30058557 pdf BRITISH STANDARD Cranes — Safety — Hand powered cranes ICS 53 020 20 BS EN 13157 2004 +A1 2009 Incorporating corrigendum October 2008 B ou gh t b y M rs T rin a M cA nu lty ,C er te x Li[.]
General definitions
3.1.1 coefficient of utilisation (safety coefficient) the arithmetic ratio between the maximum load held by the lifting equipment and its rated capacity
3.1.2 combined unit combination of a trolley and a hoist which are connected (see figure 1)
3.1.3 dynamic tests testing of lifting equipment by executing operating motions under a specified test load exceeding the rated capacity
3.1.4 lifting change in level during the movement
NOTE Lifting incorporates the vertical or the vertical and horizontal movement of the load or all combinations
3.1.5 rated capacity load that the lifting equipment is designed to lift for a given operating condition (e.g configuration, position of the load)
Figure 1 — Example of combined units
3.1.6 static tests testing of lifting equipment by applying a specified static load, exceeding the rated capacity
3.1.7 test coefficient the ratio between the load used for static and dynamic tests and the rated capacity
Definitions for hand chain blocks
A hand chain block is a device designed for lifting and lowering loads suspended from a load chain, utilizing human effort applied to a hand chain This mechanism also allows for the secure holding of the load.
5 Anchorage of the load chain
Definitions for lever hoists
D/d ratio the ratio of the minimum pitch circle diameter of the first rope layer of the drum or sheave to the calculated minimum diameter of the rope
A lever hoist is a device designed for lifting and lowering loads suspended from a lifting medium, utilizing human effort applied to a lever It also features braking mechanisms to securely hold the load in place.
5 Anchorage of the lifting medium
Figure 3 — Example of lever hoists
Definitions for jaw winches
Jaw winches are devices designed for lifting, lowering, and holding loads using a rope They operate by gripping or moving the rope with jaws, which are activated through human effort applied to one or more levers.
The operation cycle, intended solely for testing purposes, involves a lifting movement followed by a lowering movement This cycle occurs over the minimum vertical distance determined by the rope length as it traverses all relevant components of the jaw winch.
2 Guard case of the jaw and actuating mechanisms
Definitions for hand powered trolleys supporting lifting machines
3.5.1 hand powered trolleys supporting lifting machines equipment fitted with wheels which are designed for the hand powered travelling of a hooked or combined lifting
3.5.2 geared travel trolley hand powered trolley permitting horizontal travel, driven by a hand wheel which is operated by an operating chain (see figure 5)
Figure 5 — Example of geared travel trolley
3.5.3 monorail equipment comprising an overhead beam or section along which suspended loads can be moved with a trolley This equipment can also have curves, points, turntables etc
3.5.4 push travel trolley hand powered trolleys permitting horizontal travel by pushing or pulling manually on the load (see figure 6)
Definitions for drum winches
The ˜drum winch™ is a device designed for lifting, lowering, and securely holding loads that are connected to a rope or webbing wound around a drum This device is operated through crank handles or wheels, which are activated by human effort.
The D/d ratio refers to the relationship between the pitch circle diameter of the first layer of rope or webbing on a drum or sheave and the diameter of the rope or the thickness of the webbing This ratio is crucial for understanding the performance and efficiency of rope and webbing systems in various applications.
The drum pitch circle diameter is defined as twice the distance from the drum or sheave axle to the midpoint of the rope or webbing that directly contacts the drum or sheaves, specifically referring to the first layer on the drum.
1 Crank handle or operating wheel
D Drum pitch diameter d Minimum calculated rope diameter
Definitions for pulley blocks and deflection pulley
3.7.1 deflection pulley equipment used to change the direction of a rope with a sheave freely rotating on an axle to be used with drum winches and jaw winches
A pulley block is a system consisting of one or more sheaves that rotate freely on shafts, designed to alter the direction of a wire rope or rope This mechanism is commonly utilized with drum winches and jaw winches, as illustrated in figure 8.
The pitch diameter is defined as twice the distance from the axle of the drum or sheave to the center of the rope or webbing that is in direct contact with the drum or sheaves, specifically referring to the first layer on the drum.
3.7.4 sheave wheel with a groove supporting a wire rope or a fibre rope
1 Opening angle between the sides of the sheave
3 Depth of the sheave groove
5 Wire rope or rope guide
D Sheave pitch circle diameter d Nominal diameter of the lifting medium
Tables 1 to 6 outline significant hazardous situations and events related to hand-powered lifting equipment, highlighting potential risks to individuals during both normal use and foreseeable misuse Additionally, the tables reference relevant clauses in the standard aimed at mitigating or eliminating these associated hazards.
Table 1 — List for hand chain blocks of significant hazards and associated requirements
Hazard Relevant clause(s) in this standard
1.1 From machine parts or workpieces caused for example, by their:
1.1.3 Mass and stability (potential energy of elements that can move under the effect of gravity) 5.1.1
1.3.5 Drawing-in or trapping hazard 5.1.7
8 Hazards generated by neglecting ergonomic principles in machine design such as hazards caused by:
8.1 Unhealthy postures or excessive efforts 5.1.6, 5.1.8
17 Fall or ejection of objects 5.1.4, 5.1.5
18 Loss of stability/overturning of machine 7.1.1
20.6 Inadequate ability of machine to be slowed down, stopped and immobilised
21 Hazards due to work position (including operator’s position) on the machine:
21.4 Mechanical hazards at work position
23 Resulting from the handling of the machine (lack of stability) 5.1.12
26 Inadequate instructions for driver/operator 7.1.1
27 Mechanical hazards and dangerous events:
27.1 Resulting from falling load, collisions, swinging of machine caused by Uncontrolled loading – over loading 5.1.6, 7.1.1, 7.1.3
Uncontrolled amplitude of the movement 5.1.1
Unexpected/unintended movement of the loads 5.1.4, 5.1.9
Collision of more than one machine 5.1.4
27.4 Resulting from inadequate mechanical strength of parts 5.1.2 27.5 Resulting from inadequate design of pulleys, drums Not significant 27.6 Resulting from inadequate selection/integration into the machine for chains, cables, lifting accessories 5.1.8, 5.1.10
27.7 Resulting from descent of load by friction brakes 5.1.3 27.8 Resulting from abnormal assembly/test/use/maintenance conditions 7.1.1, 7.1.2
29 Hazards generated by neglecting ergonomic principles
29.1 Inadequate visibility from the operator position 7.1.1
Table 2 — List for lever hoists of significant hazards and associated requirements
Hazard Relevant clause(s) in this standard
1.1 From machine parts or workpieces caused for example, by their:
1.1.3 Mass and stability (potential energy of elements that can move under the effect of gravity)
1.3.5 Drawing-in or trapping hazard 5.2.8
8 Hazards generated by neglecting ergonomic principles in machine design such as hazards caused by:
8.1 Unhealthy postures or excessive efforts 5.2.6, 5.2.9
17 Fall or ejection of objects 5.2.3, 5.2.5, 5.2.7
18 Loss of stability/overturning of machine 7.2.1
20.6 Inadequate ability of machine to be slowed down, stopped and immobilised
21 Hazards due to work position (including operator’s position) on the machine:
21.4 Mechanical hazards at work position
23 Resulting from the handling of the machine (lack of stability) 5.2.20
26 Inadequate instructions for driver/operator 7.2.1
27 Mechanical hazards and dangerous events:
27.1 Resulting from falling load, collisions, swinging of machine caused by Uncontrolled loading – over loading 5.2.6, 7.2.1, , Uncontrolled amplitude of the movement 5.2.5, 5.2.15 Unexpected/unintended movement of the loads 5.2.3, 5.2.4, 5.2.7
Collision of more than one machine 5.2.1
27.4 Resulting from inadequate mechanical strength of parts 5.2.2
27.5 Resulting from inadequate design of pulleys, drums 5.2.10, 5.2.17
27.6 Resulting from inadequate selection/integration into the machine for chains, cables, lifting accessories 5.2.9, 5.2.11, 5.2.12,
5.2.13, 5.2.14, 5.2.16 27.7 Resulting from descent of load by friction brakes 5.2.3
27.8 Resulting from abnormal assembly/test/use/maintenance conditions 7.2.1, 7.2.2
29 Hazards generated by neglecting ergonomic principles
29.1 Inadequate visibility from the operator position 7.2.1
Table 3 — List for jaw winches of significant hazards and associated requirements
Hazard Relevant clause(s) in this standard
1.1 From machine parts or workpieces caused for example, by their:
1.1.3 Mass and stability (potential energy of elements that can move under the effect of gravity)
1.3.5 Drawing-in or trapping hazard 5.3.7
8 Hazards generated by neglecting ergonomic principles in machine design such as hazards caused by:
8.1 Unhealthy postures or excessive efforts 5.3.5, 7.3.1
17 Fall or ejection of objects 5.3.3, 5.3.5
18 Loss of stability/overturning of machine 7.3.1
20.6 Inadequate ability of machine to be slowed down, stopped and immobilised Not applicable
21 Hazards due to work position (including operator’s position) on the machine:
21.4 Mechanical hazards at work position
- contact with wheels Not applicable
23 Resulting from the handling of the machine 5.3.15
26 Inadequate instructions for driver/operator 7.3.1
27 Mechanical hazards and dangerous events:
27.1 Resulting from falling load, collisions, swinging of machine caused by Uncontrolled loading – over loading 5.3.1, 5.3.5, 7.3.1, 7.3.3 Uncontrolled amplitude of the movement Not significant
Unexpected/unintended movement of the loads 5.3.2, 5.3.4, 5.3.3,
Collision of more than one machine Not significant
27.3 Resulting from a derailment Not applicable
Inadequate mechanical strength of parts can lead to significant issues, as highlighted in section 5.3.1 Additionally, the design of pulleys and drums may not be significant enough to warrant concern The improper selection and integration of chains, cables, and lifting accessories, as discussed in sections 5.3.10, 5.3.11, and 5.3.12, can also result in problems Furthermore, the descent of loads due to friction brakes, as noted in section 5.3.2, poses additional risks.
27.8 Resulting from abnormal assembly/test/use/maintenance conditions 7.3.1, 7.3.2
29 Hazards generated by neglecting ergonomic principles
29.1 Inadequate visibility from the operator position 7.3.1
Table 4 — List for hand powered trolleys of significant hazards and associated requirements
Hazard Relevant clause(s) in this standard
1.1 From machine parts or workpieces caused for example, by their:
1.1.3 Mass and stability (potential energy of elements that can move under the effect of gravity)
1.3.3 Cutting or severing hazard 5 General
1.3.5 Drawing-in or trapping hazard 5 General
8 Hazards generated by neglecting ergonomic principles in machine design such as hazards caused by:
8.1 Unhealthy postures or excessive efforts 5.4.6
17 Fall or ejection of objects 5.4.5
18 Loss of stability/overturning of machine 7.4.1
20.6 Inadequate ability of machine to be slowed down, stopped and immobilised 5.4.3, 7.4.1, 7.4.3
21 Hazards due to work position (including operator’s position) on the machine:
21.4 Mechanical hazards at work position
23 Resulting from the handling of the machine (lack of stability) 7.4.1
26 Inadequate instructions for driver/operator 7.4.1
27 Mechanical hazards and dangerous events:
27.1 Resulting from falling load, collisions, swinging of machine caused by
Uncontrolled amplitude of the movement 5.1.1
Unexpected/unintended movement of the loads 5.4.10
Collision of more than one machine 5.4.7
27.4 Resulting from inadequate mechanical strength of parts 5.4.2, 5.4.8
27.5 Resulting from inadequate design of pulleys, drums Not significant
27.6 Resulting from inadequate selection/integration into the machine for chains, cables, lifting accessories
27.7 Resulting from descent of load by friction brakes 5.4.2
27.8 Resulting from abnormal assembly/test/use/maintenance conditions 7.4.1, 7.4.2
29 Hazards generated by neglecting ergonomic principles
29.1 Inadequate visibility from the operator position 7.4.1
Table 5 — List for drum winches of significant hazards and associated requirements
Hazard Relevant clause(s) in this standard
1.1 From machine parts or workpieces caused for example, by their:
1.1.3 Mass and stability (potential energy of elements that can move under the effect of gravity)
1.3.5 Drawing-in or trapping hazard 5.5.7, 7.5.1
8 Hazards generated by neglecting ergonomic principles in machine design such as hazards caused by:
8.1 Unhealthy postures or excessive efforts 5.5.5
17 Fall or ejection of objects 5.5.3, 5.5.4
18 Loss of stability/overturning of machine 7.1.1
20.6 Inadequate ability of machine to be slowed down, stopped and immobilised Not applicable
21 Hazards due to work position (including operator’s position) on the machine:
21.4 Mechanical hazards at work position
- contact with wheels Not applicable
23 Resulting from the handling of the machine 7.5.1
26 Inadequate instructions for driver/operator 7.5.1
27 Mechanical hazards and dangerous events:
27.1 Resulting from falling load, collisions, swinging of machine caused by Uncontrolled loading – over loading 5.5.5, 7.5.1, 7.5.3 Uncontrolled amplitude of the movement Not applicable Unexpected/unintended movement of the loads 5.5.2, 5.5.4, 5.5.6
Collision of more than one machine Not applicable
27.3 Resulting from a derailment Not applicable
27.4 Resulting from inadequate mechanical strength of parts 5.5.1, 5.5.8, 5.5.10,
5.5.11, 5.5.12 27.5 Resulting from inadequate design of pulleys, drums 5.5.9, 5.5.11, 7.5.1 27.6 Resulting from inadequate selection/integration into the machine for chains, cables, lifting accessories 5.5.10,
27.7 Resulting from descent of load by friction brakes 5.5.2 27.8 Resulting from abnormal assembly/test/use/maintenance conditions 7.5.1, 7.5.2
29 Hazards generated by neglecting ergonomic principles
29.1 Inadequate visibility from the operator position 7.5.1
Table 6 — List for pulley blocks and sheaves of significant hazards and associated requirements
Hazard Relevant clause(s) in this standard
1.1 From machine parts or workpieces caused for example, by their:
1.1.3 Mass and stability (potential energy of elements that can move under the effect of gravity)
1.3.3 Cutting or severing hazard 5 General, 7.6.1
1.3.5 Drawing-in or trapping hazard 5 General, 7.6.1
8 Hazards generated by neglecting ergonomic principles in machine design such as hazards caused by:
8.1 Unhealthy postures or excessive efforts Not applicable
17 Fall or ejection of objects 5.6.2, 5.6.3, 5.6.6
18 Loss of stability/overturning of machine 7.6.1
20.6 Inadequate ability of machine to be slowed down, stopped and immobilised Not applicable
21 Hazards due to work position (including operator’s position) on the machine:
21.4 Mechanical hazards at work position
- contact with wheels Not applicable
23 Resulting from the handling of the machine Not significant
26 Inadequate instructions for driver/operator 7.6.1
27 Mechanical hazards and dangerous events:
27.1 Resulting from falling load, collisions, swinging of machine caused by Uncontrolled loading – over loading 5.1.6, 7.1.1, 7.1.3 Uncontrolled amplitude of the movement Not applicable Unexpected/unintended movement of the loads 5.6.2, 5.6.6
Collision of more than one machine Not applicable
27.3 Resulting from a derailment Not applicable
27.4 Resulting from inadequate mechanical strength of parts 5.6.1
27.5 Resulting from inadequate design of pulleys, drums 5.6, 5.6.4, 5.6.10 27.6 Resulting from inadequate selection/integration into the machine for chains, cables, lifting accessories
27.7 Resulting from descent of load by friction brakes Not applicable
27.8 Resulting from abnormal assembly/test/use/maintenance conditions 7.6.1, 7.6.2
29 Hazards generated by neglecting ergonomic principles
29.1 Inadequate visibility from the operator position 7.6.1
5 Safety requirements and/or measures
Lifting equipment must adhere to the safety requirements outlined in this clause and be designed in accordance with the principles of EN ISO 12100, addressing relevant hazards that are not significantly covered by this European Standard.
Hand chain blocks
The trolley of a combined trolley and hand chain block shall be in accordance with 5.4
5.1.2.1 The mechanical strength shall be checked by an appropriate calculation method Hand chain blocks shall have a coefficient of utilisation (safety coefficient) of at least 4: 1
Hand chain blocks must be engineered to endure 1,500 cycles at 110% of their rated capacity without any failures or part replacements Continuous operation is required, allowing only for lubrication, and the load chain should have a lifting path of at least the specified length.
300 mm per cycle in order to get at least a complete revolution of the load chain wheel
Hand chain blocks shall have an automatic braking function during the lifting and lowering operation
The braking function shall be automatic when the operating force ceases, whether the motion is lifting or lowering
The braking device shall allow a regular descent under operator control whatever the position of the load
The brakes shall not contain asbestos
The fracture of a spring should not compromise the safety elements, except for springs utilized in load hook safety latches This can be achieved by implementing a single guided pressure spring or multiple springs Guided pressure springs must have coil spacing that is less than or equal to the wire diameter When multiple springs are employed, the remaining springs must ensure retention in the event of one spring's failure.
Hand chains shall be secured against unintentional disconnection from the hand chain wheel
To lift the rated capacity the operating effort of each operator shall not exceed 55 daN on the hand chain
To prevent overloading, the lifting effort required from each operator should adhere to specific guidelines based on the rated capacity: for rated capacities up to 1,000 kg, for capacities between 1,000 kg and 5,000 kg, and for capacities of 5,000 kg and above.
20 daN up to 55 daN on the hand chain
40 daN up to 55 daN on the hand chain
45 daN up to 55 daN on the hand chain
When the operating effort is below 20 daN at rated capacity, a hand chain block must include an independent overload protection system to prevent overloading from excessive effort on the hand chain This system should ensure that the lowering function is preserved and the load remains controlled, without causing a sudden release of the hand chain.
Accessible parts of the hand chain block shall have no sharp edges, no sharp angles, and no rough surfaces likely to cause injury
Gearing shall be guarded to prevent accidental ingress of parts of the body
Hooks shall be fitted with safety latches to prevent unintentional detachment
The top hook shall be capable of swivelling for correct positioning
Load hooks that are not produced according to recognized standards must not exhibit permanent deformation when subjected to a static load of twice their rated capacity Additionally, while a static load of four times the rated capacity may cause the hook to bend, it is essential that the load remains securely held.
This shall be ensured by selecting the appropriate materials and by the heat treatment
NOTE Standards for hooks are listed in annex A
A chain guide shall be provided to prevent the hand chain and the load chain from jumping off of the chain wheels
The selection criteria and the technical requirements shall be in accordance with EN 818-7
Load chain wheels shall be made in one piece
The coefficient of utilisation shall be at least 4 for welded load bearing calibrated link chains;
− Load chains shall be in accordance with EN 818-7, for fine tolerance short link chains (grade T)
Hand chains shall have no sharpness around the welds
5.1.11 Anchorage and end stop of the load chain
Chain anchorage devices of the fixed end type shall withstand 4 times the static chain tensile force at rated capacity without rupture
The free end of the load chain must be equipped with a chain end stop to prevent it from fully passing through This end stop should be capable of withstanding 2.5 times the static chain tensile force at its rated capacity without breaking.
Hand chain blocks, and their components shall be capable of operating within an ambient temperature range of
- 10°C to + 50°C unless another temperature range is agreed between the manufacturer and the purchaser
The braking system and the overload protection system shall only be able to be removed, modified replaced, interfered or neutralised by the use of tools
The requirement for safe handle of chain blocks is fulfilled:
− If handles, hooks, or other means for slinging is provided or;
− If the design of the chain blocks provides hand gripping points for manual handling.
Lever hoists
The trolley of a combined trolley and lever hoist shall be in accordance with 5.4.
5.2.2.1 The mechanical strength shall be checked by an appropriate calculation method Lever hoists shall have a coefficient of utilisation (safety coefficient) of at least 4 : 1
The lever hoist must be engineered to endure 1,500 cycles at 110% of its rated capacity without any failures or part replacements, requiring only lubrication for maintenance Additionally, it should facilitate a lifting path of at least 300 mm per cycle to ensure a complete revolution of the load chain wheel or drum.
Lever hoists shall have an automatic braking function during the lifting and lowering operation
The braking function shall be automatic when the operating force ceases, whether the motion is lifting or lowering
The braking device shall allow a regular descent automatically controlled whatever the position of the load
The brakes shall not contain asbestos
The fracture of a spring must not compromise the safety elements, except for springs utilized in load hook safety latches This requirement can be achieved by implementing a single guided pressure spring or multiple springs Guided pressure springs should have coil spacing that is less than or equal to the wire diameter When multiple springs are employed, the remaining springs must ensure retention in the event of one spring's failure.
Removable levers shall be capable of being secured against unintentional slippage/stripping and disconnection from the drive shaft
Levers shall have a return travel distance not exceeding 150 mm (see figure 9) After a movement of not more than 150 mm, a pawl or other load retaining device shall be engaged
To lift the rated capacity the operating effort shall not exceed 55 daN at the end of the lever
To prevent overloading, the required operating effort at the end of the lever for lifting rated capacities must adhere to specific guidelines: for rated capacities of 1,000 kg or less, the effort should range from 20 daN to 55 daN; for capacities between 1,000 kg and 5,000 kg, the effort should be between 40 daN and 55 daN; and for capacities of 5,000 kg or more, the effort must be maintained between 45 daN and 55 daN.
Lever hoists with an operating effort below 20 daN at rated capacity must include an independent overload protection system to prevent overloading from excessive lever effort This system should ensure that the lowering function is preserved and the load remains controlled, without causing a sudden release of the lever when triggered.
Figure 9 — Return travel distance of a lever hoist 5.2.7 Free spooling of the lifting medium
For the freespooling of the lifting medium, the brake system can only be released under low loading conditions It will automatically engage when the load exceeds 30 kg for capacities up to 1,000 kg, and when it surpasses 3% of the rated load for capacities above 1,000 kg.
In this respect, the load shall not be allowed to descend more than 300 mm, before the brake acts to stop the load falling
It shall not be possible to declutch or disengage the chain wheel, the drive shaft and/or other components
Accessible parts of the lever hoist shall have no sharp edges, no sharp angles, and no rough surfaces likely to cause injury
Gearing shall be guarded to prevent accidental ingress of parts of the body
Hooks shall be fitted with safety latches to prevent unintentional detachment
The top hook shall be capable of swivelling for correct positioning
Load hooks that are not produced according to recognized standards must not exhibit permanent deformation when subjected to a static load of twice their rated capacity Additionally, while a static load of four times the rated capacity may cause the hook to bend, it is essential that the load remains securely held.
This shall be ensured by selecting the appropriate materials and by the heat treatment
NOTE Standards for hooks are listed in annex A
For lever hoists with wire rope, D/d ratio for the drum shall be at least equal to 10
The pitch circle diameter of the sheave groove (D) shall be at least 12 times the nominal diameter of the wire rope (d)
The angle of the sheave groove for wire rope shall be between 45 ° and 55 °
The radius of the sheave groove for wire rope shall be between d/2 + 5 % and d/2 + 10 %
The depth of the sheave groove for wire rope shall be at least 1,5 times the nominal diameter of the rope
The ratio of belt sheave and drum diameter to the rated webbing thickness shall not be less than 15 (D/s ≥ 15) where s is the thickness of the webbing
The groove of sheave for fibre rope shall be radiused The radius shall be at least equal to half of the fibre rope diameter
Sheaves shall be fitted with a rope guide system to ensure that the rope stays located in the groove of the sheave, in case of slack rope
The drum flanges must project at least 1.5 times the diameter of the rope or the thickness of the webbing when the maximum design length is fully wound onto the drum.
5.2.11 Load and idler chain wheel
A chain guide shall be provided to prevent the load chain from jumping off of the chain wheels
The selection criteria and the technical requirements shall be in accordance with EN 818-7
Chain wheels shall be made in one piece
The coefficient of utilisation shall be: a) at least 4 for welded load bearing calibrated link chains; b) at least 4 for roller chains
Chains shall be in accordance with: a) EN 818-7, for fine tolerance short link chains (grade T); b) ISO 606, Short pitch transmission precision roller chains and chain wheels,
Wire ropes shall be in accordance with EN 12385-1 and EN 12385-4
The coefficient of utilisation of wire ropes relative to the minimum breaking strength of a wire rope shall be at least equal to 3
Wire ropes shall be supplied in single lengths with splices or connections only at the ends
The coefficient of utilisation for loadbearing fibre ropes and webbing shall be at least 7
5.2.15 Anchorage and end stop for load chain
Chain anchorage devices shall withstand 4 times the static chain tensile force at rated capacity without rupture
The free end of the load chain must be equipped with a chain end stop to ensure it does not pass through entirely This end stop is required to endure a force that is 2.5 times the static tensile strength of the chain at its rated capacity without breaking.
Rope end terminations must utilize specific devices, including an asymmetric wedge socket clevis compliant with EN 13411-6 and a symmetric wedge socket clevis in accordance with EN 13411-7, suitable for ropes with a maximum diameter.
8 mm c) Metal and resin socketing in accordance with EN 13411-4 d) Ferruled secured eyes in accordance with !EN 13411-3" using thimbles in accordance with EN 13411-1
If not otherwise specified in the above EN standards, the rope-end terminations shall withstand a force of at least
85 % of the minimum breaking force of the rope without rupture
Rope eyes with wire rope grips shall not be used as rope-end terminations
5.2.17 Rope and webbing anchor on the drum
The rope and webbing anchor on the drum, along with two frictional revolutions, must withstand at least 2.5 times the nominal forces in the rope or webbing When calculating the friction torque, the specific friction values of the materials used should be taken into account, assuming the presence of lubricants For wire ropes, the coefficient of friction considered in the calculations should not exceed 0.1.
Ropes shall be securely attached without being kinked
To ensure safety, a minimum of two windings must always be maintained on the drum and clearly marked Additionally, the rope or webbing should be designed to prevent winding in the incorrect direction These requirements can be effectively met by eliminating any braking function when the rope or webbing is wound incorrectly.
Lever hoists, and their components shall be capable of operating within an ambient temperature range of - 10°C to + 50°C unless another temperature range is agreed between the manufacturer and the purchaser
The braking system, the overload protection system and lever return devices shall only be able to be removed, modified, replaced, interfered or neutralised by the use of tools
The requirement for safe handle of lever hoist is fulfilled:
− If handles, hooks, or other means for slinging is provided or
− If the design of the lever hoist provides hand gripping points for manual handling.
Jaw winches
5.3.1.1 The mechanical strength shall be checked by an appropriate calculation method Jaw winches shall have a coefficient of utilisation (safety coefficient) of at least 4: 1
The lifting lever must be equipped with a device that restricts the force exerted through it, ensuring that the lifting force does not exceed twice the rated capacity.
5.3.1.2 The jaw winch shall withstand 400 cycles with the rated capacity with no failure, no replacement of parts, no resting time, except for lubrication of the rope
Jaw winches shall have an automatic braking function during the lifting and lowering operation
The braking device shall allow a regular descent automatically controlled whatever the position of the load
This braking function is insured if one pair of jaws is always gripping the rope throughout the operating sequence
As soon as action on one of the levers has stopped, both jaw blocks shall close ( like two independent brakes)
In the event of failure of one of the two jaw blocks, the alternating motion shall cease and the second jaw blocks shall hold the rated capacity
!The fracture of a spring shall not lead to a failure of safety elements except the springs used for load hook
Removable levers shall be capable of being secured against unintentional disconnection
The maximum force to be applied on the lever to lift the rated capacity shall not exceed 55 daN
The combination of the gear and lever provides a mechanical advantage that limits the lifting capacity to a maximum of 2.5 times the rated capacity when a force of 100 daN is applied to the lever.
Disengagement of the jaws shall only be possible at no or low load
When jaw blocks are capable of opening simultaneously for the introduction or removal of rope, a safety system shall be provided against non-intentional disengagement
Accessible parts of the jaw winch shall have no sharp edges, no sharp angles, and no rough surfaces likely to cause injury
Jaw and their actuating mechanism shall be guarded to prevent accidental ingress of parts of the body
Hooks and anchorage shall be fitted with safety latches or locking devices to prevent unintentional detachment
Load hooks that are not produced according to recognized standards must not exhibit permanent deformation when subjected to a static load of twice their rated capacity Additionally, while a static load of four times the rated capacity may cause the hook to bend, it is essential that the load remains securely held.
This shall be ensured by selecting the appropriate materials and by the heat treatment
NOTE Standards for hooks are listed in annex A
With a reduction of 10 % of the nominal wire rope diameter caused by wear, the clamping mechanism shall be capable of holding a load equal to at least 1,1 times the rated load
A jaw tightening system shall be provided which ensures minimum variation in the tightening coefficient with wear of the jaws or rope
Jaw winches shall be designed in such a way that one jaw block is always gripping the rope during lifting and lowering
The coefficient of utilization of load bearing wire ropes shall be at least 5
They shall be capable of withstanding at least 400 operational cycles at the rated capacity before reaching the discard criteria of ISO 4309
Wire ropes shall be supplied in single lengths with splices or connections only at the ends
The coefficient of utilisation for loadbearing fibre ropes shall be at least 7
Rope end terminations must utilize specific devices, including an asymmetric wedge socket clevis compliant with EN 13411-6 and a symmetric wedge socket clevis in accordance with EN 13411-7, suitable for ropes with a maximum diameter.
8 mm c) Metal and resin socketing in accordance with EN 13411-4 d) Ferruled secured eyes in accordance with !EN 13411-3" using thimbles in accordance with EN 13411-1
If not otherwise specified in the above EN-standards, the rope-end terminations shall withstand a force of at least
85 % of the minimum breaking force of the rope without rupture
Rope eyes with wire rope grips shall not be used as rope-end terminations
Jaw winches, and their components shall be capable of operating within an ambient temperature range of - 10°C to + 50°C unless another temperature range is agreed between the manufacturer and the purchaser
The braking system and the device that restricts the force applied to the lever can only be altered, removed, or disabled using tools.
The requirement for safe handle of jaw winches is fulfilled:
− If handles, hooks, or other means for slinging is provided or
− If the design of the lever hoist provides hand gripping points for manual handling.
Hand powered trolleys supporting lifting machines
When using combined units, such as trolleys paired with hand chain blocks, the hoist requirements must adhere to section 5.1 for hand chain blocks and section 5.2 for lever hoists.
The mechanical strength must be verified using a suitable calculation method, considering a load positioned at a 5° angle to the vertical Trolleys should maintain a safety coefficient of at least 4:1 to prevent failure or derailment.
If there is a risk that the trolley might move by itself because of the longitudinal slope of the travelling surface, it shall be fitted with a braking system
The fracture of a spring should not compromise the safety elements, except for springs utilized in load hook safety latches This requirement can be achieved by implementing a single guided pressure spring or multiple springs Guided pressure springs must have coil spacing that is less than or equal to the wire diameter In scenarios where multiple springs are employed, the remaining springs must ensure retention in the event of one spring's failure.
Hand chains shall be secured against unintentional disconnection from the hand chain wheel
To move the rated capacity the operating effort of each operator shall not exceed 25 daN on the hand chain
Trolleys shall incorporate features to prevent derailment such as guide rollers and/or wheel flanges
In the event of failure of a wheel, an axle or bearing, the trolley shall be prevented from falling
Hand chains shall have no sharpness around the welds
The connecting links of the hand chain shall resist without permanent deformation a force of at least 120 daN
If the trolley is not fitted with guide rollers then the wheels shall be fitted with a device, such as wheel flanges, to prevent any derailment or overturning
Trolleys shall be fitted with buffers
Trolleys and their components shall be capable of operating within an ambient temperature range of - 10°C to + 50°C unless another temperature range is agreed between the manufacturer and the purchaser
If there is a braking system, it shall only be able to be removed, modified, replaced, interfered or neutralised by the use of tools.
Drum winches
5.5.1.1 The mechanical strength shall be checked by an appropriate calculation method Hand drum winches shall have a coefficient of utilisation (safety coefficient) of at least 4: 1
The drum winch must endure 1,500 cycles at 110% of its rated capacity without any failures or part replacements, aside from the rope or webbing It should operate continuously, with the only exception being for lubrication, and the lifting path must be designed to ensure that each tooth functions under load at least once.
Hand drum winches shall have an automatic braking function during the lifting and lowering operation
The braking function shall be automatic when the operating force ceases, whether the motion is lifting or lowering
The braking device shall allow a regular descent under operator control whatever the position of the load
The brakes shall not contain asbestos
The fracture of a spring must not compromise the safety elements, except for the springs utilized in load hook safety latches This requirement can be achieved by implementing a single guided pressure spring or multiple springs Guided pressure springs should have coil spacing that is less than or equal to the wire diameter In scenarios where multiple springs are employed, the remaining springs must ensure retention in the event of one spring's failure.
Cranks and operating wheels shall be capable of being secured against unintentional disconnection from the drive shaft
Cranks and operating wheels must have a return travel distance limited to 150 mm, as illustrated in figure 7 Additionally, after this movement, a pawl or similar load-retaining device should be engaged.
To lift the rated capacity the operating effort of each operator shall not exceed 25 daN on a crank or an operating wheel
5.5.6 Freespooling of the lifting medium
For freespooling of the lifting medium, the brake system can only be released under low loading conditions It will automatically engage when the load exceeds 30 kg for capacities up to 1,000 kg, and when it surpasses 3% of the rated load for capacities above 1,000 kg.
In this respect, the load shall not be allowed to descend more than 300 mm, before the brake acts to stop the load falling
It shall not be possible to declutch or disengage the drive shaft and/or other components
Accessible parts of the hand drum winches shall have no sharp edges, no sharp angles, and no rough surfaces likely to cause injury
Gearing shall be guarded to prevent accidental ingress of parts of the body
Hooks shall be fitted with safety latches to prevent unintentional detachment
Load hooks that are not produced according to recognized standards must not exhibit permanent deformation when subjected to a static load of twice their rated capacity Additionally, while a static load of four times the rated capacity may cause the hook to bend, it is essential that the load remains securely held.
This shall be ensured by selecting the appropriate materials and by the heat treatment
NOTE Standards for hooks are listed in annex A
For drum winches with wire rope, D/d ratio for the drum shall be at least equal to 10
The ratio of belt sheave and drum diameter to the rated webbing thickness shall not be less than 15 (D/s ≥ 15), where s is the thickness of the webbing
The drum flanges must extend beyond the final layer of rope or webbing by at least 1.5 times the diameter of the rope or the thickness of the webbing, ensuring proper design when the maximum length of rope or webbing is fully wound onto the drum.
Wire ropes shall be in accordance with EN 12385-1 and EN 12385-4
The coefficient of utilisation of wire ropes relative to the minimum breaking strength of a wire rope shall be at least equal to 3
Wire ropes shall be supplied in single lengths with splices or connections only at the ends
The coefficient of utilisation for loadbearing fibre ropes and webbing shall be at least 7
5.5.12 Anchorage/ Securing from running of the lifting medium
The rope and webbing anchor on the drum, along with two frictional revolutions, must endure at least 2.5 times the nominal forces exerted on the rope or webbing For wire ropes, the friction coefficient considered in calculations should not exceed 0.1.
Ropes shall be securely attached without being kinked
To ensure safety, at least two windings must always be visible on the drum and clearly marked Additionally, the rope or webbing should be designed to prevent winding in the incorrect direction These requirements can be effectively met by eliminating any braking function when the rope or webbing is wound incorrectly.
Rope end terminations must utilize specific devices, including an asymmetric wedge socket clevis compliant with EN 13411-6 and a symmetric wedge socket clevis in accordance with EN 13411-7, suitable for ropes with a maximum diameter.
8 mm c) Metal and resin socketing in accordance with EN 13411-4 d) Ferruled secured eyes in accordance with !EN 13411-3" using thimbles in accordance with EN 13411-1
If not otherwise specified in the above EN-standards, the rope-end terminations shall withstand a force of at least
85 % of the minimum breaking force of the rope without rupture
Drum winches, and their components shall be capable of operating within an ambient temperature range of - 10°C to + 50°C unless another temperature range is agreed between the manufacturer and the purchaser
If there is a braking system it shall only be able to be removed, modified, replaced, interfered or neutralised by the use of tools.
Pulley blocks and deflection pulleys
The mechanical strength must be verified using a suitable calculation method Pulley blocks and sheaves that directly bear the load should maintain a safety coefficient of no less than 4:1.
If pulley blocks and sheaves are of the opening type to permit reeving, the opening system shall be captive and prevent inadvertent opening
Two hooks shall be fitted, one to suspend the pulley block/deflection pulley, the other to attach the load
Hooks shall be fitted with safety latches to prevent unintentional detachment
Load hooks that are not produced according to recognized standards must not exhibit permanent deformation when subjected to a static load of twice their rated capacity Additionally, while the hook may bend under a static load of four times its rated capacity, it must still securely hold the load.
This shall be ensured by selecting the appropriate materials and by the heat treatment
NOTE Standards are listed in annex A
The pitch circle diameter to the centre line of the rope (D) shall be at least 12 times the nominal diameter of the rope (d)
The groove angle shall be between 45 ° and 55 °
The radius of the groove shall be between d/2 + 5 % and d/2 + 10 %
The depth of the groove shall be at least 1,5 times the nominal diameter of the rope
The groove of sheave for fibre rope shall be radiused The radius shall be at least equal to half of the fibre rope diameter
Pulley blocks and sheaves must be equipped with a rope guide system to keep the rope properly aligned within the sheave groove, especially in situations where there is slack in the rope, requiring manual intervention.
Pulley blocks and sheaves, along with their components, must function effectively in ambient temperatures ranging from -10°C to +50°C, unless a different temperature range is mutually agreed upon by the manufacturer and the purchaser.
6 Verification of the safety requirements and/or measures
General
Compliance with safety requirements outlined in clauses 5 and 7 must be confirmed as per tables 7 to 12 These tables detail the verification types and methods that should be employed for each requirement.
Categories of verification
Verification carried out on one or several representative samples of a product manufactured in series
Verification of each unit put on the market before despatch
6.2.3 Sample verification for jaw winches
Verification by sampling on sample of a product manufactured in a series with a rated capacity less or equal to
300 kg (Minimum sampling 10% of each manufactured series).
Verification methods
6.3.1 Check of calculation, examination and measurement
6.3.1.1 Calculation check (CC in table 7 to 12)
For lifting equipment produced in series or designed individually (manufactured as a single unit) mechanical strength shall be verified by checking calculation documents
6.3.1.2 Measurement of characteristics (MC in table 7 to 12)
This method is used to determine whether characteristics/dimensions of components meet the requirements of clause 5
6.3.1.3 Visual examination (VE in table 7 to 12)
This method verifies the presence of markings on products and assesses whether certificates, documents, or drawings comply with the requirements outlined in clauses 5 and 7.
6.3.2.1 Breakage test (BT in table 7 to 12)
Lifting equipment manufactured in mass production with a rated capacity of up to 5 tons must undergo a type test at the least favorable position of the lifting medium, using a static load that is four times the rated capacity.
Lifting equipment with a rated capacity exceeding 5 tons, whether mass-produced or custom-made, must undergo a type test involving a load of four times its rated capacity if its coefficient of utilization cannot be verified through calculations.
If, after 10 minutes, the lifting equipment is still holding the test load, the test result shall be considered satisfactory
NOTE Permanent deformations can appear
6.3.2.2 Static test (ST in table 7 to 12)
Lifting equipment manufactured as single units that have not been subjected to a breakage test prior to first use, shall be subjected to a test consisting of suspending a load of:
1,5 times the rated capacity for rated capacities less than 20 t and
1,25 the rated capacity equal to or greater than 20 t for at least 10 minutes
The test is deemed satisfactory if there are no visible cracks, permanent deformations, or damage that could compromise the function or safety of the lifting equipment Additionally, the connections must remain secure and undamaged, the braking device should effectively hold the load without slipping, and the dynamic test must be feasible with the same lifting equipment following the static test.
6.3.2.3 Dynamic test (DT in table 7 to 12)
Lifting equipment shall be subjected to a dynamic operating test of 1,1 times the rated capacity
The lifting equipment will be deemed satisfactory if it successfully performs all functions during the test, shows no damage to mechanisms or structural components upon examination, and maintains secure and undamaged connections.
6.3.2.4 Functional test (FT in table 7 to 12)
Lifting equipment works at rated capacity as intended and all functions conform to the requirements and with the technical documentation
6.3.3 Additional tests for Chain blocks
6.3.3.1 Light load test (LLT in table 7)
Hand chain blocks must undergo a type test using a test load that ranges from 2% to 10% of their rated capacity, with the load being raised and lowered over a height of 250 mm to 500 mm.
When the hand chain is released at any point during raising and lowering cycle, the brake shall hold the load
6.3.3.2 End stop static test (˜ESST™ in table 7)
With the braking system deactivated and the end stop in contact with the housing the test load shall be held even if permanent deformation occurs
6.3.3.3 Endurance test (ET in table 7) ˜Hand chain blocks that are mass-produced and have a rated capacity up to 5 t shall be submitted to the following type test.™
Operate the hand chain block at 110% of its rated capacity on the lower hook for 1,500 cycles, lifting and lowering the load over a distance of 300 mm This 300 mm path guarantees that all component parts, such as gears and the load wheel, function under load Throughout the test, the load must not be placed on the floor, and an automatic counting system will track the number of lifting and lowering cycles.
The lifting and lowering cycle speed must be at least equal to the continuous working speed of an operator for one minute Testing may be conducted at higher speeds based on the drive unit utilized.
The drive unit shall run continuously during the test except for lubricating the load chain, or to replace the load chain
No other parts shall be replaced, or reworked and at the end of the test they shall show no signs of failure
For multiple strand units (e.g double, four, eight or more strand units), it is only necessary to test a single strand unit
If after the 1 500 cycles, the hand chain block is still holding the load of 150 % in a static test (see 6.3.2.2) the test result shall be considered satisfactory
6.3.4 Additional tests for lever hoists
6.3.4.1 Light load test (LLT in table 8)
Lever hoists must undergo a type test using a test load that ranges from 2% to 10% of their rated capacity, with the load being raised and lowered over a height of 250 mm to 500 mm.
When the lever is released at any point during raising and lowering cycle, the brake shall hold the load
6.3.4.2 End stop static test (ESST in table 8)
With the braking system deactivated and the end stop in contact with the housing the test load shall be held even if permanent deformation occurs
6.3.4.3 Fastening static test (FST in table 8)
The lifting medium must withstand a tensile force of 2.5 times the nominal force in the rope or webbing without slipping or breaking, provided there are at least two revolutions on the drum.
6.3.4.4 Endurance test (ET in table 8) ˜Lever hoists that are mass-produced and have a rated capacity up to 5 t shall be submitted to the following type test.™
Operate the lever hoist at 110% of its rated capacity on the lower hook for 1,500 cycles, lifting and lowering a load over a distance of 300 mm This 300 mm path guarantees that all components, such as gears and load sheaves, function under load Throughout the test, the load must not be placed on the floor, and an automatic counting system will track the number of lifting and lowering cycles.
The lifting and lowering cycle speed must be at least equal to the continuous working speed of an operator for one minute Testing may be conducted at higher speeds based on the drive unit utilized.
The drive unit shall run continuously during the test except for lubricating the load chain, the wire rope or the mechanism, or to replace the lifting medium
No other parts shall be replaced, or reworked and at the end of the test they shall show no signs of failure
For multiple strand units (e.g double, four, eight or more strand units), it’-is only necessary to test a single strand unit
If after the 1 500 cycles, the lever hoist is still holding the load of 150 % in a static test (see 6.3.2.2) the test result shall be considered satisfactory
6.3.5 Additional tests for jaw winches
6.3.5.1 Endurance test (ET in table 9) ˜Jaw winches that are mass-produced and have a rated capacity up to 5 t shall be submitted to the following type test.™
To ensure accurate testing, operate the jaw winch with a rated capacity of at least 20 m of reeved rope for 1,500 cycles without allowing the test load to touch the floor An automatic counting system will be utilized to track the number of lifting and lowering cycles throughout the test.
The lifting and lowering cycle speed must be at least equal to the continuous working speed of an operator for one minute Testing may be conducted at higher speeds based on the drive unit utilized.
The drive unit shall run continuously during the test except for lubricating the mechanism or rope or to replace the rope
The rope shall withstand 400 operational cycles before reaching the discard criteria defined in ISO 4309
6.3.6 Additional tests for drum winches
6.3.6.1 Endurance test (ET in table 11) ˜Drum winches that are mass-produced and have a rated capacity up to 5 t shall be submitted to the following type test.™
Operate the drum winch at 110% of its rated capacity for 1,500 cycles, ensuring that each tooth of the lifting medium is engaged under load at least once during the lifting and lowering process Throughout the test, the load must not be placed on the floor, and an automatic counting system will track the number of cycles performed.
Information for use of hand chain blocks
7.1.1 Instructions for hand chain blocks
The supplier shall provide information and advice as instructions for use in accordance with
The document "6.5 of EN ISO 12100-2:2003" outlines essential requirements for equipment documentation, including intended use, technical data, and operating instructions It specifies conditions for fastening, installation, transport, and storage, along with a load table based on machine configurations The document highlights particular hazards, such as jamming risks from mobile elements, and sets maximum elevation limits and ambient temperature ranges from -10°C to +50°C It addresses overheating risks in braking systems during prolonged load lowering and prohibits equipment use in hazardous environments Maintenance instructions detail servicing frequency, corrosion protection, and criteria for replacing critical components like chains and brake linings Additionally, it may include operator training advice and guidelines for adjusting the hand chain height between 500 mm and 1,000 mm from the ground, as well as information on the maximum force on the supporting structure when a rated capacity limiter is engaged.
7.1.2 Information on periodic verification and testing of hand chain blocks
The manufacturer must specify the testing and verification intervals, excluding those required by national regulations These intervals include: a) before commissioning, b) after repairs, reassembly, or extended downtime, and c) throughout the equipment's operational period.
The manufacturer shall specify a list of original items requiring specific use and testing
The manufacturer shall advise the user to look out for any defects occurring during use
7.1.3 Marking of hand chain blocks
All hand chain blocks must feature a permanent identification plate in a visible location, providing essential information such as the manufacturer's name and address, series or type designation, serial number (if applicable), rated capacity on both the cover and bottom block, year of manufacture, and the dimensions and quality of the load chains.