Bsi bs en 15011 2011 + a1 2014

EN ISO 13732-1, Ergonomics of the thermal environment — Methods for the assessment of human responses to contact with surfaces — Part 1: Hot surfaces ISO 13732-1:2006 EN ISO 13849-1:200

BSI Standards Publication

Cranes — Bridge and gantry cranes

National foreword

This British Standard is the UK implementation of

EN 15011:2011+A1:2014 It supersedes BS EN 15011:2011, which is withdrawn

The start and finish of text introduced or altered by amendment is indicated in the text by tags Tags indicating changes to CEN text carry the number of the CEN amendment For example, text altered by CEN amendment A1 is indicated by !"

The UK participation in its preparation was entrusted by Technical Committee MHE/3, Cranes and derricks, to Subcommittee MHE/3/3, Bridge, gantry and slewing jib cranes

A list of organizations represented on this subcommittee can be obtained on request to its secretary

This publication does not purport to include all the necessary provisions of a contract Users are responsible for its correct application

© The British Standards Institution 2014 Published by BSI Standards Limited 2014

ISBN 978 0 580 81499 0ICS 53.020.20

Compliance with a British Standard cannot confer immunity from legal obligations.

This British Standard was published under the authority of the Standards Policy and Strategy Committee on 30 April 2011

Amendments/corrigenda issued since publication

30 April 2014 Implementation of CEN amendment A1:2014

NORME EUROPÉENNE

ICS 53.020.20

English Version

Cranes - Bridge and gantry cranes

Appareils de levage à charge suspendue - Ponts roulants et

portiques

Krane - Brücken- und Portalkrane

This European Standard was approved by CEN on 18 December 2010 and includes Amendment 1 approved by CEN on 19 November

2013

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member

This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,

Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom

EUROPEAN COMMITTEE FOR STANDARDIZATION

C O M I T É E U R O P É E N D E N O R M A L I S A T I O N

E U R O P Ä I S C H E S K O M I T E E F Ü R N O R M U N G

CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2014 CEN All rights of exploitation in any form and by any means reserved

worldwide for CEN national Members

Ref No EN 15011:2011+A1:2014 E

Contents

Foreword 3

Introduction 4

1 Scope 5

2 Normative references 5

3 Terms and definitions 7

4 List of significant hazards 8

5 Safety requirements and/or protective measures 12

5.1 General 12

5.2 Requirements for strength and stability 13

5.3 Electrotechnical equipment 26

5.4 Non-electrotechnical equipment 28

5.5 Limiting and indicating devices 33

5.6 Man-machine interface 37

5.7 Equipment for warning 40

6 Verification of safety requirements and/or protective measures 41

6.1 General 41

6.2 Types of verification 41

6.3 Fitness for purpose testing 44

7 Information for use 46

7.1 General 46

7.2 Operator’s manual 46

7.3 User’s manual 46

7.4 Marking of rated capacities 48

Annex A (informative) Guidance for specifying the operating duty according to EN 13001-1 50

Annex B (informative) Guidance for specifying the classes P of average number of accelerations according to EN 13001-1 58

Annex C (informative) Calculation of dynamic coefficient ϕ h (t) 59

Annex D (normative) Loads caused by skewing 62

Annex E (informative) Local stresses in wheel supporting flanges 70

Annex F (normative) Noise test code 75

Annex G (informative) Actions on crane supporting structures induced by cranes 83

Annex H (informative) Selection of a suitable set of crane standards for a given application 85

Annex ZA (informative) Relationship between this European standard and the Essential Requirements of EU Directive 2006/42/EC 86

Bibliography 87

Foreword

This document (EN 15011:2011+A1:2014) has been prepared by Technical Committee CEN/TC 147 “Cranes

- Safety”, the secretariat of which is held by BSI

This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by August 2014, and conflicting national standards shall be withdrawn at the latest by August 2014

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights This document supersedes EN 15011:2011

This document includes Amendment 1 approved by CEN on 2013-11-19

The start and finish of text introduced or altered by amendment is indicated in the text by tags !"

This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s)

For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom

Introduction

This European Standard has been prepared to be a harmonised standard to provide one means for bridge and gantry cranes to conform with the essential health and safety requirements of the Machinery Directive, as mentioned in Annex ZA

As many of the hazards related to bridge and gantry cranes relate to their operating environment and use, it is assumed in the preparation of this European Standard that all the relevant information relating to the use and operating environment of the crane has been exchanged between the manufacturer and user (as recommended in ISO 9374, Parts 1 and 5), covering such issues as, for example:

— clearances;

— requirements concerning protection against hazardous environments;

— processed materials, such as potentially flammable or explosive material (e.g coal, powder type materials)

This standard is a type C standard as stated in !EN ISO 12100"

The machinery concerned and the extent to which hazards, hazardous situations and hazardous events are covered, are indicated in the scope of this European Standard

When provisions of this type C standard are different from those which are stated in type A or B standards, the provisions of this type C standard take precedence over the provisions of the other standards, for machines that have been designed and built according to the provisions of this type C standard

This European Standard does not include requirements for the lifting of persons

The specific hazards due to potentially explosive atmospheres, ionising radiation and operation in electromagnetic fields beyond the range of EN 61000-6-2 are not covered by this European Standard

This European Standard is applicable to bridge and gantry cranes manufactured after the date of its publication as an EN

2 Normative references

The following referenced documents are indispensable for the application of this document For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies

EN 81-43, Safety rules for the construction and installation of lifts — Special lifts for the transport of persons

and goods - Part 43: Lifts for cranes

EN 349, Safety of machinery — Minimum gaps to avoid crushing of parts of the human body

EN 795, Protection against falls from a height — Anchor devices — Requirements and testing

EN 894-1, Safety of machinery — Ergonomics requirements for the design of displays and control actuators

— Part 1: General principles for human interactions with displays and control actuators

EN 894-2, Safety of machinery — Ergonomics requirements for the design of displays and control actuators

— Part 2: Displays

EN 953, Safety of machinery — Guards — General requirements for the design and construction of fixed and

movable guards

!EN 1993-6", Eurocode 3 - Design of steel structures - Part 6: Crane supporting structures

!EN 12077-2", Cranes safety — Requirements for health and safety — Part 2: Limiting and indicating

devices

EN 12385-4, Steel wire ropes — Safety — Part 4: Stranded ropes for general lifting applications

EN 12644-1, Cranes — Information for use and testing — Part 1: Instructions

EN 12644-2, Cranes — Information for use and testing — Part 2: Marking

EN 13001-1, Cranes — General design — Part 1: General principles and requirements

!EN 13001-2", Crane safety — General design — Part 2: Load !actions"

!EN 13001-3-1", Cranes — General Design — Part 3-1: Limit States and proof competence of steel

structures

CEN/TS 13001-3-2, Cranes - General design — Part 3-2: Limit states and proof of competence of wire ropes

in reeving systems

!EN 13135, Cranes — Safety — Design — Requirements for equipment"

EN 13155, Cranes — Safety — Non-fixed load lifting attachments

EN 13157, Cranes — Safety — Hand powered cranes

!EN 13557:2003+A2:2008", Cranes — Controls and control stations

!EN 13586", Cranes — Access

EN 14492-2, Cranes — Power driven winches and hoists — Part 2: Power driven hoists

EN 60204-11, Safety of machinery — Electrical equipment of machines — Part 11: Requirements for HV

equipment for voltages above 1000 V a.c or 1500 V d.c and not exceeding 36 kV (IEC 60204-11:2000)

EN 60204-32:2008, Safety of machinery — Electrical equipment of machines — Part 32: Requirements for

hoisting machines (IEC 60204-32:2008)

HD 60364-4-41, Low-voltage electrical installations — Part 4-41: Protection for safety — Protection against

electric shock (IEC 60364-4-41:2005, mod.)

EN 60825-1, Safety of laser products — Part 1: Equipment classification and requirements

(IEC 60825-1:2007)

EN 60947-5-5, Low-voltage switchgear and controlgear — Part 5-5: Control circuit devices and switching

elements — Electrical emergency stop device with mechanical latching function (IEC 60947-5-5:1997)

EN ISO 3744:2010, Acoustics — Determination of sound power levels and sound energy levels of noise

sources using sound pressure — Engineering methods for an essentially free field over a reflecting plane (ISO 3744:2010)

EN ISO 4871, Acoustics — Declaration and verification of noise emission values of machinery and equipment

(ISO 4871:1996)

EN ISO 11201, Acoustics — Noise emitted by machinery and equipment — Determination of emission sound

pressure levels at a work station and at other specified positions in an essentially free field over a reflecting plane with negligible environmental corrections (ISO 11201:2010)

EN ISO 11202:2010, Acoustics — Noise emitted by machinery and equipment — Determination of emission

sound pressure levels at a work station and at other specified positions applying approximate environmental corrections (ISO 11202:2010)

EN ISO 11203:2009, Acoustics — Noise emitted by machinery and equipment — Determination of emission

sound pressure levels at a work station and at other specified positions from the sound power level (ISO 11203:1995)

EN ISO 11204:2010, Acoustics — Noise emitted by machinery and equipment — Determination of emission

sound pressure levels at a work station and at other specified positions applying accurate environmental corrections (ISO 11204:2010)

EN ISO 11688-1, Acoustics — Recommended practice for the design of low-noise machinery and equipment

— Part 1: Planning (ISO/TR 11688-1:1995)

!EN ISO 12100, Safety of machinery — General principles for design — Risk assessment and risk

reduction (ISO 12100)"

EN ISO 13732-1, Ergonomics of the thermal environment — Methods for the assessment of human

responses to contact with surfaces — Part 1: Hot surfaces (ISO 13732-1:2006)

EN ISO 13849-1:2008, Safety of machinery — Safety-related parts of control systems — Part 1: General

principles for design (ISO 13849-1:2006)

EN ISO 13857, Safety of machinery — Safety distances to prevent hazard zones being reached by upper and

lower limbs (ISO 13857:2008)

ISO 2631-1, Mechanical vibration and shock — Evaluation of human exposure to whole-body vibration —

Part 1: General requirements

ISO 3864 (all parts), Graphical symbols — Safety colours and safety signs

ISO 6336-1, Calculation of load capacity of spur and helical gears — Part 1: Basic principles, introduction and

general influence factors

ISO 7752-5, Lifting appliances — Controls — Layout and characteristics — Part 5: Overhead travelling cranes

and portal bridge cranes

ISO 12488-1, Cranes — Tolerances for wheels and travel and traversing tracks — Part 1: General

3 Terms and definitions

!For the purposes of this document, the terms and definitions given in EN ISO 12100, EN ISO 3744,

EN ISO 11202, EN ISO 11203, EN ISO 11204 and the following apply."

3.1

bridge crane

!crane able to move along rails or runways having at least one primarily horizontal girder and equipped with

at least one hoisting mechanism"

NOTE Building structures, where hoists are mounted, are not regarded as bridge cranes

3.2

gantry crane

!crane able to travel by wheels on rails, runways or roadway surfaces, or crane without wheels mounted in

a stationary position, having at least one primarily horizontal girder supported by at least one leg and equipped with at least one hoisting mechanism"

NOTE Building structures, where hoists are mounted, are not regarded as gantry cranes

3.6

underhung crane

bridge crane suspended from the lower flange of the crane track

3.7

direct acting rated capacity limiter

limiter acting directly in the chain of drive elements and limiting the transmitted force

NOTE Those limiters can be, for example, friction torque limiters, pressure limiting valves Directing acting rated capacity limiters generally have no response delay

3.8

indirect acting capacity limiter

limiter determining the transmitted force by measured signals and switching off the energy supply for the operation and, if required, triggering application of the brake torque

4 List of significant hazards

Table 1 of this clause contains all the significant hazards, hazardous situations and events, as far as they are dealt with in this European Standard, identified by risk assessment as significant for this type of machinery and which require action to eliminate or reduce the risk

Table 1 — List of significant hazards and associated requirements

in this European Standard

1.1 Generated by machine parts or work pieces, e.g

5.6.1 1.1.5 inadequacy of mechanical strength 5.2

1.2 Accumulation of energy inside the machinery,

1.3 Elementary forms of mechanical hazards

1.3.5 Drawing-in or trapping hazard

- moving transmission parts 5.6.2.5, 5.6.2.6

1.3.9 High pressure fluid injection or ejection hazard 7.3.3

2.1 Contact of persons with live parts (direct contact) 5.3.2, 5.3.3

2.2 Contact of persons with parts which have

become live under faulty conditions (indirect

contact)

5.1

2.3 Approach to live parts under high voltage 5.3

2.5 Thermal radiation or other phenomena such as

the projection of molten particles and chemical

effects from short-circuits, overloads, etc

5.1

3.1 burns and scalds, by possible

contact of persons with objects or materials with

an extreme temperature, by flames, by radiation,

5.2 Whole body vibration, particularly when

combined with poor postures 5.2.2.6, 5.6.1

7.1 Hazards from contact with harmful fluids, gases,

mists, fumes and dusts 5.4.8.4 See Introduction

See Introduction

8 Neglected ergonomic principles in machine

8.1 Unhealthy postures or excessive efforts 5.6.1

8.2 Inadequate consideration of hand-arm or foot-leg

8.3 Neglected use of personal protection equipment 7.3.3

8.6 Human errors, human behaviour 5.5.2

8.7 Inadequate design, location or identification of

8.8 Inadequate design or location of visual display

10 Unexpected start-up, unexpected overrun/over

speed (or any similar malfunction) from:

10.1 Failure/disorder of control systems 5.3.4

10.3 External influences on electrical equipment 5.3.5.3, 5.4.2 10.4 Other external influences (gravity, wind, etc.) 5.3.5.3, 5.3.6, 5.4.2,

5.5.2.2, 5.5.4 b) and c)

10.5 Errors in the software 5.3.4, 5.3.5.3, 5.4.2 10.6 Errors made by the operator (due to mismatch of

machinery with human characteristics and abilities, see No 8.6)

5.3.5.3, 5.4.2

11 Impossibility of stopping the machine in the best

possible conditions 5.4.4.1, 5.4.5.1, 5.5.2.2

14 Failure of the control circuit 5.3, 5.6.1, 5.4.2

16 Break-up during operation 5.2, 5.4.3.6.1, 7.3.3

17 Falling or ejected object or fluid 5.4.1, 7.3.3

18 Loss of stability / overturning of machinery 5.2.3

19 Slip, trip and falling of persons (related to

20 Relating to the travelling function

20.2 Movement without an operator at the driving

21 Linked to the work position (including driving

21.1 Fall of persons during access to (or at/from) the

21.2 Exhaust gases / lack of oxygen at the work

21.3 Fire (flammability of the cab, lack of

21.4 Mechanical hazards at the work position

- contact with the wheels

- fall of objects, penetration by object

- contact of persons with machine parts or tools

(pedestrian control)

5.6.2.5, 5.6.1

21.5 Insufficient visibility from the working position 5.6.1

21.8 Noise at the driving position 5.6.4

21.9 Vibration at the driving position 5.6.1

21.10 Insufficient means of evacuation/emergency exit 5.6.2, 5.4.8.3

22.1 Inadequate location of controls /control devices 5.6.1

22.2 Inadequate design of the actuation mode and/or

23 From handling the machine (lack of stability) 5.4.4.3

25.2 Drift of a part away from its stopping position 5.4.5.2

25.3 Lack or inadequacy of visual or acoustic warning

26 Insufficient instructions for the driver / operator

26.1 Movement into prohibited area 5.5.3.1, 7.2

26.3 Collision: machines-machine 5.5.3.1, 5.5.3.3,

5.5.4 e), 7.2 26.4 Collision: machines-persons 5.5.3.1, 5.5.4 e), 7.2

27.1 from load falls, collision, machine tipping caused

27.1.4 Unexpected/unintended movement of loads 5.3.4, 5.4.1, 5.4.2,

5.4.3.1, 5.6, 7.2 27.1.5 Inadequate holding devices / accessories 5.4.1, 7.2

27.1.6 Collision of more than one machine 5.5.3.1, 5.5.3.3

27.1.7 Two-block of hook to hoist 5.4.3.1, 5.5.3.2

27.2 From access of persons to load support 7.2

27.4 From insufficient mechanical strength of parts

Loss of mechanical strength, or inadequate mechanical strength

5.2, 5.4.3, 5.4.5.3, 5.4.6, 5.4.7, 7.3.3

27.5 From inadequate design of pulleys, drums 5.2, 5.4.1, 5.4.3.1

27.6 From inadequate selection/ integration into the

machine of chains, ropes, lifting accessories 5.2, 5.4.1, 5.4.3.1, 5.4.3.6.2, 7.2 27.7 From lowering of the load by

29.1 insufficient visibility from the driving position 5.6.1, 5.6.3

5 Safety requirements and/or protective measures

5.1 General

Bridge and gantry cranes shall comply with the safety requirements and/or protective measures of Clause 5

In addition, these cranes shall be designed according to the principles of !EN ISO 12100"for relevant but not significant hazards, which are not dealt with by this European Standard

Bridge and gantry cranes shall be in accordance with the following standards as amended by this European Standard:

— EN 13001-1, Cranes — General design — Part 1: General principles and requirements;

— EN 13001-2, Cranes — General design — Part 2: Load !actions";

— !EN 13001-3-1", Cranes — General Design — Part 3-1: Limit States and proof competence of steel

structures;

— CEN/TS 13001-3-2, Cranes — General design — Part 3-2: Limit states and proof of competence of wire

ropes in reeving systems;

— !EN 13135, Cranes — Safety — Design — Requirements for equipment;"

— EN 13155, Cranes — Safety — Non-fixed load lifting attachments;

— EN 13157, Cranes — Safety — Hand powered cranes;

— EN 13557, Cranes — Controls and control stations;

— EN 12077-2, Cranes safety — Requirements for health and safety — Part 2: Limiting and indicating

devices;

— EN 13586, Cranes — Access;

— EN 12644-1, Cranes — Information for use and testing — Part 1: Instructions;

— EN 12644-2, Cranes — Information for use and testing — Part 2: Marking;

— EN 60204-32, Safety of machinery — Electrical equipment of machines — Part 32: Requirements for

hoisting machines (IEC 60204-32:2008)

The requirements of this European Standard are not applicable to power driven hoist units, designed in accordance with EN 14492-2, and incorporated in a bridge and gantry cranes These hoist units shall be selected accordance to the principles depicted within A.4

5.2 Requirements for strength and stability

5.2.1 Load actions

5.2.1.1 Selection of service conditions

The service conditions that are selected and used as the basis of design, in accordance with EN 13001-1 and

EN 13001-2, shall be specified in the technical file of the crane

For cranes located outdoors, the recurrence period according to EN 13001-2 for out of service wind shall be not less than:

— 25 years for cranes located in coastal areas;

— 10 years for cranes located inland;

— 5 years for indoor cranes which may occasionally work and/or be parked outdoors

NOTE Guidance for specifying the operation duty is given in Annex A For information needed for the derivation of classification parameters see also ISO 9374-5

5.2.1.2 Selection of loads and load combinations

The basic load combinations for the load calculation shall be selected in accordance with

!EN 13001-2"

Where cranes work in atmospheres contaminated by process debris, such material accumulations deposited upon the upper surfaces of the crane shall be taken into account in the dead load computation

5.2.1.3 Determination of dynamic factors

5.2.1.3.1 Hoisting and gravity effects acting on the mass of the crane

The masses of the crane shall be multiplied with factor φ1 = 1 + δ when calculating the stresses in load combinations in accordance with EN 13001-2

!For masses with unfavourable gravitational load effect the factors shall be taken as δ =0,10 and ϕ1 = 1,10, and for masses with favourable gravitational load effect as δ = -0,05 and ϕ1 = 0,95, unless other values are obtained by measurements or calculations."

5.2.1.3.2 Determination of factor φ 2

5.2.1.3.2.1 General principles

The hoist load shall be multiplied by factor

φ

crane, when the weight of a grounded load is transferred on the hoisting medium (ropes or chains)

When assuming the most extreme conditions, the hoisting medium is slack whilst the hoist mechanism reaches its maximum hoisting speed In this condition the dynamic additional force is directly proportional to the hoisting speed, with a coefficient that depends upon the stiffness properties and mass distribution of the crane (

β

In physical crane operation there are other factors that influence the actual dynamic effect, such as control systems, dampening and flexibility of other than main components (e.g hoist slings, other lifting devices, load itself, crane foundation) These dependencies and determination of factor φ2 are represented by hoisting classes in EN 13001-2

When hoisting class is used it shall be selected according to 5.2.1.3.2.3

The hoisting speed used for the determination of the dynamic coefficient shall reflect the actual use and possible exceptional events of the crane in a realistic way Two events shall be considered as follows:

— crane in normal use where hoisting commences at a mechanism controlled speed from a slack rope condition – cases A and B as per EN 13001-2;

— exceptional case where hoisting commences at mechanism maximum speed from slack rope condition – case C as per EN 13001-2

Guidance on selection of hoisting speeds is given in 5.2.1.3.2.4

5.2.1.3.2.2 Calculation of the theoretical factor ϕ 2t

The theoretical dynamic factor ϕ2t is used for the determination of the hoisting class as defined in EN 13001-2

It shall be estimated in one of the following ways:

— make a complete dynamic simulation taking into account the elastic, inertial and dampening properties The maximum force in the hoisting medium during time of the first 3 s represents the hoist load multiplied

by factor ϕ2t;

— where applicable, the rope force history ϕh(t) may be calculated in accordance with Annex C

ϕ2t = max{ϕh(t); t < 3 s} (A similar simulation can be used for a crane with a chain hoist.);

— use one of the simplified Equation (1)

a) for a crane with a rope hoist: b) for a crane with a chain hoist:

,max

2.8 1

0,45

1500

h t

a

v

R l Z

0,45

150

h t

a

v

f l Z

v h,max is the maximum steady hoisting speed in metres per second;

R r is the rope grade according to EN 12385-4;

f uc is the ultimate strength of the chain steel in newtons per square millimetre;

l r , l c is the length of rope/chain fall in metres;

Z a is the actual coefficient of utilization of the rope/chain (total breaking force of the

rope/chain reeving system / hoist load)

The length lr / l c shall be taken as the typical distance between the upper and lower rope sheaves / chain

sprockets, when hoisting a grounded load Where a loaded part, or all of the hoist media deviates from the vertical, the length of the rope/chain fall shall be adjusted to give the equivalent flexibility in vertical direction

NOTE This simplified equation takes into account the rigidity and the masses of the crane parts and load and gives values which are approximately same as calculated according to Annex C

5.2.1.3.2.3 Selection of hoisting class

The hoisting class shall be determined in accordance with Table 2

Table 2 — Selection of hoisting class

1,07 + 0,24vh,max < ϕ2t ≤ 1,12 + 0,41vh,max HC2

1,12 + 0,41vh,max < ϕ2t ≤ 1,17 + 0,58vh,max HC3

5.2.1.3.2.4 Selection of the hoisting speed

The hoisting speed representing the normal use in load combinations A and B, and an exceptional occurrence

in load combination C, shall be selected according to the hoist drive class, HD, provided by the system and in

!EN 13001-2"

5.2.1.3.2.5 Determination of ϕ 2 and hoisting class by testing

The dynamic factor ϕ2 can also be determined by measurement from an equivalent crane The values measured with different hoisting speeds shall be directly used in calculations, without reference to a hoisting class

NOTE The dynamic increment of deflections found by measurement or dynamic simulation may include the dynamic effects from the mass of the crane including the trolley, see 5.2.1.3.1 The portion represented by the factor δ = 0,1 could

be removed from the evaluation of the final ϕ2 to avoid it being considered twice in ϕ1 and also in ϕ2

5.2.1.3.3 Load caused by travelling on uneven surfaces

The dynamic actions on the crane by travelling, with or without hoist load, on roadway or on rail tracks shall be considered by the specific factor φ4

For continuous rail tracks or welded rail tracks with finished ground joints without notches (steps or gaps) the specific factor φ4 = 1

For roadways or rail tracks with notches (steps or gaps) the specific factor φ4 shall be calculated according to

!EN 13001-2" For rubber tyred cranes the flexibility of the tyre shall be taken into account

5.2.1.3.4 Loads caused by acceleration of drives

For crane drive motions, the change in load effect, ΔS, caused by acceleration or deceleration is presented by the following equation:

ΔS = S(f) - S(i) (2) where

S(f) is the final load effect;

S(i) is the initial load effect

NOTE 1 The change in load effects, ΔS, is caused by the change of drive force, ΔF, given by the equation:

ΔF = F(f) - F(i)

where

F(f) is the final drive force;

and

F(i) is the initial drive force

Loads induced in a crane by acceleration or deceleration caused by drive forces may be calculated using rigid body kinetic models The load effect S shall be applied to the components exposed to the drive forces and where applicable to the crane and the hoist load as well As a rigid body analysis does not directly reflect elastic effects, the load effect S shall be calculated by using an amplification factor ϕ5 defined in

!EN 13001-2" as follows:

where

S(i) is the initial load effect caused by F(i);

ϕ5 is the amplification factor;

ϕp is the factor for effect of sequential positioning movements;

a is the acceleration or deceleration value;

m is the mass for which a applies

The factor ϕ5 shall be taken from Tables 3 and 4 unless more accurate factors are available from elastic model calculations or measurements The factor ϕp shall be taken from Table 5

Where the force S is limited by friction or by the nature of the drive mechanism, this frictional force shall be used instead of calculated force S

Table 3 — Factor ϕ5 for travel, traverse and slewing mechanism

!

Typical backlash for gearbox

Considerable backlash, e.g

open gears

!In general the skewing forces shall be addressed to load combination B Where the crane is provided with continuously active anti-skew devices, the forces, without the benefit of anti-skew devices (e.g failure of the device), shall be addressed to load combination C."

NOTE 1 The method given in !EN 13001-2"is applicable to rigid structures Bridge and gantry cranes can possess both rigid and flexible characteristics; therefore, a more general method is required as given here With this method also flexible structures, uneven number of wheels, unequally distributed wheel loads as well as different types of guide means and anti-skewing devices can be considered

NOTE 2 Forces arising from skewing are generated when the resultant direction of rolling movement of the travelling crane no longer coincides with the direction of the runway rail, and when the front positive guiding means come into contact with the rail This is caused by tolerances and inaccuracies, which arise in the manufacture of the crane (bores of track wheels) and that of the runway's rail (bends, kinks) The values and distribution of these forces depend chiefly upon the clearances between the runway rail and the wheel flanges or guide rollers and the latter's location, also on the number, arrangement, bearing arrangement and rotational speed synchronisation of the track wheels and structural flexibility NOTE 3 The use of anti-skew devices with travel motions reduces the guiding forces between the rail and guiding means It also reduces the lateral slip forces of the wheels, but some lateral slip remains due to wheel alignment tolerances and lateral deformations of structures, which effect should be considered

5.2.1.4.2 Skew angle

The skew angle shall be calculated as follows:

Figure 1 — Parameters of skew angle

The total skew angle to be considered in design is

α α = + α + α

where

α is the skew angle to be considered in design;

α g is the skew component s g /w b;

αw is the component due to wear - rail and wheel flange/guide roller;

αt is the component due to alignment tolerances of rail/wheel

The values for skew angles shall be determined according to Table 6

Table 6 — Skew angle computation

The skew angle shall be

α ≤ 0,015 rad

NOTE For larger track clearances the skew angle is reduced to 75 % because bridge and gantry cranes and their trolleys use the full track clearance only rarely Usually only the forward guide means is in contact with the rail

5.2.1.4.3 Friction slip relationship

The following simplified empirical relationship shall be used to calculate the friction coefficient for longitudinal and lateral slip:

μ f is the slip coefficient;

!μ0 is the friction factor:

μ0 = 0,3 for cleaned rails;

μ0 = 0,2 for non-cleaned rails in usual environment;"

e is the base of natural logarithms, 2,718;

σ

NOTE The slip factor is the ratio of the slip distance – transverse and/or longitudinal – to the corresponding travel distance For the transverse slip the slip factor is equal to the instantaneous total skewing angle (α or α+∆α) See D.3.2

!deleted text"

5.2.1.4.4 Selection of calculation methods

Either of two simplified calculation methods shall be used: either a RIGID or FLEXIBLE method The RIGID method assumes the structures of the crane and the runway to be rigid The FLEXIBLE method assumes the structure to be flexible In cases of doubt the FLEXIBLE method should be utilised

Calculation models to be adopted relative to the crane/trolley structural configuration are listed within Table 7

Table 7 — Calculation models of bridge and gantry cranes

loads due to skewing:

A

!

Bridge crane, trolley Even, horizontal, almost stiff Guide

means on one or both end carriages."

Method RIGID

B

Crane with articulation, respectively crane with flexible

support (●= articulation about an axis parallel with crane

track)

Guide means on both end carriages

Each end carriage shall be calculated separately with the method RIGID

Concerning the skewing forces the crane divides into two almost independent, individually guided carriages

C

Crane without articulation

Guide means on both end carriages

Method RIGID

D

Crane without articulation

Guide means on only one end carriage

The method depends on the flexibility of the structure

The decision is made by the result of the method RIGID

Procedure:

a) Calculate the skewing forces with the method RIGID;

b) Supply a fixed support for the end carriage with guide means Supply a floating support for the unguided end carriage (see Figure D.2c)) Apply the forces calculated with method RIGID to the floating end carriage The originally parallel end carriages receive an angle position

∆ α

µ α

( + ∆ α )

c) If

µ α

( + ∆ α µ α ) /

( ) > 1,15

5.2.1.4.5 Skewing forces for underhung cranes

The skewing forces of the underhung cranes, having rigid structure and running on the bottom flanges of rigidly fixed runway beams, shall be calculated with the same principles as the top running cranes See D.2

However, the guiding force YF may be divided on two wheel flanges of a leading bogie The minor lateral

forces of the trailing bogies may be ignored Figure 2 represents an example of the structures and one possible set of the most critical skewing force combinations

For configurations where either a runway beam (or both of them) or the bogies on one of the runways, can

float laterally, the lateral forces Y1 and Y2 are balanced by separate guiding forces YF on both leading bogies

In these cases the guiding forces ½YF shall be taken conventionally as 20 % of the maximum static vertical force Z of the wheel Y1 and Y2, frictional forces are then 10 % of the vertical wheel force of each wheel The

guiding forces, YF, and frictional forces, Y, balance each other separately on both runways, forming internal force systems within the bogies (element b) in Figure 2), and also local internal force systems within the bottom runway flanges These forces balanced locally do not impose external forces on the crane structure

Key

1 bottom flange and cut web of runway beam No 1

2 bottom flange and cut web of runway beam No 2

3 crane girder; end carriage beams under the runways not shown

4 hoist trolley with load

5 4-wheel bogies at each corner of the crane

Y 1 transverse frictional skewing forces applied between the wheels and the top surface of the bottom flange of the runway 1

Y 2 transverse frictional skewing forces applied between the wheels and the top surface of the bottom flange of the runway 2

Y F guiding force applied to the wheel flanges of the guiding bogie

F y minimum transverse forces to be also considered in bogie design as shown in element b)

Z maximum dynamic wheel force in vertical direction

Figure 2 — Skewing forces of underhung crane

Besides the skewing, the lateral forces on the bogies of the underhung cranes are created also by acceleration of the crane loaded asymmetrically and by acceleration of the hoist trolley and load These forces shall be considered according to 5.2.1.3.4

5.2.1.5 Overload condition

5.2.1.5.1 Cranes with direct acting lifting force limiter

The maximum force, Fmax.L, which is applied to the crane when the direct acting lifting force limiter operates,

shall be calculated as follows:

max L DAL H

where

Fmax.L is the maximum force in newtons;

ϕ DAL is the force-limit factor for direct acting lifting force limiters [-];

mH is the mass of the hoist load in kilograms;

g is the gravity constant 9,81 m/s2

For hydraulic systems, the factor ϕDAL shall be less than or equal to 1,4, with friction torque limiters or

pneumatic systems this factor shall be less than, or equal to 1,6

!The force Fmax.L shall be assigned to the corresponding load and stability combinations C of

EN 13001-2."

5.2.1.5.2 Cranes with indirect acting lifting force limiter

The maximum force, Fmax.L , which is applied to the crane, resulting from the operation of the indirect acting

lifting force limiter in an overload, stall load and if relevant, in a snag load case, shall be calculated as follows:

max L IAL H

where

Fmax.L is the maximum force in newtons;

ϕ IAL is the load factor for maximum force [-];

mH is the mass of the hoist load in kilograms;

g is the gravity constant 9,81 m/s2

The Fmax.L represents the final load in the hoist system after the triggering has operated and the hoist motion is

brought to rest It shall be calculated with due consideration to stiffness of the hoist mechanism and structures

as a whole, properties of stall load protection system, properties of the hoist drive system and functioning of the indirect acting limiter, see 5.5.1.2 !Guidance of a calculation method is given in the corresponding annex of EN 13001-2."

!The force Fmax.L shall be assigned to the corresponding load and stability combinations C of

EN 13001-2."

5.2.1.6 Test loads

The overload test loads to be taken into account in calculation shall be in accordance with 6.3.2

5.2.1.7 Design basis for multi point lifting in cases where the lifting forces are not equalized

For cranes, which are equipped with two or more lifting points for lifting a single load, e.g container lifting frame, the loading on an individual lifting point will depend upon the position of the load centre of gravity with respect to the lifting points Location of centres of gravities with relevant loads shall be specified in the technical file and in the operating instructions

In force calculations both the case of a mid-air load suspension and that of a load being grounded, possibly in

an inclined position or on an inclined plane, shall be considered The forces from the latter case (inclined grounding) shall be addressed to one of the load combinations A, B or C based upon its frequency of occurrence

The proof of static strength for the lifting points shall be based upon the maximum force resulting from the hoist load and maximum load eccentricity The maximum force possible in each lifting point shall be considered as a regular load in all relevant load combinations A, B and C according to EN 13001-2 Due consideration shall be given to the effect of horizontal load actions on the forces in the lifting points

The proof of fatigue strength shall take into account the whole range of centre of gravity locations, the frequency of occurrence of these locations and distribution of load values The resulting fatigue loading shall

be expressed by a series of !forces" on the lifting points and their respective frequencies of occurrence Horizontal load actions and inclined grounding shall be considered in case they appear in load combination A

5.2.1.8 Conditions of use of permissible stress method and limit state method

Selection of allowable stress method or limit state method shall be made in accordance with EN 13001-1 and

EN 13001-2

5.2.2 Limit states and proof of competence

5.2.2.1 Limit states and proof of competence of structural members

The limit states and proof of competence of structural members and connections shall be determined in accordance with !EN 13001-3-1"

5.2.2.2 Limit states of mechanical components

Proof of competence of ropes in rope drives shall be in accordance with CEN/TS 13001-3-2

NOTE A European Standard for the selection of rail wheels is under preparation While the appropriate standard is not available, the rail wheels and rails may be selected in accordance with ISO 16881-1 Other methods that are based on experimental knowledge on the wear of the used materials and which give comparable life of the wheels can be used

For other components the load effects and required life (number of cycles) shall be derived from the service and load conditions specified in 5.2.1 and they shall not exceed the limit states specified by the component manufacturer

5.2.2.3 Local stresses from wheel loads

!Trolley wheels generally transmit vertical and horizontal wheel loads The effects of these wheel loads on the supporting structure shall be taken into account in combination with global stresses

Distribution of wheel loads of a crane or a trolley shall not be considered equalised unless equalising is ensured by appropriate arrangements (e.g pinned bogies, balancers, flexibility of structures)

Stresses in the web under the rail, resulting from vertical wheel loads, shall be calculated in conformance with

EN 13001-3-1 When passing over girder cuts (e.g from main girder to cantilever), the effective distribution length is halved, which shall be taken into account in the calculation

NOTE Annex E presents one permissible method to determine the stresses in the case of cranes with the trolley travelling on the lower flange of the girder

The local stress due to the wheel load shall be combined with the global normal and shear stresses for the determination of the equivalent stress in accordance with the principles given in EN 13001-3-1

For fatigue assessment in accordance with EN 13001-3-1

• the total number of wheel overruns at the mostly loaded position shall be taken into account;

• For top-running trolleys, where the weld joint of flange/web is subjected only to transverse compressive stresses, the weld may be regarded as a fail-safe component, when selecting the specific resistant factor

γmf;

• For under hung hoists travelling on the bottom flange of a girder, the weld shall be regarded as a non safe component, when selecting the specific resistant factor γmf."

fail-5.2.2.4 Proof of strength of lifting points

Lifting points (holes and lugs) used for erection and maintenance purposes shall be calculated by either:

— using theory of plasticity with a minimum factor of 4 and welds to structures with a minimum factor of 5 against ultimate strength of steel To justify the use of this theory, the percentage elongation after fracture

of the materials shall be at least 15 %; or

— using the theory of elasticity

5.2.2.5 Elastic deformation

The elastic deformations of the crane structure shall not have a detrimental influence on the function of the crane

NOTE Information and guide values for the specification of crane girders are given in ISO 22986

5.2.2.6 Vibration frequencies of crane girders

Recommended natural frequencies of structural vibrations are given in ISO 22986 Where frequencies are lower, consideration shall be given to the effect of additional fatigue on the structure and to load control Consideration shall also be given to minimize the amplitude and duration of vibrations e.g by using stepless controls

NOTE See also 5.6.1 concerning cabins

5.2.3 Stability

5.2.3.1 General requirements

A crane is considered to be stable, when the overturning moment calculated with specified loads and factors

is smaller than the stabilising moment about any tipping axis

The partial safety factors for the proof of stability of the crane shall be taken from EN 13001-2

5.2.3.2 Gantry crane configurations

A basic crane configuration assumes a fixed legged crane standing on four or more corners

For other crane configurations an additional risk coefficient γn shall be applied for all non-favourable loads of

!EN 13001-2" based upon the leg configuration of a crane as follows:

a) cranes supported on three corners γn = 1,10;

b) cranes supported by a hinged leg in one or more of the corners:

b1) hinged leg corner lifting up γn = 1,10;

b2) fixed leg corner lifting up γn = 1,22

Cases b1) and b2) can appear on the same crane, see Figure 3

Figure 3 — Typical gantry crane configuration with cantilevers 5.2.3.3 Design of tie-downs

Where the stability of the crane does not conform to 5.2.3.1 and 5.2.3.2 in out-of service wind conditions, it shall be equipped with tie-downs The tie-downs shall be designed with the partial load factors in accordance with the EN 13001-2 and the relevant risk factors in accordance with 5.2.3.2

!The additional risk coefficient factors for design of tie-downs and their fastening points shall be taken as follows:

― for steel sections γn = 1,20;

― for wire ropes and chains γn = 1,60."

5.2.3.4 Stability of rubber tyred gantry crane (RTG)

Rubber tyred gantry cranes shall remain stable when they experience an immediate tyre deflation whilst travelling at maximum speed down a maximum incline in both the loaded and unloaded conditions

5.3 Electrotechnical equipment

5.3.1 Physical environment and operating conditions

When the physical environment or the operating conditions are outside those specified in EN 60204-32:2008, 4.4 the specification of the electrical equipment shall be amended accordingly Attention should be given to wind chill effects and solar heat gain

5.3.2 Electrical supply

High voltage equipment (exceeding 1 kV AC or 1,5 kV DC) shall comply with EN 60204-11 All references to

EN 60204-1 in EN 60204-11 shall be considered as references to the respective clauses in EN 60204-32 Where a collector system is used for the incoming supply and it cannot be totally enclosed to prevent danger

to personnel and damage by the operation of the crane or associated activities, the provisions of

EN 60204-32:2008, 12.7.1 shall apply

5.3.3 Protection against electric shock by direct contact

!Protection against electric shock by direct contact shall comply with EN 60204-32:2008, 6.2 with the following limitations:

• protection by barriers in accordance with HD 60364-4-41 is only acceptable in areas restricted to electrically skilled persons;

• protection by placing out of reach in accordance with EN 60204-32:2008, 6.2.6 is acceptable only in the case of conductor bars."

5.3.4 Control circuits and control functions

5.3.4.1 General

!The provisions of EN 60204-32:2008, Clause 9 shall apply as amended by 5.3.4.2 and 5.3.4.3 of this standard

All safety-related parts of control systems shall fulfil at least Performance Level c of EN ISO 13849-1:2008:

• control circuits built with electromechanical, hydraulic and pneumatic components shall fulfil at least Performance Level c and category 1;

• control circuits built with electronic or programmable components, respectively, shall fulfil at least Performance Level c and category 2

In high-risk applications, as specified EN 13135, a risk assessment shall be undertaken to establish a higher performance level requirement than described above

The stop function in cableless control systems as laid down in Annex C of EN 13557:2003+A2:2008 (C.3), i.e when

• either the communication is lost or disturbed or

• a stop button on the transmitter is actuated,

shall fulfil at least Performance Level c and category 3 This requirement does not concern normal use, e.g where hold-to-run push buttons are used to start and stop crane motion."

5.3.4.2 Suspension (by-pass) of safeguarding for setting, testing and maintenance purposes

The provisions specified in EN 60204-32 shall apply

Where means for temporary suspension of safeguarding is provided, the device for suspending shall be located inside an enclosure, access to which requires special tools, or other device not available for normal operation, such as a key-operated switch, shall be provided

5.3.4.3 Combined start and stop controls

Combined start and stop controls as specified in EN 60204-32:2008, 9.2.6 shall not be used for motion drives

5.3.5 Operator interface and mounted control devices

― The stop actuator of a cableless control

The function to be activated shall be indicated on or near to the button

5.3.5.3 Devices for emergency stop

The provisions specified in EN 60204-32 shall apply

Devices shall also be provided in the following locations to stop the appropriate motions:

— on the crane structure at ground level on both sides or at each corner of a cabin controlled gantry crane;

— in the machinery room;

— any other location based on risk assessment

Emergency stop devices located at control stations shall be of the palm or mushroom-headed push-button self-latching type complying with the provisions of EN 60947-5-5 The type of emergency stop devices for other locations shall be selected so as to achieve easy identification and access to them, and to avoid unintentional actuation

Where the cableless control station is the only place of control on an overhead bridge crane, an emergency stop actuator in addition to the stop button on the cableless control is not required, provided all the following conditions apply:

— it is ensured that a lost cableless control station cannot send any run command;

— there are no operator access ways on the crane;

— the crane runway has no access facilities

5.3.6 Power driven motions

All power driven motions shall be power driven at all times

NOTE Exempt is an emergency situation, when mechanical brakes may be manually released by skilled personnel, if the necessary provisions are available to stop the motion to prevent a hazardous situation occurring

All power driven motions shall be under the control of a braking system at all times The braking systems shall

be such that movements can be decelerated, the motions can be held and unintentional movements avoided The systems shall be capable of bringing a fully loaded crane to rest from the highest speed !any motion" can attain

5.4.2.2 Mechanical service brakes in power driven motions

Only power released brakes shall be used and they shall maintain their ability to stop the motion, at all times Brakes shall be protected from the ingress of substances within the environment, which are likely to have a detrimental effect on the performance of the brake

NOTE Where electrical braking systems are used, the associated mechanical brake is only subjected to limited use Special attention therefore may be needed to maintain the required mechanical braking torque, see 7.3.3

Mechanical service brakes shall engage automatically in the following cases:

— the control device returns to its neutral position;

— the power supply to the brake is interrupted;

— the emergency stop device is activated

5.4.2.3 Brakes for hoisting movements

!The brakes shall be designed to exert a restraining torque of at least 60 % greater than the maximum torque transmitted to the brake from the maximum hoist load In addition, the hoist brake shall comply with

EN 13135

Back-up braking, where required, shall be in accordance with EN 13135."

5.4.3 Hoisting equipment

5.4.3.1 Selection of serial hoist units

Where a hoist unit in accordance with EN 14492-2 is used as a component in the crane, its selection shall be based on the same classification parameters as those of the crane A.4 gives guidance on selection

5.4.3.2 Variable rated capacity

Where a crane is specified with variable rated capacity dependent upon trolley/crane position or crane configuration, the rated capacity limiters and indicators shall act accordingly

Where a crane intended for transporting hot molten masses is operated also in another mode of operation with a higher rated capacity, separate consideration shall be given to each mode of operation A lockable mode selector switch shall be provided to switch the rated capacity limiter to the respective operation mode

5.4.3.3 Variable number of hoist units on the crane bridge

Where the hoist units are able to move from one bridge to another, thus creating a case where the total lifting capacity of the hoist units can exceed the rated capacity of the bridge the control system shall ensure that the crane bridge, irrespective of the number of hoist units and the suspended loads, is not overloaded

5.4.3.4 More than one hoist unit permanently on the crane bridge

Where the total lifting capacity of the hoist units exceeds the rated capacity of the bridge, the control system shall ensure that the crane, irrespective of the loads suspended on the hoist units, is not overloaded

5.4.3.5 Hooks for handling of hot molten metal

Hooks for hot molten handling shall be designed either redundant or be of laminated construction or as a forged hook designed for a load that is at least 50 % greater than rated capacity

NOTE For hooks that directly support the ladle and are subject to possible hot metal spillage, the laminated construction type should be preferred

5.4.3.6 Boom hoisting

5.4.3.6.1 !The boom hoist mechanism shall be provided with a back-up brake and a backup upper limiter

(see EN 13135) The back-up brake shall act directly on the drum or on the primary shaft of the gear, when the components in the kinematic chain between the back-up brake and the ropes are designed with risk coefficient γn = 1,60."

5.4.3.6.2 !The boom hoist mechanism shall be provided with two independent rope-reeving systems A

failure of one rope shall be assigned to the corresponding load and stability combinations C (EN 13001-2) Design of compensating beam and rope shall be in accordance with EN 13135."

5.4.3.6.3 If a boom rope becomes slack, the boom hoist shall be brought to a standstill (see also

!EN 13135") When in the operating position, the boom !shall be supported by other means than" the ropes of the boom hoist The trolley shall not fall out of the track, at the transit point between the bridge and the boom, whatever the position of the boom The travelling trolley shall only be able to pass over to the boom when the boom is in its operating position(s)

5.4.4 Travelling and traversing

5.4.4.1 Friction drive capability

The drive and braking systems shall be designed so that they are capable of controlling and stopping movements with maximum specified slope, operational wind speed and load

When evaluating acceleration/deceleration characteristics, the frictional coefficient between the steel rail and wheel shall not be taken greater than 0,14, in the case of rubber tyres on prepared ground surfaces not greater than 0,2

5.4.4.2 Hand driven trolleys and cranes

Hand powered hoists, trolleys and where appropriate, hand powered cranes shall conform to EN 13157 as amended by this subclause

If the traversing and travelling movements of the trolley and/or the crane are hand driven the operating force required by operator, when transporting the rated load, shall not exceed:

— 250 N on a hand chain;

— 250 N on a one handed crank in the vertical plane;

— 400 N on a two handed crank in the vertical plane;

— 150 N on a one handed crank in the horizontal plane

If the traversing and travelling movements are achieved by pushing the load, the horizontal force required shall not exceed 200 N, when transporting the rated load

Hand operated gantry cranes which can inadvertently be moved shall be equipped with a braking or arresting device to prevent unintentional crane movement

5.4.4.3 Drive characteristics of the rubber tyred gantry crane (RTG)

The ratio of the wheel base and the height of the centre of gravity and the stiffness of structures of the rubber tyred gantry cranes shall be selected so that the operational accelerations and decelerations do not cause intolerable oscillations for the operator The limit values shall be as specified in ISO 2631-1

5.4.4.4 Anchoring in out-of-service wind conditions

If the minimum foreseeable friction or the braking torque of the driven wheels cannot prevent the crane or trolley from drifting away in the specified out-of-service wind conditions in accordance with EN 13001-2, the crane or trolley shall be equipped with the following:

— rail clamps that can operate at any position of the track; or

— anchor pins or other means of same function that can hold the crane in certain anchoring positions

5.4.4.6 Guide roller design

!The guide rollers shall be designed in accordance with EN 13135."

5.4.4.7 End stops

The ends of travelling and traversing tracks shall be equipped with mechanical end stops

5.4.5 Slewing equipment

5.4.5.1 Friction drive capability

The drive and braking systems shall be designed so that they are capable of controlling and stopping movements with maximum specified slope and slopes resulting from elastic deformation, operational wind speed and load

When evaluating acceleration/deceleration characteristics, the frictional coefficient between the steel rail and wheel shall not be taken greater than 0,14

5.4.5.2 Parking in out-of-service condition

The slewing mechanism shall be prevented from moving in the maximum out-of-service wind conditions This shall be accomplished either by a self-arresting drive mechanism, by brakes or by a mechanical locking device However, the performance shall not rely upon the combination of any of them

!The parking system shall meet the requirements of EN 13001-2 (γp = 1,16 for storm wind and γm = 1,1 for the holding capacity of the parking system)."

5.4.5.3 Slew bearing

The structure mounting support for the slew bearing shall be of adequate strength and stiffness, level and flat, and present a smooth surface for the bearing The bearing and its fixing bolts shall be able to withstand the maximum loading associated with load combinations A, B and C of EN 13001-2

For the proof of competence of the slew bearing lifetime, the following shall be taken into account:

a) loading conditions for the calculation shall include:

1) each load/radius combination of the system, with the relevant number of work cycles;

2) unloaded, return part of the work cycles;

3) slewing sectors specific for the work cycles;

4) load combinations A of EN 13001-2 with the partial safety factors and dynamic coefficients set to 1; b) result of the lifetime calculation shall be expressed as a total slewing distance within the lifetime of the bearing, and this shall be not less than the total slewing distance specified for the slewing motion according to EN 13001-1

5.4.6 Tolerances

5.4.6.1 Tolerances for rail mounted cranes

!The rail mounted cranes shall be manufactured within the construction tolerances of ISO 12488-1." The tolerance class shall be selected on the basis of the designed total travel distance according to that standard

5.4.6.2 The tolerances for alignment of travelling wheels of RTG

The misalignment of each wheel from the travel line shall not exceed 0,2°

Figure 4 — Alignment tolerances of tyres 5.4.7 Gear drives

The equipment shall be in accordance with !EN 13135" as amended by this standard

Gear drives shall be dimensioned according to the mechanisms classification/loading requirements selected

by referencing EN 13001-1 and EN 13001-2 for the motion under consideration

The sizing of gearing to meet the strength and durability requirements shall be calculated according to ISO 6336-1

5.4.8 Protection against special hazards

5.4.8.3 Fire hazard

Fire extinguishers shall be provided in locations where fire hazards exist including operator's cabin, machinery and electrical rooms Exits from these rooms shall conform to the access requirements of EN 60204-32:2008, 11.5.2 and 11.5.3

5.4.8.4 Processed materials and substances, used materials, fuels

5.4.8.4.1 Exhaust gases

Exhaust gases from combustion engines shall be discharged sufficiently far from the fresh air inlet of the operator's cabin and at a sufficient height above the ground level to avoid exposing personnel to harmful gases

5.4.8.4.2 Fuelling

The filling opening for the fuel tank shall not be located in the operator's cabin The filling position shall be easily accessible, preferably from ground level

5.4.8.5 Tandem operation of cranes/trolleys from a single control station

!When two or more cranes/trolleys are used for handling a single load from a single control or control station, the control systems of the individual cranes shall be interconnected to ensure that during tandem operation:

— the hoisting speeds are the same within the tolerances required for the particular application;

— the horizontal speeds are the same within the tolerances required for the particular application;

— any interruption of the operation on one crane/trolley shall have a corresponding effect on the other This requirement does not apply to fully pneumatic or hydraulic powered and operated cranes/trolleys with horizontal speeds less than 15 m/min and hoisting speeds less than 2 m/min

At horizontal speeds exceeding 60 m/min or hoisting speeds exceeding 20 m/min, the relevant motion control shall provide self-correcting synchronization and any interruption in the operation on one crane/trolley shall have a corresponding effect on the other

Where the cranes can be used separately and in tandem, the controls shall be clearly marked accordingly."

5.5 Limiting and indicating devices

5.5.1 Rated capacity limiters

5.5.1.1 General

Cranes with a rated capacity of 1 000 kg or above, or an overturning moment of 40 000 Nm or above due to the rated load shall be fitted with a rated capacity limiter complying with EN 12077-2 as amended by 5.5.1.2 and 5.5.1.3 of this standard

5.5.1.2 Indirect acting limiter

Settings of rated capacity limiters shall be such that when lifting a load exceeding the hoist load multiplied by a triggering-factor, the limiter shall be triggered In general, the triggering-factor shall be ≤ 1,1

For cranes equipped with hoists in accordance with EN 14492-2 a load exceeding the rated capacity of the hoist multiplied by the triggering-factor shall trigger the limiter The triggering-factor shall be less or equal to 1,25 A lifted load equal or greater than triggering factor times the hoist load, shall not be lifted from the ground higher than the maximum rated hoisting speed multiplied by 1 s

In cases where in normal operation the factor ϕ2 is above the triggering factor, a delayed triggering system may be needed If this is provided, it shall operate as described herein In order to allow for higher values of

ϕ2, the functioning of the rated capacity limiter may be delayed by a pre-set time value, after this time delay the limiter shall operate normally In addition an instantaneous trigger shall be provided, this shall be set to trigger immediately in cases where the force in the hoist system rises 5 % above the level of ϕ2 The final, resulting force in the hoisting system shall be calculated according to 5.2.1.5.2 Operation of this two-stage triggering system is shown schematically in Figure 5 If the hoist media force encroaches into the hatched area, triggering takes place and hoisting will be stopped

The force due to existence of ϕ2 shall be considered as a regular load in accordance with 5.2.1.3.2

Key

t time

F force in hoist media

mHg force in hoist media due to hoist load

the solid curve shows the time dependence of force level when lifting load equal to the hoist load

the dotted line shows the force level in a stall load case, rising to level c

a triggering level of the rated capacity limiter with delay - force level a is exceeded at t = t1, however the triggering needs to be delayed at least until t = t3 to avoid spurious tripping due to normal hoist impacting The vertical line limiting the hatched area indicates the trigger delay release

b triggering level of an instantaneously acting limiter – triggering at t = t2 when in a stall load case

c maximum force level occurring in stall load case

Figure 5 — !Force diagram for indirect acting lifting force limiter"

5.5.1.3 Direct acting limiter

Settings shall be such that a load equal to 1,1 times the rated capacity of the hoist can be lifted, in order to perform the dynamic overload test, see 6.3.2.3, without changing the setting of the rated capacity limiter This

setting shall not allow a load exceeding mRC multiplied by ϕ DAL to be lifted, which shall not exceed 1,6 times for frictional or pneumatic limiters and 1,4 times for hydraulic limiters, the rated capacity of the crane

In applications where a risk assessment shows an increased severity of possible harm as listed in

!EN 13135", the rated capacity limiting facility shall not rely solely upon a friction torque limiter unless the brake is placed between the friction torque limiter and the load, or the torque of the limiter is increased to a working coefficient of at least 2 when the brake is engaged, or the same increased coefficient of safety is achieved by other means

5.5.2 Indicators

5.5.2.1 Rated capacity indicator

Rated capacity indicators in accordance with EN 12077-2 shall be provided on bridge and gantry cranes where the rated capacity varies with the position of the load Such indicators shall give a visual warning at

90 % of the rated capacity and a visual or audible warning at overload

5.5.2.2 Wind speed indicator

!Cranes operating in areas where the in-service design wind speeds can be exceeded shall be fitted with wind speed indicators, unless other means are continuously available for the operator to receive the necessary information

Where a wind speed indicator is fitted it shall activate an audible warning at the wind speed at which shut down shall be initiated

Wind speed vst, defined as a 3 second gust speed, at which shut down should be initiated can be calculated

v(3) is the design in-service wind speed expressed as the gust wind velocity averaged over a period of

3 seconds as defined in EN 13001-2, in metres per second;

t is the time needed to shut down the crane from any operating position, in minutes."

5.5.3 Motion limiters

5.5.3.1 General

Cranes shall be equipped with limiters at the end of each motion in accordance with

!EN 12077-2" Where electrical limiters are used, they shall actuate a category 0 or category 1 stop according to EN 60204-32, but allow movement in the opposite direction to a safe condition

NOTE 1 Guidance regarding type and location of limiters are given in ISO 10245-5

The horizontal motions of rail mounted cranes shall be provided with additional limiters, where there is need to limit operation of the crane, trolley or load in certain areas

NOTE 2 In some applications it is maybe desirable to fit slow-down limiters in addition to limiters at the end of motions

5.5.3.2 Use of back-up limiter for hoist motion

!A backup upper limiter of hoist motion independently activated from the first, complying with EN 12077-2 shall be used in high-risk applications as described in EN 13135 A backup upper limiter shall also be used on cranes where

— the failure of the first limiter results in the dropping of the load, that directly or indirectly causes an unacceptable high risk to persons and property: or

— the intended use of the crane is such that the upper limit is approached frequently

The backup upper limiter should also be used to protect valuable properties, for example: power house cranes, shipyard cranes, harbour cranes, etc

Following the operation of the backup limiter, a restart shall only be possible in the opposite direction after a reset action, e.g by using a key-lockable hold-to-run control on the control stand or a manual reset button on the hoist An indication of the failure of the first limiter, as called for by EN 12077-2 is not required The rest action required by this clause is considered adequate indication of the failure of the first limiter

Indication and reset action are not necessary, if the backup limiter is a friction torque limiter designed to accommodate the movement energy."

5.5.3.3 Collision of cranes or trolleys

Buffers between the cranes or trolleys are sufficient systems for risk reduction, if they are able to absorb the kinetic energy resulting from the moving masses in such a way as to prevent the following:

a) the strength of the components of the crane installation being exceeded;

b) the falling or tilting of the cranes or trolleys;

c) the dropping of the load;

d) the load swaying in a hazardous manner

In other cases, anti-collision systems shall be provided

Where an anti-collision system is evaluated as being required, all relevant crane or trolley motions shall be equipped with the system The anti-collision system shall have some or all of the following features depending upon the assessment of the risks involved:

— the ability to reduce the speed of approach of the crane(s) or trolley(s) moving towards a collision;

— the ability to bring the moving crane(s) or trolley(s) to a stop before a collision occurs

The forces resulting from kinetic energy of the collision shall also be taken into account with anti-collision system unless the system meets the requirements of 5.3.4.1

The driver shall not be exposed to a deceleration exceeding 4 m/s2

NOTE Warning of approaching collisions can be required in some cases

!Where buffer end stops for the crane or the trolley are fixed by a bolt tightening friction grip joint relying only on friction, to provide the possibility of adjustment of the travel range, there shall also be

• a positive locking provided behind the end stop as a back-up means or

• the end stop construction shall be designed with a risk coefficient γn = 1,6."

5.5.4 Performance limiters

Performance limiters (see !EN 12077-2") shall be provided where necessary, for example:

a) limiting the lifting capacity locally where there are limitations due to load bearing capacity of the crane supporting structures;

b) limiting of hoisting or travelling speed and/or acceleration/deceleration dependent upon the lifted load;

NOTE Limiting of deceleration can introduce additional hazards, and it can be necessary to limit the maximum speed

c) limiting of (travelling) speed and/or acceleration/deceleration dependent upon wind conditions;

d) limiting of lifting capacity dependent upon the type of load, for example increasing safety factors for dangerous lifts

The operation of the performance limiters shall not cause additional hazards

5.6 Man-machine interface

5.6.1 Controls and control stations

Controls and control stations shall comply with EN 13557 amended as follows:

The arrangement of the controls for cranes with cabins shall comply with ISO 7752-5 The logic of the control arrangement shall be the same at each control station associated with the operation of the crane The arrangement of the controls for the cranes without cabins shall, where possible, also follow this logic

The movement of a crane motion shall only be able to be initiated from the neutral position of the control

NOTE More information on ergonomic design principles of controls and control stations is given in EN 614-1 Cabins should be constructed as specified in ISO 8566-5

Windows shall be fitted with wipers and washers and designed so that the outside surface can be readily cleaned The whole window unit shall be designed and installed so that it cannot fall outwards

The cabin shall be located so that collision with the transported load is prevented If this is not possible by location, the cabin shall be guarded with railings

To avoid uncomfortable vibrations for the operator in a cabin, the natural frequency of the structure carrying the cabin should not be less than 2 Hz Where this requirement cannot be reasonably met, amplitude and duration of vibration should be minimized e.g by using stepless controls Informative guide values of lowest frequencies are given in ISO 22986

For gantry cranes the frequency of horizontal vibrations should be not less than 0,50 Hz

5.6.2 Guarding and access

5.6.2.1 The crane shall have permanent access to all control stations, in accordance with EN 13586 Where access is provided by means of a permanent personnel lift, it shall comply with EN 81-43

If there is one exit only from a cabin controlled bridge or gantry crane, a risk assessment shall be made on the need for a special evacuation means from the cabin

NOTE For requirements not covered by EN standards noted above, guidance is given in ISO 11660-5 and EN

1993-6 and in addition the following clearances are generally recommended, as examples:

— clearance above the crane with access ways to the interrupted roof: 500 mm;

— clearance between two cranes mounted above each other with access ways in either of the cranes: 500 mm;

— clearance under the crane to the permanent obstacles: 500 mm;

— clearance between the end carriage and the building taking into account the maximum skew position and allowable wear and there is no permanent access: 50 mm

5.6.2.2 !The crane shall be designed such that access to maintenance and inspection points is possible in one of the following ways or by a combination of those:

— the crane has permanent access ways for maintenance and inspection, designed in accordance with

EN 13586;

— access is through external access ways on the surrounding building or similar permanent construction;

— access is from a mobile elevating work platform

In the two latter cases, the access relies on external means, which are not part of the crane However, those means shall be specified and their use described in the maintenance instructions of the crane

Where maintenance or inspection requires access to enclosures, the openings shall conform to EN 13586."

5.6.2.3 Some maintenance and inspection work may require the use of a safety harnesses Where such equipment is required attachment points in conformity with EN 795 shall be provided

5.6.2.4 To avoid crushing and shearing hazards the minimum distance between moving parts within the crane shall be in accordance with EN 349 unless equivalent safety is provided by other means, for example a person detector and motion limiter system

Where there is a danger of a shearing or falling hazard occurring on the access way, the transfer points shall

be provided with gates These gates shall be fitted with an interlocking device that disables the relevant motion

5.6.2.5 For cranes travelling on rails on the floor or ground level, the end carriages or the foremost bogies in

both directions shall be equipped with rail sweepers and flexible contact protection

NOTE These devices protect persons from getting to a hazardous contact with the crane They need not affect the travel drive system

Where the crane travel rails are at a lower level than 2,5 m above ground they shall be guarded, for example

by rail sweepers The clearance between the rail and the sweeper shall be less than 5 mm at levels 0,5 m to 2,5 m and less than 20 mm at levels 0 m to 0,5 m

5.6.2.6 Open gears, chain drives and similar power transmissions in personnel working and traffic zones

shall be guarded in accordance with EN 953 Exceptionally, guarding of the large slewing gears may not be required, if the drawing in point of the pinion/gear is located sufficiently remote from the access ways, in accordance with EN ISO 13857

5.6.3 Lighting

The manufacturer shall clarify needs for crane-mounted lights depending on the availability of other lights on site Attention shall be paid on lighting:

— on the working area;

— on access walkways, stairs and ladders;

— in machinery room and electric room

When a crane will be used in a working place where general illumination level is less than 20 lux, it shall be equipped with lighting that provides local illumination of at least 50 lux on the working area

NOTE These are minimum limits, which should be specified higher when required by the accuracy of the work

Lighting levels on the crane shall be a minimum value of:

— cabins, min 200 lux;

— machinery room, min 100 lux;