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DRAFT FOR DEVELOPMENT
DD CEN/TS 13001-3-2:2004Incorporating Corrigendum No. 1Cranes — General design —Part 3-2: Limit states and proof of competence of wire ropes in reeving systems
ICS 53.020.20
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DD CEN/TS 13001-3-2:2004
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This Draft for Development was published under the authority of the Standards Policy and Strategy Committee on 7 January 2005
© BSI 2006
ISBN 0 580 45306 5
National forewordThis Draft for Development is the official English language version of CEN/TS 13001-3-2:2004, including Corrigendum July 2006.When Parts 1, 2, 3.1, 3.2 and 3.3 of this standard are published, BS 2573 Parts 1 and 2 will be withdrawn.This publication is not to be regarded as a British Standard. It is being issued in the Draft for Development series of publications and is of a provisional nature because CEN/TS 13001-3-2:2004 is itself a provisional standard.NOTE A CEN/TS is a “Technical Specification” issued by CEN for an evolving technology, with a view to it being developed to full EN status within 3 years.
It should be applied on this provisional basis, so that information and experience of its practical application may be obtained.Comments arising from the use of this Draft for Development are requested so that UK experience can be reported to the European organization responsible for its conversion to a European Standard. A review of this publication will be initiated 2 years after its publication by the European organization so that a decision can be taken on its status at the end of its 3-year life. Notification of the start of the review period will be made in an announcement in the appropriate issue of Update Standards.According to the replies received by the end of the review period, the responsible BSI Committee will decide whether to support the conversion into a European Standard, to extend the life of the Technical Specification or to withdraw it. Comments should be sent in writing to the Secretary of BSI Subcommittee MHE/3/1, Crane design, at British Standards House, 389 Chiswick High Road, London W4 4AL, giving the document reference and clause number and proposing, where possible, an appropriate revision of the text.A list of organizations represented on this subcommittee can be obtained on request to its secretary. Cross-referencesThe British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Search” facility of the BSI Electronic Catalogue or of British Standards Online.
Amendments issued since publication
Amd. No. Date Comments
15623 9 March 2005 Correction to national foreword
16658 Corrigendum No. 1
31 October 2006 Correction to Clauses 2 and 3.1
TECHNICAL SPECIFICATION
SPÉCIFICATION TECHNIQUE
TECHNISCHE SPEZIFIKATION
CEN/TS 13001-3-2
December 2004
ICS 53.020.20
English version
Cranes - General design - Part 3-2: Limit states and proof ofcompetence of wire ropes in reeving systems
Appareils de levage à charge suspendue - Conceptiongénérale - Partie 3-2 : États limites et vérification d'aptitude
des systèmes de mouflage
Krane - Konstruktion allgemein - Teil 3-2: Grenzzuständeund Sicherheitsnachweis von Drahtseilen in Seiltrieben
This Technical Specification (CEN/TS) was approved by CEN on 18 March 2004 for provisional application.
The period of validity of this CEN/TS is limited initially to three years. After two years the members of CEN will be requested to submit theircomments, particularly on the question whether the CEN/TS can be converted into a European Standard.
CEN members are required to announce the existence of this CEN/TS in the same way as for an EN and to make the CEN/TS availablepromptly at national level in an appropriate form. It is permissible to keep conflicting national standards in force (in parallel to the CEN/TS)until the final decision about the possible conversion of the CEN/TS into an EN is reached.
CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia,Slovenia, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATIONC OM ITÉ EUR OP ÉEN DE NOR M ALIS AT IONEUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36 B-1050 Brussels
© 2004 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN national Members.
Ref. No. CEN/TS 13001-3-2:2004: E
Incorporating Corrigendum July 2006
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Contents Page
Foreword......................................................................................................................................................................4
Introduction .................................................................................................................................................................5
1 Scope ..............................................................................................................................................................5
2 Normative references ....................................................................................................................................5
3 Terms, definitions, symbols and abbreviations .........................................................................................63.1 Terms and definitions ...................................................................................................................................63.2 Symbols and abbreviations ..........................................................................................................................6
4 General............................................................................................................................................................8
5 Proof of static strength .................................................................................................................................85.1 General............................................................................................................................................................85.2 Vertical hoisting.............................................................................................................................................85.2.1 Design rope force ..........................................................................................................................................85.2.2 Inertial and gravitational effects...................................................................................................................95.2.3 Rope reeving efficiency ..............................................................................................................................105.2.4 Non parallel falls ..........................................................................................................................................115.2.5 Horizontal forces on the hoist load............................................................................................................115.3 Non vertical drives.......................................................................................................................................125.3.1 Design rope force ........................................................................................................................................125.3.2 Equivalent force...........................................................................................................................................135.3.3 Inertial effects...............................................................................................................................................145.3.4 Rope reeving efficiency ..............................................................................................................................145.3.5 Non parallel falls ..........................................................................................................................................145.4 Limit design rope force ...............................................................................................................................14
6 Proof of fatigue strength.............................................................................................................................156.1 General..........................................................................................................................................................156.2 Design rope force ........................................................................................................................................166.2.1 Principle conditions ....................................................................................................................................166.2.2 Inertial effects...............................................................................................................................................166.2.3 Non parallel falls ..........................................................................................................................................176.2.4 Horizontal forces in vertical hoisting ........................................................................................................186.3 Limit design rope force ...............................................................................................................................186.3.1 Basic formula ...............................................................................................................................................186.3.2 Rope force history parameter.....................................................................................................................186.3.3 Rope force spectrum factor........................................................................................................................196.3.4 Relative total number of bendings.............................................................................................................196.3.5 Minimum rope resistance factor ................................................................................................................206.4 Further influences on the limit design rope force....................................................................................206.4.1 Basic formula ...............................................................................................................................................206.4.2 Diameters of drum and sheaves ................................................................................................................206.4.3 Tensile strength of wire ..............................................................................................................................216.4.4 Fleet angle ....................................................................................................................................................216.4.5 Rope lubrication...........................................................................................................................................226.4.6 Multilayer drum ............................................................................................................................................226.4.7 Groove radius...............................................................................................................................................226.4.8 Rope types....................................................................................................................................................23
Annex A (normative) Number of Relevant Bendings ............................................................................................24
Annex B (informative) Guidance for selection of design number of hoist ropes used during the usefulcrane life .......................................................................................................................................................27
Annex C (informative) Selection of suitable set of crane standards for a given application............................28
Bibliography..............................................................................................................................................................29
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Figures
Figure 1— Example for the acting parts of hoist mass ..........................................................................................9
Figure 2 — Example for Rope Reeving Efficiency ................................................................................................10
Figure 3 — Angle βmax...............................................................................................................................................11
Figure 4— Horizontal force......................................................................................................................................12
Figure 5 — Examples for non vertical drive...........................................................................................................13
Figure 6— Example for rope tightening .................................................................................................................13
Figure 7 — Lifting positions ....................................................................................................................................18
Figure 8 — Fleet angles ...........................................................................................................................................21
Figure 9 — Groove radius........................................................................................................................................22
Table 7 — Factor ff6...................................................................................................................................................22
Figure A.1 — Number of relevant bendings...........................................................................................................26
Tables
Table 1 — Symbols and abbreviations.....................................................................................................................6
Table 2 — Partial safety factors γp ..........................................................................................................................14
Table 3 — Minimum rope resistance factor γrb .....................................................................................................15
Table 4 — Classes SR of rope force history parameter sr .....................................................................................19
Table 5 — Reference ratio RDd .................................................................................................................................20
Table 6 — Factor ff3...................................................................................................................................................22
Table 7 — Factor ff6...................................................................................................................................................22
Table A.1 — Bending counts...................................................................................................................................24
Table A.2 — Examples for the number of relevant bendings w ..........................................................................25
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Foreword
This document (CEN/TS 13001-3.2:2004) has been prepared by Technical Committee CEN/TC 147 “Cranes —Safety”, the secretariat of which is held by BSI.
The CEN/TC 147/WG 2 "Cranes — Design and Principles" is held by DIN.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the followingcountries are bound to announce this Technical Specification: Austria, Belgium, Cyprus, Czech Republic, Denmark,Estonia, Finland, France, Germany, Greece, Hungary Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta,Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom.
This European Technical Specification is one Part of EN 13001. The other parts are as follows:
Part 1: General principles and requirements;
Part 2: Load effects;
Part 3.1: Limit states and proof of competence of steel structures;
Part 3.3: Limit states and proof of competence of wheel/rail contacts;
Part 3.4: Limit states and proof of competence of machinery.
Annex A is normative, annexes B and C are informative.
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Introduction
This Technical Specification has been prepared to be a harmonized standard to provide one means for themechanical design and theoretical verification of cranes to conform with the essential health and safetyrequirements of the Machinery Directive, as amended. This standard also establishes interfaces between the user(purchaser) and the designer, as well as between the designer and the component manufacturer, in order to form abasis for selecting cranes and components.
This Technical Specification is a type C standard as stated in EN ISO 12100-1:2003.
The machinery concerned and the extent to which hazards are covered are indicated in the scope of this standard.
1 Scope
This Part 3-2 of the Technical Specification EN 13001 is to be used together with Part 1 and Part 2 and as suchthey specify general conditions, requirements and methods to prevent mechanical hazards of wire ropes in reevingsystems of cranes by design and theoretical verification.
NOTE 1 Specific requirements for particular types of crane are given in the appropriate Technical Specification for theparticular crane type.
The following is a list of significant hazardous situations and hazardous events that could result in risks to personsduring normal use and foreseeable misuse. Clauses 5 to 6 of this standard are necessary to reduce or eliminatethe risks associated with the following hazard:
Exceeding the limits of strength.
This Technical Specification is applicable to cranes which are manufactured after the date of approval by CEN ofthis standard and serves as reference base for the Technical Specifications for particular crane types.
NOTE 2 CEN/TS 13001-3-2 deals only with limit state method according to EN 13001-1.
2 Normative references
This Technical Specification incorporates by dated or undated reference, provisions from other publications. Thesenormative references are cited at the appropriate places in the text and the publications are listed hereafter. Fordated references, subsequent amendments to or revisions of any of these publications apply to this TechnicalSpecification only when incorporated in it by amendment or revision. For undated references the latest edition ofthe publication referred to applies (including amendments).
EN 1990:2002, Eurocode — Basis of structural design.
EN 12385-4, Steel wire ropes — Safety — Part 4: Stranded ropes for general lifting applications.
EN 13001-1, Cranes — General Design — Part 1: General principles and requirements.
EN 13001-2, Cranes — General Design — Part 2: Load effects.
CEN/TS 13001-3-1, Cranes — General design — Part 3-1: Limit states and proof of competence of steel structures.
EN 13411-1, Terminations for steel wire ropes — Safety — Part 1: Thimbles for steel wire rope slings.
EN 13411-2, Terminations for steel wire ropes — Safety — Part 2: Splicing of eyes for wire rope slings.
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EN 13411-3, Terminations for steel wire ropes — Safety — Part 3: Ferrules and ferrule-securing.
EN 13411-4, Terminations for steel wire ropes — Safety — Part 4: Metal and resin socketing.
EN 13411-6, Terminations for steel wire ropes — Safety — Part 6: Asymmetric wedge sockets.
EN ISO 12100-1:2003, Safety of machinery — Basic concepts, general principles for design — Part 1:Basicterminology, methodology (ISO 12100-1:2003).
ISO 4306-1:1990, Cranes vocabulary.
ISO 4309, Cranes — Wire ropes — Code of practice for examination and discard.
3 Terms, definitions, symbols and abbreviations
3.1 Terms and definitions
For the purposes of this Technical Specification, the terms and definitions given in EN ISO 12100-1:2003,EN 1990:2002 and clause 6 of ISO 4306-1:1990 apply.
3.2 Symbols and abbreviations
For the purposes of this Technical Specification, the symbols and abbreviations given in Table 1 apply.
Table 1 — Symbols and abbreviations
Symbols,abbreviations Description
a AccelerationC Total number of working cycles (see EN 13001-1) during useful life of craneD Relevant diameterDdrum Minimum pitch diameter of drumDsheave Minimum pitch diameter of sheaveDcomp Minimum pitch diameter of compensating sheaved Rope diameterdbearing Diameter of bearing or shaftFequ Equivalent forceFgd Part of Fequ induced by gravity, exclusive mass of payload, amplified by γp
Fgl Part of Fequ induced by gravity forces of mass of payload, amplified by γp
Fo Part of Fequ induced by any other forces, amplified by γp
FRd,s Limit design rope force for the proof of static strengthFRd,f Limit design rope force for the proof of fatigue strengthFSd,s Design rope force for the proof of static strengthFr Part of Fequ induced by resistances, amplified by γp
FSd,f Design rope force for the proof of fatigue strengthFt Part of Fequ induced by rope tightening forces, amplified by γp
Fu Minimum rope breaking forceFw Part of Fequ induced by wind forces, amplified by γp
ff Factor of further influencesff1 Factor of diameter ratio influenceff2 Factor tensile strength of wire influenceff3 Factor of fleet angle influenceff4 Factor of lubrication influenceff5 Factor of multilayer drum influenceff6 Factor of groove radius influenceff7 Factor of rope type influence
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Table 1 (concluded)
Symbols,abbreviations Description
fS1 Rope force increasing factor from rope reeving efficiencyfS2 Rope force increasing factor from non parallel fallsfS3 Rope force increasing factor from horizontal accelerationf*Si Rope force increasing factors in fatigueg Gravity constanti Index for cycles of lifting and loweringkr Rope force spectrum factorlr Number of ropes used during useful life of the craneq Height distributionmH Mass of hoist load (see EN13001-2)mHr Mass of hoist load that is acting on the rope falls under considerationmred Rotatory rope driven massmtrans Translational rope driven massn nf
Number of contact points passed by ropeNumber of falls or reeving lines
nfs Number of fixed sheave between drum and moving partnm Mechanical advantageR0 Minimum tensile strength of the wire used in the ropeRDd Reference ratio of rope bending diameter to rope diameterrg Groove radiusSR Class of rope force historysr Rope force history parametert Rope type factorw Number of relevant bendings per lifting movementwc Bending countwD Number of bendings at reference pointwtot Total number of bendingsz, zi, zmin, zmax Height coordinatesα Angle of slopeβ, βmax Angles between falls and line of acting forceγ Angle between gravity and projected rope in plane of Fh and gγn Risk coefficientγp Partial safety factorγrb Minimum rope resistance factor (static)γrf Minimum rope resistance factor (fatigue)δ Design fleet angleε Angle between sheave planesηs Efficiency of single sheaveηtot Total efficiency of rope driveνr Relative total number of bendingsφ Dynamic factor for inertial or gravity effectsφ* Dynamic factor for inertial or gravity effects in fatigueφ2 Dynamic factor for hoisting an unrestrained grounded loadφ5 Dynamic factor for loads caused by accelerationφ6 Dynamic factor for testloadω Angle between the sheave groove sidesLi
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CEN/TS 13001-3-2:2004 (E)
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4 General
In all cranes running wire ropes are stressed by loads (described by a load spectrum) and by bendings. Bothconstitute the rope force history, classified in classes SR (see 6.3.2). Classes SR are used for the selection of thewire rope and diameters of drums and/or sheaves. They are independent of time.
The proof of competence for static strength and the proof of competence for fatigue strength shall be fulfilled for theselection of ropes and components. This standard is for design purposes only and should not be seen as aguarantee of actual performance.
To ensure safe use of the rope the discard criteria according to ISO 4309 shall be applied.
The wire rope should be in accordance with EN 12385-4. Rope terminations shall meet the requirements ofEN 13411-1, EN 13411-2, EN 13411-3, EN 13411-4 and EN 13411-6.
5 Proof of static strength
5.1 General
For the proof of static strength it shall be proven that for all relevant load combinations of EN 13001-2
sRdsSd FF ,, ≤ (1)
where:
FSd,s is the design rope force
FRd,s is the limit design rope force.
5.2 Vertical hoisting
5.2.1 Design rope force
The design rope force FSd,s in vertical hoisting shall be calculated as follows:
npSSS1f
HrsSd γγfff
ngmF ⋅⋅⋅⋅⋅⋅⋅
= 32, φ (2)
where:
mHr is the mass of the hoist load (mH) or that part of the mass of the hoist load that is acting on the ropefalls under consideration (see Figure 1). The mass of the hoist load includes the masses of thepayload, lifting attachments and a portion of the suspended hoist ropes. In statically undeterminedsystems, the unequal load distribution between ropes depends on elasticities and shall be taken intoaccount.
g is the gravity constant
nf is the number of falls carrying mHr
φ is the dynamic factor for inertial and gravity effects as shown in 5.2.2
fS1 to fS3 are the rope force increasing factors as shown in 5.2.3 to 5.2.5
γp is the partial safety factor (see EN 13001-2)γp = 1,34 for regular loads (load combinations A)
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γp = 1,22 for occasional loads (load combinations B)γp = 1,10 or exceptional loads (load combinations C)
γn is the risk coefficient (see EN 13001-2)
Figure 1— Example for the acting parts of hoist mass
5.2.2 Inertial and gravitational effects
5.2.2.1 Dynamic factors
For vertical hoisting the maximum inertial effects from either hoisting an unrestrained grounded load or fromacceleration or deceleration shall be taken into account by the dynamic factor φ.
5.2.2.2 Hoisting an unrestrained grounded load
2φφ = (3)
where:
φ2 is the dynamic factor for inertial and gravity effects when hoisting an unrestrained grounded load (seeEN 13001-2)
5.2.2.3 Acceleration or deceleration of the hoistload
ga
5 ⋅+= φφ 1 (4)
where:
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φ5 is the dynamic factor for loads caused by acceleration (see EN 13001-2)
a is the vertical acceleration or deceleration
g is the gravity constant
5.2.2.4 Testload
6φφ = (5)
where:
φ6 is the dynamic factor for testload (see EN 13001-2)
5.2.3 Rope reeving efficiency
The increase of the design rope force by the rope reeving efficiency is given by
totSf
η1
1 = (6)
The total efficiency of the rope drive ηtot shall be calculated as follows:
S
nS
m
nS
tot
mfs
n ηηη
η−
−⋅=
1)(1)(
(7)
where:
ηS is the efficiency of a single sheave:ηS = 0,985 for sheave with roller bearingηS = 0,985 × (1 - 0,15 × dbearing / DSheave ) for sheave with plain bearing
Other values for ηS may be used if verified by test results for the applied rope, sheave or bearing.
nm is the mechanical advantage (see example in Figure 2)
nfs is the number of fixed sheaves between drum and moving part
Figure 2 — Example for Rope Reeving Efficiency
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5.2.4 Non parallel falls
When the rope falls are not parallel the rope force is increased. The rope force increasing factor fS2 shall bedetermined for the most unfavourable position. For simplification fS2 may be calculated by
maxS β
fcos
12 = (8)
where:
βmax is the maximum angle between the falls and the direction of load (see Figure 3)
Figure 3 — Angle βmax
5.2.5 Horizontal forces on the hoist load
The rope force increasing effect of the horizontal forces (e. g. by crab or crane accelerations, wind) may beneglected in applications with free swinging loads.
However in applications with several non parallel ropes (rope pyramid, see Figure 4) the horizontal forces increasethe rope force considerably. This effect shall be taken into account. For simplification the rope force increasingfactor fS3 may be calculated by
2tan
13 ≤⋅⋅
+=γgm
FfH
hS (9)
where:
Fh is the horizontal force on the hoist load
mH is the mass of the hoist load
g is the gravity constant
γ is the angle between gravity and the rope projected in the plane of Fh and g
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Figure 4— Horizontal force
5.3 Non vertical drives
5.3.1 Design rope force
The design rope force FSd,s in non vertical drives (see examples in Figure 5 and Figure 6) shall be calculated asfollows:
nSSf
equSd,s γff
nF
F ⋅⋅⋅⋅= 21φ (10)
where:
Fequ is the equivalent force acting on the rope falls under consideration as shown in 5.3.2. In staticallyundetermined systems, the unequal load distribution between ropes depends on elasticities and shallbe taken into account.
nf is the number of falls or reeving lines
φ is the dynamic factor for inertial effects as shown in 5.3.3
fS1 , fS2 are the rope force increasing factors as shown in 5.3.4 and 5.3.5
γn is the risk coefficient (see EN 13001-2)
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Figure 5 — Examples for non vertical drive
Figure 6— Example for rope tightening
5.3.2 Equivalent force
In general the load actions of gravity forces, resistances (e. g. rolling or gliding, wheels, bearings), rope tighteningforces, wind forces and any other forces (e. g. buffer forces, forces from climatic effects) contribute to theequivalent force Fequ as illustrated in equation 11. Those load actions shall be amplified by partial safety factors γp(see EN 13001-2) for the load combination under consideration, as given in Table 2.
otwrglgdequ FFFFFFF +++++= (11)
where:
Fgd is that part of Fequ that is induced by gravity forces of the rope driven masses, exclusive the mass ofthe payload, amplified by the relevant partial safety factor.
Fgl is that part of Fequ that is induced by gravity forces of the rope driven mass of the payload, amplified bythe relevant partial safety factor.
Fr is that part of Fequ that is induced by resistances, amplified by the relevant partial safety factor.
Fw is that part of Fequ that is induced by wind forces, amplified by the relevant partial safety factor.
Ft is that part of Fequ that is induced by rope tightening forces (see example in Figure 6), amplified by therelevant partial safety factor.
Fo is that part of Fequ that is induced by any other forces, amplified by the relevant partial safety factor.Lice
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Table 2 — Partial safety factors γp
DescriptionRegular loadsLoad combinations A
Occasional loadsLoad combinations B
Exceptional loadsLoad combinations C
Fgd Gravitation on masses,exclusive mass of payload 1,22 1,16 1,1
Fgl Gravitation on payload 1,34 1,22 1,1
φ Inertia 1,34 1,22 1,1
Fr Resistances 1,34 1,22 1,1
Ft Rope tightening 1,22 1,16 1,1
Wind forces: In service — 1,22 1,16FwWind forces: Out of service — — 1,1
Snow and ice — 1,22 1,1
Temperature — 1,16 1,05Fo
Buffer forces — — 1,1
5.3.3 Inertial effects
In non vertical drives the inertial effects from accelerations shall be taken into account by the dynamic factor φcalculated as follows:
( )equ
predtrans
Famm γφ
φ⋅⋅⋅+
+= ∑∑ 51 (12)
where:
Σmtrans is the sum of translational rope driven masses, referred to the coordinate of acceleration
Σmred is the sum of rotatory rope driven masses (see examples in Figure 5 and Figure 6), referred to thecoordinate of acceleration
a is the acceleration or deceleration
φ5 is the dynamic factor for loads caused by acceleration (see EN 13001-2)
γp is the partial safety factor, as given in Table 2, line inertia
Fequ is the equivalent force
5.3.4 Rope reeving efficiency
The increase of the design rope force by the rope reeving efficiency is given by the rope force increasing factor fS1,calculated as shown in 5.2.3, equations 6 and 7.
5.3.5 Non parallel falls
The increase of the design rope force by non parallel falls is given by the rope force increasing factor fS2, calculatedas shown in 5.2.4 and equation 8.
5.4 Limit design rope force
The limit design rope force FRd,s is given by
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rb
uRd,s γ
FF = (13)
where:
Fu is the minimum breaking force of the rope as specified by the manufacturer
γrb is the minimum rope resistance factor.
The minimum rope resistance factor γrb is dependent on the geometry of the reeving system and is given by
4
0,534,1 8,0
−
+=
dD
γrb (14)
where:
D is the minimum relevant diameter: D = Min(Dsheave ; 1,125*Ddrum ; 1,125*Dcomp)
d is the rope diameter.
Table 3 gives minimum rope resistance factors for selected ratios of D/d.
Table 3 — Minimum rope resistance factor γrb
D/d 11,2 12,5 14,0 16,0 18,0 20,0
γrb 3,06 2,75 2,52 2,30 2,16 2,05
6 Proof of fatigue strength
6.1 General
According to test results the fatigue strength of ropes in terms of number of bendings is approximately inverselyproportional to the second power of the applied rope tension force. With the additional requirement that the ratio ofthe rope bending diameter D to the rope diameter d increases with the number of bendings wtot according to
( )totw
dD
2log125,1~ (15)
(i. e. D/d increases by 1,125 for increasing wtot by 2), the rope force to number of bendings relationship followsclosely the power -3. Therefore this additional requirement is used in the classification of the rope force history.
When calculating the number of bendings, one lifting movement is considered to comprise both a lifting andlowering action. In non vertical drives to and from movements are treated respectively.
For the proof of fatigue strength it shall be proven that
Rd,fSd,f FF ≤ (16)
where:
FSd,f is the design rope force for fatigue
FRd,f is the limit design rope force for fatigue.
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6.2 Design rope force
6.2.1 Principle conditions
The design rope force FSd,f shall be calculated for regular loads (load combinations A) only, with partial safetyfactors γp, risk coefficient γn and rope efficiency set to 1.
For vertical hoisting:
*3
*2
*f, SS
f
HrSd ff
ngmF ⋅⋅⋅⋅
= φ (17)
where:
mHr is the mass of the hoist load (mH) or that part of the mass of the hoist load that is acting on therope (see Figure 1).
g is the gravity constant
nf is the number of falls carrying mHr
φ* is the dynamic factor for inertial and gravity effects as shown in 6.2.2*2Sf , *
3Sf are the rope force increasing factors as shown in 6.2.3 to 6.2.4
For non-vertical drives:
*2
*S
f
equSd,f f
nF
F ⋅⋅= φ (18)
where:
Fequ is the equivalent force acting on the rope according to the principles of 5.3.2.
nf is the number of falls or reeving lines
φ* is the dynamic factor for inertial effects as shown in 6.2.2
*2Sf is the rope force increasing factor as shown in 6.2.3
Instead of the rope force increasing factors f*si the factors fsi as given in clause 5 may be used.
Instead of the dynamic factor φ* the factor φ as given in clause 5 may be used.
6.2.2 Inertial effects
As the inertial effects act for short time only, they do not affect all bendings. Therefore the dynamic factors φ* may
be calculated by
φφ =* for 1=w or (19)
( )3
3* 1
ww φφ +−
= for 2≥w
where:
w is the relevant number of bendings per lifting movement (see annex A).
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φ is the dynamic factor (see 5.2.2 or 5.3.3)
6.2.3 Non parallel falls
For the proof of fatigue strength the distribution of height and angle within the working range can be taken intoaccount by
3
max
min
3*2 )(cos
)(∫=
z
zdz
zzqf S β
(20)
where:
z are height coordinates as shown in Figure 7.zref is the reference heightThe whole working range is from zmin to zmax.The most frequent working range is from z1 to z2.
β(z) is the angle between rope and line of the acting force
q(z) is the height density of the crane use in the working range
∫ =max
min
Z
1)(z
dzzq (21)
When the crane operates approximately equal on all heights of the most frequent working range, the densityfunction is constant
12
1)(zz
zq−
= (22)
and f*S2 may be calculated as
9,0
1
2
2
*2 1
)(cos11
−
−⋅
−+=
zzzz
zf
ref
refS β
(23)
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Figure 7 — Lifting positions
6.2.4 Horizontal forces in vertical hoisting
If horizontal acceleration and lifting acceleration act together regularly, f*S3 shall be calculated by
3*3 SS ff = (24)
where:
fS3 is the rope force increasing factor calculated from an average angle γ (see 5.2.5)
When horizontal forces and lifting acceleration do not act together regularly, f*S3 may be set to 1.
6.3 Limit design rope force
6.3.1 Basic formula
The limit design rope force FRd,f shall be calculated by
frfr
uRd,f f
γsF
F ⋅⋅
=3
(25)
where:
Fu is the minimum breaking force of the rope as specified by the manufacturer
sr is the rope force history parameter
γrf is the minimum rope resistance factor
ff is the factor of further influences.
6.3.2 Rope force history parameter
In analogy to stress history parameter (see EN 13001-1), the rope force history parameter is given by
rrr νks ⋅= (26)
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where:
kr is the rope force spectrum factor
νr is the relative total number of bendings.
The rope force history parameter shall be determined either by direct use of equations (26), (27), (28) and (29) orsimplified by selection of a class SR from Table 4.
Table 4 — Classes SR of rope force history parameter sr
Class SR0 SR1 SR2 SR3 SR4 SR5 SR6 SR7 SR8 SR9
sr 0,008 0,016 0,032 0,063 0,125 0,25 0,5 1,0 2,0 4,0
6.3.3 Rope force spectrum factor
The rope force spectrum factor kr is calculated by
∑=
⋅
=
max
1
3i
i tot
i
Sd,f
Sd,f,ir w
wFF
k (27)
where:
i is the index of one lifting movement with FSd,f,i
imax is the total number of lifting movements per rope, considering all the working cycles, numbers ofwhich per rope equals to C/lr
FSd,f,i is the design rope force in lifting movement i
FSd,f is the maximum design rope force
wi is the relevant number of bendings in one lifting movement i (see annex A).
wtot is the total number of bendings during the useful life of a rope.
C is the total number of working cycles during the useful life of the crane (see EN 13001-1)
lr is the design number of ropes used during the useful crane life(Guidance for lr is given in the annex B)
The total number of bendings wtot is calculated by
∑=
=max
1
i
iitot ww (28)
where:
wi is the relevant number of bendings per lifting movement (see annex A).
imax is the total number of lifting movements per rope
6.3.4 Relative total number of bendings
The relative total number of bendings is calculated by
D
totr w
wν = (29)
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where:
wtot is the total number of bendings during the useful life of a rope
wD is the number of bendings at reference point: 5
105 ⋅=Dw .
6.3.5 Minimum rope resistance factor
The minimum rope resistance factor γrf shall be
γrf = 7 (30)
6.4 Further influences on the limit design rope force
6.4.1 Basic formula
The factor ff takes into account further influences on the limit design rope force:
7654321 fffffff fffffffff ⋅⋅⋅⋅⋅⋅= (31)
where:
ff1 to ff7 are the factors of influences as given in 6.4.2 to 6.4.7.
6.4.2 Diameters of drum and sheaves
As explained in 6.1 the additional requirement that the ratio D/d of the rope bending diameter D to the ropediameter d increases with the number of bendings wtot according to equation 15 is incorporated in equation 24. D isthe minimum relevant diameter
)125,1;125,1;( compdrumsheave DDDMinD ⋅⋅= (32)
The reference ratio value of D/d is calculated by
⋅= 0,004log2
125,110rs
DdR (33)
Table 5 gives standardized values of RDd in terms of classes SR:
Table 5 — Reference ratio RDd
Class SR0 SR1 SR2 SR3 SR4 SR5 SR6 SR7 SR8 SR9
RDd 11,2 12,5 14,0 16,0 18,0 20,0 22,4 25,0 28,0 31,5
The factor ff1 is calculated by
R
dD
fDd
f1 = (34)
The chosen ratio D/d shall not be less than 11.2 and shall be selected such that ff1 becomes greater than 0,75.Lice
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6.4.3 Tensile strength of wire
A non-linear relationship between the tensile strength level Rr of the wire and the limit design rope force shall betaken into account by
4,0
21770
=
rf R
f , for Rr > 1770 (35)
ff2 = 1, for Rr ≤ 1770
where:
Rr is the level of requirement of breaking force (tensile strength) which is designated by a number (e. g.1770, 1960 etc.), see EN 12385-4.
6.4.4 Fleet angle
Fleet angles at sheaves or drums are illustrated in Figure 8. Fleet angles shall always be counted positive. For aselected point of the rope, the design fleet angle δ being associated with the most frequent working range shall betaken into account by factor ff3 according to Table 6. The design fleet angle is calculated by
3 1
3
n
n
jj∑
==δ
δ (36)
where:
δj is the fleet angle at the tangential contact point j of rope at drum or sheave (see Figure 8)
n is the number of contact points passed by the most bent part of the rope (See Figure 8 for an examplewith n = 6)
Figure 8 — Fleet angles
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Table 6 — Factor ff3
design fleetangleδ
non rotationresistant rope
rotationresistant rope
≤0,5° 1,0 1,0
1,0° 0,9 0,9
2,0° 0,75 0,7
3,0° 0,7
4,0° 0,67not covered
Intermediate values may be interpolated
6.4.5 Rope lubrication
For lubricated ropes the factor ff4 is set to one. For ropes without lubrication (e. g. clean room) the factor ff4 shall beff4 = 0,5.
6.4.6 Multilayer drum
Multilayer drums reduce the limit design rope force. A factor ff5 < 0,8 shall be applied.
6.4.7 Groove radius
The ratio of groove radius rg to rope diameter d and the requirements for angle ω between the sides of a sheave(see Figure 9) shall be taken into account by ff6 according to Table 7.
Figure 9 — Groove radius
Table 7 — Factor ff6
rg/d ω ff60,53 1
0,55≤60°
0,84
0,6 0,75
0,7 0,63
0,8 0,58
≥ 1,0
No requirement
0,54
Intermediate values may be interpolated
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6.4.8 Rope types
Differing bending fatigue performance of the various rope types shall be taken into account by the factor 7ff , givenby
tf f
17 = (38)
where
t is the rope type factor.
In general for non-rotation resistant ropes with 6 to 10 outer strands, t = 1 is valid. For other rope types values of tin the range of 0,95 to 1,25 may be specified by the rope manufacturer.
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Annex A(normative)
Number of Relevant Bendings
One lifting movement comprises both a lifting and lowering action. The number of relevant bendings w of a ropeduring one lifting movement shall be established for the most unfavourable part of the rope by counting the sum ofbending counts wc according to Table A.1 and A.2.
When the loads in lifting and lowering are different (e. g. when loads are deposited at upper level), w/2 for the liftedload and w/2 for the lowered load shall be used. In these cases, both lifting and lowering are each considered asone lifting movement for the calculation of the rope force spectrum factor.
Table A.1 — Bending counts
Type of bending Illustration Bending count
Any bending with a deflection
angle α less than 5°wc = 0
Rope termination wc = 0
Compensating sheave/whip wc = 0
Drum wc = 1
Sheave with same sense bending
(angle ε between planesless than 120°)
wc = 2
Sheave with reverse sense bending
(angle ε ≥ 120°)wc = 4Li
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Table A2 shows examples assuming movements where the most unfavourable part of the rope runs from the drumover all sheaves.
Table A.2 — Examples for the number of relevant bendings w
w = 1 w = 3 w = 5 w = 5
w = 7 w = 7 w = 7
If during the cycle the rope runs only over a part of the sheaves, w depends on the length of the stroke. Figure A.1gives an example:
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Keya1, a2, a3 length between sheavesc1, c2, c3 circumferential length1 rope travel distance w = 112 rope travel distance w = 103 rope travel distance w = 6
Figure A.1 — Number of relevant bendings
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Annex B(informative)
Guidance for selection of design number of hoist ropes used during theuseful crane life
Item no. Type of crane Operation method S-class (seeEN 13001-3-1)
Number ofropes lr
1 Hand-operated cranes S0 – S2 1-2
2 Assembly cranes S0 – S2 1-2
3 Powerhouse cranes S1 – S3 1-3
4 Warehouse cranes Intermittent operation S4 – S5 3-6
5 Warehouse cranes, lifting beam cranes,scrapyard cranes Continuous operation S6 – S8 6-14
6 Workshop cranes S3 – S5 2-6
7 Bridge cranes, skull cracker cranes Grab, magnet, spreader S6 – S8 6-14
8 Ladle cranes S6 – S8 6-14
9 Pit cranes S7 – S9 8-20
10 Stripper cranes, charging cranes S8 – S9 10-20
11 Forging cranes S6 – S8 6-14
12 Hook service S4 – S6 3-8
13
Unloaders, stocking and reclaiming bridges,semi-portal cranes, portal cranes with trolley orslewing crane Grab, magnet, spreader S6 – S9 6-20
14 Travelling conveyor gantries with fixed or slidingconveyor(s) S3 – S5 2-6
15 Shipbuilding cranes, slipway cranes, fitting-outcranes Hook service S3 – S5 2-6
16 Hook service S4 – S6 3-8
17Wharf cranes, slewing cranes, floating cranes,level-luffing slewing cranes Grab, magnet, spreader S6 – S8 6-14
18 High-capacity floating cranes, high capacitygantry cranes S1 – S3 1-3
19 Hook service S3 – S5 2-6
20Shipdeck cranes
Grab, magnet, spreader S4 – S6 3-8
21 Revolving tower cranes for construction service S1 – S4 1-4
22 Erection cranes, derricks Hook service S1 – S3 1-3
23 Hook service S3 – S5 2-6
24Rail-mounted slewing cranes
Grab, magnet, spreader S4 – S6 3-8
25 Locomotive cranes, licensed for in-trainHaulage S4 – S5 3-6
26 Hook service S2 – S5 2-6
27Loader cranes, mobile cranes
Grab, magnet, spreader S4 – S6 3-8
28 High capacity loader and mobile cranes S1 – S3 1-3
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Annex C(informative)
Selection of suitable set of crane standards for a given application
Is there a product standard in the following list that suits the application?
EN 13000: 2004 Cranes — Mobile cranes
prEN 14439:20002 Cranes — Tower cranes
PrEN14985:2004 Cranes — Slewing jib cranes
WI 00147032 Cranes — Bridge and gantry cranes
EN 13852-1:2004 Cranes — Offshore cranes — Part 1: General purpose offshore cranes
EN 13852-2:2004 Cranes — Offshore cranes — Part 2: Floating cranes
prEN 14492-1:2004 Cranes — Power driven winches and hoists — Part 1: Power driven winches
prEN 14492-2:2002 Cranes — Power driven winches and hoists — Part 2: Power driven hoists
EN 12999:2002 Cranes — Loader cranes
EN 13157:2002 Cranes — Hand powered cranes
prEN 13155:1998 Cranes — Non-fixed load lifting attachments
EN 14238:2004 Cranes — Manually controlled load manipulating devices
YES
Use it directly, plus the standardsthat are referred to NO
Use the following:
EN 13001-1:2004 Cranes — General design — Part 1: General principles and requirements
EN 13001-2:2004 Cranes — General design — Part 2: Load actions
CEN/TS 13001-3-1:2003 Cranes — General design — Part 3.1: Limit states and proof of competence of steel structures
CEN/TS 13001-3-2:2003 Cranes — General design — Part 3.2: Limit states and proof of competence of wire ropes
WI 00147 050 Cranes — General design — Part 3.3: Limit states and proof of competence of wheel / rail contacts
EN 13135-1:2003 Cranes — Equipment — Part 1: Electrotechnical equipment
prEN 13135-2:2000 Cranes — Equipment — Part 2: Non-electrotechnical equipment
EN 13557:2003 Cranes — Controls and control stations
EN 12077-2:1998 Cranes safety — Requirements for health and safety — Part 2: Limiting and indicating devices
EN 13586:2003 Cranes — Access
prEN 14502-1:2002 Cranes — Equipment for the lifting of persons — Part 1: Suspended baskets
prEN 14502-2:2002 Cranes — Equipment for the lifting of persons — Part 2: Moveable cabins
EN 12644-1:2001 Cranes — Information for use and testing — Part 1: Instructions
EN 12644-2:2000 Cranes — Information for use and testing — Part 1: Marking
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Bibliography
[1] Feyrer, Klaus: Drahtseile — Bemessung, Betrieb, Sicherheit. Berlin, Heidelberg: Springer-Verlag 2000.ISBN 3-540-67829-8
[2] Feyrer, Klaus: Laufende Drahtseile — Bemessung und Überwachung. Renningen-Malsheim: Expert-Verlag1998. ISBN 3-8169-1481-0
[3] Feyrer, Klaus: Biegewechselzahl und Ablegereife von Spiral-Rundlitzenseilen. Fördern und Heben 5/1997Vereinigte Fachverlage GmbH. ISDN 0441-2636
[4] EN ISO 12100-2:2003, Safety of machinery — Basic concepts, general principles for design — Part 2:Technical principles and specifications (ISO 12100-2:2003).
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