Bsi bs en 12385 3 2004 + a1 2008

BRITISH STANDARD BS EN 12385 3 2004 +A1 2008 Steel wire ropes — Safety — Part 3 Information for use and maintenance ICS 77 140 65 ?? ? ??????? ? ??????? ? ??? ? ?????????? ? ?????? ? ?? ? ????????? ?[.]

This Bri sh Stan ard was

published u der the authoriy

This British Stand rd is the UK implementation of EN 1 3 5-3:20 4+A1:20 8

It super edes BS EN 1 3 5-3:20 4 which is withdrawn

The start and finish oftext introduced or altered b amendment is indicated in

the text b tag s Tag s indicating changes to CEN text car y the number of the

CEN amendment For ex mple, text altered b CEN amendment A1 is

ind icated b !"

The UK p rticip tion in its prep ration was entrusted to Tech ical Commit e

MHE/ 2, Wire ropes

A l st of org anizations represented on this commit e can be obtained on

request to its sec etary

This publ cation do s not purport to include al the neces ary provisions of a

contract User are responsible for its cor ect a pl cation

Compl anc with a British Standard cannot c nfer im munity f om

legal obl gations

This Euro e n St an ard wa a prov ed b CEN o 2 July 0 4 a d in lu e A me dme t 1 a prov ed b CEN o 14 Fe ru ry 2 0

CEN memb rs are b u d to c mply wit h t he CEN/ CENELEC Int ern l R eg latio s whic st ip lat e t he c n it io s for giv in t his Euro e n

St an ard t he st atu of a n tio al st an ard wit ho t a y alt eratio Up-t o-d t e lst s a d biblo ra hic l refere c s c n ernin s c n t io al

st an ard ma b o t ain d o a plc tio to th CEN Ma a eme t Ce tre or t o a y CEN memb r

This Euro e n Sta d rd e ist s in t hre oficial v ersio s (En ls ,Fre c , Germa ) A v ersio in a y t her la g a e ma e b t ra slat io

u d r th re p n ibi t y of a CEN memb r int o it s own la g a e a d n tifie to th CEN Ma a eme t Ce t re h s t he s me st at us a th

oficial v ersio s

CEN memb rs are th n tio al st an ard b die of Aust ria, Belgium,Bulg ria,Cy pru , Cz c R ep blc,De mark , Est onia,Finla d,

Fra c ,Germa y , Gre c , Hu g ry , Ic la d, Irela d,It aly ,L tv ia,Lit hu nia, L x mb urg,Malt a,Net herla d , Norway ,Pola d, Portu al

R oma ia,Slov akia, Slov enia, Sp in,Swe e ,Swit zerla d a d Unit ed K in d m

E U ROPE A N COMMI TT E FO STA N DA RDI ZA TI ON

COMIT EU OPÉ N DE NORMALISATION

EUR PÄISCHES KOMIT E FÜ N RMUN

Management Cent re: rue de St as art ,3 B- 10 0 Brus els

© 2 0 CEN All rig t s of e ploitat io in a y form a d b a y me n re erv ed

worldwid for CEN n t io al Memb rs

R ef No EN 12 8 -3:2 0 +A 1:2 0 :E

Contents

p g

F reword .3

Intro u tion

4 1 Sc p 5

2 Normativ ref ere c s .5

3 Terms a d d finitions 5

4 List of sig ific nt hazards .5

5 Safety instru tio s a d informatio for use a d mainte a c 6

Ann x A (informativ ) Ex ample of g n ral information for use a d mainte a c 7

Ann x B (informativ ) Guid n e o ro e sele tio 13 Ann x C (informativ ) Material h alth a d safety informatio on ste l wire rop a d its c mp n nt p rts 18 Re uireme ts of EU Dire tiv 9 /37/EC .21 Ann x ZB (informativ ) Relatio ship b twe n this Euro e n Sta d rd a d th Es e tial Re uireme ts of EU Dire tiv 2 0 /42/ EC .2

Ann x ZC (informativ ) Relatio ship b twe n this Euro e n Sta d rd a d th Es e tial Re uireme ts of EU Dire tiv 95/16/EC .2

Biblo ra hy 24

Ann x ZA (informativ ) Relatio ship b twe n this Euro e n Sta d rd a d th Es e tial

!

!

!

Fore word

This d c me t (EN 123 5-3:20 4 A 1:20 8) h s b e prep red b Te h ic l Commite CEN/TC 16 “Ch in ,

rop s, we bin , sln s a d a c s o e - Safety”, th s cretariat of whic is h ld b BSI

This Euro e n Sta d rd s al b giv n th statu of a n tio al sta d rd, eith r b p blc tio of a id ntic l te t or

b e d rs me t, at th late t b Se temb r 20 8, a d c nflctin n tio al sta d rd s al b with rawn at th

late t b Se temb r 20 8

This d c me t in lu e Ame dme t 1, a prov d b CEN o 20 8-02-14

This d c me t s p rse e EN 123 5-3:20 4

Th start a d finis of te t introd c d or altered b ame dme t is in ic te in th te t b ta s ! "

This d c me t h s b e pr ep red u d r a ma d te giv n to CEN b th Europ a Commis io a d th Europ a

Fre Tra e A ss ciatio , a d s p orts e s ntial req ireme ts of EU Directiv (s)

For relatio s ip with EU Directiv (s), s e informativ A nn x s ZA, ZB a d ZC, whic are inte ral p rts of this

d c me t

Th oth r Parts of this Europ a Sta d rd are:

Part 1: Ge eral req ireme ts

Part 2: Definitio s, d sig atio a d cla sific tio

Part 4: Str an e rop s for g n ral lftin a plc tio s

Part 5: Str an e rop s for lfts

Part 6: Str an e rop s for min s afts

Part 7: Lo k d c i rop s for min s afts

Part 8: Str an e h uln a d c rr yin -h uln r op s for c blewa in talatio s d sig e to c rr y p rso s

Part 9: Lo k d c i c rr y in rop s for c blewa in talatio s d sig e to c rr y p rso s

Part 10: Spir al ro e for g n ral structural a plc tio s

A cc rdin to th CEN/CENELEC Internal Re ulatio s, th n tio al sta d rds orga iz tio s of th folowin

c u tri s are b u d to impleme t this Euro e n Sta d rd: Au tri , Belgium, Bulg ri , Cy ru , Cz c Re u lc,

De mark, Esto ia, Finla d, Fran e, Germa y, Gree e, Hu g ry, Ic la d, Irela d, Italy, Latvia, Lith a ia,

Lu emb urg, Malta, Neth rl n s, Nor way , Pola d, Portu al, Roma ia, Slo a ia, Slo e ia, Sp in, Swe e ,

Switz r la d a d Unite Kin d m

This d c me t is a ty e C sta d rd a state in EN 10 0

This d c me t h s b e prep red to s p ort th oth r Parts of this sta d rd th t c n ern th ms lv s with th

p rtic lar req ireme ts for ste l wire rop s to b u e in s e ific a plc tio s

Th ty pe of rop s c n erne a d th e te t to whic h z rds are c v re are in ic te in th s o e of this

d c me t

W he provisio s of this ty e C sta d rd ar e diferent fom th s whic are state in ty e A a d B sta d rds, th

pro isio s of this ty e C sta d rd ta e prec d n e o er h pro isio s of th oth r sta d rd , for informatio for

u e a d mainte a c a c rdin to th pr ovisio s of this ty pe C sta d rd

1 Scope

This d c me t s e ifie th ty e of informatio for u e a d mainte a c of ste l wire rop s to b provid d b th

rop ma ufa turer or to b in lu e in th ma ufa turer’ h n b o th t a c mp nie a ma hin , pie e of

e uipme t or in talatio of whic th ste l wire rop forms a p rt

Th p rtic lar h z rds c v red b this d c me t are id ntifie in cla s 4

For ste l wire ro e c nformin to Parts 8 a d 9 u e o c blewa in talatio s d sig e to c rr y p rs n ,

a ditio al informatio for u e a d mainte a c is giv n in prEN 12927-7

For ste l wire rop sln s, s e ific informatio o u e a d mainte a c is giv n in EN 13 14-2

This d c me t is n t a plc ble to ste l wire rop s ma ufa ture b fore th d te of p blc tio of this d c me t b

CEN

Th folowin referen e d c me ts are in is e s ble for th a plc tio of this d c me t For d te refere c s,

o ly th e itio cite a ple For u d te refere c s, th late t e itio of th refere c d d c me t (in lu in a y

ame dme ts) a ple

EN 10 0:19 6, S afety ofmac hin ery — Princ ip le for ris k as s es s ment

EN 10 0:19 8, S afety ofm ac hin ery – Terminology

EN 123 5-2:20 2, S te l wire ro e — Safety — Part 2: D efinitions , des ignatio an d c las s ific ation

EN ISO 1210 -2:20 3, S afety ofmac h in ery - Basic c onc epts , general principle s for design - Part 2 : Tech ic al

princ ip le (I S O 12 10 -2:20 03)

For th p rpo e of this d c me t, th terms a d d finitio s giv n in EN 10 0:19 8, EN 123 5-2:20 2 a d th

vis al e amin tio c rri d o t b a c mp te t (train d a d e p r ie c d) p rso , a d wh re n c s ar y,

s p leme te b oth r me n , s c a me s reme t or ele tro-ma n tic n n-d structiv te tin , in order to

d te t d ma e or d te or atio whic mig t afe t th fitn s for u e of th rop

4 List of significant hazards

Ta le 1 c ntain al th sig ific nt h z rds, h z rdo s situ tio s a d e e ts, a far a th y are d alt with in this

sta d rd, id ntifie b r is a s s me t a d whic req ire a tio to elmin te or r ed c th ri k

Ta le 1 — Hazards a d as o iate re uireme ts

u er of th ste l wire rop s a d

th ma hin r y ma ufa turer

This informatio s al in lu e temp rature lmits, u e in e c ptio aly h z rd u c n itio s, first u e, h n ln a d

in talatio a d mainte a c

A n e ample of s c informatio is giv n in A nn x A

5.3 Rope sele tion

For stran e ro e this informatio s al in lu e g id n e o rop c n tructio in relatio to a rasio a d we r,

ty e of c re in relatio to cru hin of th rop at th drum, wire finis in r elatio to c rro io , dir ectio of la a d

ty e in relatio to dire tio of c i n , rotatio al c ar acteristic in r elatio to u e of a swiv l a d fle t a gle efe ts

A n e ample of s c informatio is giv n in A nn x B

5.4 Mate ria l hea lth and sa fety information on stee l w ire rope a d its c mpone t parts

This informatio s al in lu e d tais of al th in ivid al mate als th t form p rt of th finis e rop a d g n ral

informatio relatin to o c p tio al prote tiv me s res, emerg n y me ic l proc d re , s fety (in lu in a y fire

or e plo io h z rds) a d dis o al

A n e ample of s c informatio is giv n in A nn x C

Annex A

(informative)

Ex ample of general information for use and maintenance

A.1.1 T emperature

A.1.1.1 Ste l wire ro es ma e from c rb n ste l wires

A cc u t s o ld b ta e of th ma imum temp rature th t ma b r ea h d b th wir e rop in s rvic A n

u d restimatio of th temp rature in olv d c n le d to a d n erou situ tio

Stra d d rop s with fibre c res or ibre c ntres c n b u e u to a ma imum of 10 °C

Stran e rop s with ste l c res a d s iral rop s (i.e s iral stra d a d lo k d c i) c n b u e u to 20 °C

alth u h s me d -ratin of th workin lo d lmit is n c s ar y, th amo nt b in d p n e t u o th e p s re

time at hig temp rature a d th diameter of th wir es For o eratin temp ratures b twe n 10 °C a d 20 °C

th lo s in stre gth ma b a s me to b 10 %

For temp ratures a o e 20 °C s e ial lu r ic nts ma b n c s ar y a d gre ter lo s s in stren th th n state

a o e wi n e to b ta e into a c u t Th rop or ma hin r y ma ufa turer s o ld b c nta te

Th stre gth of ste l wire r op s wi n t b a v rs ly afe te b o eratin temp rature a low a – 4 °C a d n

red ctio from th workin lo d lmit is n c s ar y ; h we er, ro e p rforma c ma b red c d, d p n in u o

th efe tiv n s of th rop lu ric nt at low temp ratures

W he th rop is fite with a termin tio , als refer to A 1.1.2

A.1.1.2 Termin tio s

In a ditio to th lmits state a o e for ro e, a d u le s oth r wis s e ifie b th ro e ma ufa turer or th

ma ufa turer of th ma hin , e uipme t or in talatio , th folowin o eratin temp ratures mu t n t b

e c e e :

Turn-b c e e with aluminium ferrule: 15 °C

Ferrule-s c red e e with ste l ferrule: 20 °C

So k t fi e with a le d-b s d alo : 8 °C

So k t fi e with zin or a zin -b s d alo : 120 °C

So k t fi e with resin – refer to resin s c etin sy stem d sig er’s in tructio s

A.1.2 Use in ex ce tionaly hazardous c ndit ions

In c s s wh re e c ptio aly h z rdo s c n itio s are k own to e ist, e.g ofs ore a tivitie , th lftin of p rs n

a d p te tialy d n erou lo d s c a molte metals, c rrosiv mate als or radio a tiv materials a risk

a s s me t s o ld b c rri d o t a d th workin lo d lmit s le te or a ju te a c rdin ly

A.2 Before put ing the rope into first use

A.2.1 Inspe ting the rope a d doc me ts

Th rop s o ld b u wrap e a d e amin d imme iately after d lv r y in or der to c e k its id ntity a d c n itio

a d to e s r e th t th ro e a d its termin tio (s), if a y, are c mp tible with th ma hin ry or e uipme t to whic

th y are to b ata h d in s rvic

NOT E If damage to th rop or its p ck age is o served, this sh uldb recorded o th delvery n te

Th Certific te of c nformity b th rop ma ufa turer s o ld b k pt in a s fe pla e, e.g with th cra e

h n b o , for id ntific tio of th rop wh n c rr yin o t p r io ic th r ou h e amin tio s in s rvic

NOT E T he rop sh uld n t b used for lfting p rp ses with ut th user h ving a Certificate in his p s es io

A.2.2 Storing the rope

A cle n, wel-v ntiate , dry , d st free, u d rco er lo atio s o ld b s le te Th rop s o ld b c v red with

If s p le o a reel, th r eel s o ld b rotate p ri dic ly d ri g lo g p rio s of storag , p rtic la y in warm

e vironme ts, to prev nt migratio of th lu r ic nt fom th ro e

Th rop s o ld n t b stored in area s bje t to ele ate temp ratures a this ma afe t its future p rorma c

In e treme c s s its o gin l a -ma ufa ture brea in force c uld b s v rely re u e re d ri g it u fit for s fe

u e

Th rop s o ld n t b alowe to ma e a y dir ect c nta t with th flo r a d th re l s o ld b s p sitio e th t

th re is a flow of air u d r th re l

NOT E Faiure to e sure th a ove may result in th rop b coming co tamin ted with foreign mater a d start th o set of

corrosio eve b fore th ro e is p t into service

Preferably, th reel s o ld b s p orte in a A -fame or cradle sta din o grou d whic is c p ble of s fely

s p ortin th total ma s of rop a d r eel

Th rop s o ld b in p cte p rio ic ly a d, wh n n c s ar y, a s ita le rop dres in , whic is c mp tible with

th ma ufa tu n lu r ic nt, s o ld b a ple

A ny wet p c a in , e.g s c cloth, s o ld b remo e

Th rop markin s o ld b c e k d to v rify th t it is le ible a d relate to th c rtific te

W he remo in from store, th p n iple 'first in, first o t' s o ld b a ple

A.2.3 Che k ing the c ndition of rope rela ted parts of the ma hine , e uipme nt or instalation

Before in tal n th n w rop , th c n itio a d dime sio s of rop relate p r ts, e.g drums, s e v s a d rop

g ards, s o ld b c e k d to v rify th t th y are within th o eratin lmits a s e ifie b th o gin l e uipme t

ma ufa turer

For rop s workin o cran s th efe tiv groo e diameter s o ld b at le st 5 % a o e th n min l rop

diameter Th groo e diameter s o ld b c e k d u in a s e v g u e

Sh a e s o ld als b c e k d to e s re th t th y are free to rotate

Un er n circ msta c s s o ld th a tu l rop diameter b gre ter th n th pitc of th drum In th c s of mu

lti-la er c i n , th relatio s ip b twe n th a tu l ro e diameter a d th pitc s o ld b a s s e

W he groo e b c me e c s iv ly worn, it ma b p s ible to h v th m re- ma hin d Before d in s , th

s e v or drum s o ld b e amin d to d termin if s ficie t stren th wi remain in th u d rly in mate al

s p ortin th ro e after th ma hinin h s b e c rri d o t

NOT E W he grooves b come worn a d th ro e is pinch d at it sides, stra d a d wire moveme t is restricted a d th

a i ty of th rop to b nd is reduced, th s afecting ro e p rforma ce

A.3 Handl ng and instal ing the rope

A.3.1 Ge era l

Th proc d re for in tal n th ro e s o ld b c rrie o t in a c rda c with a d taie pla is u d b th u er of

th ste l wire rop

Th ro e s o ld b c e k d to v rify th t it is n t d ma e wh n u lo d d a d wh n tran p rte to stora e

c mp u d or site Du n th s o er atio s, th rop its lf s o ld n t c me into c nta t with a y p rt of th lftin

d vic , s c a th h o of a cra e or a fork of a fork lft truc We bin sln s ma b h lpful

A.3.2 Rope suppled in a coi

Th c i of ro e s o ld b pla e o th grou d a d role o t straig t, e s ri g th t it d e n t b c me

c ntamin te with d st, g t, moisture or oth r h rmful material

Th rop s o ld n v r b p le awa from a statio ar y c i a this wi in u e tur n into th ro e a d form kink s

If th c i is to larg to p y sic ly h n le it ma n e to b pla e o a turnta le whic wi alow th rop to b

p id o t a th e d of th rop is p le awa from t he c i Corre t meth d of p yin o t rop from a c i are

s own in Fig re A 1

Fig re A.1 — Cor e t metho s of p yin o t ro e f rom a c i

A.3.3 Rope suppled on a ree l

A s aft of a e u te stre gth s o ld b p s e thro g th re l b r e a d th re l pla e in a s ita le sta d whic

alows it to rotate a d b br ak d to a oid o erru d ri g in talatio

W here multi-lay er c i n is in olv d th rop s o ld b pla e in e uipme t th t h s th c p bi ty of providin a

b c te sio in th rop a it is b in tra sferred fom th s p ly r eel to th drum This is to e s re th t th

u d r lyin la s of rop , p r tic larly in th b tom la er, are wo n tig tly o th dr um

Th s p ly reel s o ld b p sitio e s c th t th fle t a gle d ri g in talatio is k pt to a minimum

If a lo p forms in th rop it s o ld n t b alowe to tig te to form a kin

Th re l sta d s o ld b mo nte s a n t to create a re erse b n d rin re vin , i.e for a drum with a

u d r win rop , ta e th rop of th b tom of th s p ly re l (s e Fig re A 2)

Fig re A.2 – Tra sfer of w ire ro e from re l to drum with c ntrol of ro e te sio – botom of re l to b tom

of drum

ty pe or s o ld h v th s me la ty pe a d dire tio a th n w rop A ltern tiv ly, a le gth of fibre or ste l rop of

a e u te stren th ma b re v d into th s stem for u e a a piot/me s n er ln A swiv l s o ld n t b u e

d ri g th in talatio of th ro e

Mo itor th r op c refuly a it is b in p le into th system a d e s re th t it is n t o stru te b a y p rt of th

structure or me h nism th t ma d ma e th rop a d res lt in a lo s of c ntrol

A.3.4 Cut ing the rope

If it is n c s ary to c t th ro e, s c re s rvin s s o ld b a ple o b th sid s of th c t mark Th le gth of

e c s rvin for a stran e ro e s o ld b at le st e u l to two rop diameters

On s rvin eith r sid of th c t mark is u u ly s ficie t for preforme rop s (s e EN 123 5-2) For n

n-preforme ro e , rotatio -e ista t r op s a d p ralel-clo e ro e a minimum of two s r vin s e c sid of th c t

mark is re omme d d

Preferably, c tin of th rop s o ld b d n u in a hig s e d a rasiv dis c ter Oth r s ita le me h nic l

or hy draulc s e ri g e uipme t ma b u e alth u h n t rec mme d d wh n th rop e d is to b weld d or

bra e Wh n c tin , e s re a e u te v ntiatio to a oid a y b id-u of fume fom th ro e a d its c n titu nt

p rts Se A nn x C

NOT E Some sp cial rop s co tain s nth tic material which, wh n h ated to a temp rature high r th n n rmal productio

proces ing temp ratures, wi decomp se a dmay give of toxic fumes

NOT E Ro e produced from carbo ste l wires in th form as- ship ed is n t co sidered a h alth h zard During

su sequ nt proces ing (e.g cuting, welding, grinding, cle ning) dust a d fumes may b produced which co tain eleme ts th t

may afect exp sed p rso s

A fter c tin , faiure to c rrectly s c re th ro e e d is lk ly to le d to sla k e s or distortio s in th ro e

A n alternativ meth d of c tin is b fu in a d ta e n , a proc s whic is d sig e to pre e t th wir es a d

stran s from u la in

A.3.5 ‘Running in’ the new ro e

W here p s ible, ‘ru in’ th n w rop b o eratin th e uipme t slowly, preferably with a low lo d for a n mb r of

cy cle This e a le th n w rop to a ju t its lf grad aly to th workin c n itio s Th rop s o ld n v r 'run in'

A.4.1 Inspe ting a d ex amining the rope

In p ctio a d thro g e amin tio inter vals a d dis ard crite a s o ld b in a c rda c with th folowin :

Cran rop s – ISO 4 0 ;

Lift rop s – ISO/FDIS 4 4 ;

Ca lewa rop s – pr EN 12927-7

A.4.2 Lubric ting the rope in servic

Th prote tio pro id d b th o gin l ma ufa turin lu ri a t is n rmaly a e u te to pre e t d ter ioratio d e to

c rro io d ri g s ipme t, storag a d th e rly lfe of th rop ; h we er, in order to o tain o timum p rorma c ,

mo t ro e wi b n fit fom th a plc tio of a s rvic lu ric nt, th ty e of whic wi b d p n e t u o th rop

a plc tio a d th e vironme tal c n itio s to whic th rop is e p s d

Th s rvic lu ri a t mu t b c mp tible with th o gin l ma ufa tu n lu ri a t a d in th c s of a tra tio

driv rop , n t imp ir its fictio al c ara teristic Refer to th rec mme d tio s of th ro e ma ufa turer or th

origin l e uipme t ma ufa turer

Ty pic l meth d of a plyin th s rvic lu ri a t are b brus , dr ip fe d, p rta le pres u s d s ray or hig

pres ure This later system is g n raly d sig e to force th s rvic lu ri a t into th rop u d r hig pr es ure

whie simulta e u ly cle nin th rop a d remo in moisture, resid al lu ri a t a d oth r c ntamin nts

Faiure to a ply a s rvic lu ric nt c uld re ult in a r ed ctio in th p rforma c of th ro e a d at worst, le d to

u d te ta le internal c rro io

A pplc tio of to mu h a d th wro g ty e of lu ri a t ma le d to a a c mulatio of foreig d br is o th

s rfa e of th rop This c uld r es lt in a rasiv d ma e to th rop , th s e v a d th drum It ma als ma e it

dific lt to d termin th true c n itio of th ro e for e alu tio a ain t dis ard cr ite a