
When a machine can be operated from multiple control stations, including both fixed and remote options, it is essential to install an operating mode switch This switch ensures that movements can only be initiated from the designated control station, enhancing safety and operational efficiency.
Product-making machines must feature both automatic and manual modes of operation A mode selector switch will control these two modes, ensuring compliance with section 5.3.
5.3.3 An emergency stopping device (see 5.6.2 of !EN 12629-1:2000+A1:2010" and clause 6 of
According to EN 954-1:1996, emergency stopping devices must be installed near hazardous areas and locations where work such as adjustment, maintenance, or servicing occurs Each machine should be equipped with at least one emergency stopping device to ensure safety.
On spinners and extruders, an emergency stop device shall be installed on the four edges of these machines
Except for spinner and vibrodistributor working together which shall be stopped simultaneously by the same emergency stop, it is acceptable that the emergency stop only stops the machine involved.
Safety of machines and working equipment - General
Steam pipes, joints, and valves must be strategically positioned and designed to prevent burns, ensuring that any surfaces that may come into contact with hot pipes adhere to specified temperature limits.
!EN ISO 13732-1", contact less than 1 s) or steam ejection in the accessible areas (steam deflectors to provide in accordance with EN ISO 3457)
A dust and oil collection equipment according to 5.8 of !EN 12629-1:2000+A1:2010" shall be provided for the sawing, the oiler and the sweeping machines
Detection devices, such as electrosensitive protective devices compliant with EN 61496, must be installed in areas where operators may enter danger zones These devices should be strategically positioned to effectively detect crouching individuals working on the beds, as outlined in section 5.2.2 of EN 12629-1:2000+A1:2010 for further guidance.
The supports where the machine or its parts are put for cleaning shall be designed as to ensure stability
Machines must be designed to avoid any components that could catch on limbs or clothing, such as control hand-wheels or steel wire containers, which should ideally feature solid flanges instead of spokes If this is not feasible, appropriate protective measures must be implemented to prevent entanglement or drawing-in.
The machines will be engineered to minimize the physical strain on operators For instance, tensioning stations will incorporate mechanized aids or handling systems to facilitate the movement of the cylinder in mono-tensioning or the hydraulic group in multi-tensioning, thereby alleviating the laborious nature of the tasks.
Noise and vibration
For noise reduction and information, see 5.7 of !EN 12629-1:2000+A1:2010"
dampers shall be fitted between the bed and the foundation block in order to minimise the transmission of vibrations;
Vibrators in manufacturing machines must be isolated from other machine components If isolation is not feasible, the operator's seat should be equipped with suspension to ensure safety and comfort.
Additional requirements for specific machines and equipment
The machine should be designed to enable personnel to prepare cast concrete without the need to walk on the track where the release agent has been applied.
By design, the rails shall not be protruding and with a minimum channel width (see example in Figure 1);
For the production of easily accessible moulds, such as beams, a hydraulic or mechanical system must be implemented to facilitate opening Additionally, measures should be in place to prevent unintended tilting or closing of the mould sides due to control system failures or unauthorized actuation, which can be achieved through mechanical restraint devices or key-controlled systems.
5.6.1.2 Strands tensioning and detensioning equipment
The transverse anchors and combs shall be dimensioned in order to resist to the great and repeated stresses for tensioning and holding the wires or strand tensioned
During the tensioning process of strands or wires, it is essential to have devices that can contain the energy released from the rupture of a strand or the slipping of an anchor point These containment devices may include cables or chains attached laterally to the bed Additionally, a mobile shield must be positioned vertically and transversally at each end of the bed and the mold, with mobile guards installed above the anchor points for added safety.
A warning device shall be provided to warn the personnel about dangerous periods during which strands will be put under tension (for instance by a flashing optical signal)
A "tensioning control station" shall be provided so that:
the operator can have a wide view of the bed;
the operator can check the hydraulic pressure looking at the manometer placed on the tensioning station;
in cases of connectable/disconnectable mobile hydraulic group for each bed, the operator cannot access behind the tensioned strands (e g by combination of guarding and location of the control station);
The cylinders shall act strictly in parallel (e g by a flow balancer);
A safety device shall be provided on the tensioning equipment prohibiting any body part passing behind the cylinder
5.6.1.3 Wire/strand pulling/pushing machines
In order to limit the risks of wire whirling/whipping, a guiding device of the unwounded wire from the drum according to 5.2.1 of !EN 12629-1:2000+A1:2010" shall be installed
A survey device of the end of drum shall be provided to avoid the complete unwinding of the wire
A wire chute shall be provided to collect the cut wires on soil at the outlet of the machine
A protection shall be installed for the wire transmission rollers, for the cutting and for the movement of the guiding device of the unwound wire (5.2 and 5.3 of !EN 12629-1:2000+A1:2010")
To ensure safety, a fixed guard must prevent access to the pit where wire pushing machines and wire-guides are installed along the bed Additionally, the opening designed for easy wire removal must adhere to the specifications outlined in Table 1.
A protection of the carriage and the rollers of the strand pulling machine shall be installed (see 5.2.1 and 5.2.2 of
Mobile machines shall be so arranged as to avoid arms or legs being caught beneath the wheels (see 5.12.1 of
!EN 12629-1:2000+A1:2010") Otherwise they shall be fitted with foot guards (cowcatcher) according to Table 1 "toes" of !EN 349:1993+A1:2008" (see also Figure 1);
To prevent crushing or shearing hazards in mobile machines, it is essential to maintain safe distances between machines and fixed elements, as outlined in EN 349 In areas with limited space, access must be restricted using guards or safety devices, as specified in EN 12629-1:2000+A1:2010 Additionally, sensitive bars that comply with EN 1760-2 should be installed at the front and rear of machines to prevent body crushing These bars must activate a shutdown mechanism that halts energy supply to moving parts, ensuring safety without introducing additional risks Proper placement of these bars is crucial for detecting crouching individuals and monitoring entry into the vibrodistributor.
Mobile machines used for tasks such as concrete casting, sawing, and tarpaulin handling must be designed with safety features, like safety bars, to prevent operators from being crushed, sheared, or severed between two machines or between a machine and a fixed obstacle.
Limiting devices, such as block ends and automatic stop controls, must be installed on mobile machines to ensure they stop safely at the end of the bed The design of these block ends should take into account various safety considerations.
strength to the impact generated by the machine;
protruding of these devices that can result in a fall of a person;
that they shall not be damage the detection devices (see 5.5.2.1.2.b))
Mobile machines must be fitted with an operator-controlled sound signal (klaxon) and an automatic visual signal (flashing light) while traveling on beds, in accordance with the standards outlined in EN ISO 7731.
To ensure safe handling of machines, it is essential to provide appropriate means such as eyebolts and rings Additionally, centring devices should be installed to facilitate guided descent on rails or during machine transfer Furthermore, mechanical aids like cranes and lift-trucks must be available for the movement of machines, apparatus, and products.
For machines with on board energy supply, batteries shall be used to make the machine autonomous on its
The design of the machine's plug-in/out connection must allow for floor-level access If the connection is positioned higher than 1,900 mm, appropriate means of access must be provided.
If the operator's station does not face the forward motion of the machine or lacks a direct view of the movement zone, indirect vision aids such as mirrors must be installed Additionally, the controls for the lifting aids should be easily accessible and user-friendly.
The driver's station must be safeguarded from potential collisions with elevated mobile equipment, such as bridge cranes and trucks, as outlined in section 5.5.2.1.4.c) This can be achieved through automatic stopping of the bridge crane prior to entering the machine's operational zone, followed by manual control of the crane by the machine operator within the working area Additionally, remote-controlled machines should be considered in these safety measures.
the speed of movement of the machine shall be adapted to the displacement of the operator (1,3 m/s max., acceleration 0,5 m/s 2 );
the control of the machine displacement shall be hold-to-run;
The remote control must not be overridden, such as in the case of deadman control, which serves as an automatic safety feature that halts the machine after prolonged actuation or inactivation This is particularly relevant for tarpaulin machines, ensuring they return to their primary position Additionally, this applies to machines operated by a ride-on driver.
the speed shall not exceed 1,3 m/s at return (unloaded);
a hold to run control and a platform with a guard-rail for the driver shall be installed
5.6.2.2 Additional specific requirements to mobile machines
5.6.2.2.1 Sweeping machine, vacuum cleaner, oiler, wire-guide
Equipment for cleaning tracks and moulds shall limit the emission of dust
NOTE Vacuum should be preferred to blow
The design of the cleaning machine shall be so as to permit safe assembly/dismantling, adjustment of the brush (see 5.3 of !EN 12629-1:2000+A1:2010");
A detection system shall be provided to stop the carriage in case of blockage of the strands
Oilers shall avoid airborne emission of oil by covers
NOTE A vacuum and filtering system may be added
The concrete hopper of the machine shall be equipped with fixed guards (see 5.2 of
!EN 12629-1:2000+A1:2010") preventing the access to the mobile parts (discharge gate, paddle wheel);
To ensure safety during the operation of combined machines, such as the spinner and vibrodistributor, it is crucial to prevent any internal machine movement towards the operator This can be achieved by implementing sensitive devices and emergency stop bars, as illustrated in Figure 1.
Consideration shall be made to replace manual operations by mechanized aids for:
concrete collect and discharge between hollow core slabs or joists;
automatic storage and installation of inserts (combs) for plain slabs;
storage, transport and laying of separators
Vibrodistribuers shall be equipped with a local lighting for the working area This lighting shall be pressurised- water and cement proofed
5.6.2.2.3 Tarpaulin paying out/winding in machine
The following points shall be taken into account during the design:
trapping/incarceration between the tarpaulin and the machine;
mechanical hazards due to power transmission;
shearing between the rays of the drum and the fixed parts of the machine (e g full rim and hand-guard);
easy fixing/changing of the tarpaulin, e g by hangers or cables
A tool guard as defined and specified in EN 13862 shall prevent access to the upper half part of the tool
A self closing guard (see 3.3.2 of !EN 953:1997+A1:2009") shall prevent access to the sawing parts during operation, as well as the projection of the sawed particles
Collecting devices (e g vacuum device) of cut harden products shall be considered to avoid operator’s efforts/unhealthy postures
The cutting zone shall not be accessible before the complete stop of the cutting wheel by interlocking guards with guard locking (see 5.2.4 of !EN 12629-1:2000+A1:2010")
The tool shall be loosened only by a voluntary action of the operator (direction of blocking and cutting) (see 5.1.6.1 of !EN 13862:2001+A1:2009")
The tool guard shall be able to resist the repeated cutting strengths (see annex C of
For maintenance operation under the saw, see 5.2.3 of !EN 12629-1:2000+A1:2010"
Sawing machines shall be equipped with a local lighting for the working area This lighting shall be pressurised-water and cement proofed.
Summary of the safety measures given in relation to the significant hazards listed in clause 434
Table 8 — Safety measures for pre-stressing bed, fixed or mobile tensioning equipment and self stressing bed (see annex A)
Hazards zones as per Figures A.1 and
Crushing detensioning cylinders, jacking devices releasing 1.1 5.1 5.6.1.1
Failure of control system failure of the hydraulic balancing of the multi-strand tensioning cylinders: mechanical break 8.1 5.4 5.6.1.2
Impact chain or guard ejection due to rupture of strands (wire or bundles) 1.5 5.3.1 5.6.1.2, 7.2.3
Ejection of parts chain or guard ejection due to rupture of strands (wire or bundles) 1.7 5.3.1 5.6.1.2, 7.2.3
Neglecting use of personal protective equipment initial training of the personnel 7.4 7 7.1
All kinds of guards lack of guards on the bed during the tensioning 9.1 5.1.1 5.6.1.2.1, 7.2.3 All kinds of guards bed end guards kept open after the pre-tensioning of the wires 9.1 5.6.1.2, 7.2.3
Crushing falling of the single wire stressing jack 1.1 5.6.1.2
Perforation, puncture breaking of the strand or wire (quality of steels) 6.4 7.2.1 Excessive efforts tensioning by single wire cylinder (height, support of the single wire stressing jack) 7.2 5.9 5.6.1.2, 7.2.3
Neglecting use of personal protective equipment lack of advice, written instructions, PPE adapted to human (glasses, gloves, sound protection) 7.4 5.5, 7 7.1
Human error not respecting the order of tensioning the wires
Human error excessive tensioning of the wire that result in a break of the wire 7.6 7.3
All kinds of guards lack of sound or light signals to warn of tensioning 9.1 5.5 5.6.2.1.3, 7.2.3
Hazards zones as per Figures A.1 and
Shearing between button-heads and transverse anchor (during pre-tensioning) 1.2 5.6.1.2
Impact rupture of a transverse anchor 1.5 5.6.1.2
Contact with harmful products cleaning products of the transverse anchor 6.2 7.1
Fire cleaning products of the transverse anchor 6.3 5.4, 7.1, 7.2.2
Perforation, puncture Ends of strands (breaking of reinforcement or button- holding, or button-heads slipping in the anchors) 6.4 5.6.1.2 Perforation, puncture transverse anchor disengagement after cutting of the steel 6.4 7.1
Human error assembling of the anchor grips (mixing of new, old, different… parts), forget to clean and to check 7.6 7.2 7.2.2
Shearing with the bed accessories (removable walls, mobile vibrator) 1.2 5.6.1.1
Slip, trip and falling falling from/into the casing (assembly of the reinforcements, concrete smoothing…) 1.8 5.3.7, 7.3 5.2.3
6 Shearing with the mobile part of the single wire stressing jack during tensioning 1.2 5.6.1.2
7 Cutting sharp edges in beds and casing 1.3 5 -
Drawing-in or trapping strands (wire or bundles) under tension (failure of the anchoring, slippage of the locking device) 1.4 5.6.1.2
Impact strands (wire or bundles) under tension (failure of the 1.5 5.6.1.2
Hazards zones as per Figures A.1 and
Contact or inhalation of dangerous mist, oil, fluids, gas, fumes, dusts releasing agents (contact and inhalation during spraying on the bed) 6.1 5.8.2 5.6.1.1
Contact with harmful products contact with green concrete (cement caused affections) 6.2 7.4
Fire releasing and hydraulic oil 6.3 7.7 5.4
Perforation, puncture breaking of the strand or wire (damaged wires or short length) 6.4 7.2.1
Inadequacy with human anatomy low position of the beds and height of the casings during manufacturing, cleaning and handling operations
(curved back or tilted in the casing) 7.3 5.6.1.1
Neglecting use of personal protective equipment lack of advice, written instructions, PPE adapted to human (glasses, gloves, sound protection) 7.4 7 7
Human error non-stop of the tensioning at the indications provided on the bed or on the manometer (breaking of the steels and of the equipment) 7.6 5.5 5.6.1.2, 7.3
All kinds of guards lack of sound or light signals to warn of tensioning 9.1 5.5 5.6.1.2
Drawing-in or trapping by strands (wire or bundles) during setting up 1.4 5.6.1.2
Impact by strands (wire or bundles) during setting up 1.5 5.6.1.2
Neglecting use of personal protective equipment initial training of the personnel 7.4 7 7.1
Impact falling of the end bed mobile guard (mobile cover, shield, grid) 1.5 5.1.1 5.2.3
All kinds of guards bed end guards kept open after the pre-tensioning of the wires 9.1 7.2.3
11 Ejection of fluids under pressure hoses under hydraulic pressure, hot fluids of the hydraulic circuits, feeding of the cylinders for tensioning of reinforcements 1.6 5.10 5.4
Errors of fitting inverting the tensioning equipment hydraulic ropes 8.2 5.9, 5.10 5.4
Hazards zones as per Figures A.1 and
Ejection of parts rupture of the pneumatic rope of the bed vibrator 1.7 5.10 7.1 Electrical contacts (direct or indirect) motor, branch boxes, electrical resistances under the beds, plugs 2.1 5.12.1 5.6.2.1.5
Hearing losses (deafness) fix and mobile vibrators on vibratory bed, poker vibrator 4.1 5.7 5.5
Neurological and vascular disorders contact with vibrating bed and/or moulds (direct vibration by poker vibrators, vibrating beams, fixed or mobile vibrators)
Contact or inhalation of dangerous mist, oil, fluids, gas, fumes, dusts releasing agents (contact and inhalation during spraying on the bed) 6.1 5.6.2.2.1, 7.2.3
Contact with harmful products contact with green concrete (cement caused affections) 6.2 7.4
Fire releasing and hydraulic oil 6.3 7.7 5.4
Fire electrical groups (hydraulic group, control of the heating of the beds) 6.3 5.6 7.2.3
Inadequacy with human anatomy low position of the beds and height of the casings during manufacturing, cleaning and handling operations (curved back or tilted in the casing)
Inadequacy with human anatomy lack of opening of the beds to facilitate the reinforcements mounting (posts, beams) 7.3 5.6.1.1
Neglecting use of personal protective equipment lack of advice, written instructions, PPE adapted to human (glasses, gloves, sound protection) 7.4 5.5, 7 7.1
Hazards zones as per Figures A.1 and
Electrical contacts (direct or indirect) motor, branch boxes, electrical resistances under the beds, plugs 2.1 5.6 5.6.2.1.5
Hearing losses (deafness) hydraulic groups of the tensioning cylinders of strands
Contact or inhalation of dangerous mist, oil, fluids, gas, fumes, dusts hydraulic fluids (tensioning equipment, cylinders) 6.1 5.10 5.4, 5.6.1.2
Fire releasing and hydraulic oil 6.3 7.7 5.4
Fire electrical groups (hydraulic group, control of the heating of the beds) 6.3 5.6, 7.7 7.2.3
Unhealthy postures location of the tensioning and tension relieving equipment for single strand compared to the tensioned wires and to the manometer 7.1 5.9 5.6.1.2
Unhealthy postures location of the controls of the hydraulic equipment compared to the bed 7.1 5.9 5.2.2, 5.3
Table 9 — Safety measures for bed sweeper, vacuum cleaner, oiler, wire-guide machines (see annex B)
Hazards zones as per Figure B.1 Hazards Localisation/scenario References
Crushing between the machine and an other machine or obstacle on the same bed 1.1 5.6.2.1.2, 7.1
Impact with an obstacle or by the machine, when changing of track (lifting) 1.5 5.6.2.1.6, 7.1, 8
Impact with an other machine (or obstacle) on the same track 1.5 5.6.2.1.2, 7.1
Impact with an other machine (or obstacle) situated on a bed in the vicinity 1.5 5.6.2.1.2, 7.1
Electrical contacts (direct or indirect) presence of water 2.1 5.6.2.1.5
Contact with harmful products contact with the dry concrete (dust), of cleaning
Human error non stop of the machine at the end of the bed or in front of an obstacle (person, machine) 7.6 5.6.2.1.2
Crushing of the driver or other operator at crossing of machines located on 2 neighbouring beds 1.1 5.12 5.6.2.1.2, 7.1
Impact by the reduced visibility of the driver when travelling in the opposite direction 1.5 5.6.2.1.6
Impact by the high and over-located position of the operator
(on platform): impact with obstacles or loads handled over the machine (bucket…) 1.5 5.2.2, 5.6.2.1.6
Slip, trip and falling access at a height during hooking and unhooking of the machine to change its bed 1.8 5.3.7, 7.3 5.6.2.1.4
Hazards zones as per Figure B.1 Hazards Localisation/scenario References
Neglecting the use of personal protective equipment (PPE) can lead to serious safety risks, particularly when there is a lack of guidance, written instructions, or inadequate PPE that does not fit the human body, such as glasses, gloves, ear protectors, dust masks, and oils Additionally, the initial training of personnel is crucial to ensure proper PPE usage and compliance with safety standards.
Human error non stop of the machine at the end of the bed or in front of an obstacle (person, machine) 7.6 5.6.2.1.2
Errors of fitting unintended start up (sweeper) 8.2 5.4, 5.6.3 -
Controls locking of the moving controls to make the operator free during the operation which has been rendered semi- automatic (return of the machine) 9.1 5.6.2.1.6
Controls uncontrolled failure of the safety devices (cells, switches, emergency stops, relays…) 9.1 5.4 5.3
3 Crushing of feet by the wheels of the machine on rails 1.1 5.12.1 5.6.2.1.1
Crushing when changing of tracks (lifting) 1.1 5.6.2.1.6, 7.1, 8
Impact with an obstacle or by the machine, when changing of track (lifting) 1.5 5.6.2.1.2, 7.1
Ejection of parts breaking of the lifting accessories during the lifting 1.7 7.1, 8 Slip, trip and falling access at a height during hooking and unhooking of the machine to change its bed 1.8 5.3.7, 7.3
Improper handling of machines between beds can lead to unhealthy postures, particularly when lifting and lowering equipment Additionally, a lack of consideration for human anatomy can exacerbate these issues, especially when accessing heights during machine adjustments.
Human error derailment when transferring (risk of machine fall) 7.6 5.6.2.1.4.c)
Hazards zones as per Figure B.1 Hazards Localisation/scenario References
Crushing when changing the brush 1.1 5.3 5.6.2.2.1
Drawing-in or trapping by the sweeper 1.4 5.2 5.4
Ejection of parts parts of the rotating sweeper 1.7 5.2 5.6.2.2.1
Hearing losses (deafness) sweeper work 4.1 5.7 5.5
Neurological and vascular disorders resonance generated by the sweeper rotation, the vacuum machine 5.1 5.5
Contact or inhalation of dangerous mist, oil, fluids, gas, fumes, dusts dust when sweeping, aspiration of the sprayed oil 6.1 5.6.2.2.1
Unhealthy postures access to the machine controls for cleaning and maintenance 7.1 5.3 5.2.2, 5.6.2.2.1
Excessive efforts change of manufacturing, adjustments, machine parts or tools' handling, (sweeper) 7.2 5.3, 5.9 5.6.2.2.1
Failure of control system falling of the sweepers supports 8.1 5.4 -
Errors of fitting unintended start up (sweeper) 8.2 5.6.3 -
Shearing of the upper parts of the body by the mobile transmission parts (pinions, chains, pulling cables, slide, cylinders…)
Ejection of fluids under pressure hydraulic ropes of the cylinders and of the hydraulic group: break, leakage 1.6 5.8.2, 5.10, 7.7 5.6.1.2
Hazards zones as per Figure B.1 Hazards Localisation/scenario References
Unhealthy postures access to the machine controls for cleaning and maintenance 7.1 5.3.7, 7.3, 5.9 5.2.1, 5.2.2
Excessive efforts change of manufacturing, adjustments, machine parts or tools' handling, (sweeper) 7.2 5.3, 5.9 5.6.2.1.4.c)
Cutting sharp edges of the frame of the machine and tools 1.3 5 -
Drawing-in or trapping by the loops formed by the pre-stressing wires when they are pulled by a tendon pulling machines 1.4 5.6.1.3.1
Electrical contacts (direct or indirect) presence of water 2.1 5.6.2.1.5
Contact with harmful products contact with the dry concrete (dust), of cleaning
Human error non stop of the machine at the end of the bed or in front of an obstacle (person, machine) 7.6 5.12 5.6.2.1.2.c)
Drawing-in or trapping by the electrical cable into the drum 1.4 5.6.1.3
Electrical contacts can occur directly or indirectly through power sources connected by electric lines, sticks, or cable drums on the ground, or by friction with moving components Factors such as insulation, positioning, connections, wear, and shutdowns play a crucial role in the effectiveness and safety of these electrical contacts.
9 Slip, trip and falling checking/filling of the oil tank 1.8 5.8 5.4, 8
Fire simultaneous presence of oil and electricity 6.3 7.7 5.6.2.1.5
Electrical contacts (direct or indirect) motor, derivation boxes, protruding plugs, panels, electrical boxes 2.1 5.6.1 5.6.2.1.5
Hearing losses (deafness) hydraulic groups, motors 4.1 5.7 5.5
Fire simultaneous presence of oil and electricity 6.3 5.6.1, 7.7 5.6.2.1.5
Controls locking of the moving controls to make the operator free during the operation which has been rendered semi- automatic (return of the machine)
Controls uncontrolled failure of the safety devices (cells, switches, emergency stops, relays…) 9.1 5.4 -
13 All kinds of guards after maintenance and/or cleaning operation 9.1 7.2.3
All kinds of guards after an impact on the guard that render it ineffective 9.1 7.1
14 Slip, trip and falling connection of the machine to the aerial electrical power line (mobile stick) 1.8 5.6.2.1.5
Table 10 — Safety measures for bed layout machine (see annex C)
Hazards zones as per Figure C.1 Hazards Localisation/scenario References
Crushing of a person between the machine and an other machine or obstacle on the same bed 1.1 5.6.2.1.2,7.1
Shearing of feet between 2 machines 1.2 5.12 5.6.2.1.2, 7.1
Impact with an other machine (or obstacle) on the same track 1.5 5.6.2.1.2, 7.1
Impact with an other machine (or obstacle) situated on a bed in the vicinity 1.5 5.6.2.1.2, 7.1
The presence of water on electrical contacts, whether direct or indirect, can lead to continuous machine operation at the bed's end or in front of obstacles such as people, machines, or safety chains Therefore, it is crucial to carefully design and position limiting devices to ensure safety and compliance.
2 Crushing of feet by the wheels of the machine on rails 1.1 5.12.1 5.6.1.1, 5.6.2.1.1
Crushing when changing of track (lifting) 1.1 7.1
Impact with an obstacle or by the machine, when changing of track (lifting) 1.5 7.1
Hazards zones as per Figure C.1 Hazards Localisation/scenario References
Crushing by mobile working parts (layout head) 1.1 5.4
Shearing by mobile working parts (layout head) 1.2 5.4
Contact with harmful products paint that serves to layout 6.2 7
Perforation, puncture by the moving layout head 6.4 5.4
Unhealthy postures reach of machine actuators for cleaning and maintenance 7.1 5.3, 5.9 5.2.2
Excessive efforts changing of manufacturing, adjustments, handling of parts or tools 7.2 5.3, 5.9 5.6.1.2
Failure of control system unintended start up 8.2 5.6.3 -
All kinds of guards after maintenance and/or cleaning operation 9.1 7.2.3
Shearing of fingers by mobile transmission parts (pinions, chains, belts, sliding, cylinders…) 1.2 5.1.1 5.4
Ejection of fluids under pressure pneumatic hoses of the cylinders: braking, leakage 1.6 5.10 5.4 Unhealthy postures reach of machine actuators for cleaning and maintenance 7.1 5.3, 5.9 5.2.2
All kinds of guards after maintenance and/or cleaning operation 9.1 7.2.3
6 Cutting sharp angles of the frame of the machine and of the tool 1.3 5, 5.2.1 -
Ejection of parts connection of the machine to the aerial power line
Electrical contacts can be established directly or indirectly through collector wires, sticks, or cable drums in contact with the ground or in friction with moving components Key factors affecting these contacts include insulation, positioning, connections, wear, cutting, and the use of batteries.
Hazards zones as per Figure C.1 Hazards Localisation/scenario References
Electrical contacts (direct or indirect) motor, derivation boxes, protruding plugs, panels, electrical boxes, batteries 2.1 5.6.1 5.6.2.1.5
Electrical contacts can be established directly or indirectly through collector wires, cables, or drums that may come into contact with the ground or mobile components Factors such as insulation, positioning, connections, wear, and cutting, as well as batteries, play a crucial role in the effectiveness and safety of these electrical connections.
Fire ((Not in Table 3)) electricity 6.3 5.6.1 5.4
Unhealthy postures reach of the machine actuators during manual operation mode 7.1 5.9 5.2.2
Excessive efforts changing of manufacturing, adjustments, handling of parts or tools 7.2 5.3, 5.9 5.6.2.1.4.c)
Neglecting use of personal protective equipment initial training of the personnel 7.4 7 7.1
Failure of energy supply loss of the references (computerized or automatic machine) 8.1 5.4 -
Failure of control system unintended start up 8.2 5.6.3 -
Electrical contacts can be established directly or indirectly through collector wires, sticks, or cable drums in contact with the ground or by interacting with moving components Key factors affecting these contacts include insulation, positioning, connections, wear, cutting, and the use of batteries.
Table 11 — Safety measures for strand pushing/pulling machine (see annex D)
Hazards zones as per Figure D.1 Hazards Localisation/scenario References
Drawing-in or trapping by roping of the wires during distribution 1.4 5.6.1.3.1, 5.6.1.3.2
Drawing-in or trapping by rotation of the drums 1.4 5.6.1.3.3
Impact by the end of a bobbin (whipping of the free wire end) 1.5 5.6.1.3.1
Impact with the rotation of the drums 1.5 5.6.1.3.3
Hearing losses (deafness) distribution of the wires from the drums 4.1 5.7 5.5
Perforation, puncture by cut wires and strips 6.4 7.1
2 Crushing on the falling of several wires from the intermediary wire chute of the wire-saw on the operator’s feet 1.1 7.5
Inadequacy with human anatomy fall into the wire-guide delivery pit 7.3 5.6.1.3.2
Shearing of the upper parts by the mobile transmission parts
(pinions, chains, pulling cables, cylinders, rods…) 1.2 5.2.1 - Unhealthy postures access to the machine parts for cleaning and maintenance 7.1 5.3 5.3.2
Hazards zones as per Figure D.1 Hazards Localisation/scenario References
Shearing by mobile working parts (ironing and pushing rollers, shearing part) 1.2 5.2 -
The operation of engines, rollers, and saws, along with the risk of falling wires, can lead to hearing losses, including deafness Additionally, unhealthy postures may arise during access to machine parts for cleaning and maintenance Proper wire-guiding techniques, along with the strategic layout and use of pulling rollers, are essential to mitigate these risks.
Excessive efforts manual pressurisation on the mechanical devices for locking the pulling wires 7.2 5.9
Excessive efforts changing of manufacturing, adjustments, handling of parts or tools 7.2 5.3, 5.9 5.4
Neglecting use of personal protective equipment absence of advice, written instructions, PPE in inadequacy with the human body (glasses and vapour, gloves, ear protectors, dust mask and oils) 7.4 7 7.1, 7.3
Neglecting use of personal protective equipment initial training of the personnel 7.4 7.1, 7.3
Inadequate local lighting constraining location (shadow, dazzling, insufficient lighting) 7.5 5.9 -
Errors of mounting changing of manufacturing, adjustments 8.3 5.3, 5.9 5.3.3
All kinds of guards after maintenance and/or cleaning operation 9.1 7.2.3
Shearing of fingers: movement of the wires evacuation beam, machine cleaning, adjustments 1.2 5.3 5.6.1.3.1
Hazards zones as per Figure D.1 Hazards Localisation/scenario References
Ejection of fluids under pressure hydraulic ropes of the cylinders and of the hydraulic group: break, leakage 1.6 5.8.2, 5.10, 7.7 5.6.1.2, 5.4
Burns hot hydraulic oil (leakage of the cylinders and ropes) 3.1 5.10, 5.8.2, 7.7 5.4
Hearing losses (deafness) hydraulic group 4.1 5.7 5.5
Contact with or inhalation of fluids, gas, mist hydraulic oil (cylinders, group) 6.2 5.10, 5.8.2, 7.7 5.6.1.2
Fire simultaneous presence of oil and electricity 6.3 7.7 5.6.2.1.5
9 Ejection of parts breaking of the pulling carriage wire, during the machine operation 1.7 5.6.1.3.3
10 Slip, trip and falling on the remaining oil on soil 1.8 5.8.2 5.2.2
11 Neurological and vascular disorders circulation of the wire in the guide 5.1 5.6.1.3.1
Fire simultaneous presence of oil and electricity 6.3 7.7 5.6.2.1.5
Unhealthy postures location of the machine actuators and their relating operation 7.1 5.9 5.2.2
Human error Inadequate layout of actuators, inconsistency between the direction of the actuators’ operation and the direction of the mobile parts
Failure of control system unintended start up (rollers, cutting) 8.2 5.6.3 -
Controls insufficient emergency stop device taking into account the length of the guiding beam 9.1 5.6.2 5.3.3
Controls uncontrolled failure of the safety devices (switches, emergency stops, relays…) 9.1 5.4, 5.6 5.3
Table 12 — Safety measures for vibrodistributor, spinner, extruder (see annex E)
Hazards zones as per Figure E.1 Hazards Localisation/scenario References
Crushing of a person between the machine and an other machine or obstacle on the same bed (including impact of a person between the mobile hopper and the machine hopper)
Shearing of feet between 2 machines or machine parts 1.2 5.6.2.1.1, 5.6.2.2.2,
Impact with the moving machine 1.5 5.12 5.6.2.1.2, 5.6.2.2.2,
7.1 Impact with an other machine or obstacle and the machine on the same track 1.5 5.6.2.1.2, 5.6.2.2.2,
7.1 Impact with an other machine (or obstacle) situated on a bed in the vicinity 1.5 5.6.2.1.2, 5.6.2.2.2,
7.1 Electrical contacts (direct or indirect) simultaneous presence of water and electricity 2.1 5.6.2.1.5, 5.6.2.2.2,
The use of a grating harrow towed by a machine can lead to perforation and puncture issues Additionally, the lack of mechanized devices for handling accessories connected to machine parts can result in unhealthy postures when inserting them into green concrete.
5.6.2.1.4.c), 5.6.2.2.2 Human error non stop of the machine at the end of the bed or in front of an obstacle (person, machine) 7.6 5.6.2.1.2.c)
Crushing of the driver or other operator at the crossing point of 1.1 5.6.2.1.2, 7.1
Hazards zones as per Figure E.1 Hazards Localisation/scenario References
Crushing when changing of track (lifting) 1.1 5.11 5.6.2.1.4.b),
Impact with an obstacle during the change of track (lifting) 1.5 5.6.2.1.6
Ejection of parts breaking of the lifting accessories during the lifting 1.7 7.1, 8 Slip, trip and falling access at a height during hooking and unhooking of the machine to change its bed 1.8 5.3.7, 7.3 -
Unhealthy postures during machine handling can lead to human error and derailment, increasing the risk of machine falls Additionally, failures in energy supply while changing tracks, particularly when the machine is being lifted and translated by motors or jacks, pose significant safety concerns.
Interference with speech communication alternate movements of drawers and helmets of concrete hopper 4.2 5.7 5.5, 5.6.2.2.2
Interference with speech communication movements of the green concrete smoothing systems 4.2 5.7 5.5
Neurological and vascular disorders resonance generated by the vibrators of the machine, the bed and/or the extruders 5.1 5.5
Contact with or inhalation of fluids, gas, mist release agent on beds and machine tools 6.1 7.2.3
During the casting, finishing, and cleaning processes of green concrete, exposure to unhealthy substances can occur, potentially leading to health issues associated with cement Additionally, the cleaning of machinery used in concrete work poses risks, as concrete projections can inadvertently enter the eyes, highlighting the importance of safety measures in these operations.
Unhealthy postures access to the machine parts for cleaning, adjustments and maintenance 7.1 5.3 5.2.2
Hazards zones as per Figure E.1 Hazards Localisation/scenario References
Crushing by mobile working parts (vibrating box, drawer, smoothing system, sealing helmets and harrow of hopper concrete) 1.1 5.4
Shearing of the upper parts by the mobile working parts (vibrating box, drawer, guillotine/cutter, support of the poker vibrator, sealing helmets and harrow of the concrete hopper)
Interference with speech communication alternate movements of drawers and helmets of concrete hopper 4.2 5.7 5.5, 5.6.2.2.2
Interference with speech communication can occur during the operation of green concrete smoothing systems, specifically models 4.2, 5.7, 5.5, and 5.6.2.2.2 Additionally, contact with unhealthy substances during the casting, finishing, and cleaning processes of green concrete can lead to health issues associated with cement exposure Furthermore, the projection of concrete during machine cleaning poses a risk of eye injuries, highlighting the importance of safety measures in these operations.
Unhealthy postures access to the machine parts for cleaning, adjustments and maintenance 7.1 5.3 5.2.2
Excessive efforts changing of manufacturing, adjustments, handling of parts or tools 7.2 5.3, 5.9 5.6.2.2.2
Neglecting use of personal protective equipment absence of advice, written instructions, PPE in inadequacy with the human body (glasses and vapour, gloves, ear protectors, dust mask and oils) 7.4 7.1
Hazards zones as per Figure E.1 Hazards Localisation/scenario References
Shearing of fingers: cleaning of the concrete feeder screws 1.2 5.6.2.2.2, 7.5
Drawing-in or trapping by the harrow of the concrete hopper 1.4 5.6.2.2.2, 7.5
Unhealthy postures access to the machine parts for cleaning, adjustments and maintenance 7.1 5.3,5.9 5.2.2
Failure of control system unintended start up (harrow of hopper, tilting of surface finishing device) 8.2 5.6.3 -
Errors of mounting Inversion of the directions of rotation of concrete feeding screws , connections of jacks/cylinders, of vibrators
10 Cutting sharps edges of the frame of the machine and tools 1.3 5 -
The article discusses the risks associated with electrical power lines and machinery, highlighting the dangers of drawing-in or trapping by the drum of the electrical power line (1.4 5.6.2.1.5) and the pulling wire of the machine and winch (1.4 5.1 7.5) It also addresses the hazards of slips, trips, and falls caused by the pulling wire of the spinner or electrical cable when in contact with soil or a bed (1.8 5.6.2.1.5).
Electrical contacts can occur directly or indirectly through collector wires, cables, or drums in contact with the ground These contacts may also arise from the friction of electrical cables against moving components, which can affect insulation, positioning, connections, and wear, as well as during shutdowns or battery usage.
Ejection of fluids under pressure hydraulic ropes of the cylinders and of the hydraulic group: breaking, leakage 1.6 5.8.2, 5.10, 7.7 5.4
Burns hot hydraulic oil (leakage of cylinders and ropes) 3.1 5.8.2, 5.10, 7.7 5.4
Hearing losses (deafness) hydraulic group 4.1 5.7 5.5
Contact with or inhalation of fluids, gas, mist hydraulic oil (cylinders, group) 6.1 5.4, 5.6.1.2, 7.1
Fire simultaneous presence of oil and electricity 6.3 5.6.2.1.5
14 Ejection of fluids under pressure compressed air of the poker vibrator (breaking of a rope) 1.6 5.10 -
Hazards zones as per Figure E.1 Hazards Localisation/scenario References
Ejection of fluids under pressure water ropes under high pressure (concrete smoothing) 1.6 5.10 - Electrical contacts (direct or indirect) simultaneous presence of water and electricity 2.1 5.6.2.1.5
Ejection of parts breaking of the pulling wire of the spinner during machine operation 1.7 5.6.1.3.1
Slip, trip and falling with the pulling wire of the spinner or electrical cable of the machine on soil or on bed 1.8 5.6.2.1.5
Slip, trip and falling verification of the concrete level in the concrete hopper 1.8 5.2.2
Slip, trip and falling during cleaning of the hopper 1.8 5.2.4
Unhealthy substances contact with the green concrete during casting, finalising, cleaning (disease generated by the cement) 6.2 5.4, 7.1, 7.2.3, 7.4,
7.5 Unhealthy substances projection of concrete during cleaning of the machine: projections into the eyes 6.2 7.5
Inadequacy with human anatomy access at a height during hooking and unhooking of the machine to change its track 7.3 5.4
Neglecting use of personal protective equipment absence of advice, written instructions, PPE in inadequacy with the human body (glasses and vapour, gloves, ear protectors, dust mask and oils) 7.4 7.1
Slip, trip and falling connection of the machine to the aerial electrical power line (mobile stick) 1.8 5.6.2.1.5 electrical power source by collector wires and/or stick or
Hazards zones as per Figure E.1 Hazards Localisation/scenario References
Electrical contacts (direct or indirect) motor, derivation boxes, protruding plugs, panels, electrical boxes 2.1 5.6.2.1.3
Fire simultaneous presence of oil and electricity 6.3 5.6.2.1.5
After an impact, various types of guards can become ineffective, leading to uncontrolled failures of safety devices such as cells, switches, emergency stops, and relays This can result in the disabling of safety devices to perform specific operations, like starting a bed or controlling concrete in a hopper.
Hearing losses (deafness) fixed vibrators on vibrating boxes or vibrating beams and poker vibrators 4.1 5.7 5.5
Neurological and vascular disorders resonance generated by the vibrators of the machine, the bed and/or the extruders 5.1 5.5
Neglecting use of personal protective equipment absence of advice, written instructions, PPE in inadequacy with the human body (glasses and vapour, gloves, ear protectors, dust mask and oils)
Errors of mounting Inversion of the directions of rotation of concrete feeding screws, connections of jacks/cylinders, of vibrators 8.3 5.10 -
Controls locking of the moving controls to make the operator free during the operation which has been rendered semi- automatic (return of the machine) 9.1 5.12.2 5.6.2.1.6
Hazards zones as per Figure E.1 Hazards Localisation/scenario References