CEN/TC 147

Date: 2025-01-15

prEN 13135:2025

WI00147197

CEN/TC 147

Secretariat: SFS

Cranes — Safety - Design — Requirements for equipment

Krane — Sicherheit - Konstruktion — Anforderungen an die Ausrüstungen

Appareils de levage à charge suspendue — Sécurité - Conception — Prescriptions relatives à l'équipement

ICS:

Descriptors:

Contents Page

European foreword 4

Introduction 5

1 Scope 6

2 Normative references 6

3 Terms and definitions 8

4 Safety requirements and/or protective measures 11

4.1 General 11

4.2 Electrical equipment 11

4.2.1 General 11

4.2.2 Physical environment and operating conditions 11

4.2.3 Electrical supply 11

4.2.4 Protection against electric shock by direct contact 12

4.2.5 Control circuits and control functions 12

4.2.6 Operator interface and mounted control devices 12

4.2.7 Power driven motions 13

4.2.8 Selection of motors 13

4.3 Mechanical equipment 21

4.3.1 General 21

4.3.2 Clutches and couplings 21

4.3.3 Brakes 21

4.3.4 Gear drives 24

4.3.5 Wheels on rails 25

4.3.6 Rope systems 26

4.3.7 Chain systems 29

4.3.8 Belt systems 30

4.3.9 Adjustment rods 32

4.3.10 Compensating means 32

4.4 Structures associated with mechanical equipment 32

4.4.1 Structures 32

4.4.2 Structural equipment 32

4.5 Fluid power systems 34

4.5.1 Controls and control devices of fluid power systems 34

4.5.2 Protective measures 34

4.5.3 Overload testing 35

4.5.4 Hydraulic equipment 35

4.5.5 Pneumatic equipment 37

4.6 Fixed load lifting attachments 39

4.6.1 General 39

4.6.2 Hooks 39

4.7 Equipment for safeguarding 40

4.7.1 General 40

4.7.2 Safety related functions of control systems 41

4.7.3 Measures to decrease the consequences of loss of drive power 41

4.7.4 Safety devices to prevent overrunning of movements 41

4.7.5 Derailment safety device 42

4.7.6 Provisions to prevent tipping 43

4.7.7 Storm-locking 43

4.7.8 Anti-collision device 44

4.8 Environmental effects 44

4.8.1 Protection against weakening of material 44

4.8.2 Temperature 44

4.9 High risk applications 45

4.9.1 General 45

4.9.2 Decreasing of the probability of occurrence of harm 45

4.9.3 Additional requirements for the transportation of hot molten metal 48

5 Verification of the safety requirements and/or protective measures 51

6 Information for use 55

6.1 General 55

6.2 Instructions for operation in exceptional situations 55

6.3 Instructions for installation and maintenance 55

6.4 Maintenance instructions in the case of high risk applications 56

6.5 Marking 56

Annex A (informative) List of significant hazards 57

Annex B (informative) Selection of a suitable set of crane standards for a given application 60

Annex C (informative) Design of rail wheel flanges 62

Annex D (informative) Guidance on rope systems 65

Annex ZA (informative) Relationship between this European Standard and the essential requirements of Regulation (EU) 2023/1230 aimed to be covered 66

Bibliography 69

European foreword

This document (prEN 13135:2025) has been prepared by Technical Committee CEN/TC 147 “Cranes - Safety”, the secretariat of which is held by SFS.

This document is currently submitted to the CEN Enquiry.

This document supersedes EN 13135:2013+A1:2018.

prEN 13135:2025 includes the following significant technical changes with respect to EN 13135:2013+A1:2018:

— updating of normative references;

— revision of List of significant hazards, move it to Annex A and re-numbering of other Annexes;

— revision and update of Table A.1;

— revision of Annex ZA.

This document has been prepared under a standardization request addressed to CEN by the European Commission. The Standing Committee of the EFTA States subsequently approves these requests for its Member States.

For relationship with EU Legislation, see informative Annex ZA, which is an integral part of this document.

For the relationship with other European Standards for cranes, see Annex B.

Introduction

This document is a harmonized standard to provide one means for equipment for cranes to conform with the essential health and safety requirements of the Machinery Regulation, as mentioned in Annex ZA.

This document is a type C standard as stated in EN ISO 12100:2010.

This document is of relevance, in particular, for the following stakeholder groups representing the market players with regard to machinery safety:

— machine manufacturers (small, medium and large enterprises);

— health and safety bodies (regulators, accident prevention organizations, market surveillance etc.).

Others can be affected by the level of machinery safety achieved with the means of the document by the above-mentioned stakeholder groups:

— machine users/employers (small, medium and large enterprises);

— machine users/employees (e.g. trade unions, organizations for people with special needs);

— service providers, e.g. for maintenance (small, medium and large enterprises);

— consumers (in case of machinery intended for use by consumers).

The above-mentioned stakeholder groups have been given the possibility to participate at the drafting process of this document.

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

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

This document specifies requirements for the design and selection of electrical, mechanical, hydraulic and pneumatic equipment used in all types of cranes and their associated fixed load lifting attachments with the objectives of protecting personnel from hazards affecting their health and safety and of ensuring reliability of function.

NOTE Specific requirements for particular types of cranes, and for load lifting attachments, are given in the appropriate European Standard.

The electrical equipment covered by this document commences at the point of connection of the supply to the crane (the crane supply switch) including systems for power supply and control feeders situated outside the crane, e.g. flexible cables, conductor wires or bars, electric motors and cableless controls.

The principles to be applied for cranes transporting hazardous loads are given in this document. Particular requirements are given for cranes transporting hot molten metal.

This document does not cover the detail design of individual items of equipment except with regard to their selection for specific aspects of use.

The proof of competence calculations and related strength requirements or safety margins of equipment and components are not covered by this document.

NOTE Some safety margins are given here for issues not covered in the EN 13001 series.

Hazards due to noise are not covered by this document. They are addressed in safety standards specific to each type of crane.

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 document.

The significant hazards covered by this document are identified in Annex A.

This document is not applicable to cranes manufactured before the date of its publication.

The following documents are referred to in the text in such a way that some or all of their content constitutes requirements 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 818‑1:1996+A1:2008, Short link chain for lifting purposes - Safety - Part 1: General conditions of acceptance

EN 818‑7:2002+A1:2008, Short link chain for lifting purposes - Safety - Part 7: Fine tolerance hoist chain, Grade T (Types T, DAT and DT)

EN ISO 14118:2018, Safety of machinery - Prevention of unexpected start-up (ISO 14118:2017)

EN 12077‑2:2024, Cranes safety - Requirements for health and safety - Part 2: Limiting and indicating devices

EN 12385‑4:2002+A1:2008, Steel wire ropes - Safety - Part 4: Stranded ropes for general lifting applications

EN 13001‑1:2015, Cranes - General design - Part 1: General principles and requirements

EN 13001‑2:2021, Crane safety - General design - Part 2: Load actions

EN 13001‑3-1:2012+A2:2018, Cranes - General Design - Part 3-1: Limit States and proof competence of steel structure

EN 13001‑3-2:2014, Cranes - General design - Part 3-2: Limit states and proof of competence of wire ropes in reeving systems

EN 13001‑3-5:2016+A1:2021, Cranes - General design - Part 3-5: Limit states and proof of competence of forged and cast hooks

EN 13155:2020, Crane - Safety - Non-fixed load lifting attachments

EN 13411‑1:2002+A1:2008, Terminations for steel wire ropes - Safety - Part 1: Thimbles for steel wire rope slings

EN 13411‑3:2022, Terminations for steel wire ropes - Safety - Part 3: Ferrules and ferrule-securing

EN 13411‑4:2021, Terminations for steel wire ropes - Safety - Part 4: Metal and resin socketing

EN 13411‑6:2004+A1:2008, Terminations for steel wire ropes - Safety - Part 6: Asymmetric wedge socket

EN 13480‑3:2024, Metallic industrial piping - Part 3: Design and calculation

EN 13557:2024, Cranes - Control devices and control stations

EN IEC 60204‑11:2019, Safety of machinery - Electrical equipment of machines - Part 11: Requirements for equipment for voltages above 1 000 V AC or 1 500 V DC and not exceeding 36 kV (IEC 60204-11:2018

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

EN 62745:2017,^[1] Safety of machinery - Requirements for cableless control systems of machinery (IEC 62745:2017)

EN ISO 4413:2010, Hydraulic fluid power - General rules and safety requirements for systems and their components (ISO 4413:2010)

EN ISO 4414:2010, Pneumatic fluid power - General rules and safety requirements for systems and their components (ISO 4414:2010)

EN ISO 12100:2010, Safety of machinery - General principles for design - Risk assessment and risk reduction (ISO 12100:2010)

EN ISO 13732‑1:2008, 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 13849‑1:2023, Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design (ISO 13849-1:2023)

EN ISO 13850:2015, Safety of machinery - Emergency stop function - Principles for design (ISO 13850:2015)

ISO 4306‑1:2007, Cranes — Vocabulary — Part 1: General

ISO 4309:2017, Cranes — Wire ropes — Care and maintenance, inspection and discard

ISO 4347:2015, Leaf chains, clevises and sheaves — Dimensions, measuring forces, tensile strengths and dynamic strengths

ISO 6336‑1:2019, Calculation of load capacity of spur and helical gears — Part 1: Basic principles, introduction and general influence factors

ISO 6336‑2:2019, Calculation of load capacity of spur and helical gears — Part 2: Calculation of surface durability (pitting)

ISO 6336‑3:2019, Calculation of load capacity of spur and helical gears — Part 3: Calculation of tooth bending strength

ISO 6336‑5:2016, Calculation of load capacity of spur and helical gears — Part 5: Strength and quality of materials

ISO 10300‑1:2023, Calculation of load capacity of bevel gears — Part 1: Introduction and general influence factors

ISO 10300‑2:2023, Calculation of load capacity of bevel gears — Part 2: Calculation of surface durability (macropitting)

ISO 10300‑3:2023, Calculation of load capacity of bevel gears — Part 3: Calculation of tooth root strength

ISO 12482:2014, Cranes — Monitoring for crane design working period

ISO 12488‑1:2012, Cranes — Tolerances for wheels and travel and traversing tracks — Part 1: General

For the purposes of this document, the terms and definitions given in EN ISO 12100:2010, ISO 4306‑1:2007, EN 60204-32:2008 and the following apply.

ISO and IEC maintain terminology databases for use in standardization at the following addresses:

— IEC Electropedia: available at https://www.electropedia.org/

— ISO Online browsing platform: available at https://www.iso.org/obp

3.1

backup brake

brake that is additional to the service brake that is able to stop and hold the load

Note 1 to entry: A backup brake can have fewer design cycles than the service brake.

Note 2 to entry: Such a brake is also known as emergency brake or safety brake.

3.2

backup limiter

limiter that is only activated if other (primary) limiting means fail to operate as intended

3.3

belt system

system for supporting and moving load or crane part via belt and wheel arrangement, comprising the belts and all the attachments and parts which are in contact with the belts

EXAMPLE Belt drive wheels, belts, belt reversing wheels, belt terminations and belt guides.

3.4

chain system

system for supporting and moving load or crane part via chain and wheel arrangement, comprising the chains and all the attachments and parts which are in contact with the chains

EXAMPLE Chain drive wheels, chains, chain reversing wheels, chain terminations and chain guides.

3.5

compensating beam

beam to equalise forces at the ends of two ropes

Note 1 to entry: The amount of compensation is limited by the permitted movement of the beam.

3.6

compensating sheave

sheave which performs the function of compensating beam in a continuous rope system

Note 1 to entry: The amount of compensation is not limited by the movement of the sheave.

3.7

hoisting mechanism

drive mechanism for lifting and lowering the load

[SOURCE: ISO/DIS 4306‑1:2024, 7.1, modified – alternate term is used]

3.8

load bearing chain

assembly of load bearing components

3.9

load bearing component

mechanical or structural component which is stressed by the hoist load

3.10

load hook

device attached to chain, rope, bottom block or lifting attachment from which the load, load handling devices or slings can be suspended

3.11

laminated hook

load hook consisting of several parallel oriented plates

EXAMPLE Typically used for transporting hot molten substances.

Note 1 to entry: Also known as multi-plate hook.

3.12

rated capacity

rated load

maximum net load that the crane is designed to lift for a given crane configuration, load location and operating condition

Note 1 to entry: For mobile cranes, replace net load in the definition by hoist medium load.

Note 2 to entry: For net load and hoist medium load, see ISO 4306-1:2007.

3.13

redundant

multiple arrangement of components and/or sub-assemblies arranged so that if one of the components or sub-assemblies fails, the function is still operational

Note 1 to entry: The function can be with limited performance.

3.14

rope anchorage

arrangement comprising the parts between the rope termination and the fixed load bearing structure

EXAMPLE Pins, bolts, compensating beams, tension rods.

3.15

sheave

rotating element with one or more grooves for guiding and/or changing the direction of the rope (chain) without essential change of the rope (chain) force

[SOURCE ISO/DIS 4306‑1:2023, 7.25]

3.16

rope system

system for supporting and moving load or crane part via rope and sheave arrangement, comprising the ropes and all the attachments and parts which are in contact with the ropes

EXAMPLE Wire ropes, sheaves, compensating sheaves, rope terminations and rope guides.

Note 1 to entry: Rope attachment on the drum is included but the rope drum itself is outside of this definition.

3.17

rope termination

equipment to connect the end of the rope to a rope anchorage

3.18

self-locking braking device

braking device whose braking effect is accomplished solely as a result of movement to be braked

3.19

single failure proof hoisting mechanism

hoisting mechanism comprising several parallel chains of components, arranged so that in case of failure of any single component in the total mechanism, the hoisted mass is not dropped

Note 1 to entry: After the failure, the mechanism is not necessarily functional as such.

3.20

vertical movement

movement of hoist load or of a crane part, where the slope of the path of the moved mass is 5 % or steeper in relation to horizontal level

Machinery shall conform to the safety requirements and/or protective measures of this clause. In addition, the machine shall be designed according to the principles of EN ISO 12100:2010 for relevant but not significant hazards, which are not dealt with by this document.

NOTE Specific requirements for particular crane types can be given in the appropriate European Standards, see Annex B.

The electrical equipment shall conform to EN 60204-32:2008 as amended in this document.

High voltage equipment (exceeding 1 000 V AC or 1 500 V DC) shall conform to EN IEC 60204-11:2019. All references to EN 60204-1 in EN IEC 60204-11:2019 shall be considered as references to the respective clauses in EN 60204-32:2008.

When the physical environment or the operating conditions are outside those specified in 4.4 of EN 60204-32:2008, the specification of the electrical equipment shall be amended accordingly.

Wind chill effects and solar heat gain shall be taken into account where appropriate.

The electrical equipment shall be designed to operate correctly in the conditions specified in 4.3 of EN 60204-32:2008. Where the cable length and cross section would cause voltage drops in excess of those allowed under EN 60204-32:2008, the selection of equipment shall be based on actual voltages.

When calculating the voltage drop, the position of the hoisting appliance in relation to its supply point shall be taken into account. The starting (I_D) and rated (I_Ν) currents of the motors operating simultaneously shall be taken into account.

NOTE 1 The rated current (I_Ν) cannot necessarily be considered to mean the nameplate current of the motor but the current drawn by the motor at full rated load.

For squirrel-cage induction motors I_D (starting current), refer to the motor’s catalogue. In case the motor is controlled by an electronic drive (soft-starter, frequency converter etc.), the maximum current occurring during operation shall be considered as starting current, although the highest current does not necessarily occur when starting the motion.

NOTE 2 With direct starting of squirrel cage motors, I_D is typically five to ten times I_Ν. For slip-ring motors, I_D is typically two times I_Ν. With electronic drives, the starting current depends on the converter type and on its adjustments; with frequency converters in hoisting motions I_D is typically below two times I_Ν.

Where the crane-supply-switch is not readily accessible on the access way to the crane, the crane-disconnector and disconnectors for special circuits shall be capable of breaking the short circuit current of the associated circuits.

For each circuit or part of the electrical equipment, protection against electric shock by direct contact shall, whenever practicable, be provided by enclosures or insulation of live parts in accordance with EN 60204-32:2008.

Where these measures are not practicable,

— in electrical operating areas and enclosed electrical operating areas, protection by barriers in accordance with HD 60364-4-41:2017 may be provided;

— only in the case of conductor bars and conductor wires, protection by placing out of reach in accordance with EN 60204-32:2008 may be provided.

Where means for temporary suspension of safeguarding in accordance with EN 60204-32:2008, 9.2.4 is provided,

— the device for suspending shall be located inside an enclosure, access to which, requires special tools, or

— other means, not available for normal operation, e.g. a key-operated switch or password protection, shall be provided.

Suspension of safeguarding shall also limit the performance of the machine or have other means (e.g. automatic restoration of the safeguarding after power-off or a time delay) to avoid prolonged suspension.

Push-buttons and similar control devices that alternately initiate and stop an action, shall not be used for motion drives.

Cableless controls and control functions shall be in accordance with 9.2.7 of EN 60204-32:2008 and EN 62745:2017.

Control devices and control stations and their operating positions shall be in accordance with EN 13557:2024.

The function of each control actuator shall be indicated on or adjacent to it.

The colours of push-buttons shall be in accordance with EN 60204‑32:2008, 10.2 and colours to be used are as in the Table 1 unless otherwise stated in the instruction for use.

Table 1 — Colours of push buttons

All powered motions shall be power driven at all times during normal operation.

General

Motors for a crane motion shall be designed such that the motors have enough capacity:

— to perform the specified, consecutive working cycles without overheating;

— to start the motion with a specified acceleration;

— to maintain the specified speed of the motion.

Decisive duty features for sizing of crane motors are short-term factors such as the starting period of the motion or a single work cycle. Consequently, the basic crane duty parameters of EN 13001-1:2015 – the hoist load spectrum and total number of work cycles – are not relevant for sizing the motor as an electrical component. The average distance per work cycle of each motion in accordance with EN 13001-1:2015 shall be taken into account, when determining an appropriate rating type of the motor duty and thermal power rating requirement.

The following, related factors shall be taken into account together with the motor itself:

— features of the electrical drive system (rated current and voltage with resulting motor torque characteristics, speed regulation and type of braking);

— cyclic duration factor of the specified duty;

— number of cycles/hour;

— type of power feed;

— degree of protection (environment conditions);

— ambient temperature in the motor location;

— altitude of the operating site.

Loadings

General

The loads to be applied in 4.2.8.5 to 4.2.8.7 shall be in accordance with EN 13001-2:2021, setting all the dynamic factors ϕ_i = 1 and the partial safety factors γ_p = 1. The hoisted load shall be applied with the value of the rated load, unless otherwise specified. The wind state for an outdoor crane shall be that specified for the crane and applied in calculation of wind forces in accordance with EN 13001-2:2021. Travel resistance shall be taken into account as an external load action.

In transforming the load actions to a motor torque, the internal efficiency (friction) of the mechanical system shall be taken into account.

For the thermal capacity calculation in 4.2.8.7, the load combinations A of EN 13001-2:2021 shall be applied, with the addition of in-service wind force during controlled movement in accordance with EN 13001-2:2021 into each load combination.

For the torque calculations in 4.2.8.5 and 4.2.8.6, the load combinations B of EN 13001-2:2021 shall be applied, applying the in-service wind force required for starting drive forces in accordance with EN 13001-2:2021.

Travel resistance

The total travel resistance due to rolling resistance and bearing friction in cases, where a wheel is running on a flat surface, shall be calculated by multiplying the wheel force perpendicular to the running surface by a rolling friction factor.

Values given in the Table 2 shall be used for the rolling friction factors for a steel wheel equipped with roller bearings.

Table 2 — Rolling friction factors for steel-steel contact

Wheel friction

The friction factor, see Table 3, for a rail/wheel contact to calculate the traction and braking capacity of a drive mechanism shall be determined, taking into account the ambient conditions and the provisions for cleaning of the rail.

Table 3 — Friction factors

Multiple motors for a motion

In cases where two or more motors drive the same motion, the following shall be considered:

— synchronisation of the mechanisms, if required due to the needs of the application;

— division of external load actions to the motors, taking into account properties and geometric proportions of the mechanical configuration;

— effect on motors, limiting their capabilities to develop torque, e.g. due to slippage of driven wheels or due to current limit of a single or multiple drive system(s) supplying the motors.

Mechanical strength

The proof of mechanical strength of the motor components shall be done in accordance with the general principles specified for mechanical components. The rated load shall only be applied in the calculations, without consideration to variation of actual hoisted loads. Dynamic impacts in motor torque, e.g. due to change of direction of the torque, shall be taken into account.

Mechanical strength of the motor shafts and shaft gears, which are subject to metal fatigue under cyclic loading due to motor rotation, shall be designed for a fatigue limit under maximum torque.

The bearing housings of hoist motors shall be designed such that in case of failure of rolling elements of a bearing, the capability to hold the torque is not lost.

A motor and its possible overspeed protection shall be selected so that the maximum safe operating speed of the motor will not be exceeded under any foreseen conditions.

NOTE See EN 60034‑1:2010, 9.6.

Torque requirement for vertical movements

General

In addition to primary hoisting of the load, this clause shall also be applied to combined vertical and horizontal movement of hoist load or dead weight of a crane part, where the slope of the path of the moved mass is 5 % or steeper in relation to horizontal level.

Determination of required torque

The maximum torque at the motor shaft (M_max) shall be calculated by transforming the external load actions determined in 4.2.8.2 to a torque at the motor shaft, applying the maximum values of load actions. The load action due to acceleration of the motion may be omitted. The configuration of the mechanical transmission and efficiency (friction) of the transmission shall be taken into account.

In order to be able to develop the necessary torque for lifting the rated load, for compensating for variations in the mains voltage and frequency and for compensating for variations in the motor characteristics, the torque developed by the motor shall satisfy the following condition:

(1)

where

Where the drive system characteristics vary by the value of hoisted loads (e.g. smaller loads at higher speeds with field weakening systems), the proof of the motor torque requirement shall be done, in addition to the rated load, also with any other hoisted load/motor torque combination, which is relevant to the safety and performance of hoist drive. In such cases, the torques M_D and M_max in Formula (1) shall be taken as those relevant for these conditions.

Key

Figure 1 — Determination of torque M_D for different types of torque curves

Table 4 — Safety factors k_V for vertical motions

Torque requirement for horizontal motions

General

This clause shall be applied in cases, where the slope of the path of the moved mass is less than 5 % in relation to horizontal level. This clause covers trolley traversing, crane travelling, slewing and level luffing movements.

The maximum external load actions – including the acceleration of the movement – with the magnitude they resist the motion shall be transformed to a torque at the motor shaft, taking into account the configuration of the mechanical transmission and efficiency (friction) of the transmission.

For movements driven through friction between driving wheels and a runway, the values of individual wheel loads and the limitation of transmissible torque due to friction shall be taken into account.

Determination of required torque

Account shall be taken of the sum of forces resisting the movement resulting from the dead weight, the hoisted load and operating conditions such as:

— deformation of the running surface;

— friction of the wheels on straight sections and in curves;

— wind forces;

— gradients in the track;

— necessary force to move the power supply system.

In order to guarantee the starting of the motion to the intended direction, at a specified acceleration and under specified wind conditions, the sum torque developed by the motors shall satisfy the conditions of Formulae (2) and (3).

For reaching the specified acceleration in average wind conditions, the drive system shall satisfy the requirement of the Formula (2).

(2)

For reaching a specified acceleration in the maximum wind conditions, the drive system shall satisfy the requirement of the Formula (3).

(3)

where in Formulae (2) and (3)

Thermal capacity requirement

Cyclic duration factor

Intensity of the motor duty is described through a cyclic duration factor ED. This factor is specified for periodic intermittent motor duty calculated as follows:

(4)

where

The factor is used for thermal power rating of motors in S3-type intermittent duty.

Mean equivalent torque and power

The mean equivalent power is a power comparable to the thermal capacity of a motor. The power is derived through motor torques due to external loadings. The mean equivalent torque shall be determined as a function of the affecting torques during the working cycles.

When arranging a work cycle into different phases such as acceleration, deceleration and steady movement, the number of which is n, the mean equivalent torque shall be calculated using the following formula:

(5)

where

If the crane can perform several work cycles in a 10 min period, a variety of hoist loads shall be taken into account so that the mean equivalent torque is calculated over a total period of approximately 10 min.

If an average work cycle takes 10 min or longer – including the idle times – the torques shall be calculated applying the rated load only, without consideration of variety in magnitude of loads.

For the calculation of the torques in Formula (5), the true characteristics of work cycles shall be taken into account with consideration of the following:

— loaded and unloaded phases of a work cycle;

— lifting and lowering of the load;

— acceleration and deceleration loadings;

— mechanical efficiency, both increasing and decreasing the motor torque;

— wind loading in accordance with 4.2.8.2.1, both head wind and tail wind.

The mean equivalent power shall be calculated using the formula:

(6)

where

Motor power requirement in general

With the exception of 4.2.8.7.4, the thermal power rating of the motor shall meet the following requirement:

(7)

where

P_mot may be taken in accordance with S3-duty in cases where the motion is intermittent and repeated in periods of 10 min or shorter during an average work cycle. The power P_mot shall be that related to a cyclic duration factor ED fitting closest to the actual, average work cycle.

P_mot may be taken in accordance with S2-duty in cases where the motion is continuous for a considerable period of time, typically up to 1 h, and in between the work cycles the motion is in rest for a long period of time, for a minimum of several hours.

P_mot may be taken in accordance with S1-duty for any type of use, except what is given in 4.2.8.7.4.

S1-rated squirrel cage motors with direct starting

For calculation of thermal capacity of S1-rated squirrel cage motors with direct starting and in intermittent duty, high starting currents and consequent thermal impact shall be taken into consideration.

Motor requirements in driving to stowage position

In out-door cranes, which have only a limited number of stowage positions, the travelling drive system shall be capable of moving the crane from any working position to the nearest available stowage position. The following requirements in selection of motors apply:

— the safety factor used with the Formula (3) is k_H = 1,3;

— the wind load applied with the Formula (3) is the in-service wind force required for starting drive forces;

— the motor power rating for Formula (6) shall be taken in accordance with S2-duty and duration comparable with the travelling time to the stowage position.

Power correction for ambient temperature and altitude

For the motor selection, the rated power of the motor P_mot shall be corrected as a function of altitude if this exceeds 1 000 m and the ambient temperature if this exceeds 40 °C. The correction factor k shall be taken from the Figure 2, unless other values are specified in the motor’s instructions.

Key

Figure 2 — Power correction factor k as function of ambient temperature and altitude

NOTE Figure 2 is based upon EN 60034-1 with motor insulation class F and integrated cooling in the motor. For other insulation and cooling arrangements, an applicable value can be received from the motor manufacturer.

Power conversion for low ED-factors in S3-duty

For intermittent duty of type S3 in cases where the thermal power of a motor is not given below ED-factor 40 %, the thermal motor power greater than those in Table 5 for lower ED-factors shall not be used for design.

Table 5 — Power conversion for low ED-factors

The following basic principles shall apply in the design of mechanism or selecting the components of the mechanisms:

— The rated characteristics of the components shall conform to the corresponding applicable loading conditions in terms of maximum loading, load spectrum and number of load cycles; test loads of cranes shall be taken into account as an exceptional loading.

The component shall bear information on design and usage parameters of the component, so that the crane manufacturer is able to choose the component with appropriate safety margins to loads and lifetime.

— Deformation of structures due to loads and thermal expansion shall not introduce stresses in mechanisms or they shall be taken into account in design.

— Mechanisms and components shall be accessible for inspection, adjustment, maintenance and dismantling for repair.

— Vibrations of the mechanisms shall be limited so that they do not cause excess amount of discomfort for the crane operator, maloperation of the functioning of the equipment or reduction in the life of the components;

NOTE See e.g. ISO 21940‑11:2016.

The type of clutch/coupling shall be selected on the basis of the design of the driving mechanism and its operation.

The rated torque of the clutch/coupling, at the specified operating conditions, shall be greater than the maximum static torque on the shaft of the clutch/coupling.

The maximum permissible torque of the clutch/coupling, at the specified operating conditions, shall be greater than the peak torque occurring during operation, taking into account the peak frequency and the permissible wear.

Where elastic elements are used in couplings to transmit the torque, e.g. to dampen impacts or to compensate geometric differences, the system shall be so designed that the force flow is retained in case of a failure of such elements.

General

The brakes shall be capable of bringing a fully loaded crane to rest, without excessive shock, from the highest speed it can attain.

Services brakes shall be such that it is not possible to affect the braking effect without the use of a tool.

Service brakes shall engage automatically in the following cases:

— the control device returns to its neutral position; the brakes may be engaged with delay, if the drive system brings the movement into stop;

— the power supply to the brake or associated motor is interrupted;

— the emergency stop is activated; in emergency stop category 0 the brakes shall engage immediately, in category 1 after electric braking has brought the motion into stop;

— the stop function of cableless control is activated;

— the safety related control system has initiated a stop function.

NOTE In a hydraulic system this requirement is fulfilled, for example by devices which prevent the motion from moving.

Where multiple service brakes are used in connection with a single drive motion, the application of any single brake shall activate all brakes.

In the case of 3-phase supply, brakes shall engage automatically when two phases of the power supply of the associated drive motion are interrupted.

In case of the failure of one phase, the system shall ensure that the load will not drop and other motions can be stopped by using the brakes or other means.

EXAMPLE Service brakes can be for example:

—   frictional mechanical brake with brake linings;

—   mechanical braking by self locking gears, such as worm gears;

—   hydraulic braking system by braking valve;

—   pneumatic braking system by braking valve.

Service brakes

Service brakes shall be of the frictional mechanical type or hydraulic/pneumatic locking type and shall be power released unless specified otherwise in the product standards.

The brakes shall maintain their ability to stop the motion, at all times, taking into account:

— the number of braking operations in a given period based on crane duty and type of operation, e.g. for determination of heating and heat dissipation under successive brake cycles;

— the type of drive control;

— the braking after interruption of power to the drive motor, e.g. due to activation of emergency stop;

— the kinetic energy of all rotating and linearly moving masses;

— the difference of potential energy of the lowered masses during braking;

— the load for dynamic tests;

— the action of maximum in-service wind from any direction.

With spring-loaded brakes, brake springs shall be compression springs and shall be guided. If the braking force is applied by pre-stressed springs, the failure of any spring in the brake shall not reduce the available torque by more than 20 %. If fewer than five springs are used, they shall be dimensioned such that the wire diameter is greater than half the coil pitch in the working condition to prevent screwing in of the two spring parts in the event of a wire break.

Brake linings shall be made of asbestos free material.

Bonding or riveting of brake linings shall take account of the heating and wear of the lining under all working conditions.

The coefficient of friction and other properties of the lining shall be suitable for the purpose during normal operation taking into account atmospheric conditions, temperature variations and the maximal peripheral speed at the friction surface.

Where the brakes are exposed to ingress of oil, grease and environmental conditions, which are likely to have a detrimental effect on the performance of the brake, the brakes shall be protected.

It shall be possible to check the wear of the brake lining(s) and to re-adjust the brake without the need to dismantle the brake. To ensure safe operation of the brake between such checks or maintenance periods, either sufficient torque reserve or a self-compensating system shall be provided.

Brakes shall be such that the user cannot adjust the preset braking effort without using a tool.

Where electrical braking systems are used, the associated mechanical brake is only subjected to limited use, which shall be taken into account in the instructions; see 6.3.

Fatigue design of the mechanical parts of the brake shall be based on the maximum torque setting of the brake and the number of brake cycles (on-off cycles), which is taken as a multiple of the specified number of work cycles for the crane. A number of brake cycles of 2 000 000 shall be used for fatigue design of mechanical parts of the brake unless a lower value is specified.

The number of brake cycles shall be between four and eight times the number of work cycles of the crane. Other values may be used for a particular application, where justified by measurements.

Brakes for vertical movements

In addition to 4.3.3.2, the brakes shall be designed:

— to exert a restraining torque of at least 60 % greater than the maximum torque transmitted to the brake from regular loads in accordance with EN 13001-2:2021 with all dynamic factors ϕ_i and partial safety factors γ_p set to 1;

— to ensure the reaction time of the braking is such that it does not allow the load to accelerate to a lowering speed greater than 1,5 times the rated lowering speed, unless otherwise specified in the product standards.

NOTE The specified speed limit 150 % is the final speed resulting from the triggering and braking sequence, considering all the response delays in the system.

In some applications, the brakes for hoisting requires a manual release facility, which allows the load to be brought to a safe position in a controlled manner or is used to prevent tightening of hoist ropes in case of a jammed load. This release facility shall be such that it can only be operated by special equipment or tools which require active operation at all times. The information for use shall provide information on the safe use of such equipment.

Brakes for horizontal movements

Brakes shall be designed so that they are capable of stopping the movement from its maximum speed with maximum specified slope of the crane support, maximum in-service wind speed and load. Braking distance shall not be longer than acceleration distance needed from standstill to rated speed.The brakes together with the rolling resistance and without assistance of powered braking:

— shall create a braking force that is 25 % higher than the drifting force due to maximum in-service wind;

— shall have the heat capacity to absorb the energy when stopping the travel motion from maximum speed in maximum in-service tail wind.

For movements due to friction between driving wheels and a runway, the values of individual wheel loads and the limitation of transmissible force due to friction shall be taken into account. The friction coefficient shall be taken in accordance with the Table 3.

The in-service wind drifting force shall be calculated applying the in-service wind force required for Starting Drive Forces in accordance with EN 13001-2:2021, 4.2.3.1.

The self-locking braking device type shall only be used as parking brakes.

Backup brakes for vertical movements

Where used, the backup brake shall be capable of stopping the hoisted masses falling from the speed reached after the failure of the first brake or of parts of the load bearing chain between the backup brake and the drive motor.

Backup braking shall be initiated immediately following a failure within the service brake system or within the load bearing chain which would result in descent of the load in an uncontrolled manner. In the case of an emergency stop, the backup brake shall be applied with a delay that allows the service braking system to bring the hoist movement to a stop, unless the repeated backup braking function has been taken into account in its design. When backup braking has been initiated in response to a system failure, its reset shall only be possible by using special means.

In rope hoisting mechanisms, the backup brake shall be located;

— on the rope drum, or

— where acting through mechanical connection to the drum, be designed with the risk coefficient γ_n = 1,60 applied on the braking torque for all components in the kinematic chain between the back-up brake and the drum.

In chain hoisting mechanisms the back up brake shall be located on the sprocket drive shaft.

General

The type of connection between the driving and driven mechanisms shall be such that no impermissible and uncontrolled stresses or deformations are produced in the gears or bearings.

Where a self locking condition of a gear can occur, the dynamic shock-forces generated by this condition shall be taken into account in the design of the drive mechanism.

EXAMPLE This condition can occur for example with worm gears:

—   at a high gear ratio, or

—   at high ratio of driven masses at the output shaft of the gear versus rotating masses at the input shaft of the gear.

Gears and bearings shall be provided with lubrication that maintains the designed working conditions of these components.

When selecting the type of rolling bearings, the temperature limits of the bearings shall be taken into account.

Where drain plugs, breathers or oil level indicators with upper and lower limits are provided, they shall be easily accessible.

Gears

The proof of static and fatigue strength for cylindrical (i.e. spur and helical) gears shall be in accordance with ISO 6336:

— basic principles, introduction and general influence factors ISO 6336-1:2019;

— calculation of surface durability (pitting) ISO 6336-2:2019;

— calculation of tooth bending strength ISO 6336-3:2019;

— strength and quality of materials ISO 6336-5:2016.

The proof of static and fatigue strength for bevel gears shall be in accordance with ISO 10300:

— introduction and general influence factors ISO 10300-1:2023;

— calculation of surface durability (pitting) ISO 10300-2:2023;

— calculation of tooth root strength ISO 10300-3:2023.

NOTE The proof of static and fatigue strength for worm gears can be demonstrated using ISO/TS 14521:2020.

Gear housing

The housing of the gear box shall have sufficient rigidity to ensure that the gear shaft alignments and centre distances are maintained under all working conditions and shall be supported on the structure and/or connected to the driving and driven mechanisms in such a way that no impermissible stresses or deformations are produced in the shafts, gears or bearings.

Regardless of the type of gear housing (cast or welded), measures shall be taken to ensure that residual stresses causing impermissible deformations have been eliminated.

Means preventing load drop during disconnection of drive torque

Certain applications, (e.g. hoist speed change by means of stage gear), can require to disconnect the motor shaft from the gear under load. This shall only be possible if the shaft on the load side has been locked.

Travel wheels

Wheels on rails shall incorporate features to prevent unintentional derailment if derailment is not prevented by other means. This requirement can be fulfilled by use of guiding devices such as guide rollers and/or wheel flanges.

Alignment of wheels on rails shall be in accordance with ISO 12488-1:2012.

The height and thickness of a wheel flange shall be such that the flange can resist the horizontally acting wheel forces, with the specified wear limits taken into account.

NOTE Guidance on the nominal dimensions of wheels, when taken into use, is given in Annex C.

In order to prevent hazards when changing the wheels, the crane shall be fitted with jacking or slinging points or other arrangements made to support the crane during this operation.

Guide rollers

Measures shall be taken to prevent hazards resulting from falling components in the event of failure of a guide roller. This is achieved, for example, by selecting suitable materials and dimensioning the components, taking into consideration the use for which they are intended.

The guide rollers of overhead travel or traverse drives shall be designed with additional load factor γ_S = 1,5 in relation to the load bearing capacity of the bearings (static and dynamic) or guarded so that falling of the roller is prevented in case of a failure.

Guide roller alignment shall be in accordance with ISO 12488-1:2012.

General

In working and traffic areas to which personnel have unlimited access, the components of the rope systems and rope run-on points shall be installed or guarded in such a way that crane operations can be conducted with a minimized risk of trapping or drawing-in of hands or arms into jamming-prone areas.

The safety, operation and lifetime of the rope system components are influenced by specific characteristics and properties of the system. Practical guidelines for choosing suitable parameters are provided in Annex D.

Rope drums

The thickness of the drum shell shall be determined by calculation or by tests. If not covered by calculation or tests, a wear allowance shall be added to the drum thickness. The wear allowance shall take into account factors such as material hardness, environment and intended service conditions.

Where a single layer of rope coiling is not possible, provision shall be made for multi-layer coiling.

Rope drums shall be grooved or correct spooling of the rope on the drum ensured by other means. Grooving shall be smooth and free from surface defects liable to damage the rope and the edges shall be rounded. The groove shape, depth and pitch shall provide sufficient coiling, laying and clearance between adjacent rope turns on the drum, taking into account the rope tolerance, rope fleet angles and dynamic behaviour of the rope system and its suspension.

The drum shall be designed such that at an extreme operating position, a length of unclamped rope equivalent to at least two drum revolutions remains on the drum.

At an extreme operating position with maximum rope wound on the drum, the last (outermost) layer of rope shall have at least one empty revolution per layer of rope to compensate the effects of:

— the lengthening of the rope in service during the maintenance interval;

— displacement of the setting point of the limiter at the extreme operating position;

— the readjusting of the limiter for the minimum operating position as a result of lengthening of the rope.

Rope drums shall incorporate features that prevent the rope from coming off the end of the drum. Suitable measures are e.g. flanges or rope guides with motion limiters.

Multi-layer drums shall be provided with a guide at each point where the rope enters the next layer.

NOTE In multi-layer coiling after the first layer is coiled onto a drum, the rope needs to cross the underlying rope in order to advance across the drum in the second layer. The points at which the turns in the upper layer cross those in the lower layer are known as the crossover points, and the rope in those areas is susceptible to increased abrasion and crushing.

The flanges and other side limitations shall be flat and extend not less than 1,5 times the rope diameter beyond the outmost rope layer, measured from the outside of the rope.

Ropes

Ropes shall be selected for the particular application and be made of suitable materials so that they withstand the design forces for the design life of the rope.

Operating environment shall be taken into account and where necessary greasing, galvanising or special rope materials shall be considered.

When selecting ropes, the temperature limit of the rope shall be taken into account. In the case of steady-state temperatures exceeding 100 °C, ropes shall have cores of steel or other heat-resisting material.

Steel wire ropes for rope systems shall conform to EN 12385-4:2002+A1:2008.

Ropes manufactured from material other than steel shall only be used if the wear conditions are known and the discard criteria are recognizable. The following safety requirements connected to the specific application shall be considered:

— fatigue;

— environment;

— structure of rope;

— terminations;

— elasticity and plasticity of the rope;

— rope drum;

— sheaves;

— guides/rope runs;

— fastening;

— anchorage.

Rope systems shall be designed in such a way that the inspections specified in ISO 4309:2017 can be carried out over the whole length of the rope. The inspection interval shall be related to the design life of the rope.

If deterioration of the rope is likely to advance at a greater rate internally than externally, such as would be expected when polymer sheaves are used exclusively in conjunction with single-layer spooling, the particular discard criteria and/or any additional inspection/testing method(s) shall be specified in the instructions for use.

NOTE ISO 4309:2017 does not include discard criteria for those crane ropes that run exclusively through polymer sheaves and spool on and off the drum in a single layer.

In the case of a load suspended by a single-fall rope system and not guided, rotation resistant ropes shall be used.

Where the rope is wound in several layers, the rope shall have a steel core.

Rope sheaves

Rope sheaves shall have protection against the ropes jumping out of the grooves (e.g. in the case of a slack rope). The distance between the edge of the sheaves and the protective means shall not exceed 1/3 of the rope diameter or 8 mm, whichever value is the smaller.

In case of a sheave failure, the rope shall not become detached from the sheaves suspension, even with cantilevered arrangements.

The strength of sheaves shall be determined by proof of competence calculation or by tests. The running surfaces for the rope shall be smooth and free from surface defects liable to damage the rope and the edges shall be rounded.

The groove shape, flange opening and depth shall provide sufficient laying of the rope taking into account the rope tolerance, rope fleet angles and dynamic behaviour of the rope system that the rope cannot come into contact with the edge of the groove section.

Where a rope sheave consists of more than one piece, the pieces shall have a positive engagement.

Rope guides and runs

Means shall be provided to avoid rope damage due to the rope moving out of its intended position on the drum.

Rope systems shall be arranged so that the ropes do not become damaged through contact with each other or with other crane parts.

Where the sheave is not in the vertical plane it shall be ensured that the rope contact will remain in the bottom of the sheave groove.

Rope terminations and fittings

General

The rope ends shall be such that the structural weave of the rope is maintained.

Rope fastening on drum

The fastening elements of the fixing point of the rope shall be selected, taking into account the rope and drum contours. The rope shall not be bent or compressed over sharp edges. The rope fastening shall not become detached even when the tension in the rope is zero.

The fixing point of the rope shall be accessible for maintenance and replacement of the rope.

Where two or more ropes lead from a drum to a single moving part, provision shall be made to accommodate unequal lengths of ropes.

Rope fastening on the drum together with at least two frictional revolutions of the rope shall be capable of withstanding not less than 2,5 times the maximum static force in the rope. In the verification calculation, the coefficient of the friction between the rope and the drum shall not be assumed greater than 0,1.

Where the rope fastening relies on the friction from two rope revolutions and clamping action, two or more clamps shall be used and shall be placed in line. The anchorage of the rope to the drum shall not decrease the breaking force of the rope by more than 20 %.

Rope anchorage

Rope anchorage shall be such that bending of the rope and other additional stresses on the rope are avoided. With ropes which are not of the rotation resistant type, the rope anchorage shall be made in such a way that it is not possible for the rope to twist about its longitudinal axis.

The following fittings may be used as rope anchorage:

a) asymmetric wedge socket that shall be in accordance with EN 13411-6:2004+A1:2008. The free end of the rope shall be secured to prevent it being pulled through the wedge socket with a device which shall be capable of holding 10 % of the maximum static force in the rope;

b) metal and resin socketing that shall be in accordance with EN 13411-4:2021;

c) ferrules and ferrule securing that shall be in accordance with in accordance with EN 13411-3:2022 with thimbles that shall be in accordance with EN 13411-1:2002+A1:2008.

Thimbles with circular (round) shape, rope eyes or rope grips shall not be used as rope anchorages.

If not otherwise specified in the above mentioned European Standards, the rope-end terminations shall withstand a force of at least 85 % of the minimum breaking force of the rope without rupture.

General

In working and traffic areas to which personnel have access, the components of the chain systems and chain run-on points shall be installed or guarded in such a way that crane operations can be conducted with a minimized risk of trapping or drawing-in of hands or arms into jamming-prone areas.

Chain systems shall have a device to ensure the correct running of the chain over the chain system components and to prevent the chain from jumping out, twisting and jamming. The components of the chain system (i.e. chain, chain sprockets, chain wheels and chain guides) shall match each other in terms of dimensions and materials in such a way that the chains are not overstressed by bending.

The chain system design shall be such that torsion in the chain does not occur.

NOTE Torsion in a chain can be avoided by use of a swivel bearing at the bottom block or by guiding the load and the chain arrangement appropriately.

The design and lubrication plan of the chain system shall ensure that the discard criteria of the chain and associated components due to wear is reached before fatigue rupture.

Chains

For hoisting mechanisms, short link chains shall be in accordance with EN 818-1:1996+A1:2008 and EN 818-7:2002+A1:2008.

Roller chains or leaf chains shall conform to ISO 4347:2015. The working coefficient of roller chains shall be at least 4 for manual and at least 5 for powered hoisting applications. The breaking load shall be verified by testing.

NOTE Design characteristics of roller chain with associated sprocket are given in ISO 606.

Chain wheels and sprockets

Chain wheels and sprockets shall be such that the chains are not overstressed by bending.

With short link chains and roller chains, the chain wheels shall be of mono-bloc design.

Where a chain wheel or sprocket consists of more than one piece, the pieces shall have a positive engagement.

With short link chains and roller chains, positive chain movement shall be effective up to the discard limit of the chain sprocket.

Chain guides and runs

Chain systems shall be provided with devices, which ensure that the chain runs properly over chain drive sprockets and chain guide wheels and which prevent the chain from jumping out, twisting and jamming.

Chain anchorage and attachments

Chain anchorage and attachment devices shall withstand not less than four times the static chain tensile force at rated capacity without rupture.

The free end of an open chain shall be fitted with a chain end stop to prevent it from passing completely through the sprocket assembly housing. The end stop shall be capable of reliably absorbing the expected forces.

Threaded connections shall be secured against un-intentional disconnection. Provisions shall be provided to check the condition of the fastening.

General

In working and traffic areas to which personnel have access, the components of the belt systems and belt run-on points shall be installed or guarded in such a way that crane operations can be conducted with a minimized risk of trapping or drawing-in of hands or arms into jamming-prone areas.

The system shall be such that the belt is subject to uniform loading over its entire width under regular loading conditions.

If an inclined pull is possible, measures shall be taken to avoid excessive loading in the edge zones of the belt, e.g. moveable suspension of the lifting appliance.

Provisions shall be made to ensure tight winding of the belt on to the drum in case of slack belt situation.

Belt drums

The thickness of the drum shell shall be determined by proof of competence calculation or by tests.

Provisions shall be provided to ensure that the belt shall not run off the side of the drum. Rims shall be such that they do not damage the belt that runs against them.

The ratio of the belt drum diameter to the nominal belt thickness shall be greater than or equal to 18.

Belts

Belts shall be selected for the particular application and be made of suitable materials so that they withstand the designed forces for the design life of the belt.

Belt systems shall be designed in such a way that the inspections can be carried out over the whole length of the belt. Inspection interval specified by the manufacturer shall be related to the design life of the belt.

The materials of the belt shall be such that:

— environmental influences do not result in premature failure;

— damage caused by sharp edges or temperature influences do not lead to sudden failure of the belt;

— contact with the belt does not constitute a danger of injury due to the type of belt.

Belts with or without metallic inlay shall only be used if the wear conditions are known and the discard criteria are verifiable. The belts shall have a certificate giving the limit states as defined in the belt’s instructions.

Belt wheels

The strength of wheels shall be determined by proof of competence calculation or by tests. The running surfaces for the belt shall be smooth and free from surface defects liable to damage the belt and the edges shall be rounded.

Belt wheels shall be designed in a way that prevents the belt coming into contact with the edges of the wheel, taking into account the belt tolerance, belt fleet angles and dynamic behaviour of the belt drive system. Wheels shall have protection against the belts jumping out of the wheel (e.g. in the case of a slack belt).

In case of a wheel failure, the belt shall not become detached from the wheel suspension, even with cantilevered arrangements.

The ratio of belt wheel to the nominal belt thickness shall be greater than or equal to 18.

Belt guides and runs

Means shall be provided to avoid belt damage due to the belt moving out of its designed position on the drum or wheels.

Belt systems shall be arranged so that the belts do not become damaged through contact with each other or with other crane parts. In addition, account shall be taken of the gravitational force to ensure that belt edges do not come into contact with wheel or drum flanges.

Belt fastening on drums

The fastening elements of the fixing point of the belt shall be selected taking into account the belt and drum contours. The belt shall not be bent or compressed over sharp edges.

The fixing point of the belt shall be accessible for maintenance and replacement of the belt.

Where two or more belts lead from a drum to a single moving part, provision shall be made to accommodate unequal lengths of belts.

Belt fastening onto the belt drum shall be made in such a way that at least 2,5 times the remaining static force at the fastening device is accommodated when the rated capacity is applied to the hoist taking into account the friction effect of the winding on the drum. The specific friction values of the particular materials shall be considered for calculation of the friction torque. It shall be assumed that lubricants are present on the materials.

Belt drums shall incorporate features so that the belt can be securely attached to them without damage or bending.

A minimum of two windings shall always remain on the drum. Provision shall be provided to prevent the belt from being wound onto the drum in the wrong direction.

Belt anchorage and terminations

Belt anchorage and termination means shall withstand four times the static belt tensile force at rated capacity without destruction of the anchorage and its fastening elements.

Threaded connections on belt anchorage devices shall be locked to prevent un-intentional loosening. The state of the fastening shall be verifiable.

Rod length adjustment means shall incorporate locking against un-intentional loosening. The design of adjustment rod anchorages shall be such that they minimize possible bending stresses in the adjustment rod.

EXAMPLE A turnbuckle at the rope termination is an adjustment rod.

Where rope, chain or belt systems incorporate multiple leads from one or more driving mechanisms to the same load attachment and equal loading of leads is assumed, compensating means between the leads shall be provided.

EXAMPLE Suitable compensating means are for example beams or sheaves.

The working range of compensating beams shall be designed in such a way that the length differences of the two leads can be equalised without causing any impermissible misalignment of the beam. The compensating beam shall be fitted with a movement limitation stop.

Compensating means shall be accessible for inspection, including the leads with small movement in compensating sheaves. Attention shall be taken to systems with small movements in the sheaves due to the inherent risk of corrosion and the difficulty of its detection.

The configuration and flexibility of the load bearing structure shall ensure that the braked wheels have such contact with the rail or ground that safe stopping of the crane or the trolley can be achieved.

NOTE For guidance on crane and runway tolerances, see ISO 12488-1:2012.

The deformation and vibration behaviour of structures shall be such that the associated equipment operates correctly. For limits, see standards for specific crane types.

Fasteners shall be secured in such a way that unintended loosening is prevented, e.g. controlled tightening or lock nuts. Spring lock washers shall not be used.

If rails are integrated into the load bearing beams, they shall be fastened with fit bolts, friction grip bolts together with adequate friction surfaces, or by welding. If the connection of the rail to the structure is not shear-resistant, restraints shall be provided to prevent longitudinal movements and/or creeps of the rail.

General

Cranes that travel at ground level on rails shall be equipped with track cleaners; the clearance between the rail and the track cleaner shall be less than 20 mm.

Where cranes are routinely dismantled, transported and reassembled at a different site, the equipment shall be provided with slinging and attachment points, where weight, shape or dimensions so require. The slinging and attachment points shall be clearly shown in the information for use. The equipment and associated slinging and attachment points shall be designed on the basis of the forces to be expected during transportation, assembly, tests, use and maintenance. The number and arrangement of these points shall be provided so that the equipment cannot change its position in any unintended way during handling.

Where there are hazards on persons or crane e.g. due to heat radiation or falling objects, appropriate protective devices shall be provided.

Rope-braced structures

Guy ropes or bracing ropes used for outdoor applications shall be protected from corrosion, e.g. by means of galvanised steel wires.

NOTE Spiral ropes have higher rigidity and smaller surface exposed to corrosion compared with stranded ropes. However, stranded ropes with steel core can be used for cranes intended for frequent changes of location, due to their better resistance to bending. For definitions for rope types, see EN 12385-2.

Parallel ropes for bracing a component shall be of the same rope construction but may be of different directions of rope lay.

Ropes shall be anchored by means of structural devices, e.g. articulated joints, to be bend-free and prevented from rotating. Ropes shall be capable of being tensioned after installation, e.g. using a turnbuckle without the ropes being subjected to any additional twisting stresses.

Ropes shall be terminated in accordance with 4.3.6.6.3.

The minimum radii of rope saddles and minimum diameters of posts shall be in accordance with Table 6.

Table 6 — Rope saddles and posts

Rope saddles shall have a groove matched to the rope diameter.

Counterweights

Counterweights and their components shall be accommodated in housing or secured in such a way that they cannot become loose, and their position in relation to each other and to the crane cannot change unintentionally. Moveable counterweights shall be guided, have protective covering at all accessible points, and their movements outside the designed working range shall be limited by the construction (e.g. by end stops).

Counterweights of cranes that can be removed totally or partially for transporting and using the crane in different configurations shall be designed so that:

— parts shall not become mixed up, and

— assembly and dismantling are possible without additional hazards.

The weight shall be marked on removable parts of counterweights.

Counterweights, their fastening systems and covers shall be such that it is not possible for their mass to change as a result of the effects of weather or losses.

If moveable counterweights are not automatically moved as a function of the jib position, the relevant position of the counterweights shall be indicated by a display that is visible from the operating position. This indicating device is not required if the position of the counterweight is clearly recognizable from the driver's cab.

Controls and control devices shall be in accordance with EN 13557:2024.

Control devices shall be selected so that no pressure and flow disturbances can occur, and their level of performance is kept.

Control devices shall be arranged in the control system so that no unintentional functions of the systems (by reaction or similar) can occur. In particular, measures in accordance with EN ISO 14118:2018 shall be taken to prevent unexpected start up.

Control devices in control systems shall be selected and arranged in such a way that in the case of a power failure spring forces return the control into a neutral position.

Emergency stop

Where an emergency stop is installed, it shall be in accordance with EN ISO 13850:2015.

Operation of the emergency stop shall interrupt the energy supply and stop all motions.

NOTE Pneumatic direct controlled hoist fulfils the requirements of EN ISO 13850:2015, when the actuating elements are positively connected with the energy switching part.

Fluid power protection

Disconnecting from the fluid power supply shall be possible without creating hazardous movements.

NOTE See EN ISO 14118:2018.

In the case of power loss, the zero position of the power valves shall be reached automatically.

Mechanical protection

Moving parts (such as cylinders) shall be arranged or covered so that their exposure to the environment and contact with other objects or persons is prevented.

Cylinders in load lifting attachments (such as clamps and grabs) may be without guards if their protective effect is considered as insignificant in the expected working conditions.

Those adjustable safety and performance related devices that can cause a hazardous situation, if their pre-set values are modified, shall have means to prevent or indicate their readjustment by non-authorized persons. Devices outside of lockable switchgear cabinets shall have irreversible indicators, such as lead-seals, covers, or cup, which shall be destroyed before a readjustment. An irreversible indicator is not necessary if special tools (specified in the instructions of the adjustable safety device) are necessary for readjustment.

Each hydraulic circuit shall be provided with means for checking the pressure.

Hydraulic systems shall be such that possible bursting in hoses or expanders do not cause any damage to adjacent components, and are positioned away from access areas. Protective elements, e.g. hoods, covers, oil pans, etc. may be used.

The fluid power systems shall facilitate the required test pressure during the dynamic and static overload tests as specified in the European Standards for the particular crane types.

For hydraulic systems, no measurable unintended leakage shall be permitted other than slight wetting insufficient to form a drop during the overload tests.

General

Hydraulic equipment shall be in accordance with EN ISO 4413:2010 and the following clauses.

Hydraulic systems shall comprise components and auxiliary materials that are compatible and suitable for the given environmental conditions (temperature, humidity).

Materials and auxiliary materials

The materials used, (e.g. metals, pressure liquids, grease, coolant), shall be compatible among each other.

Pressure liquids shall be selected so that internal leakage and its effects are kept as low as possible.

The composition of the liquids shall be so that it does not represent any risk for the operating personnel of the machine.

If grease can get into contact with the pressure liquid, it shall be compatible with the pressure liquid.

Elastomeric, polyamide, rubber or equivalent material used for static and dynamic sealing systems, flexible and semi-rigid lines and for coating several components (e.g. reservoirs) shall be compatible with the other materials of components and systems and withstand pressures acting on it.

NOTE For elastomeric materials, see ISO 6072.

Energy converter

Cylinders

Hydraulic cylinders for any movements that work against gravity shall be equipped with automatic means, e.g. load holding valves, to prevent any uncontrolled movement in the case of hydraulic line failure. Where load holding valves are used, they shall be connected directly to the cylinders exclusively using metallic connecting elements. Hydraulic connections between the load holding valve and the cylinder shall consist of steel tubes; hoses shall not be used. In case more than one cylinder is used for such movement, provisions shall be made to ensure that all load holding valves close at the same moment.

The piston and the piston rod shall be connected to each other so that they shall not detach while operating.

Telescopic cylinders with two or more telescopic sections shall be such that the pistons are prevented from moving out of the cylinders. The extension or the re-entry of the stems of the telescopic cylinders shall be carried out in a defined order.

The seal material(s) shall be selected so that they are compatible with the chemical composition of the fluid used and withstand the temperature, rated pressure and rated speed, without excess leakage or extrusion.

Cylinders shall be fitted in the equipment so that no impermissible load from reaction occurs.

The strokes of cylinders shall be limited by means of mechanical limit stops, provided these are designed in such a way that all forces occurring can be taken up. Otherwise, the movements shall be limited by other devices (cushioning in the end positions, limit switches).

Motors and Brakes

Hydraulic motors for any movements that work against gravity shall be equipped with load holding valves to prevent lowering in the case of a pressure failure. The load holding valves shall be connected directly to the motors exclusively using metallic connecting elements. Hydraulic connections between the load holding valve and the motor shall consist of steel tubes; hoses shall not be used. In case more than one motor is used for such movement, provisions shall be made to ensure that all load holding valves close at the same moment.

The hydraulic motors shall be capable of developing a torque of 1,4 times the maximum torque required to hold and move to a safe position a load of the rated capacity of the motion concerned.

Loads shall be held securely by use of brakes or self-locking gears.

NOTE Where hydraulic motors are used, internal leakage can cause excessive creep.

It shall be possible to release the brake only if there is sufficient pressure to maintain the load.

Connecting elements and accessories

Tubes

Tubes shall be secured so that impermissible additional load (pressure, bending, temperature) does not occur during operation and wear and corrosion is avoided. This can be done by arranging flexibility by bends and by supports.

The calculation of the necessary tube wall thickness shall be done in accordance with EN 13480-3:2024.

Hose assemblies

Hoses shall be installed so that no torsional strain occurs during fitting. The permissible bend radius shall not be less than the minimum defined by the hose instructions and contact with obstacles or adjacent components shall be avoided.

In order to reduce the risk of fatigue fracture of hoses, the instructions of the hose shall be followed for the hose installation.

The rated burst pressure of hoses shall be equal or greater than four times the maximum operating pressure.

The marking on the hoses and fittings shall be in accordance with EN ISO 4413:2010.

When assembling fittings to hoses, the hoses shall not be older than four years as hoses lose their properties over time even when stored in good conditions.

When specifying the lifetime of hoses, the usage under high temperatures, bending changes and impulse frequencies shall be taken into account.

NOTE For guidance, see EN 853.

To enable checking the surface of the hoses and the manufacturing date by inspection, the hoses shall not be painted.

Where damage on the hoses causes a risk of lashing, means shall be installed to prevent the lashing.

When failure of a hose assembly can constitute a whiplash hazard, the hose assembly shall be restrained or shielded by suitable means.

Hoses shall be installed in such a way as to prevent damage from lashing i.e. the violent movement of the hose due to pressure changes in the hydraulic fluid.

Where hose leakages can cause risk of fire, the hoses shall be shielded.

For hydraulic hoses containing fluid with a working pressure of more than 5 MPa (50 bar) and/or having a temperature over 50 °C and which are located within 1,0 m of the crane operator position at a fixed control station, deflecting shields shall be provided to protect the crane operator from hazards arising from sudden hose failure where no other component or structure of the crane performs this function.

Hoses intended to withstand a pressure of more than 15 Mpa shall not be fitted with reusable end fittings.

Hydraulic hoses that are used for the connection of interchangeable equipment shall be designed or identified or located to avoid any incorrect connection causing a hazard, e.g. to reverse the direction of movement of a hydraulic cylinder.

Reservoirs

The reservoir shall be equipped with a fluid level indicator. The reservoir shall contain all the fluid that can flow from the system during normal operation or maintenance in accordance with the intended use. The reservoir size shall be such that a sufficient fluid quantity within the permissible temperature ranges is available at all operating states.

The reservoir shall be located in the installation so that the necessary supply of fluid to the pump is ensured.

Means (e.g. breathing of the reservoir) shall be provided to ensure that impermissible pressure states in the reservoir do not occur.

Additional protective measures for hydraulic equipment

Overpressure and overspeed

Hydraulic systems shall be protected against overpressure of the liquid and overspeed of the load. These protective devices shall act on the hydraulic circuits and elements so that the flow rate and pressure are limited to admissible values.

Fire

The design of the hydraulic systems shall be such that leaking oil cannot cause a fire. Devices reaching higher temperatures when being operated (also electrical equipment through sparks or short-circuit) shall be thermally separated from devices carrying oil by means of a suitable enclosure, in order to avoid ignition. Under these circumstances, flame-retardant hydraulic liquid shall be used

NOTE See ISO 7745.

Inspection and check

Inspection and check of hydraulic systems shall be done in accordance with EN ISO 4413:2010.

General

Pneumatic equipment shall be in accordance with EN ISO 4414:2010 and the following clauses.

All components and materials of equipment shall be compatible and capable of safe functioning in the presumed ambient conditions.

Pneumatic cylinders for any movements that work against gravity shall be equipped with a securing system to prevent creeping.

It shall be possible to release the securing system only if there is sufficient pressure to maintain the load.

Air pressure

Sufficient air pressure shall be available for all the operating states at any point of the equipment in order to fulfil all functions. A loss of pressure shall not result in a fall of load or uncontrolled displacement of the load or crane.

Maximum speed

Significant differences between lowering and lifting speeds which can exist in hoists with pneumatic drives shall be taken into account in the design.

Ambient conditions

Ambient conditions shall be defined and taken into account in selection of the equipment.

Energy converter

Cylinders

Pistons and piston rods shall be connected in such a way that they shall not disconnect. Cylinders shall be arranged in such a way that any hazard due to movements is excluded. If required, covers shall be fitted.

Telescopic cylinders with two or more telescopic sections shall be such that the pistons shall not move out of the cylinders. The extension or the re-entry of the stems of telescopic cylinders shall be carried out in a defined order.

Motors

Motors shall be such that they do not create hazards either as a result of heating up or icing up.

Brakes

Hoists using pneumatically released brakes shall be such that unintentional lowering of load is prevented.

NOTE This requirement is fulfilled, for example, if the brake releases only when the motor provides a sufficient moment for holding the load or for controlling the load-movement.

Control units/control systems

System-inherent reaction times as a function of control line lengths shall be reduced to a minimum.

Machine movements shall not be triggered by venting control lines.

Control equipment for starting pneumatically operated cranes shall automatically return to the zero position after being released.

Power valves zero position venting cross sections shall be dimensioned to prevent malfunction of the brake.

In addition to the requirements specified in this clause, the fixed load lifting attachments shall conform to the requirements of EN 13155:2020 where applicable and not in contradiction with this document.

The stress history classification (S) of the fixed load lifting attachment shall conform to the usage parameters specified for the crane (C, Q, P) in accordance with EN 13001-1:2015.

Different S-classification is permissible, but that shall be clearly marked on the attachment and in the crane documentation.

Hydraulic, pneumatic lines and electric cables for fixed load lifting attachments shall be installed in such a way that no damage is caused during foreseen operating processes.

Fixed load lifting attachments whose capacity can be impaired by wear, corrosion or similar damaging effects shall be designed in such a way that their condition can be checked by inspection. The limits of wear, corrosion and deformations shall be taken into account when designing the fixed load lifting attachments.

Connections and individual parts of fixed load lifting attachments shall be designed so that they are prevented from unintentional loosening.

Bottom blocks shall be provided with additional weights, if necessary, to ensure that lowering with no load from the highest position is possible.

The fixed load lifting attachment shall be tested for fitness for purpose together with the crane by using the test conditions specified for the crane.

Measures shall be taken to prevent unintentional release of the load due to grounding or impact. The backup battery for a load handling magnet shall be able to hold the load for at least 20 min after loss of the power supply.

When selecting the materials, the ambient effects shall be taken into account, e.g. temperatures, thermal radiation when transporting hot molten materials.

Hooks for cranes shall be forged, cast or made of rolled steel plate. Cast hooks are not permissible for high risk applications (see 4.9). There shall be no welding on the load bearing parts of hooks.

Means shall be provided to prevent unintentional detachment of the load, unless this is avoided by the application. The requirement can be fulfilled e.g. by providing a safety device such as a safety latch closing the opening of a hook or by shape of the hook.

Forged and cast hooks shall be in accordance with EN 13001-3-5:2016+A1:2021.

A plate hook can have one or several plate elements. These shall be cut from steel plate so that the rolling direction of the plate is parallel with the loading direction of the hook. The inner edge of plate elements shall be finished smooth after cutting by machining or grinding. Plate elements in a laminated hook shall all be of equal thickness and of equal shape and shall be connected by riveting.

Where a plate hook is equipped with a wear or impact protection, these shall be easily removable for inspection of the hook. For a typical arrangement of wear or impact protection of laminated hooks, see Figure 3.

A laminated hook with a minimum of four plate elements is considered to be a single failure proof construction.

Load capacity of a plate hook shall be determined in accordance with EN 13001-3-1:2012+A2:2018. Evaluation of stresses shall be done either analytically (by applying curved beam bending theory in accordance with EN 13001-3-5:2016+A1:2021 or by means of finite element modelling) or experimentally by measurement.

Key

Figure 3 — Laminated hook

Where inherently safe design measures are not practicable, appropriate safeguarding means shall be applied in accordance with EN ISO 12100:2010. Safety related functions shall conform to EN 12077‑2:2024 as amended in this document.

The risk reduction may comprise of one or more safeguards for a specific function; e.g. limiting of movement may consist of a mechanical restraint (a mechanical end stop/buffer) and a limiting function in the control system. In such a case, the requirements for each subsystem are less stringent than if applying only one safeguard.

A performance level shall be evaluated for each safety related function of the control system in accordance with EN ISO 13849‑1:2023. It shall either

— conform to the required performance level as specified in the relevant product standard

or in case a relevant product standard is not available,

— conform to the required performance level as determined by risk analysis.

In determining the required performance level, account shall be taken also of other risk reduction measures than the control system, such as mechanical protecting devices (e.g. end stops, buffers, force limiters) and duplication of protective systems. At least the following safety related functions shall be addressed:

— overload protection;

— limiting of overturning moment;

— limiting of relevant motions (e.g. hoisting, luffing, slewing, travelling);

— emergency stop;

— over speed control of variable speed hoisting drives.

The control system is defined in EN ISO 12100:2010, Annex A to end at the output of the power control elements. By this definition, e.g. mechanical brakes, load holding valves, gearboxes and other comparable elements are considered to belong to the operating part of the system and not to the safety related control system.

Where it can reasonably be foreseen that the loss of drive power can result in a hazardous situation due to a suspended load, means shall be provided to enable the load to be brought to a safe position.

EXAMPLE This can be achieved, for example:

—   by a device on the brake for manual release of the brake allowing the loads to be lowered or the crane to be moved in a controlled manner, or

—   the rope anchorage being designed in such a way that it can be lowered by an auxiliary hoist, or

—   supporting the load with spacing material.

All movements with limited operating range shall be interrupted and stopped within the specified slowing-down path by means of limiters. Examples of movements are:

— the lifting and lowering movement of hoisting mechanism;

— the luffing movement of a jib;

— the telescoping movement of a jib;

— the slewing movement when limited;

— the travel movement of the trolley;

— the travel movements of the cranes running on rails.

NOTE Suitable means are e.g. buffers, electrical limiting devices, adjustable sliding couplings, and pressure valves.

If the movement is limited by buffers only, these buffers shall absorb the kinetic energy of the moving masses and limit the forces so that the component strength of the crane installation is not exceeded.

Buffer forces shall be calculated from the kinetic energy of 85 % of the nominal travelling speed of the moving crane masses excluding the freely suspended load (free to sway horizontally) and for trolleys from the kinetic energy of 100 % of the nominal travelling speed of the moving masses of the trolley excluding the freely suspended load.

NOTE For more guidance, see EN 13001-2:2021.

Where braking is actuated by a limiting function before the buffer collision occurs:

— for cranes and trolleys not exposed to wind forces, the buffer forces shall be calculated from the kinetic energy of 70 % of the nominal travelling speed of the moving masses excluding the freely suspended load;

— for cranes and trolleys exposed to wind forces, the buffer forces shall be calculated from the kinetic energy of 85 % of the nominal travelling speed of the moving masses excluding the freely suspended load. Where the wind forces are included in the buffer calculation, 70 % of the nominal travelling speed may be applied.

Where friction grip type connection is used between the end stop and its supporting structure, the connection shall be designed with a specific resistance factor γ_SS = 1,8, in accordance with EN 13001‑3‑1:2012+A2:2018.

In the calculation, the resistance factor to motion due to the frictional contact between wheels and rails may be set to f = 0,18.

The operator of the crane shall not be exposed to a deceleration exceeding 4 m/s² when the movement is limited.

Where a second limiter (backup limiter) is provided, it shall be installed so that it does not activate if the first limiter stops the motion as intended.

Recoil prevention devices shall be provided if there is a risk of tipping over backwards if the load is suddenly removed e.g. in the case of luffing jibs. An appropriate substitute mass shall be entered in the calculation of the kinetic energy and the buffer forces in lieu of that of the rotating parts or translational moving parts.

Means shall be provided to prevent the crane or trolley from leaving the track, falling or overturning in the event of a single wheel failure. This can be achieved by inherent design or the provision of protective devices.

Where the hoisted load or sudden release of a load can cause a wheel of the trolley or crane to rise more than 70 % of the flange height or guiding height of the roller, means of retaining the crane or trolley shall be provided.

Contactless guided cranes (e.g. inductively guided cranes) shall be equipped so that their travel is stopped immediately, when the guiding system is interrupted or a hazardous fault is detected.

The tracks of rail-mounted cranes and of trolleys on cranes shall be fitted with end stops so that the cranes or trolleys are prevented from leaving the track.

Rails, switches and turntables shall be interlocked so that the cranes or trolleys can run over them without derailment.

Means shall be provided to prevent racks, spindles, pistons or telescope sections leaving their guides unintentionally.

Cranes prone to tipping over when coming into contact with travel end stops shall be provided with means of slowing down their travel speed before contact with the end stops is made.

Where dead weight of a crane or trolley does not provide sufficient/adequate stability, they shall be fitted with devices that prevent their tipping over.

Where a wind speed monitoring system is provided, it shall warn the crane operator when the wind speed level approaches the maximum design level of in-service wind. The warning level shall be set such that the crane operator has enough time to finish the on-going lifting operation, to move the crane to the storm-locking position and to bring the crane out-of-service including all necessary operations specified in the operation manual.

Wind speed at which wind warning is given can be calculated as follows:

(8)

where

In the shutdown condition, the crane shall be able to withstand the specified out-of-service wind without tilting and drifting. The out-of-service wind force shall be calculated in accordance with EN 13001‑2:2021.

For movements held against drifting through friction between braking wheels and a runway, the values of individual wheel loads and the limitation of transmissible torque due to friction shall be taken into account. The friction coefficient shall be taken in accordance with the Table 3 in 4.2.8.2.3.

Where the crane does not have sufficient inherent capacity to avoid its tilting or drifting and such state cannot be achieved by changing its configuration or position, additional means of locking shall be provided, e.g. tie downs or anti-drift devices. Activation of the locking devices while the crane is travelling shall be prevented. Holding action of the locking devices shall not require continuous power. Examples of anti-drift devices are:

— positive locking (pin, bolt, chain, end stop, etc.);

— rail tongs actuated by external force (manually operated or automatic);

— self amplifying friction type clamp;

— rail brake of the friction type dependent on the wheel force on the rail head.

Where several cranes are manoeuvred simultaneously in the same place with risk of collision, it shall be prevented, e.g. by providing buffers or anti-collision devices.

Buffers between the cranes or trolleys shall be seen as sufficient anti-collision devices for risk reduction, if they are able to absorb the kinetic energy resulting from the moving masses in such a way to prevent the following:

— the strength of the components of the crane installation being exceeded;

— the falling or tilting of the cranes or trolleys;

— the dropping of the load;

— the load swaying in a hazardous manner, and

— the operator being exposed to a deceleration exceeding 4 m/s².

In other cases, anti-collision systems shall be provided.

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

— the ability to reduce the speed of the crane parts moving towards a collision;

— the ability to bring the moving crane parts to a stop before a collision occurs.

NOTE Warning of approaching collisions can be required in some cases.

When materials can deteriorate in an unpredictable manner (e.g. non-metallic materials subjected to the effects of wear, corrosion, creep or UV-radiation), the system shall be so designed that an uninterrupted force flow is retained in case of a failure of such materials (e.g. plastic elements in couplings, fastening of the cabin with rubber dampener).

Selection of materials considering ambient temperature

Materials shall be selected for an ambient temperature range of the crane.

The material used in the equipment of the crane shall be selected so that the equipment maintains its properties in the operational and out-of-service temperature specified for the crane. If this is not possible, warming up/cooling down systems and/or standby warming shall be arranged.

Protection against hot parts due to operation

Surfaces of parts of the crane shall have their temperature limited in the following three cases:

a) surfaces accessible from the working zone of the crane operator;

b) surfaces accessible by crane operators on their way to the control station;

c) surfaces accessible from the traffic zone.

On access ways and working areas where unintentional touching of potentially hot surfaces in accordance with EN ISO 13732-1:2008 is likely, these surfaces shall be guarded.

Protection against hot parts due to ambient conditions

Parts, which can become hot due to ambient conditions and require intentional touching shall be made from materials of low heat conductivity (such as plastic, wood).

When designing or selecting equipment for cranes, the intended use of which carries a high risk application, the safety requirements or measures of 4.9 shall apply. Although these clauses are focused on the hoisting mechanism, effects of increased severity of possible harm related to other motions of the crane shall also be considered.

Increased severity can be caused by e.g.:

a) danger to cause a chain reaction: a failure of the hoisting mechanism can endanger the strength of the whole crane or large parts of it;

b) release of large amount of thermal energy: e.g. hot molten metal;

c) release of dangerous materials, chemicals or gases: the crane is handling dangerous materials or transporting loads over receptacles or pipelines containing such dangerous materials.

General

The probability of failure in the load bearing chain shall be decreased by application of one or more of the following methods:

a) apply a risk coefficient in the design of components;

b) duplicate components in the load bearing chain which prevent the load from being dropped in the event of single failured component. These additional components are part of the load bearing chain during normal use;

c) specify an enhanced inspection and maintenance program for the crane, e.g. upgrade the criteria for replacing parts, define shorter inspection intervals, provide a condition monitoring system;

d) upgrade the level of quality control in some or all points of the process, e.g. enlarge the scope of non-destructive testing, mark parts for traceability of material.

Measures belonging to the groups a) and b) of the above mentioned methods are specified in 4.9.2.2 to 4.9.2.3 and 4.9.3. Measures in the group c) shall be detailed in the maintenance manual, see 6.4. This document does not deal with group d).

Applying of a risk coefficient

Where this method is used, load bearing components shall be designed with an increased value of design hoist load m_Hn obtained by multiplying the gross load m_H, by the risk coefficient γ_n in accordance with EN 13001-2:2021:

(9)

where

NOTE 1 The gross load is the total suspended load on the crane (see ISO 4306-1:2007).

NOTE 2 Different values of risk coefficients can be specified for different parts of the crane.

NOTE 3 The risk coefficient γn applies both on static and fatigue design of equipment.

Duplicating components

Duplicated components of hoisting mechanism shall be calculated for both conditions as follows:

a) Regular loading condition, where all the components of the mechanism operate as a whole sharing the hoisted load. This shall be assigned to Load Combination A in accordance with EN 13001-2:2021 and used in the proof of fatigue strength of the mechanism.

b) Exceptional loading condition, taking into account a failure of any single component of the mechanism. The loading on the remaining part of the mechanism during the failure incident shall be assigned to Load Combination C (EN 13001-2:2021) and used in the proof of static strength of the remaining part. Dynamic impact due to failure shall be taken into account, either determined by analysis or a dynamic impact factor equal to 1,5 on the total load shall be used for the remaining system. The remaining steel wire rope shall fulfil as a minimum rope resistance factor γ_rb = 2,5 as defined in EN 13001‑3‑2:2014.

Components, which do not distinguish between fatigue/static design criteria (e.g. brakes, electric motors), shall be designed for a failure condition similarly as for regular loads.

Risk coefficients specified for the application in question, need not to be applied for duplicated components.

The design of the duplicated load suspension system shall minimize the sway and tilting of the load if one of the suspensions breaks, so as not to cause a hazard.

In the case of duplicated load suspension systems, the compensating device, e.g. a compensating beam, shall be fitted with damping devices that minimize the impact forces if a suspension breaks. The device shall be equipped with a limiter that will stop the hoisting movement, when the compensation range is exceeded. Clearance to the ceiling and headroom restrictions, as appropriate shall be considered in the design of compensating beam.

Examples of duplications of components in hoisting mechanisms are given in Table 7.

Table 7 — Examples of arrangements of duplication of components

NOTE This document does not deal with non-fixed load lifting attachments, which are also designed in accordance with the arrangement selected for the crane.

Control system of the hoisting movement

The safety related control functions defined in 4.7.2 shall conform to performance level d of EN ISO 13849-1:2023.

Unless the hazard is eliminated by other means, a backup limiter for the upper limit of the hoisting shall be provided.

Where a backup limiter is provided, it shall activate both the service brake and the backup brake where provided. This requirement does not apply to mechanically activated backup brakes.

Devices for safety functions shall be provided with equipment necessary for the verification of its function. This equipment shall allow the verification to be carried out without a need for a disconnection of conductors or a manual override of terminals. See also 4.2.5 and 6.4.

A display shall be provided for hoisting mechanisms with rated capacity greater than 10 t, showing the crane operator the actual hoisted load or percentage of the rated capacity.

General

Where several bridge cranes can be operated simultaneously in the same place, with risk of collision, an anti-collision system shall be provided.

Where a duplicated rope system is required (i.e. the rated capacity is greater than 40 t, see Table 8), supports shall be provided which prevent drop of the hoist drum in the case of a shaft or gear housing break. The backup brake shall function even with the drum resting on the support. The system shall indicate the hoist drum resting on the support.

For hoisting mechanisms with rated capacity greater than 5 t, a load history recorder shall be provided.

Where the lifting operations need more than one hoisting mechanism working simultaneously, the control systems shall be interconnected, so that any interruption of the operation on one mechanism shall have a corresponding effect on the other.

Where debris deposits prevent visual inspections of the steel structure, the fatigue strength resistance factor γ_Mf = 1,25 shall be used for fatigue design in accordance with EN 13001‑3‑1:2012+A2:2018.

Cranes handling hot molten metals shall be provided with derailment protection for crane and trolley.

The main girder of box construction without possibility of inside inspection shall be designed with a risk coefficient γ_n in accordance with EN 13001‑2:2021.

Decreasing the risk dropping load

General

Cranes whose primary application is handling of hot molten metal may contain equipment or design circumstances where the rules given in 4.9.3.2.2 to 4.9.3.2.5 need not be applied. Such cases are

— an auxiliary hoist intended for maintenance purposes only;

— a loading condition of the main hoisting mechanism, where this is used in an application to lift heavier loads than those in handling of hot molten metal e.g. for maintenance or repair purposes. A switch to change the use mode from handling of hot molten metal to special heavy lift and a visual indication of the selected mode shall be provided.

NOTE See EN 60204-32:2008, 9.2.4.

Where an auxiliary hoist is intended to tilt a foundry ladle laden with hot molten metal, the auxiliary hoist shall be designed for this particular purpose as a high risk application. As a deviation to general requirements of 4.9.3, the auxiliary hoist may be designed in accordance with the requirements of item No. 1 of the Table 8 for all rated capacities, i.e. the risk coefficient γ_n = 1,5 applied to the whole mechanism, including the fixed load lifting attachment. The final safety ratios, after applying all relevant design factors, shall be at least 5,6 for ropes and 6,3 for chains, respectively.

Decreasing the probability of failure of the hoisting mechanism

The minimum requirements for the components of the load bearing chain of hoisting mechanism shall be in accordance with Table 8. The requirements are aimed at decreasing the probability of dropping the load with high thermal energy by measures proportionate to the consequences. Methods to achieve this employ increased safety factors or duplication of components of load bearing chain in the hoisting mechanism and increased reliability of the control system.

NOTE These requirements do not take into account the need for hoisting or lowering the load following a failure of a component.

Table 8 — Additional requirements for the load bearing chain of the hoisting mechanism handling hot molten metal

Duty parameters of hoisting mechanism

The hoisting mechanisms shall be designed at least to load spectrum factor kQ and number of work cycles C fulfilling the condition kQ × C ≥ 32 000.

NOTE For k_Q and C, see EN 13001‑1.

Design of rope systems

For hoisting mechanism with steel wire rope, the following shall apply:

— multilayer spooling on hoist drum shall be prevented;

— where the rope climb out of the drum groove is possible, a mechanical rope guide or device shall stop the hoist movement;

— rotation resistant steel wire rope is not allowed except in a single fall rope suspension system or two-fall reeving systems where there is a risk of instability of the hook block.

Design of hooks

The hooks shall be made either as single failure proof hooks (see 4.6.2) or designed with risk coefficient γ_n = 1,5 in accordance with 4.9.2.2.

Forged hooks shall be made of a material resistant to ageing.

Bearings shall be designed to withstand prevailing ambient temperatures.

Design of gear housing of hoisting mechanism

Where the gear housing is equipped with a breather, this shall be equipped with a filter.

Due to their lower ductility, which will induce lower resistance against impact following foreseeable misuse, gear housings made of grey cast iron in accordance with EN 1561:2023 or aluminium alloys are not permissible in hoisting mechanisms carrying hot molten metal for rated capacity above 40 t.

Decreasing the probability of failure of the control system of the hoisting movement

A backup limiter for the upper limit of the hoisting shall be provided. The backup limiter shall be mechanically activated directly by the hook block or other fixed load lifting attachment. To exclude common cause failures, activation of the backup limiter shall be mechanically and electrically separated from the first upper limiter.

With an exception of chain hoists, operation of the additional safety equipment shall be indicated to the crane operator, e.g. backup brake, equaliser device, backup limiters, backup supports for the rope drum.

High ambient temperature and dust shall be considered in the choice of electrical and other apparatus, or adequate cooling shall be arranged.

Protection against thermal radiation and ejection of hot particles

General

If the control station is exposed to thermal radiation and/or ejection of hot particles, it shall be provided a cabin with thermal protection.

To avoid ageing of material due to the exceeding of the maximum permissible equilibrium temperature due to thermal radiation from hot molten masses, either suitable material shall be selected, or additional protection shall be provided.

To avoid the sticking and blocking of moveable parts due to the ejection of hot particles, additional protection of these parts shall be provided; e.g. chain curtain and/or thermal protection plates.

All parts subject to hazard from thermal radiation and the ejection of hot particles shall be considered starting with those nearest to the open surface of the hot molten mass, e.g.:

— hook block;

— load lifting attachments (with holding slings, straps, bolts, rollers);

— rope on drum;

— trolley.

The thermal protection plates shall be designed and attached to load lifting attachments so that they do not prevent their regular inspection. The thermal protection plates shall be made from material resistant to heat and mechanical damage. There shall be insulation between the protection plate and the protected part (for instance air gap, mineral wool, etc.).

Design of thermal protection plates shall also take into account the clearance to steel wire rope with consideration to load sway.

Cabins and access

The cabin windows shall be made of double glass for insulation. The outer glasses shall be of safety type (not laminated).

The cabin shall be equipped with air conditioning including filtering and with a fire extinguisher.

Based on a risk analysis, shields may be required above and/or in front of the cabin.

An emergency exit facility separate from the normal exit shall be provided from the cabin.

The methods to be used to verify conformity with the requirements given in Clause 5 are detailed in Table 9.

Table 9 — Methods to be used to verify conformity with the safety requirements

Information and instructions for the commissioning, use, regular tests, inspections and maintenance of the equipment shall be included in the instructions of the crane.

The provisions of EN ISO 12100:2010, 6.4 and Clause 17 of EN 60204-32:2008 shall apply.

Operating principles of safety devices and requirements in the event that these devices are triggered, e.g. resetting the emergency stop device, shall be described in the information for use.

Features especially designed for such a situations (e.g. manual release of hoist brakes) shall be described and information on safe use shall be provided within the information for use.

All maintenance and repair work required to ensure the safe functioning of the equipment shall be described, e.g:

— lubrication of ropes, chains, gearboxes, bearings, hooks, etc.;

— inspection of wearing parts such as ropes, chains, hooks, belts, brake linings and wheels. Specification of test and inspection intervals and wear criteria;

— discard criteria of ropes in accordance with ISO 4309:2017;

— rope reeving and spooling directions onto the drum;

— checks and/or adjustment of safety devices;

— instructions for replacement of a hook nut and a hook;

— protection of electrical devices and bearings when arc welding is carried out on the crane;

— prevention of excessive paint from being applied to critical areas, for example limit switch, drain hole, etc.

Attention shall be taken in the inspection instructions to leads with small movement in compensating sheaves.

Instructions shall be given for the operation time of hoses, based upon ageing of their material. Information provided on the marking of hoses shall be referred to, see also 4.5.4.4.2.

Instructions shall also be given for maintaining the braking capacity of mechanical brakes, which are subject to minimal wear due to the performance of their operational systems.

NOTE This can occur with electrical braking systems or backup brakes.

If during maintenance and repair work, specific hazards to people can occur, e.g. due to potentially hot parts, precaution of those hazards shall be provided in the maintenance manuals.

Position and correct use of slinging points or slinging position for handling of equipment shall be described.

In cases of high risk application due to failure of a mechanism, the probability of occurrence shall be decreased by ensuring the operational condition of this equipment during crane use. Means of increasing the reliability of the equipment are e.g.:

— interval between inspections is shorter than usual;

— scope of inspections is more thorough than usual;

— inspection methods are more accurate than usual;

— discard criteria is more stringent than usual.

The appropriate actions, methods and criteria shall be given in the maintenance instructions.

A discard criteria for ropes in duplicated rope systems in high risk applications shall be specified. Criteria specifying the number of broken wires shall reduce the number to 70 % of that given in ISO 4309:2017. Where parallel-closed or rotation resistant steel wire rope is used in the hoist movement, discard criteria of the rope, in addition to what is given in ISO 4309:2017, shall also be expressed in number of hoisting cycles in the maintenance document.

The number of hoisting cycles shall be based on the expected displacements of the hoisting motion, type of steel wire rope, the load spectrum, environment and the reeving system (the number of sheaves, orientation of sheaves, reverse bending cycles etc.).

As a precaution, in the case of a component failure in a duplicated or single failure proof system, the manufacturer shall instruct the user not only to replace the failed component, but also the equivalent component in the parallel part of the system.

Procedures shall describe how to verify safety systems, e.g. the backup brake and backup limiter. The backup brake can be verified on a lower speed. The backup upper limiter for hoist range shall be tested by disconnecting the first limiter and then the motion driven through at both low and high speed.

Instructions shall be given for monitoring of design life of equipment in accordance with ISO 12482:2014.

In addition to the provisions contained in EN ISO 12100:2010, 6.4.4 and EN 60204-32, equipment shall be provided with the following information in a lasting and legible manner, if applicable:

— specifications of the hydraulic connection in the case of an external hydraulic power supply;

— specifications of the pneumatic connection in the case of an external pneumatic power supply;

— specifications of the electrical connection in the case of an external electrical power supply.

Interchangeable accessories, supplied as part of the crane, shall be marked clearly and permanently in order to avoid misuse and/or faulty assembly; e.g. components of supports structures for different configurations shall be marked with the name of the manufacturer or supplier, type number, serial number.

Separate lifting devices (e.g. lifting beams, grabs) shall be marked with their lifting capacity and volume, where relevant.

1. 
   (informative)
   
   List of significant hazards

Table A.1 contains all the significant hazards as listed in CEN Guide 414:2017, hazardous situations and events, as far as they are dealt with in this document, identified by risk assessment as significant for equipment within the scope of this document, and which require action to eliminate or reduce the risk.

Requirements set for equipment included in this document do not necessarily cover all hazards, which can occur due to installation of equipment into a crane. Such hazards shall be evaluated and actions taken in the design of the crane.

Table A.1 — List of significant hazards and associated requirements

1. 
   (informative)
   
   Selection of a suitable set of crane standards for a given application

Table B.1 — Crane standards

1. 
   (informative)
   
   Design of rail wheel flanges

The radial wheel force is typically proportional to the wheel diameter and the width of contact between the wheel and the rail. The lateral force applied to the wheel flange is proportional to the vertical force. To resist the bending and shear stresses due to the acting lateral force on the flange, the thickness should increase with the wheel diameter and width.

The flange height should be proportional to the wheel diameter in such a way that the risk of the flange climbing on the top of the rail is minimized.

According to practiced design principals, wheel flanges are acceptable when the thickness and height of the flanges meet the following conditions.

Flange thickness t is calculated by:

(C.1)

Flange height h is calculated by:

for D ≥ 125 mm (C.2)

for D < 125 mm (C.3)

where

The formula of the flange thickness applies to wheel materials with a nominal value of ultimate strength equal to or greater than 600 N/mm².

For other materials, e.g. bronze, stainless steel, hardened flange surface, the wearing properties may allow or require different values of the flange thickness.

Figure C.1 — Wheel dimensions

The root radius R of the wheel flange shall be greater or equal to 1 mm (R ≥ 1 mm) and the flange angle β shall be greater or equal to 1 degree (β ≥ 1°), see Figure C.1.

Values rounded off to 0,5 mm are given in the Table C.1 for a selection of values of B.

Table C.1 — Figures for the thickness and height for some usual values of B

Dimensions in millimetres

1. 
   (informative)
   
   Guidance on rope systems

Table D.1 — Recommendations for rope system parameters

Rope system item	Parameter values
Rope drum detail	0,525 × d ≤ r ≤ 0,56 × d p ≥ 1,1 × d and p ≥ d + 2 mm 0,33 × d ≤ h1 ≤ 0,45 × d; for single layer spooling 0,28 × d ≤ h1 ≤ 0,45 × d; for multi-layer spooling h2 ≥ 1,5 × d
	d    is the rope diameter r    is the radius of the groove bottom D1  is the pitch circle diameter of the rope drum
Rope sheave detail	0,52 × d ≤ r3 ≤ 0,56 × d 30° ≤ ω ≤ 60° (symmetric) h3 ≥ 1,4 × d
	D2   is the pitch circle diameter of the rope sheave Opening angles ω < 45° should only be used in systems, where rope sheaves do not move in axial direction and fleet angles are less than 1°. Otherwise, rope side contact would cause hazardous twist on the rope.
Fleet angles	The figure shows four different fleet angles φ: βL, βR, (βL+α) and (βL-α). For each of these it should apply that: φ ≤ 4°     non-rotation resistant ropes φ ≤ 2°     rotation resistant ropes 0,5° ≤ φ ≤ 1,5°   multi-layer drums; to ensure correct spooling For drums without grooves it may be set α = 0.

1. 
   (informative)
   
   Relationship between this European Standard and the essential requirements of Regulation (EU) 2023/1230 aimed to be covered

This European Standard has been prepared under a Commission’s standardization request C(202X)XXXX final^[2] Commission Implementing Decision of DD Month YYYY2 to the European Committee for Standardization and to the European Committee for Electrotechnical Standardization as regards machinery in support of Regulation (EU) 2023/1230 of the European Parliament and of the Council (M/XXX) 2 to provide one voluntary means of conforming to essential requirements of Regulation (EU) 2023/1230 of the European Parliament and of the Council of 14 June 2023 on machinery (OJ L 165, 29.6.2023).

Once this standard is cited in the Official Journal of the European Union under that Regulation, compliance with the normative clauses of this standard given in Table ZA.1 confers, within the limits of the scope of this standard, a presumption of conformity with the corresponding essential requirements of that Regulation, and associated EFTA regulations.

Table ZA.1 — Correspondence between this European Standard and Annex III of Regulation (EU) 2023/1230

WARNING 1 — Presumption of conformity stays valid only as long as a reference to this European Standard is maintained in the list published in the Official Journal of the European Union. Users of this standard should consult frequently the latest list published in the Official Journal of the European Union.

WARNING 2 — Other Union legislation may be applicable to the product(s) falling within the scope of this standard.

Bibliography

[1] EN 853, Rubber hoses and hose assemblies - Wire braid reinforced hydraulic type - Specification

[2] EN 1561:2023, Founding - Grey cast irons

[3] EN 12385‑2+A1:2008, Steel wire ropes — Safety — Part 2: Definitions, designation and classification

[4] EN 60204‑1, Safety of machinery - Electrical equipment of machines - Part 1: General requirements

[5] EN 60034‑1:2010, Rotating electrical machines - Part 1: Rating and performance

[6] EN IEC 61000‑6-2, Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity standard for industrial environments (IEC 61000‑6-2)

[7] HD 60364-4-41:2017,^[3] Low-voltage electrical installations - Part 4-41: Protection for safety - Protection against electric shock (IEC 60364‑4‑41:2005/A1:2017)

[8] ISO 606, Short-pitch transmission precision roller and bush chains, attachments and associated chain sprockets

[9] ISO 21940‑11:2016,^[4] Mechanical vibration — Rotor balancing — Part 11: Procedures and tolerances for rotors with rigid behaviour

[10] ISO 6072, Rubber — Compatibility between hydraulic fluids and standard elastomeric materials

[11] ISO 7745, Hydraulic fluid power — Fire-resistant fluids — Requirements and guidelines for use

[12] ISO/TS 14521:2020, Gears — Calculation of load capacity of worm gears

1. As impacted by EN 62745:2017/A11:2020. ↑

2. This template is to be used in draft harmonised standards in support of the Machinery Regulation.

   Since the Standardization Request in support of Machinery Regulation is not yet adopted (expected to take place in 2024 and then accepted by CEN and CENELEC BTs) the reference and the date of the Standardization Request are not known and therefore the references shall be kept as ‘C(202X)XXXX’, ‘DD Month YYYY’ and ‘M/XXX’.

   When the Standardization Request is adopted, this template will be revised to include the number references and the date of the adopted Standardization Request. ↑

3. As impacted by HD 60364-4-41:2017/A11:2017 and HD 60364-4-41:2017/A12:2019. ↑

4. As impacted by ISO 21940‑11:2016/AMD1:2022. ↑