PrEN 15011 Krane Englisch

EUROPEAN STANDARD DRAFT
NORME EUROPÉENNE prEN 15011

EUROPÄISCHE NORM
September 2004
ICS
English version
Cranes - Bridge and gantry cranes
Appareils de levage à charge suspendue - Portiques et Kräne - Brücken und Portalkräne

ponts roulants
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 147.
If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which
stipulate the conditions for giving this European Standard the status of a national standard without any alteration.
This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other language
made by translation under the responsibility of a CEN member into its own language and notified to the Management Centre has the same
status as the official versions.
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.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES 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 reserved Ref. No. prEN 15011:2004: E
worldwide for CEN national Members.
prEN 15011:2004 (E)
Contents Page
Foreword ............................................................................................................................................................. 5
Introduction ........................................................................................................................................................ 6
1 Scope...................................................................................................................................................... 7
2 Normative references ........................................................................................................................... 7
3 Definitions.............................................................................................................................................. 9
4 List of hazards....................................................................................................................................... 9
5 Safety requirements and/or protective measures ........................................................................... 16
6 Verification of safety requirements and/or protective measures .................................................. 37
7 Information for use ............................................................................................................................. 41
Annex A (informative) Guidance for classification, forces and stresses to be used in
proof of competence calculation....................................................................................................... 46
A.1 Classification of load handling and positioning parameters ......................................................... 46
A.2 Guidance for classification of average linear displacements ........................................................ 50
A.3 Calculation of dynamic coefficient φ2 ............................................................................................... 51
A.4 Calculation example for coefficient φ2 .............................................................................................. 54
A.5 Calculation of skewing forces for bridge cranes............................................................................. 56
A.5.1 Calculation parameters and formulae............................................................................................... 56
A.5.2 Example for calculating the forces resulting from skewing in the case of bridge
cranes................................................................................................................................................... 61
A.5.3 Estimating the forces resulting from skewing for bridge cranes with 4 crane travel
wheels and flange guiding ................................................................................................................. 62
A.5.4 Estimating the forces resulting from skewing for bridge cranes with 4 crane travel
wheels and guide rollers .................................................................................................................... 63
A.6 Calculation of skewing forces for gantry cranes............................................................................. 65
A.6.1 Crane models ...................................................................................................................................... 65
A.6.2 Principles for calculation ................................................................................................................... 67
A.6.3 Calculation models (Type B and D)................................................................................................... 71
A.6.4 Calculation example 1 to determine the forces resulting from skewing on gantry
cranes (model type B)......................................................................................................................... 73
A.6.5 Calculation example 2 to determine the forces resulting from skewing on gantry
cranes (model type D)......................................................................................................................... 76
A.7 Distribution of wheel load under rail................................................................................................. 77
A.7.1 Local stress under rail........................................................................................................................ 77
A.7.2 Stress condition in a solid web under rail........................................................................................ 80
A.8 Local stresses in wheel supporting flanges .................................................................................... 80
A.8.1 General ................................................................................................................................................. 80
A.8.2 Local stresses in wheel supporting flanges (Main girder as I – beam)......................................... 81
A.8.3 Local stresses of a box girder with the wheel loads on the bottom flange .................................. 83
A.9 Example on calculation of classification parameters for weld and wheel load ........................... 86
A.9.1 General ................................................................................................................................................. 86
A.9.2 Crane operating conditions ............................................................................................................... 86
A.9.3 Method of operation and tasks .......................................................................................................... 86
A.9.4 Frequency of stress cycles ................................................................................................................ 87
A.9.5 Classification of the stress histories ................................................................................................ 89
A.9.6 History parameter s of stresses and class S : ................................................................................. 89
A.10 Example on classification of a bridge crane .................................................................................... 90
A.10.1 General ................................................................................................................................................. 90
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prEN 15011:2004 (E)
A.10.2 Crane specification ............................................................................................................................. 90

A.10.3 Crane duty ........................................................................................................................................... 91
A.10.4 Results of the preliminary strength analysis of the girder ............................................................. 92
A.10.5 Classification ....................................................................................................................................... 92
A.11 Guidance on recommended maximum deflection of girders ....................................................... 102
A.12 Guidance on recommended minimum frequencies of girders..................................................... 103
A.13 Accelerations and dynamic factors φ5 (informative) ..................................................................... 104
Annex B (informative) Guide for selection of rail wheels .......................................................................... 106
B.1 Rail wheel size................................................................................................................................... 106
B.1.1 General ............................................................................................................................................... 106
B.1.2 Determining the mean load .............................................................................................................. 107
B.1.3 Determining the useful rail width b ................................................................................................. 107
B.1.4 Determining the limiting pressure PL .............................................................................................. 108
B.1.5 Determining the coefficient c1 ......................................................................................................... 108
B.1.6 Determining the coefficient c2 ......................................................................................................... 109
B.2 Determination of the class of mechanism of the travel wheel ..................................................... 110
Annex C (informative) Risk assessment for the evaluation of the requirements for the
anti-collision system......................................................................................................................... 111
C.1 Principles of risk assessment ......................................................................................................... 111
C.1.1 General ............................................................................................................................................... 111
C.1.2 Probability of a collision................................................................................................................... 111
C.1.3 Effects of a collision ......................................................................................................................... 111
C.2 Probability of a collision................................................................................................................... 111
C.2.1 Probability Factors............................................................................................................................ 111
C.2.2 Speed Factor ..................................................................................................................................... 112
C.2.3 Visibility Factor ................................................................................................................................. 112
C.2.4 Environmental factor ........................................................................................................................ 113
C.2.5 Number of cranes Factor.................................................................................................................. 113
C.3 Effects of a collision ......................................................................................................................... 114
C.3.1 General ............................................................................................................................................... 114
C.3.2 Effects on crane factor ..................................................................................................................... 114
C.3.3 Load form factor, El........................................................................................................................... 114
C.3.4 Injury potential factor ....................................................................................................................... 116
C.3.5 Injury type factor ............................................................................................................................... 116
C.4 Action required.................................................................................................................................. 117
Annex D (informative) Scoring system for risk assessment on load-person interference.................... 118
Annex E (normative) Noise test code .......................................................................................................... 119
E.1 Scope.................................................................................................................................................. 119
E.2 References ......................................................................................................................................... 120
E.3 Definitions.......................................................................................................................................... 120
E.4 Description of machinery family ..................................................................................................... 120
E.5 Calculation method........................................................................................................................... 120
E.5.1 Principle of the method .................................................................................................................... 120
E.5.2 Calculation ......................................................................................................................................... 120
E.6 Sound pressure level determination at control stations by measurement................................. 122
E.6.1 Measurement points ......................................................................................................................... 122
E.6.2 Installation and mounting conditions ............................................................................................. 122
E.6.3 Operating conditions ........................................................................................................................ 123
E.7 Uncertainties ..................................................................................................................................... 124
E.8 Information to be recorded .............................................................................................................. 124
E.9 Information to be reported ............................................................................................................... 124
E.10 Declaration and verification of noise emission values ................................................................. 124
Annex F (normative) Particular requirements valid for the cranes during lifting of persons................ 125
Annex G (Informative) Actions on crane supporting structures induced by cranes.............................. 126
G.1 Actions induced by cranes .............................................................................................................. 126
G.2 Dynamic factors ................................................................................................................................ 127
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prEN 15011:2004 (E)
Annex H (informative) Information labels.................................................................................................... 128

Annex I (informative) Selection of a suitable set of crane standards for a given application ............... 130
Annex ZA (informative) Relationship of this European Standard with EU Directives ............................ 132
Bibliography ................................................................................................................................................... 133
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prEN 15011:2004 (E)
Foreword
This document (prEN 15011:2004) has been prepared by Technical Committee CEN/TC 147 “Cranes
- Safety”, the secretariat of which is held by BSI.
This document is currently submitted to the CEN Enquiry.
This document has been prepared under a mandate given to CEN by the European Commission and
the European Free Trade Association, and supports essential requirements of EU Directive(s).
For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this
document.
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prEN 15011:2004 (E)
Introduction
This document is a harmonized European Standard to provide one means for bridge and gantry
cranes to conform with the Essential Health and Safety Requirements of the Machinery Directive
98/37/EEC .
This European Standard is a type C standard as stated in EN 1070.
The machinery concerned and the extent to which hazards, hazardous situations and events are
covered are indicated in the scope of this document.
When provisions of this type C standard are different from those which are stated in a B standard, the
provisions of this type C standard take precedence over the provisions of the other standards, for
machines that have been designed and built according to the provisions of this type C standard.
Absolute safety of the crane cannot be ensured by design, as operation depends on the skills of the
operators, maintenance personnel and inspectors as well as on numerous technical parameters in the
crane or its environment which may have large scatter. Therefore selections provided by this standard
reflect only the state of the art at the time of writing.
As many hazards related to bridge and gantry cranes depend on the place and use of the crane, it is
assumed that the correct information has been exchanged between the manufacturer and user (as
suggested in the ISO 9374-1 and 5), e.g:
 Clearances
 Requirements concerning protection against hazardous environment
 Processed materials, such as potentially flammable or explosive material (e.g. coal, powder type
materials).
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prEN 15011:2004 (E)
1 Scope
This European standard specifies the safety requirements for the bridge and gantry cranes. This
standard is not applicable to runways and other supporting structures.
The standard deals with all significant hazards, hazardous situations and events relevant to bridge
and gantry cranes, when used as intended and under conditions foreseen by the manufacturer (see
clause 4).
The specific hazards due to potentially explosive atmospheres, underground work, ionizing radiation,
and operation in electromagnetic fields beyond the range of EN 50082-2 are not covered by this
standard. Also the additional loads due to mounting on a floating or tilting basement are not covered
by this standard.
This standard includes requirements for the lifting of persons.
NOTE The use of cranes for lifting of persons may be subject to specific national regulations.
This European Standard is applicable to bridge and gantry cranes which are manufactured after the
date of approval by CEN of this standard.
2 Normative references
The following referenced documents are indispensable for the application of this document.
For dated references, only the edition cited applies. For undated references, the latest edition
of the referenced document (including any amendments) applies.
EN 292-1: 1991, Safety of machinery — Basic concepts, general principles for design — Part 1: Basic
terminology, methodology
EN 292-2: 1991/A1: 1995, Safety of machinery — Basic concepts, general principles for design —
Part 2: Technical principles and specifications
EN 294: 1992, Safety of machinery - Safety distance to prevent danger zones being reachedby the
upper limbs
EN 547-1, Safety of machinery — Human body measurements — Part 1: Principles for determining
the dimensions required for openings for whole body access into machinery
EN 547-2, Safety of machinery — Human body measurements — Part 2: Principles for determining
the dimensions required for access openings
EN 614-1, Safety of machinery — Ergonomic design principles — Part 1: Terminology and general
principles
EN 894-1, Safety of machinery — Ergonomics requirements for the design of displays and control
actuators — Part 1: General principles for human interactions with displays and control actuators
EN 894-2, Safety of machinery — Ergonomics requirements for the design of displays and control
actuators — Part 2: Displays
prEN 894-3, Safety of machinery — Ergonomics requirements for the design of displays and control
actuators — Part 3: Control actuators
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prEN 15011:2004 (E)
EN 953, Safety of machinery — Guards — General requirements for the design and construction of
fixed and movable guards
EN 954-1, Safety of machinery — Safety-related parts of control systems — Part 1: General principles
for design
prEN 1005-3, Safety of machinery — Human physical performance — Part 3: Recommended force
limits for machinery operation
EN 1070, Safety of machinery — Terminology
EN 10002-1:1990, Metallic materials — Tensile testing — Part 1: Method of test (at ambient
temperature)
EN 12077-2: 1998, Cranes safety — Requirements for health and safety — Part 2: Limiting and
indicating devices
EN 12644-1: 2001, Cranes — Information for use and testing — Part 1: Instructions
EN 12644-2: 2000, Cranes — Information for use and testing — Part 2: Marking
prEN 13001-1, Cranes — General Design — Part 1: General principles and requirements
prEN 13001-2, Cranes — General Design — Part 2: Load actions
prCEN/TS 13001-3.1, Cranes — General Design — Part 3.1: Limit States and Proof of Competence
of Steel Structures
prEN 13135-1, Cranes — Equipment — Part 1: Electrotechnical equipment
prEN 13135-2, Cranes — Equipment — Part 2: Non-electrotechnical equipment
EN 13202, Ergonomics of the thermal environment — Temperatures of touchable hot surfaces —

Guidance for establishing surface temperature limit values in production standards with the aid of
EN 563
prEN 13557, Cranes — Controls and control stations

,
prEN 13586 Cranes — Access
prEN 14492-2 Cranes — Power driven winches and hoists — Part 2: Power driven hoists
EN 60073, Basic and safety principles for man-machine interface, marking and identification —
Coding principles for indication devices and actuators
EN 60204-32, Safety of machinery — Electrical equipment of machines — Part 32: Requirements for
hoisting machines
EN 60825-1, Safety of laser products — Part 1: Equipment classification, requirements and user's
guide
EN 61310-2, Safety of machinery — Indicating, marking and actuation —- Part 2: Requirements for
marking
ISO 3864, Safety colours and safety signs
ISO 7752-5, Lifting appliances — Controls — Layout and characteristics — Part 5: Overhead
travelling cranes and portal bridge cranes
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prEN 15011:2004 (E)
ISO 8566-5, Lifting appliances — Cabin — Part 5: Overhead travelling cranes and portal bridge
cranes
ISO 10245-5, Cranes — Limiting and indicating devices — Part 5: Overhead travelling and portal
bridge cranes
ISO/FDIS 11660-5, Cranes — Access, guards and restraints — Part 5: Bridge and Gantry Cranes
ISO/CD 12488-1, Cranes — Tolerances of cranes and tracks — Travel and Traverse —
Part 1: General
ISO 1680: 1999, Acoustics — Test code for the measurement of airborne noise emitted by rotating
electrical machines
EN ISO 3744: 1995, Acoustics — Determination of sound power levels of noise sources using sound
pressure — Engineering method in an essentially free field over a reflecting plane
EN ISO 11202: 1995, Acoustics — Noise emitted by machinery and equipment — Measurement of
emission sound pressure levels at a work station and at other specified positions — Survey method in
situ
EN ISO 11203: 1995, Acoustics — Noise emitted by machinery and equipment — Determination of
emission sound pressure levels at a work station and at other specified positions from the sound
power level
EN ISO 11204: 1995, Acoustics — Noise emitted by machinery and equipment — Measurement of
emission sound pressure levels at a work station and at other specified positions — Method requiring
environmental
3 Definitions
For the purposes of this document, the terms and definitions of EN 1070, ISO 1680, EN ISO 3744, EN
ISO 11202, EN ISO 11203, and EN ISO 11204 apply together with the following.
3.1
bridge crane
a crane having at least one primarily horizontal girder moving along tracks on which is mounted at
least one hand, or power driven, hoist
3.2
gantry crane
a crane having at least one essentially horizontal girder supported by at least one leg moving along
tracks and equipped with at least one hand, or power driven, hoist
3.3
limit of the crane
the contact point between the crane and fixed environment
4 List of hazards
Table 1 contains all the significant hazards, hazardous situations and events, as far as they are dealt
with in this standard, identified by risk assessment as significant for this type of machinery and which
require action to eliminate or reduce the risk.
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prEN 15011:2004 (E)
Table 1 — List of significant hazards and associated requirements

No. Hazard (as listed in EN 1050:1997) EN EN 292-2 Other EN- Relevant
292-1 standars clause(s) in this
and ISO- standard
standards
1 Mechanical hazards 4.2
1.1 Generated by machine parts or 4.2 3.1, 3.2, 4
workpieces, e.g. by:
1.1.1 Shape
1.1.2 relative location 5.4.2
1.1.3 mass and stability EN 13001 5.2
1.1.4 mass and velocity EN 13135-2 5.3.3, 5.4.2.5
1.1.5 inadequacy of mechanical. .strength EN 13001 5.2
1.2 Accumulation of energy inside the 4.2 3.8, 6.2.2
machinery, e.g. by:
1.2.1 elastic elements (springs)
1.2.2 fluids under pressure EN 13135-2 5.3.1
5.7
1.2.3 the effect of vacuum
1.3 Elementary forms of mechanical 4.2.1
hazards
1.3.1 Crushing 4.2.1, 3.2 EN 294, EN 5.1, 5.4.2,
4.2.2 349 7.1.1.1
1.3.2 Shearing 4.2.1, 3.2, 4.1.1 EN 13586 5.4.2.4, 5.4.2.6
4.2.2
1.3.3 Cutting or severing 4.2.1, 3.2 ISO 8566-1
4.2.2 6.3,
EN 13557
1.3.4 Entanglement hazard 4.2.1,
4.2.2
1.3.5 Drawing-in or trapping hazard 4.2.1 3.11, 4.1.1, EN 953 5.4.2.7 to 5.4.2.9
- moving transmission parts 6.1.2 EN 294
1.3.6 Impact 4.2.1 5.3.3.5, 5.4.1.5
7.2.1.1.4
1.3.7 Stabbing or puncture hazard 4.2.1
1.3.8 Friction or abrasion hazard 4.2.1 3.3.b
1.3.9 High pressure fluid injection or 4.2.1 3.3.a EN13135-2 7.2.2.2
ejection hazard
2 Electrical hazards due to: EN13135-1 5.1

2.1 Contact of persons with live parts 4.3 EN 60204-32
(direct contact)
2.2 Contact of persons with parts which 4.3 EN 60204-32
have become live under faulty
conditions (indirect contact)
2.3 Approach to live parts under high EN 60204-32
voltage
2.4 Electrostatic phenomena 4.3 EN 60204-32
2.5 Thermal radiation or other 4.3 EN 60204-32
phenomena such as the projection of
molten particles and chemical effects
from short-circuits, overloads, etc.
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prEN 15011:2004 (E)
Table 1 — List of significant hazards and associated requirements (Continued)

and ISO- standard
standards
3 Thermal hazards, resulting in:
3.1 burns and scalds, by possible 4.4 3.6.3 EN 563, 5.3.5.1, 7.2.3.3.
contact of persons with objects or EN 13135-2
materials with an extreme
temperature, by flames, by radiation,
etc.
3.2 Hot or cold working environment. 4.4 EN 13557
4 Hazards generated by noise, 4.5 3.2, 3.6.3, 4

resulting in:
4.1 Hearing losses 5.4.4
4.2 Interference with speech 5.4.4, 7.2.1.2.2
communication, signals,..
5 Hazards generated by vibration 4.6 3.2, 3.6.3

5.1 Use of hand-held machines. -
5.2 Whole body vibration, particularly 5.2.2.6

when combined with poor postures
6 Radiation
6.0 External radiation See introduction
6.1 Low frequency , radio frequency 4.7 5.3.5.2.1
radiation, micro waves
6.2 Infrared, visible, UV-light 5.3.5.2.2
6.3 X and gamma rays -
6.4 Alpha, beta rays, electron or ion 4.7 3.7.3, 3.7.11
beams; neutrons
6.5 Lasers 4.7 EN 60825-1 5.3.5.2.3
7 Processed materials and

substances, used materials, fuels
7.1 Hazards from contact with harmful 4.8 3.3.b, 3.4 EN 60204-1: 5.3.5.3
fluids, gases, mists, fumes and dusts cl. 14.3 See Introduction
7.2 Fire or explosion hazard 4.8 3.4 See Introduction
7.3 Biological and micro-biological 4.8 -
hazards.
8 Neglected ergonomic principles in 4.9 3.6

machine design e.g. hazards from:
8.1 Unhealthy postures or excessive 4.9 3.6.1, 3.6.4, EN 547-1. -2 5.4.1.6 to 5.4.1.7
efforts 6.2.1-6
8.2 Inadequate consideration of hand- 4.9 3.6.2, 3.6.9 EN 614-1

arm or foot-leg anatomy
8.3 Neglected use of personal protection 5.5 3.6.6, 5.4, 5.5.3.1.3
equipment 5.5.1d
8.4 Inadequate local lighting 3.6.5 5.4.3
8.5 Mental overload or underload, stress 4.9 3.6.4 5.4.1.3, 7.2.1.2.7
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prEN 15011:2004 (E)

and ISO- standard
standards
8.6 Human errors, human behaviour 4.9 3.6, 3.7.8, 5.3.3.4, 5.4.1,
3.7.9, 5, 7.2.1
6.1.1
8.7 Inadequate design, location or 3.6.6, 3.7.8 ISO 7752-5 5.4.1
identification of manual controls
8.8 Inadequate design or location of 3.6.7, 5.2 EN 894-1, - 5.5.2
visual display units 2, -3
9 Combination of hazards 4.10 EN 13001-2 5.6
Hazardous events
(Events which may result in risk from one or several of the basic hazards)
10 Unexpected start-up, unexpected
overrun/overspeed (or any similar
malfunction) from:
10.1 Failure/ disorder of control systems 3.17, 3.7, 6.2.2 EN 60204-32 5.4.1
3.15, EN 954,
3.16 EN 418
10.2 Restoration of energy supply after an 3.7.2
interruption
10.3 External influences on electrical 4.3 3.4, 3.7.11
equipment
10.4 Other external influences (gravity, 3.7.3
wind, etc.)
10.5 Errors in the software 3.7.7
10.6 Errors made by the operator (due to 4.9 3.6, 3.7.8,
mismatch of machinery with human 3.7.9, 5,
characteristics and abilities, see No. 6.1.1
8.6)
11 Impossibility of stopping the 3.7, 3.7.1, 5.3.3.1
machine in the best possible 6.1.1
conditions
12 Variation in the rotational speed of 3.2, 3.3 -
tools
13 Failure of the power supply 3.16 3.7, 3.7.2 EN 60204-32 5.3.1.1
14 Failure of the control circuit 3.7, 6.2.2 EN 60204-32 5.3.1.1
15 Errors of fitting 4.9 5.5, 6.2.1
16 Break-up during operation 4.2.2 3.3 5.2, 7.2.2,
7.2.3.1 to 7.2.3.2
16.1 Thermal effect on the crane 5.3.1.1
17 Falling or ejected object. or fluid 1.3.6, 3.3, 3.8 EN 13586 5.3.1.1, 5.4.2.1,
1.3.9, 7.2.2.2
4.2.2
18 Loss of stability / overturning of 4.2.2 6.2.5
machinery
Loss of rigid body stability 4.2.2 3.3, 6.2.5 EN13001-2 5.2.3
19 Slip, trip and falling of persons 4.2.3 6.2.4 EN 13586 5.4.2
(related to machinery)
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prEN 15011:2004 (E)
No. Hazard (as listed in EN 1050:1997) EN EN 292-2 Other EN- Relevant clause(s)
292-1 standars in this standard
and ISO-
standards
Additional hazards and hazardous events due to mobility

20 Relating to the travelling function
20.1 Uncontrolled movement of crane A1:Annex.A,
when starting the engine 3.3.2, 3.3.4
20.2 Movement without a driver at the A1:Annex.A, 5.3.1.1
driving position 3.3.2
20.3 Movement without all parts in a safe A1:Annex.A,
position 3.3.2
20.4 Excessive speed of pedestrian A1:Annex.A, EN 13557
controlled machinery 3.3.4
20.5 Excessive oscillations when moving 5.3.3.2, 5.4.1.4
20.6 Insufficient ability of machinery to be 5.3.1.1, 5.3.3.1,
slowed down, stopped and 5.3.3.3, 7.2.1.2.3,
immobilized 7.2.1.2.6
21 Linked to the work position
(including driving station) on the
machine
21.1 Fall of persons during access to (or EN 13586, 5.4.2.1
at/from) the work position ISO 11660-5
21.2 Exhaust gases / lack of oxygen at the 5.3.5.3.2
work position
21.3 Fire (flammability of the cab, lack of EN 13557
extinguishing means)
21.4 Mechanical hazards at the work
position
- contact with the wheels 5.4.2.5,
- fall of objects, penetration by object 5.4.2.7
- contact of persons with machine
parts or tools (pedestrian control.)
21.5 Insufficient visibility from the working EN 13557 5.4.1.1, 5.4.1.6
position
21.6 Inadequate lighting 5.4.3
21.7 Inadequate seating A1:Annex.A, EN 13557,
3.2.2 ISO 8566-5
21.8 Noise at the driving position See item 4. 5.4.4.2
21.9 Vibration at the driving position See item 5. 5.2.2.6
21.10 Insufficient means of A1:Annex.A, EN 13586, 5.3.5.3.1
evacuation/emergency exit 3.2.1 EN 60204-32
22 Due to the control system 5.4.1
22.1 Inadequate location of controls See 8.1, 8.2
/control devices
22.2 Inadequate design of the actuation ISO 7752-1, 5.3.1.1, 5.4.1.1-2
mode and/or action mode of controls -5
23 From handling the machine (lack of A1:Annex.A, 5.3.3.3
stability) 3.1.3
24 Due to the power source and to
the transmission of power
24.1 Hazards from the engine and the A1:Annex.A,
batteries 3.4.8, 3.5.1
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prEN 15011:2004 (E)
and ISO-
standards
25 From/to third persons
25.1 Unauthorized start-up/use A1:Annex.A, EN 60204-32
3.3.2 5.4
25.2 Drift of a part, away from its stopping
position
25.3 Lack or inadequacy of visual or A1:Annex.A, 5.5
acoustic warning means 1.7.4, 3.6.1
26 Insufficient instructions for the
driver / operator
26.1 Movement into prohibited area 7.2.1.2.4
26.2 Tipping - Swinging 7.2.1.1.6, 7.2.1.2.5
26.3 Collision: machines-machine. ISO 10245-5 7.2.1.1.4-5,
7.2.1.2.9
26.4 Collision: machines-persons 7.2.1.1.4-5,
26.5 Ground conditions 7.2.1.2.3
26.6 Supporting conditions 7.2.1.2.10
Additional hazards and hazardous events due to load lifting

27 Mechanical hazards. and events
27.1 from load falls, collision, machine
tipping caused by:
27.1.1 lack of stability A1:Annex.A, 5.2.3
4.1.2.1
27.1.2 Uncontrolled loading -overloading – A1:Annex.A, 5.3.2.1
overturning moment exceeded 4.2.1.4
27.1.3 Uncontrolled amplitude of A1:Annex.A, 5.4.1.4
movements 4.1.2.6a
27.1.4 Unexpected/unintended movement A1:Annex.A, EN 13135-1, 5.4.1.1
of loads 4.1.2.6c -2
27.1.5 Inadequate holding devices / A1:Annex.A, EN 13135-2 5.3.1.1
accessories 4.1.2.6e,
4.4.1
27.1.6 Collision of more than one machine A1:Annex.A, 5.3.3.6
4.1.2.6b
27.1.7 Two-block of hook to hoist 5.3.2.2
27.2 From access of persons to load A1:Annex.A, 7.2.1.1.8
support
27.3 From derailment A1:Annex.A, EN 13135-2 5.3.3.7-8
27.4 From insufficient mechanical strength
of parts
Loss of mechanical strength, or 4.2 3, 5.2, 5.3.4, 7.2.2
inadequate mechanical strength A1:Annex.A,
4.1.2.3
27.5 From inadequate design of pulleys, A1:Annex.A, EN 13135-2 5.3.1.1
drums 4.1.2.4
27.6 From inadequate selection/ A1:Annex.A, EN 13135-2 5.3.1.1,
integration into the machine of 4.1.2.4-5, 5.2.1.1.2(4)
chains, ropes, lifting accessories 4.3.1-2
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prEN 15011:2004 (E)
and ISO-
standards
27.7 From lowering of the load by A1:Annex.A, EN 13135-2
friction brake 4.1.2.6d
27.8 From abnormal conditions of A1:Annex.A, 5.6, 7.1, 7.2.1.2.8
assembly/ testing/ use/ maintenance 4.4.1, 4.4.2d
27.9 Load-person interference (impact by A1:Annex.A, 5.4.1.5
load) 4.1.2.6b,
4.1.2.7,
4.2.3
28 Electrical hazard
28.1 from lightning A1:Annex.A, EN 13135-1 7.2.2.3
4.1.2.8
29 Hazards generated by neglecting
ergonomic principles
29.1 insufficient visibility from the driving A1:Annex.A, EN 13557 5.4.1.6
position 4.1.2.7,
4.4.2c
Additional hazards, hazardous situations and events due to lifting or moving of persons
34 Mechanical hazards and
hazardous events due to:
34.1 Inadequate working coefficients A1:Annex.A, 5.7
6.1.2
34.2 Failing of load control A1:Annex.A, 5.7
6.1.3
34.3 Failing of controls in person carrier A1:Annex.A, 5.7
(function, priority) 6.2.1
34.4 Overspeed of person carrier A1:Annex.A, 5.7
6.2.3
35 Falling of person from person A1:Annex.A,
carrier 6.3.1-3
36 Falling or overturning of person A1:Annex.A,
carrier 6.4.1-2
37 Human error, human behaviour A1:Annex.A,
6.5
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prEN 15011:2004 (E)
5 Safety requirements and/or protective measures
5.1 General
For those hazards which are relevant, though not significant, bridge and gantry cranes shall conform
to EN 292 in addition to the requirements of this clause..
Bridge and gantry cranes shall be in accordance with the following standards:
 prEN 13001-1, Crane safety — General design — Part 1: General principles and requirements;
 prEN 13001-2, Crane safety — General design — Part 2: Load actions;
 prEN 13001-3-1, Cranes — General design — Part 3: Limit states and proof of competence of
steel structures;
 prEN 13135-1, Cranes — Equipment — Part 1: Electrotechnical equipment;
 prEN 13135-2, Cranes — Equipment — Part 2: Non-electrotechnical equipment;
 prEN 13557, Cranes — Controls and control stations;
 EN 12077-2, Cranes safety — Requirements for health and safety — Part 2: Limiting and
indicating devices;
 prEN 13586, Cranes — Access;
 EN 12644-1, Cranes — Information for use and testing — Part 1: Instructions;
 EN 12644-2, Cranes — Information for use and testing — Part 2: Marking;
 prEN 12644-3, Cranes — Information for use and testing — Part 3: Fitness for purpose;
 prEN 14492-2, Cranes — Power driven winches and hoists — Part 2: Power driven hoists.
This standard provides more detailed requirements and selections of parameters for bridge and
gantry cranes in cases which the above mentioned standards have left open or where the provisions
of the above mentioned standards do not apply. Therefore those provisions have been modified in this
standard in accordance with the specific characteristics of bridge and gantry cranes.
5.2 Requirements for strength and stability
5.2.1 Load actions
5.2.1.1 Selection of service conditions
5.2.1.1.1 Selection of classification parameters
The service conditions that are selected and used as the basis of design, in accordance with EN
13001-1, shall be specified in the technical file of the crane.
NOTE 1 Two examples on estimation of classification parameters are given in A.11. Also support in
classification is provided by ISO 9374-5: Cranes — Information to be provided — Part 5 : Overhead travelling
cranes and portal bridge cranes.
NOTE 2 If the classification parameters cannot be adequately derived or estimated on the basis of the
foreseen use guidance for selection is given in Annex A
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prEN 15011:2004 (E)
5.2.1.1.2 Multiple lifting points
NOTE For cranes which are equipped with multiple reeving systems for lifting single loads the loading on
the individual reeving system will depend on the position of the load centre of gravity with respect to the lifting
points.
Normal case
The design of the rope reeving system shall be based on the maximum load expected in the system
based on the rated load and load eccentricity which shall be specified in the technical file and in the
operating instructions.
Special case
The reeving system design may be based on the rated load divided by the number of systems, when
the following conditions are met:
1) A load limiter is fitted on each rope system which limits the maximum load to not greater than
75 % of the total load in one rope system. This load limiting system shall allow the full speed
performance of the crane to be achieved.
2) The eccentricity of loading shall be equally distributed in average and not permanently
skewed to one rope system. Examples of such loading are ISO Containers, steel products
lifted with slings or magnet hooks.
3) The total load limiting system shall prevent the lifting of more than 100 % of the rated load at
the rated speeds and accelerations.
4) The selection of the rope, reeving components and the attached structures and mechanisms
shall comply with the specified classifications of the load spectrum, Qx, number of working
cycles, Uy, and number of positioning movements, Pz, with evenly distributed rated load of
the whole system. Each rope system shall comply with one step lower load spectrum class,
Qx-1, with maximum eccentric loading, while other classifications remain the same.
5.2.1.2 Determination of factor φ2
5.2.1.2.1 Selection of φ2
The dynamic load factor φ2 shall be determined in one of the following ways:
 on the basis of the hoist class, HC, (see EN 13001-2),

 by direct calculation in accordance with A.3 in Annex A
 experimentally
When the determination of factor φ2 is based on the hoist class (HC1 to HC4) the elasticity proporties
of the crane shall correspond to the selected hoist class in accordance with the tables 2 and 3 in
clause 4.1.2.2.1 of EN 13001-2.
When φ2 is calculated in accordance with A.3 in Annex A, the hoisting speed shall be based on the
relevant type of hoist drive, see Table 3 in EN 13001-2.
When the hoist mechanism is equipped with a hoist force limiter, φ2 determined for load
combination C1 shall be replaced by the limiter factor φDAL or φIAL depending on the type of the limiter.
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prEN 15011:2004 (E)
5.2.1.2.2 Effect of lifting force limiter
Lifting force limiters may be used for controlling the loading of electrically, pneumatically or
hydraulically powered hoists.
Lifting force limiters act automatically by:
 limiting the force flow (direct lifting force limitation), or

 switching off and stopping the lifting drive (indirect force limitation).
Direct acting lifting force limiters act directly in the chain of drive elements and limit the transmitted
force. Limiters may be, for example, slipping clutches, pressure limiting valves, etc. Direct acting lifting
force limiters generally have no response delay and require no braking path.
The maximum force which applies to the crane when the direct acting capacity limiter operates is
φDAL ⋅ mH ⋅ g.
φDAL : factor for direct acting lifting force limiters
mH : mass of the gross or hoist load
g : gravity constant
Indirect acting lifting force limiters measure the load using a sensor and switch off the energy supply
for the lifting operation and, if required, switch on a brake. Evaluation of the measured values and
filtering of interference signals require time and act as a triggering delay.
The triggering factor α is specified as a ratio between the mass which triggers the limiter and the rated
hoist load of the hoist mechanism.
The maximum force which applies to the crane when the indirect acting rated capacity limiter operate
is φIAL ⋅ mH ⋅ g
The factor φIAL is calculated as follows:
φIAL = φ2 ⋅ α [1]
where φ2 is for load combination C1
Values for φDAL and α are given by the hoist manufacturer in accordance with prEN 14992-2 .
5.2.1.3 Loads caused by acceleration
Bridge and gantry cranes are generally fitted with drives for cross travel, slewing and long travel and
hoist drives. Further types of drive for other motions are possible and shall be evaluated in
accordance with the contents of this section.
Rigid body analysis does not directly reflect elastic effects. Due to this, the change in load effects ∆S
= S(f) - S(i) due to the change of drive force ∆F = F(f) - F(i) , shall be multiplied by a factor φ5 and
algebraically added to the initial load effect S(i) present before the change of drive forces (f : final ; i :
initial ) ( see figure 6 in EN 13001-2 ) .
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prEN 15011:2004 (E)
Additional operating conditions for suspended loads apply for hoist units such as:
 switching on the lifting motion;

 switching off the lifting motion;
 switching on the lowering motion;
 switching off the lowering motion.
Inertia forces acting on the supporting structure when drive mechanisms and hoists are accelerated or
braked shall be determined in accordance with the following equation:
Ŝ = S(i) + φ5 ⋅ ∆S [2]
(see also EN 13001-2 , Subclause 4.1.2.4)
For drives without any backlash, or in cases in which the existing backlash does not influence
dynamic forces, the factors φ5 given in A.12 in Annex A may be used instead of exact calculation or
measurement.
The specified factors φ5 shall be multiplied again with a factor φPo = 1.2 ... 1.5
(φ5, tot = φ5 ⋅ φPo ) for scheduled positioning movements.
Figure 6b in clause 4.1.2.4 of EN 13001-2 , shows the change of the drive force for the positioning
case, where φ5 = φ5, tot .
The acceleration and/or braking values for the types of drive mechanism may be used in many cases
to calculate the load effect Ŝ .
Using the following equation
Ŝ = S(i) + φ5 , tot ⋅ aw,o ⋅ mw,o [3]
the maximum forces from, for example, cross travel, slewing, long travel or lifting of the load can be
calculated.
Where:
- S(i) : initial load effect caused by F(i)
- φ5 , tot : factor
- aw,o : acceleration or braking value
- mw,o : corresponding load for which aw,o applies.
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prEN 15011:2004 (E)
5.2.1.4 Loads caused by skewing
5.2.1.4.1 Origin of skewing effects
The contents of 4.3.4 of EN 13001 provide no generally applicable methods for calculating the loads
caused by skewing for the various crane types. There are also limitations here concerning the axle-
related arrangement of the travel wheels and the wheel loads for each side of the crane.
The following section provides generally applicable basic calculation methods for determining the
loads caused by skewing for suspension, bridge and gantry cranes.
Forces arising from skewing are generated when the resultant direction of rolling movement of the
travelling crane no longer coincides with the direction of the runway rail, and when the front positive
guiding means come into contact with the rail. As is well known, this unavoidable abnormality is
caused by tolerances and inaccuracies which arise in the manufacture of the crane (bores of track
wheels) and of the runway (bends, kinks). The values and distribution of these forces depend chiefly
on the clearances of wheel flanges or rollers, also on the number, arrangement, bearing arrangement
and rotational speed synchronization of the track wheels and on the location of the guide rollers (if
any), or in other words on the systems of the travel mechanism and of the supporting structure.
5.2.1.4.2 Suspension cranes
NOTE Suspension cranes usually travel on runways, which are fixed or supported to sway. This means, that
it is necessary to distinguish between the following features, when assessing the forces resulting from skewing:
— type of support ( swaying , fixed )

— type of guiding means ( wheel flange, guide roller )
— dimension or calculation of forces
— direction of forces.
The deformation characteristics of the crane, crane runway and support may, if required, be
considered in the calculation.
5.2.1.4.2.1 Suspension cranes with flange guiding
For crane runways with swaying supports, only horizontal lateral forces Fy ij have to be considered on
the front guiding means or group of guiding means ( front in the direction of travel ) in the dimension
of ( ±) 1/10 of the vertical wheel loads ( max. R, min. R , without factors φi ).
An example is shown in figure 1.
20
prEN 15011:2004 (E)
Fy11 = 1/10 R11 R11 R21 Fy21 = 1/10 R21

Fy12 = 1/10 R12 R12 1 R22 Fy22 = 1/10 R22
2 3
4
Key
(shown : R11 , R12 ≥ R13 , R14 )
1 Trolley
2 Rail 1
3 Rail 2
4 Span l
5 Side 1
6 Side 2
Figure 1 — Suspension crane with guide flanges, crane runway with swaying supports
For fixed crane runways horizontal lateral forces Fy ij shall be considered for all wheel support points
(max. R, min. R) in the dimension of ( ± ) 1/10 of the vertical wheel loads (without factors φi ).
5.2.1.4.2.2 Suspension cranes with guide rollers
The usually low play between the guide rollers of the crane and the crane runway allows only low
deformation characteristics between crane, crane runway and supports both for swaying and fixed
crane runway support arrangements. In this case skewing forces are calculated in accordance with
5.2.1.4. 3 for a suspension crane.
5.2.1.4.3 Top running bridge cranes
A.5 in Annex A describes basic methods for calculating the forces caused by skewing for bridge
cranes travelling on rails and guided by travel wheels with flanges or guide rollers.
5.2.1.4.4 Gantry cranes
A.6 in Annex A describes basic methods for calculating the forces caused by skewing for gantry
cranes travelling on rails taking into account hinged and rigid legs.
5.2.1.5 Test loads
The overload test load to be taken into account in calculation shall be in accordance with 6.3.3 or
6.3.4.
Performance tests and functional tests specified in clause 6 do not have to be verified by calculation.
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prEN 15011:2004 (E)
5.2.1.6 Conditions of use of permissible stress method and limit state method
Selection of allowable stress method or limit state method shall be made in accordance with prEN
13001-1 and -2.
5.2.2 Limit states and proof of competence
5.2.2.1 Limit states and proof of competence of structural members
The limit states of the materials, connections and elastic stability of the structural members shall be
determined in accordance with prCEN/TS 13001-3.1.
5.2.2.2 Limit states of mechanical components
EN standard for the selection of rail wheels (prENV 13001-3.3) is under preparation. While the
appropriate standard is not available, the rail wheels and rails shall be selected in accordance with
annex B of this standard. Other methods that are based on experimental knowledge on the wear of
the used materials and which give comparable life of the wheels can be used.
5.2.2.3 Local stresses from wheel loads
The stresses of a supporting structure transmitted from local wheel loads shall be calculated and
allocated to the load combinations A, B and C (table 10 and 11 of prEN 13001-2) taking into account
the relevant φi factors.
Travel wheels generally transmit vertical and tangential wheel loads. The effects of these wheel loads
on all further load transmitting elements of the supporting structure shall be proven for local stresses.
If no exact proof is provided, the stresses from vertical wheel loads may be calculated in accordance
with:
 Annex A.7 in the case of cranes with cross travel rails (arranged centrally above the girder web)
and
 Annex A.8 in the case of cranes with the hoist travelling on the lower flange of the girder.
The local stress due to the wheel load shall be combined with the global normal and shear stresses
for the determination of the equivalent stress intensity in accordance with the principles given in
prEN 13001-2.
For fatigue assessment, the number of rail wheel overruns per work cycle shall be estimated. See
also the example in annex A.9.
The fatigue safety factors shall be adjusted in accordance with Table 8 in prCEN/TS 13001-3.1.
5.2.2.4 Proof of strength of lifting points
Instead of complicated calculations with the theories of elasticity the special lifting points (e.g. lugs or
holes) may be calculated with the theory of plasticity as follows: The special lifting points shall be
designed with factor 4 and their welds to the structures shall be designed with the factor 5 against
ultimate strength of steel. To justify the use of this theory, the elongation A5 (EN 10002-1) of the
materials shall be at least 15 %.
5.2.2.5 Elastic deformation
The elastic deformations of the crane structure shall not have a detrimental influence on the function
of the crane.
22
prEN 15011:2004 (E)
Annex A.10 provides information and guide values for the specification of crane girders for usual
bridge and gantry cranes.
5.2.2.6 Vibrational frequencies of crane girders
To avoid uncomfortable vibrations for the operator in a cabin, the natural frequency of the structure
carrying the cabin should not be less than 2 Hz. For long spans this requirement may be too difficult to
meet with economically feasible stiffness. Therefore, lower frequencies may be allowed, but amplitude
and duration of vibrations should be minimized by using stepless controls and smooth speed
transitions. Informative guide values of lowest frequencies are given in annex A.11.
For gantry cranes the frequency of horizontal vibrations should be not less than 0,50 Hz.
5.2.3 Stability of the rail mounted gantry crane
5.2.3.1 General requirements
Proof of stability of the gantry crane shall be calculated in accordance with prEN 13001-2.
A rail-mounted crane is considered to be stable, if none of the supporting corners of the crane will lift
up in the calculations of the specified load conditions.
A rubber tyred gantry crane (RTG) is considered to be stable when the crane does not turn over.
5.2.3.2 Additional requirements for gantry cranes with cantilevers
From the stability point of view the gantry cranes with cantilevers can be divided in three groups as
follows:
b) cranes with fixed legs on both rails;

c) cranes with a hinged legs on opposite rail to the direction of the cantilever;
d) cranes with a hinged leg on the same side as the cantilever.
Cases b) and c) can appear in the same crane, see Figure 2
b) c)
Figure 2 — Gantry crane configurations with cantilevers
For cranes in groups b) and c) the verification of stability by calculation shall be made by multiplying
the partial safety factors on the row 2 in Table 11 in prEN 13001-2 by the high risk coefficient:
 γn = 1,12 for case b)

 γn = 1,25 for case c).
This applies to all relevant load combinations in Table 11 in prEN 13001-2.
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prEN 15011:2004 (E)
5.2.3.3 Design of tie-downs
Furthermore, if the stability of the crane does not conform to prEN 13001-2 for storm wind conditions,
it shall be equipped with tie-downs designed with the partial load factors in accordance with the same
standard.
The material resistance factors γm for design of tie-downs and their fastening points shall be taken as
follows:
 for steel sections γm = 1,34;
 for wire ropes and chains γm = 2,50.
5.2.3.4 Stability of RTG in case of collision
The RTG shall maintain stability even in the case when one of the corners of the crane is suddenly
stopped by an obstacle while travelling down the maximum slope at maximum speed.
5.3 Requirements for equipment
5.3.1 General
5.3.1.1 The electrotechnical, mechanical, hydraulic and pneumatic equipment shall conform to
prEN 13135-1 and prEN 13135–2.
5.3.1.2 Control system(s) for the control of crane movements shall be designed to conform to the
following:
— electromechanical control circuits : category 1 of EN 954-1;

— electronically controlled safety related parts of control circuits:
either
to conform to category 2 or 3 of EN954-1, depending on the nature of the protective function
or
to be equipped with a redundant solution (electronic, electromechanical) where the back-up protection
cannot be automatically reset.
5.3.2 Hoisting equipment
5.3.2.1 Overload protection
5.3.2.1.1 Setting of direct acting rated capacity limiter
The equipment shall be set in a way that a load equal to 110 % of the rated capacity can be lifted to
perform the dynamic overload test, (see 6.3), without changing the setting of the rated capacity limiter.
With this setting a load exceeding 160 % of the rated capacity shall not be lifted.
NOTE The figure 160 % corresponds with φ DAL.
5.3.2.1.2 Setting of indirect acting rated capacity limiter
The setting shall be such that a load exceeding the rated capacity multiplied by the triggering-factor
shall trigger the limiter (load > α⋅mRC). The triggering-factor shall be less than or equal to 1,25
(α ≤ 1,25). A load greater than α times the rated capacity shall not be lifted over a distance greater
than the maximum rated hoisting speed multiplied by 1 second.
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prEN 15011:2004 (E)
5.3.2.1.3 Local load limitation
In addition to the requirements of (prEN 14492-2) the rated capacity of the hoist shall be limited to a
lower level locally, when the load bearing capacity of the structure or mechanisms on site so require.
See also 5.3.3.4.
5.3.2.1.4 Variable number of hoisting units on the same bridge
A material handling system in a workshop may allow hoisting trolleys to be moved from one bridge to
another thus creating a case where the total lifting capacity of the hoisting units exceeds the rated
capacity of the bridge. The risks arising from such cases shall be minimized using one of the
following methods:
1) Based on a special risk assessment backed by experience, considering the possibility of use
of more than one hoist unit simultaneously, give instruction and labels of permitted total load.
2) Design the bridge to allow the total load of the expected maximum number of hoisting units.
3) Provide the system with load measuring and summarizing devices in connection with the
rated capacity limiter of the bridge. For setting of the rated capacity limiter the weakest load
bearing components and the foreseen most unfavourable load combinations shall be
considered.
5.3.2.1.5 More than one hoisting unit permanently on the same bridge
If the hoisting units can be used independent and the total lifting capacity of the hoisting units exceeds
the rated capacity of the bridge, the risks arising from such cases shall be solved using one of the
following methods:
1) Design the bridge to allow the total load of hoisting units.
2) Provide the system with load measuring and summarizing devices in connection with the
rated capacity limiter of the bridge. For setting of the rated capacity limiter the weakest load
bearing components and the foreseen most unfavourable load combinations shall be
considered.
If the hoists can only be used working together and an overload situation cannot be expected, then
overload protection is only necessary for the single hoist. In this case, the foreseen use of the crane
has to be described in the operator's manual.
5.3.2.2 Use of a back-up limiter
The second (back-up) upper limiter of hoist motion as defined in prEN 13135-2 shall be used at least
in the following types of cranes:
 Cranes handling hot molten metal;
 Paper roll handling cranes;
 Cranes handling dangerous chemicals;
 Power house cranes for turbine handling;
 Shipyard cranes for loads ≥ 50 t;
 Cranes used for lifting of persons, unless there is a second trolley, independent rope or chain that
carries the basket.
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prEN 15011:2004 (E)
5.3.2.3 Boom hoisting
5.3.2.3.1 The boom hoist mechanism shall be provided with a back-up brake (see prEN 13135-2).
The back-up brake shall act directly on the drum or it may act on the primary shaft of the gear when
the components in the kinematic chain between the back-up brake and the ropes are designed with
risk coefficient γn = 1.60.
5.3.2.3.2 If a boom rope becomes slack, the boom hoist shall be brought to a standstill. When in
the operating position, the boom may not hang in the ropes of the boom hoist. The trolley shall not fall
out of the track, at the transit point between the bridge and the boom, whatever the position of the
boom, The travelling trolley may only pass over to the boom when the boom is in its operating
position(s).
5.3.3 Travel and traverse
5.3.3.1 Friction drive capability
The travel and traverse drive and braking systems shall be designed so that they are capable of
controlling and stopping movements with maximum specified slope and maximum operational wind
speed for any load - wind area combinations within the specified limits.
When evaluating accelerations or stopping, the friction coefficient between the rail and the wheel shall
not be taken to be greater than 0,12 and the friction coefficient between rubber tyre and ground shall
not be takent to be greater than 0,15.
Power driven travel and traverse systems shall be provided with brakes.
5.3.3.2 Hand driven trolleys and cranes
If it is possible that the horizontal force due to the slope of the track is greater than the friction force
that resists the horizontal motion, the hand powered trolley or crane shall be provided with a
brake/brakes.
If the travelling and traversing movements are realized only by pushing on the load, the horizontal
force required shall not exceed 550 N when the maximum load is transported and no braking system
is required.
If the travelling and traversing movements are realized only by a hand driven mechanism, the
operating force required by each operator:
 on a hand chain shall not exceed 250 N;

 on one handed crank in the vertical plane shall not exceed 250 N;
 on two handed crank in the vertical plane shall not exceed 400 N;
 one handed crank in the horizontal position shall not exceed 150 N;
when the rated capacity is transported and no braking systems is required.
Gantry cranes which can travel freely when pushed without a load shall have devices fitted to their
wheels to limit movement when loads are lifted.
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prEN 15011:2004 (E)
5.3.3.3 Drive characteristics of the rubber tyred gantry crane (RTG)
The ratio of the wheel base and the height of the centre of gravity and the stiffness of structures of the
rubber tyred gantry cranes shall be selected so that:
 the operational accelerations and decelerations do not cause intolerable oscillations for the driver.
Values are specified in ISO 2631-1.
 the crane maintains stability even in the case where one of the corners of the crane is suddenly
stopped by an obstacle while travelling at a maximum slope down with maximum speed.
5.3.3.4 Anchoring in out-of-service wind conditions
If the minimum foreseeable friction or the braking torque of the driven wheels can not prevent the
crane or trolley from drifting away in the specified out-of-service wind conditions in accordance with
prEN 13001-2, the crane or trolley shall be equipped with the following:
 rail clamps that can operate at any position of the track, or

 anchor pins or other means of same function that can hold the crane in certain anchoring
positions.
5.3.3.5 Limiters and indicators for horizontal motions
To minimize further hazards as a consequence of human errors or failure of the control systems the
crane shall be equipped with limiters at the end of each motion in accordance with EN 12077-2.
Minimum requirements for the application of motion limiters are given in ISO 10245-5.
Rail mounted cranes shall be provided with automatic limiters connected, if necessary, to load
sensors in the following circumstances:
a) Where there are limitations due to load bearing capacity of the crane supporting structures;
b) where there is a potential hazard of collision with buildings or objects; or
c) where there is a potential hazard of collision due to not achieving the required safety clearances.
5.3.3.6 Collision of cranes or trolleys
NOTE Buffers between the cranes or trolleys are most often sufficient for risk reduction unless the possible
collision of the swinging loads create a hazard.
5.3.3.6.1 Functions of anti-collision systems
Collision avoidance system shall be considered whenever a system of cranes may occupy the same
working zone. This may also apply to the hoist trolleys on the same bridge. The need for such a
system as well as the necessary safety category (EN 954-1) shall be evaluated by means of a risk
assessment.
When a system is evaluated as being required all potentially conflicting cranes shall be equipped with
the system. The anti-collision system shall have some or all of the following features depending on the
assessment of the risks involved in the system:
 Notice of warning of approach of hazard;

 Reduce the speed of approach of the crane(s) moving towards the hazard;
 Stop the moving crane(s) before the collision.
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prEN 15011:2004 (E)
5.3.3.6.2 Risk assessment
The risk assessment shall look at the factors involved in the probability of a collision and the effects of
a collision on the safety of persons. A method of collision avoidance risk assessment is outlined in
informative annex C.
5.3.3.6.3 Limit of system
The collision control systems specified in this subclause are meant to confront only those risks arising
from the collision between the cranes in the system and not the collision of the load(s) to other moving
or fixed features in the operating area. Potential collision due to these factors may also be a reason
for the installation of an anti-collision system.
5.3.3.7 Anti-derailment equipment
If the sudden release of a load can cause the trolley or crane to rise more than 70 % of the flange
height or guiding roller height then a means of retaining the crane or trolley shall be provided.
The maximum stored energy in the bridge structure shall be used to evaluate the lift of the whole
mass of the crane.
In the event of an occurrence which gives rise to a derailment, the trolley or crane shall not fall. This is
achieved as follows:
 lateral guides or buffers;

 vertical guides;
 dimensions of the trolley/end carriages, are such that the trolley/end carriages cannot fall from
the bridge or gantry.
5.3.3.8 Guide roller design
Guide rollers shall only be used in cranes or trolleys that move on a rail that has no steps on the sides
of the rail (Tolerance class 2 of ISO 12488-1, minimum). Alternatively, the guide rollers of the elevated
travel or traverse drives shall be designed or guarded so that falling of the roller is prevented in case
of the bearing failure.
5.3.4 Tolerances
5.3.4.1 The tolerances for rail mounted cranes and tracks
The rail mounted cranes shall be manufactured within the tolerances of ISO 12488-1. The tolerance
class shall be selected on the basis of the designed total travel distance according to that standard.
5.3.4.2 The tolerances for alignment of travelling wheels of RTG
Permitted max. deviation from the centre line of wheels is ± 0,2° for each wheel.
0,2º
º
0,2
Figure 3 — Alignment tolerances of tyres
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prEN 15011:2004 (E)
Tyre diameter refers to the outer diameter of a tyre with normal tread fitted on a measuring rim. Tyre
diameter, max. indicates the maximum diameter of a normal tyre on a measuring rim, including growth
while in service.
Examples of tolerances for industrial tyres:
ETRO-standard: diameter ± 2 % (diagonal-ply tyre);

width + 3 % (radial-ply tyres);
+ 8 % (diagonal-ply tyre).
An example of a tolerance given by a tyre manufacturer.
Tolerance for the radius of static loaded industrial tyre ± 2,5 % (deflected by the static load)
5.3.5 Protection against special hazards
5.3.5.1 Hot surfaces
On access ways where unintentional touching (0,5 seconds contact time) of potentially hot surfaces is
likely, these surfaces shall be guarded or marked in accordance with prEN 13202 annex B.
5.3.5.2 Radiation
5.3.5.2.1 Radio control
Radio controls are usually operated in the high-frequency range UHF 400-475 MHz. The transmitting
power is in the range of approx. 10 mW and thus for this combination of frequency and power no risk
is known to persons.
If, in special cases, equipment is usedwhich doesn't conform to this requirement, the necessary
measures shall be subjected to a special analysis of the risks by the manufacturer and be clarified
with the user, if required. The safety instructions in the operating instructions of the radio control
manufacturer shall be observed.
5.3.5.2.2 Infrared control
For the usually used infrared controls where the wave length is in the range of 800-950 nm no risk is
known to persons.
If, in special cases, equipment is used which does not conform this requirement the necessary
measures shall be subjected to a special analysis of the risks by the manufacturer and be clarified
with the user, if required. The safety instructions in the operating instructions of the infrared control
manufacturer shall be observed.
5.3.5.2.3 Laser beams
Laser beams are used on cranes only in special cases, such as for measuring distances or for data
transmission.
The laser equipment shall conform to EN 60825-1.
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prEN 15011:2004 (E)
5.3.5.3 Processed materials and substances, used materials, fuels
5.3.5.3.1 Fire extinguishers
Egress from the rooms where fire extinguishers may be needed shall conform to the access
requirements in 12.5.2 and 12.5.3 of EN 60204-32.
5.3.5.3.2 Exhaust gases
Exhaust gases from combustion engines shall be discharged so that risks to the driver and others in
the vicinity are minimized.
5.3.5.3.3 Fuelling
The filling opening for the fuel tank shall not be located in the operator's cabin. The filling position
shall be easily accessible, preferably from ground level.
5.4 Requirements for man-machine interface
5.4.1 Controls and control stations
5.4.1.1 General requirements
Controls and control stations shall be in accordance with the appropriate clauses of prEN 13557 with
the following additions:
Control devices shall conform to the appropriate clauses of EN 614-1, prEN 894-3 and EN 61310-2.
The actuation forces shall conform to prEN 1005-3. The arrangement of the controls shall be in
accordance with ISO 7752-5. The shape and the minimum size of the cabin shall be in accordance
with ISO 8566-5.
A cable-less controlled crane may not be equipped with a separate E-stop actuator, if the following
apply:
 the cable-less control station is the only place of control and

 there is practically no risk that the driver would loose the controls off the hands for longer than 3
seconds, or it is reliably ensured that a lost cable-less control station will not send any run
command and
 there is no maintenance platform on the crane.
5.4.1.2 Control logics
Logics of the control systems shall be built to support natural human behaviour. Control systems shall
conform to EN 60073 and EN 60204-32.
5.4.1.3 Performance and capacity requirements
The lifting capacity, speeds of movements and control characteristics of the crane shall be fitted with
the crane capacity requirements so as not to cause overload for an experienced operator.
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prEN 15011:2004 (E)
5.4.1.4 Pendulation control
5.4.1.4.1 The speed control systems of the horizontal drives shall be selected and fit with the
maximum speed in such a manner that a single command of a speed transient will not cause
hazardous swaying of the load type handled.
5.4.1.4.2 When the horizontal speed exceeds 1 m/s, the influence of E-stop or collision with the
buffers on the load sway shall be considered. If the sway due to such large speed transients creates
hazards, the rate of speed transients shall be reduced by appropriate means (soft braking, limiters).
5.4.1.5 Avoidance of load impacts
NOTE The risk of an impact between the load and persons or other equipment is influenced by several
factors, these include the design features of the crane to resist load sway, the skill and experience of the trained
drivers and the type and place of the operations undertaken with the crane. The design features, which can limit
sway, range from a suitable selection of the drive controls and various methods of rope reeving to active anti-
sway systems.
The level of driving skill in restricting sway is generally highest for those cranes having a dedicated driver
performing the tasks. Lower levels of skill are to be expected from less frequent users. The risk of an impact will
naturally depend on the numbers of persons/machines or other obstructions in the crane's zone of action.
The selection of the appropriate design features and training levels shall be the subject of a risk-
assessment. The following factors should be considered:
 Speed of operation;
 Form of control Drive;
 Number of persons in zone;
 Number of obstructions in zone;
 Experience skill of the driver;
 Number of hourly operations;
 Systems of rope reeving and sway control ;
 Integrity of the load.
A form given in annex D may be used to assist selection of the appropriate mix of design features and
operation practice to be used.
5.4.1.6 Positioning of the control station
The control station should be positioned in such a way that uncomfortable positions of the driver's
body causing muscle strain are avoided or at least the periods of exposure are limited, for example,
looking downwards or backwards.
NOTE In the case where the crane driver is positioned vertically or nearly vertically above the load and the
crane is nearly in continuous duty there is a risk of insufficient balance of the body of the driver resulting in long
time stressing of the muscles and bones of the neck and back. In such a case the following measures should be
considered:
 installing supports for shoulders and head of the driver, or
 installing additional means for viewing the load such as camera systems on crane, cabin and/or
spreader.
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5.4.1.7 Information
More information on ergonomic design principles of controls and control stations are specified in
EN 614-1.
5.4.2 Guarding and access
5.4.2.1 The crane shall have permanent access to all control stations, in accordance with prEN
13586. Guidance on design requirements of permanent or movable access for maintenance is given
in ISO 11660-5.
5.4.2.2 If maintenance or inspection requires access to enclosures, the openings shall conform to
EN 547-1 and -2.
5.4.2.3 If the use of a safety belt is intended for working on the crane, attachment points for the
belt shall be provided at the relevant zones.
5.4.2.4 Movement of a crane or a part of crane may create a crushing or shearing hazard when
there are fixed objects near the contour lines of the crane (or part) travelling path. To eliminate these
hazards the clearances between the moving parts should be made as large as possible. The
minimum clearances shall be designed in accordance with ISO 11660-5. For walkways that the crane
operator uses regularly on the way to the control station the handrails shall be designed in
accordance with clause 6.6 of prEN 13586.
Exceptions to these rules may be allowed, if the same targets are reached by other means of
protection, e.g. a reliable person detector and motion limiter system. Such design shall be based on a
special risk assessment of the particular case.
5.4.2.5 The cabin shall be located so that collision with the handled load is prevented. If this is
not possible by location, the cabin shall be guarded with railings that can absorb the collition energy..
5.4.2.6 There is a shearing hazard when a person enters the crane walkway from a runway
walkway or from a slewing part of the trolley to the non-slewing part, and the operator may actuate the
movement simultaneously.
Where the access point can be provided with a gate in the crane part, it shall be fitted with an
interlocking device that disables the relevant motion. For other points of access, warning labels shall
be fitted and instructions given to the crane operator and any personnel moving on the crane to make
sure that the movements are not started while persons are passing shearing points.
5.4.2.7 For cranes travelling on rails on the floor or ground level, the end carriages or the
foremost bogies in both directions shall be equipped with the following
 rail sweepers, unless the design provides for such task;

 flexible contact warning devices, such as a rope loop.
The contact point of the runway and the wheels, that is at a lower level than 2,5 m shall be guarded,
e.g. by rail sweepers. The clearance between the runway and the rail sweeper shall be less than 5
mm at heights 0,5 to 2,5 m and less than 20 mm at heights 0 to 0,5 m.
5.4.2.8 Open gears, chain drives and similar power transmissions in permanent access zones
shall be guarded in accordance with EN 953. Exceptionally, guarding of the large slewing gears may
not be required, if the drawing in point of the pinion/gear is located sufficiently remote from the crane
driver access ways , (see EN 294).
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prEN 15011:2004 (E)
5.4.2.9 Hook blocks shall be designed to minimize the risk of drawing-in the hand between the
rope and a sheave.
Hand powered mechanisms for travelling or traversing shall be fitted with means to prevent the hand
chain from jumping off the chain wheels.
NOTE For functional and inspection reasons the rope drums, brakes and couplings are not generally
covered or guarded, as there should be no people near the machinery during normal crane operation.
5.4.3 Lighting
5.4.3.1 Manufacturers shall crane mounted lights depending on the availablility of other lights on
site. Lighting may be required in the following areas:
 on the working area;

 on access walkways, stairs and ladders;
 in machinery room and electric room.
5.4.3.2 When a crane will be used in a working place where general illumination level is less than
15 lux, it shall be equipped with lighting that provides local illumination of at least 50 lux on the
working area. These are minimum limits which should be exceeded when required by the accuracy of
the work.
When relevant, rooms shall have lighting as follows:

 cabins, min 200 lux;
 machinery room, min 100 lux;
 electric room, 100 lux.
5.4.3.3 A socket for extra local light shall be provided in each room including the cabin, in an
electrical cubicle, and other points requiring maintenance, if the ambient illumination is not adequate.
5.4.3.4 Cranes with a ride-on driver shall be equipped with battery powered emergency exit
lighting, unless there is emergency illumination on site.
5.4.4 Reduction of noise by design
5.4.4.1 General
Normally noise is not a significant hazard in the bridge and gantry cranes. Noise may be a significant
hazard in cases where the operators position is situated close to one or more of the mechanisms or
components mentioned in 5.4.4.1, when their power level or operational speed is high.
When noise is a significant hazard there is need for low noise design. In this case the methodology for
low noise design in EN ISO 11688-1 shall be considered.
NOTE EN ISO 11688-2 gives useful information on noise generation mechanisms in machinery.
5.4.4.2 Main sources of noise in bridge and gantry cranes are:
 hoisting mechanism (motor, gear, brakes)

 trolley traversing mechanism (motor, gear, brakes, especially rail/wheel contact)
 crane travel mechanism (motor, gear, brakes, especially rail/wheel contact)
 crane festoon (small festoon trolley wheels may be noisy)
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prEN 15011:2004 (E)
 trolley festoon
 electrical cubicles
 external devices, e.g. motor fans
 hydraulic pumps, either on the trolley or in the load lifting attachment (especially the grabs)
 combustion engines and power generators.
5.4.4.3 Measures to reduce noise at the source
Typical measures to reduce noise are:

 selection of low noise components
 use of elastic mountings that prevent the transmission of structure born noise from the
components to the structures
Other measures of identical or better efficacy can be used.
5.4.4.4 The protective measures
Typical measures are:

 the use of noise reducing housing around noisy componets
 the use of improved noise isolation in the cabin, if any.
5.4.4.5 Evaluation methods for determining of the sound levels are described in the noise
test code in the Annex E.
NOTE Effects of the supporting structure and the surrounding building (if applicable) are out of the scope of
this standard.
5.4.5 Information on residual noise
The information on residual noise shal be given to the user, see clause 7.
5.5 Equipment for information and warning
5.5.1 General
The crane driver, servicemen, inspectors, slingers and other persons working or visiting in the danger
zone of the crane shall be informed of the hazards related to the crane and its operations, and on
possible actions needed or to be avoided in order to avoid the harms. EN 292-2 gives the principles of
presenting such information with labels. EN 12644-2:2000 presents requirements and information on
marking of the crane.
Guidance on use of visual information labels is given in informative annex H. Requirements on visual
and acoustic information and warning means are given in the following clauses.
5.5.2 Location of the visual display unit
Location of the visual display units shall be in accordance with EN 894-1 and 2 to minimize the
operator's head motions but still avoiding unnecessary hindrance of the field of vision over the
working area.
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prEN 15011:2004 (E)
5.5.3 Visual and acoustic warning means
5.5.3.1 Visual warning means
NOTE Visual warning means are safety colours, pictorial signs, text warnings, and warning lights.
5.5.3.1.1 Safety colour
Safety colours shall be of contrasting colours, which will cause the “warning marks” standing out of
the operating environment, in accordance with ISO 3864. Safety marking shall be distinctive on the
crane and visible in daylight and at the night from all distances between 100 m and 5 m when directly
in front of the lawful beams of headlamps.
Colours shall have reasonable life for the anticipated operating environment.
5.5.3.1.2 Warning lights
Flashing warning lights shall be used to attract attention to the moving crane and trolley. Lights shall
be installed in such a manner as to be visible from the normal position of crane operators and viewers
on the ground level and. to attract attention of the maintenance personnel to the travelling trolley.
The colour of the flashing warning lights shall be yellow or amber. Flashing rate 60/min to 120/min.
5.5.3.1.3 Signs and texts
The crane should be designed so that use of personal protection equipment isuneccessary. However,
if they are deemed adequate to ensure safety during operation or certain phases of maintenance, this
shall be indicated by a clearly visible sign at the entrance of the crane or the danger zone (e.g. safety
belt or harness, glasses, ear plugs, helmet).
5.5.3.2 Acoustic warning means
Acoustic warning means are electrically operated warning horns and loudspeakers (optional).
Cranes shall be equipped with visual and/or acoustic warning means to indicate movement of the
crane in any directions and, if needed to indicate operations of hoist mechanisms.
Such warning means are not required for floor controlled cranes, when the crane driver has to stay
close to the load because of the position of the control panel and when the crane driver has a view of
the load movement and, for gantry cranes, a view also of the runway.
5.6 Installation and dismantling
Long lasting and critical erection procedures shall be designed considering the possibility of
unexpected interruption of work, for instance, failure of a single component. The structures shall be
secured or be able to lay down, if external conditions change worse, e.g. during high wind conditions.
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5.7 Particular requirements for lifting of persons
5.7.1 General
Except in emergencies, bridge and gantry cranes shall not be used for lifting or moving people unless
they are equipped with features specified in annex F, in accordance with the classification specified in
5.7.2.
5.7.2 Classification according to frequency of lifting of persons
5.7.2.1 The lifting and moving of persons is considered under three (3) main groups of
classification and the requirements which are valid to each group are specified in 5.7.2.2 to 5.7.2.4.
5.7.2.2 Group 1 - Those cranes where the principal use is the transportation of persons and
loads.
An example of such machine is a suspended stacker crane storing rolls of material or bars using a
fixed or telescopic guiding mast.
Typically, the driver is always present on the load suspension mechanisms when the crane is being
driven.
5.7.2.3 Group 2 - Those cranes which are frequently, but not principally, used for lifting people.
Examples of such machines are as follows:
 Ship to shore container cranes whose operation requires that persons are transported on the
spreader or head block beams to perform rigging or de-rigging operations on the ship borne
container stack;
 Automatic storage stacker cranes where the manual controlled use is not expected to exceed
10 % of the total movements of the crane
The use characteristics of this group may include daily use but less than 10 % of the total crane
moves would involve the transport of persons.
5.7.2.4 Group 3 - This group includes cranes where the crane is used occasionally for the lifting
and transport of persons
The use characteristics of this group are up to 20 days use per year. Often, in groups of 3 to 5 days of
such activity followed by normal load use.
Examples of such machines are as follows:
 Common crane types, bridge, gantry, portal, semi-portal etc. but the tasks to be performed
include the transport of persons to achieve access to an object being served by the crane.
Painting platforms, or assembly and maintenance platforms are the envisaged uses.
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6 Verification of safety requirements and/or protective measures
6.1 General
Where applicable, individual components may be separately verified or tested. Conformity to the
safety requirement and/or protective measure (specified in clause 5) shall be verified by the methods
given in tables 2 and 3.
6.2 Types of verification
Table 2— Verification methods for requirements

Visual inspection V
Measurement M
Testing T
Calculation C
Engineering assessment EA
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prEN 15011:2004 (E)
Table3 — Methods to be used to verify conformity with the safety requirements and/or
protective measures
Clause Title of the clause Method of verification
number
5 Safety requirements and/or protective measures ---

5.1 General Methods specified in referred
standards
5.2 Requirements for strength and stability This clause describes the
methods of verification of the
strength and stability of the
crane by calculation
5.3 Requirements for equipment ---

5.3.1 General ---
5.3.1.1 --- Methods specified in referred
standards
5.3.1.2 --- EA
5.3.2 Hoisting equipment ---
5.3.2.1 Overload protection ---
5.3.2.1.1 Setting of direct acting rated capacity limiter T
5.3.2.1.2 Setting of indirect acting rated capacity limiter T
5.3.2.1.3 Local load limitation T
5.3.2.1.4 Variable number of hoisting units on the same
bridge
1. 1. V
2. 2. C
3. 3. T
5.3.2.1.5 More than one hoisting unit permanently on the C, T, V

5.3.2.2 Use of a back-up limiter V
5.3.2.3 Boom hoisting V, T
5.3.3 Travel and traverse ---
5.3.3.1 Friction drive capability C
5.3.3.2 Hand driven trolleys and cranes V, M, T
5.3.3.3 Drive characteristics of the rubber tyred gantry crane C, T
5.3.3.4 Anchoring in out-of-service wind conditions C, V
5.3.3.5 Limiters and indicators for horizontal motions V
5.3.3.6 Collision of cranes or trolleys EA
5.3.3.7 Anti-derailment equipment C, V
5.3.3.8 Guide roller design V
5.3.4 Tolerances M
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prEN 15011:2004 (E)
Table 3 — Methods to be used to verify conformity with the safety requirements and/or
protective measures (Cont.)
Clause Title of the clause Method of verification

number
5.3.5 Protection against special hazards ---

5.3.5.1 Hot surfaces V, M
5.3.5.2 Radiation V (documents)
5.3.5.3 Processed materials and substances, used materials, EA, V
5.4 Requirements for man machine interface ---
5.4.1 Controls and control stations ---
5.4.1.1 General requirements EA, M
5.4.1.2 Control logics EA
5.4.1.3 Performance and capacity requirements EA
5.4.1.4 Pendulation control EA, V
5.4.1.5 Avoidance of load impacts EA
5.4.1.6 Positioning of the control station EA, V
5.4.1.7 Information EA
5.4.2 Guarding and access ---
5.4.2.1 --- V
5.4.2.2 --- M
5.4.2.3 --- V
5.4.2.4 --- M, EA
5.4.2.5 --- EA
5.4.2.6 --- V, EA
5.4.2.7 --- V
5.4.2.8 --- V, EA
5.4.2.9 --- EA
5.4.3 Lighting ---
5.4.3.1 --- EA
5.4.3.2 --- M
5.4.3.3 --- V
5.4.3.4 --- V
5.4.4 Reduction of risks resulting from noise M, EA
5.5 Equipment for information and warning ---
5.5.1 General V
5.5.2 Location of the visual display unit V
5.5.3 Visual and acoustic warning means EA, V
5.6 Installation and dismantling EA
5.7 Particular requirements for lifting of persons EA, C, V
7 Information for use EA, V
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prEN 15011:2004 (E)
6.3 Fitness for purpose testing
6.3.1 General
The crane shall be test loaded prior to putting it into use to verify that there is no major negligence in
design or manufacturing, despite all calculations, inspections and other verifications.
6.3.2 Performance test
The rated capacity of the crane shall not, in general, be exceeded during performance test.
6.3.3 Dynamic and static overload tests
6.3.3.1 The crane shall be tested dynamically, using the maximum nominal speeds for each drive
movement and overload that is at least 110 % of the rated capacity.
6.3.3.2 The crane fitted with powered-driven hoist shall be tested statically using an overload that
is the greater of
e) 125 % of the rated capacity,

f) the rated capacity multiplied by factor φ2 that has been used in design calculation in load
combinations A.
The crane fitted with hand powered hoist shall be tested statically using an overload that is the greater
than 150 % of the rated capacity. If the hand powered hoist is equipped with the direct acting limiter,
the static test shall bein accordance with 6.3.1.2.4.
6.3.3.3 The static test shall be carried out in one or more of the critical trolley positions, such as
the middle span, the ends of the cantilevers. The static tests carried out at the cantilevers also cover
the requirements for the stability testing.
6.3.3.4 For cranes that are equipped with a direct acting hoist torque limiter, the static test shall
be carried out so, that a mass equal to 1,6 times the rated capacity is lifted by the hoist. The mass
shall not leave the ground before the load limiter operates in any speed possible for the hoist.
6.3.4 Alternative test method for cranes fitted with powered driven hoists
When the dimensioning of the drives allow, the tests in 6.3.3.1 to 6.3.3.3 may be replaced with just a
dynamic test, using the maximum nominal speeds for each drive movement and overload that is not
less than that obtained by multiplying the rated load by coefficient Ct,dyn in Table 5.
Table 4 — Test load coefficient Ct,dyn

Load φ2 < 1.2 φ2 < 1.4 φ2 > 1.4
≤ 30 t 1,20 1,25 1,30
≤ 100 t 1,15 1,20 1,25
> 100 t 1,1 1,15 1,20
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prEN 15011:2004 (E)
6.3.5 When more than one hoisting mechanismis used in a crane, the overload testing shall be
carried out in the most unfavourable combinations of loads in the specified use.
6.3.6 In addition, each hoist shall be overload tested individually.
6.3.7 In general, each hoisting mechanism shall be overloaded with individual loads. One
common load may be used, when
 the individual hoists, including their drives and controls, have been overload tested in advance,
and
 the adequate distribution of load between the hoists is assured.
7 Information for use
7.1 Instructions for installation
In case that it is foreseen that the manufacturer will not carry out the assembly or erection, instruction
on slinging of the girders and components shall be given.
7.2 Instruction
NOTE Attention is drawn to clause 5 of EN 292-2:1991/A1:1995.
7.2.1 Instructions for safe use
7.2.1.1 General
The crane shall be provided with instructions in accordance with EN 12644-1 and the following
requirements.
7.2.1.2 Driver’s manual
7.2.1.2.1 If there is more than one hoist mechanism in the crane or there are special limitations for
the rated capacity on certain areas of the girder or a boom, a full description of the permissible loads
of each hoist and the permissible combinations of the hoists shall be given. Descriptions of the
operation of the load limiter and indicator systems shall also be included.
7.2.1.2.2 To avoid accidental release from the hook and the load fall the driver’s manual shall give
instructions on safe slinging.
7.2.1.2.3 The driver’s manual shall warn about remaining hazards related to a falling load or a part
of the load in case of a failure in the load bearing components or a failure in compiling and attaching
the load.
7.2.1.2.4 The driver’s manual shall give information on correct operation of the crane by the
operator to avoid impact ,by the moving load, to persons or property.
7.2.1.2.5 The driver's manual shall give instructions on means of ensuring condition, installation
and operation of the warning means.
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prEN 15011:2004 (E)
7.2.1.2.6 The driver's instructions shall inform the correct ways of using multiple commands in
order to suppress the sway instead of boosting it.
7.2.1.2.7 The driver's manual shall include a procedure for shutting down the crane and leaving it in
an out-of-service condition.
7.2.1.2.8 Bridge and gantry cranes are not, in general, intended for lifting persons. Information on
use of these cranes for lifting persons temporarily, is given in 5.7. Prohibition of lifting persons or
provisions for lifting of persons, if permitted, shall be given in the driver's manual.
When the crane or the load lifting attachment is not intended for the lifting of persons, but the load
lifting attachment or the typical loads have such a shape that allows a person to enter and stay during
lifting, the crane driver shall be instructed to refuse of lifting the persons.
7.2.1.2.9 For manually driven gantry cranes intended for free travelling (not rail guided) information
shall be given on the restrictions of travelling when the crane is loaded.
7.2.1.3 Owner’s manual
7.2.1.3.1 The owner’s manual shall inform on training for the slingers and the crane driver.
7.2.1.3.2 Where crane generated or ambient noise may disturb communication between the
operator and the slingers or other personal the user's manual shall draw attention to arrangement of
other means of communication e.g. use of hand signals, radio.
7.2.1.3.3 Instructions on the use of rubber tyred gantries (RTG) shall indicate the limits of working
conditions regarding the wheel friction and give requirements on removal of snow and ice or
improvement of friction by using salting or sanding.
7.2.1.3.4 For rubber tyred gantries, movements into prohibited areas shall be prevented e.g. by
marking those areas in a visible way and giving information and training to the operator by the
organization (or a person) in charge of the operating area.
7.2.1.3.5 The owner’s manual shall inform about necessary training on the control of load sway.
7.2.1.3.6 If the crane is not equipped with an automatic clamping system for anchoring in out-of-
service conditions, the owner's manual shall inform by a formula (or a table) the wind speed at which
the use of the crane shall be stopped and the crane shut down.
NOTE 1 Wind speed vst for stopping the crane by a formula
[
v st = v 2p − (2300 ⋅ t ) 0.5 ]
0.5
where
vst = wind speed for stopping the crane, m/s
vp = permissible in-service wind speed, m/s
t = time needed to shut down the crane, min
NOTE 2 The method of measuring the wind speed should be agreed between the user and the manufacturer.
Regardless of the given limit speeds the installation of a wind speed indicator is not required for all cranes
according to the normal practice.
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prEN 15011:2004 (E)
7.2.1.3.7 When relevant, the owner's manual shall draw attention to possible mental underload of
the crane driver. Mental underload is possible, if the operator actions are required only infrequently
resulting from lack of work or too advanced automation. This may cause loss of awareness and
increase risk of operation error.
7.2.1.3.8 Where clearances conform to ISO 11660 5 and EN 13586, the instructions shall inform
that the clearances shall be maintained for as long as the crane is used. Any exceptions to these
standards shall be described and the conditions necessary to maintain an equal level of safety should
be described.
7.2.1.3.9 If the crane manufacturer supplies the anti-collision system with the crane, a full
description of its functions shall be supplied to the owner.
7.2.1.3.10 The loads transmitted to the rails shall be presented in accordance with annex G.
7.2.1.3.11 The owner's manual shall give information on noise according to clause 1.7.4f of EN 292-
2 Annex 1 determined according to Annex E.
NOTE When the crane is used in noisy environment the operators and servicemen may need to
use ear protection.
7.2.2 Instructions for regular checks, inspections and tests
7.2.2.1 Information shall be provided in accordance with to the following standards:
 EN 12077-2;
 EN 12644-1;
 prEN 13135-1;
 prEN 13135-2.
The manufacturer should list the parts and specify the limits for abrasion and wearing, in the
instruction handbook, including but not limited to the following:
Hoisting mechanisms
 sheaves;
 ropes (ISO 4309), pins and rope terminals;
 ropedrums;
 hooks;
 twistlocks;
 fork lift arms;
 brake linings, discs, drums;
 couplings;
 slipring elements in motors;
Travelling and traversing mechanisms
 wheels (steel or rubber tyres);

 steering levers;
43
prEN 15011:2004 (E)
 chains and sprockets;

 trolley and travel rails ;
 guide rollers.
7.2.2.2 In rubber tyred gantries a puncture of the tyre constitutes a serious hazard for persons in
the vicinity. The maintenance manual shall state the necessary regular inspections of tyre and rim
conditions and also the ground conditions on the working area.
7.2.2.3 The instructions for checking the crane condition after a lightning strike shall state the
following:
 If during the working period the crane is subject to a lightning strike, the initial start-up procedures,
proving limits, overload detection systems etc. shall be repeated. In addition, the hoist rope and
any motion bearing shall be inspected for damage.
 If a lightning strike is considered to have occurred in the out of service condition, the hoist rope
and motion bearings shall be inspected before setting to work.
7.2.2.4 The triggering point of the overload limiter, with its tolerance, shall be recorded in the log
book of the crane. The manufacturer shall provide information on how to check that the setting has
not changed with time, and how to reset the triggering value.
7.2.3 Instructions for maintenance
7.2.3.1 The maintenance manual shall include instructions on replacement of worn out or
damaged parts.
7.2.3.2 Multi-piece rims and tyres may be a risk for health and safety because the release of
large quantities of energy in an uncontrolled mannerif, for example, a. rim cracks or disintegrates.
Therefore the manufacturer of a RTG shall give safety instructions regarding inspection and
maintenance of rims, wheels and tyres and for inflation of tyres as well as the dismounting of multi-
piece rims.
7.2.3.3 The operator's and maintenance manuals shall identify potentially hot componentswhich
should not be touched.
7.2.3.4 The maintenance manual shall give instructions on the disposal of all materials that are
replaced during maintenance and final dismantling.
7.3 Marking of rated capacities
7.3.1 The rated capacity of the crane is the maximum load permitted to be lifted with any hoist
mechanisms simultaneously. This rated capacity shall be marked on the main girder of the crane.
Example: RC 50 t
7.3.2 The rated capacity of each hoist mechanism shall be marked at least on each fixed load lifting
attachment.
7.3.3 If there are any limitations with the simultaneous use of the hoist mechanisms, they shall be
marked either on the control consoles or on the girders. For examples, see Table 5.
7.3.4 If the rated capacity of the crane is limited to lower values on certain areas of the girder or the
boom, such areas and their rated capacity shall be marked clearly on the structure.
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prEN 15011:2004 (E)
Table 5 — Examples of marking the rated capacity

Description of limitations Marking of permissible combinations
1. Any hoist may be used together with the others within H1 + H2 + H3

the limits of the rated capacity of the crane (marking voluntary)
2. Hoist 1 may be used together with hoist 2 or with hoist H1 + H2; H1 + H3

3 simultaneously; hoist 2 and 3 shall not be used
together
3. Hoist 1 and hoist 2 may be used together or hoist 3 H1 + H2; H3

separately; hoist 3 shall not be used together with
hoist 1 and 2
4. Any hoist shall be used just alone; no combinations H1; H2; H3

permissible
5. Hoists 1 to 3 can lift 100, 50 and 30 t; rated capacity H1 + H3; H1; 60t + H2
of the crane is 120 t. Hoists 1 and 3 may be used
together to lift up to 120 t. When used together with
hoist 2, the load of hoist 1 shall not exceed 60 t.
6. The maximum difference of the loads of the hoists 1 |H1 - H2| < 50 t
and 2 is limited to 50 t.
If the hoists have a fixed order on the girders (i.e. not passing each other) the markings shall follow the
order of the hoists seen from both sides of the girder(s).
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prEN 15011:2004 (E)
Annex A
(informative)
Guidance for classification, forces and stresses to be used in proof
of competence calculation
A.1 Classification of load handling and positioning parameters
Tables A.1, A.2 and A.3 give information on typical ranges of classification parameters for bridge and
gantry cranes according to their use, speed and control systems.
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prEN 15011:2004 (E)
Table A.1 — Guidance for classification of working cycles, U, load spectrum factor, Q, and hoist classes, HC
General lifting and handling

Special tasks Process operation Heavy duty
e.g. workshops, auxiliary operation.
occasional crane operation e.g. erection and assembly e.g. production, foundry, storage e.g. ports, scrapyards, loading
container, handling
OPERATION
Manual Floor Cabin Manual Floor Cabin Floor Cabin Automatic Cabin Automatic
powered control control powered control control control control control control control
U0 - U2 U2 - U4 U3 - U5
Q0 - Q2 Q1 - Q3 Q2 - Q3
HC1 HC1 - HC2 HC1 - HC2
CONTROL
TYPE
Indirect Indirect Direct Direct Direct Direct Direct Direct Direct Direct Direct
Indirect pick-up pick-up pick-up pick-up pick-up pick-up pick-up pick-up pick-up pick-up pick-up
pick-up with with with with
with with with with with electro- active with with electro- active
with load hook load hook passive passive vacuum magnet special passive vacuum magnet special
load hook and/or and/or special special lifting lifting lifting special lifting lifting lifting
and/or slings slings hooks hooks device device devices hooks device device devices
slings
U2 - U4 U3 - U5 U4 - U6 U4 - U6 U5 - U7 U6 - U7 U6 - U8 U4 - U6 U5 - U7 U6 - U8 U7 - U9
Q1 - Q3 Q2 - Q4 Q2 - Q4 Q2 - Q4 Q3 - Q4 Q3 - Q5 Q4 - Q5 Q2 - Q4 Q3 - Q4 Q3 - Q5 Q4 - Q5
LOAD
HANDLING DEVICE
HC1 - HC2 HC2 - HC3 HC2 - HC3 HC2 - HC3 HC2 - HC3 HC3 - HC4 HC2 - HC4 HC2 - HC3 HC2 - HC3 HC3 - HC4 HC2 - HC4
- hand powered cranes - assembly and dismantling - production cranes - scrapyard cranes
cranes
- factory cranes - railroad cranes authorized - automatic cranes - ram cranes
for use in railways
- maintenance cranes - shipbuilding cranes - foundry cranes - container cranes
- dockyard cranes - soaker cranes - unloading cranes
- cranes aboard ships - stripper cranes, charging cranes - wharf cranes
- storage cranes - shipdeck cranes
POSSIBLE
CRANE
TYPE
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prEN 15011:2004 (E)
Table A.2 — Guidance for classification of positioning moves of hoist drives, P

Lifting drives
high accuracy low accuracy
positioning positioning
requirement requirement
Characte- low high Low High speed
Drives Control Connection ristics speed speed speed
single 2- , 4- , 6- , 8- pole P3
speed Together with KSAG
Squirrel-cage rotor
( 8 connections )
two 4/2- , 8/2- , 12/2- pole P3

speeds load
together with MSEG independent
F5 , F10 Micro speed P2
subsynchronous
no lowering brake control P2
creep load
subsynchronous
travel dependent
counter- torque hoisting control P2
stage
counter- torque travel control
two 4/2- or 8/2- pole micro speed
speeds combination of KL + SL unit and
low-speed
in combination with micro speed
winding ,
P2
load
F5 , F10
SL (2-, 4-, 6-pole ) in combination independent
with micro speed P2
Eldro control 1:5 creep speed
stage , P2
more than 20 different connections )
with load
Eldro control 1:10
cross independent
with frequency encoder P2
travel
stage with controlled eddy-current brake
Load P2
dependent
with frequency converter P1
with regulated eddy-current brake P1

Slip-ring rotor
Load
30-60 % 4-rope grab control independent
with differential limit switch P2
0-60 % stator phase – angle control P1 P1 P1
analog field –
weakening P0 P0 P0
0-100 % operation
digital
possible
DC
P0 P0 P0
10-100 % current-link inverter Load P0 P0 P0
independent
4-100 % voltage-link inverter P0 P0 P0
flux-vector oriented inverter Load P0 P0 P0

independent
torque-regulated inverter Load P0 P0 P0
independent
field –
Squirrel-cage rotor
load -sway damping

weakening
operation
0-100 % synchro control P0 P0 P0
possible
4-rope grab control with and P1 P1 P1
with torque regulation without
with regenerative braking speed
feedback
KSAG: smooth starting units KL : Squirrel-cage rotor MSEG: motor control units SL : Slip-ring rotor
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prEN 15011:2004 (E)
Table A.3 — Guidance for classification of positioning moves of travel drives, P

Travel drives
high accuracy low accuracy
positioning positioning requirement
requirement
Characte- low high speed low speed High speed
Drives Control Connection ristics speed
single 2- , 4- , 6- , 8- pole P3
speed together with KSAG P3
Squirrel-cage rotor
load
two 4/2- , 8/2- , 12/2- pole P3
( 8 connections )
independent
speeds
together with MSEG P2
F5 , F10 micro speed P2
subsynchronous
no creep lowering brake control
travel subsynchronous load
stage counter- torque hoisting control dependent
counter- torque travel control P2
two 4/2- or 8/2- pole micro speed

speeds combination of KL + KS unit and low- P2
speed winding ,
in combination with micro speed
F5 , F10 load
P2
independent
SL (2-, 4-, 6-pole ) in combination P2
with micro speed
Eldro control 1:5 creep speed
with stage , P2
( more than 20 different connections )
cross load
Eldro control 1:10
travel independent
with frequency encoder P2
stage
with controlled eddy-current brake
load P2
dependent
with frequency converter P1
with regulated eddy-current brake

30- P1
Slip-ring rotor
60 % 4-rope grab control load

with differential limit switch independent P2
0-60 % stator phase-angle control P1 P1 P1
analog field –
weakening P0 P0 P0
0-100 % operation
digital
DC
possible
P0 P0 P0
10- current-link inverter load P0 P0 P0
100 % independent
4-100 % voltage-link inverter P0 P0 P0
flux-vector oriented inverter load

independent P0 P0 P0
torque-regulated inverter load
independent P0 P0 P0
field –
Squirrel-cage rotor
load - sway damping

weakening
synchro control operation P0 P0 P0
0-100 %
possible
4-rope grab control with and P0 P0 P0
with torque regulation without
with regenerative braking speed
feedback
KSAG: smooth starting units KL: Squirrel-cage rotor MSEG: motor control units SL : Slip-ring rotor
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prEN 15011:2004 (E)
A.2 Guidance for classification of average linear displacements

When classifying average linear displacements, the following should be specified:
 the maximum distances available for each motion;
 the typical working cycles in the different tasks of the crane.
An example is illustrated in Figure A.1, see also clause A.10
In some applications it may be significant to consider also the return movements:
 is the number of return movements without load equal to the number of the working cycles or can
the crane move from one task to the next one without an unloaded movement?
 is the average displacement of the empty hook as great as the average displacement with the
load?
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prEN 15011:2004 (E)
l1
s1
S
H h1
l1 : average displacement from long travel crane

s1 : average displacement of cross traverse of the trolley
h1 : average displacement of hoisting
Figure A.1 — Illustration of the distances L, S, H in crane operation
Table A.4 shows the classification into classes D for these average displacements l1 , s1 and h1
(see prEN 13001–1 , table 3).
Table A.4 — Example for classification into classes D
Distances L = 90 m S = 22 m H = 12 m
Average displacements l1 = 55 m s1 = 12 m h1 = 5 m
Classes Di D7 D5 D3
A.3 Calculation of dynamic coefficient φ2
The following calculation method results in determination of the rope force history φh(t) when a
grounded load is lifted starting with a slack rope and taking into account the elasticity of the
crane bridge and the hoist rope.
The maximum value determined represents factor φ2 .
In addition to the general equations specified here, A.4 shows an example for calculation.
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prEN 15011:2004 (E)
The history of the dynamic rope force factor can be calculated using the equation:
•
φh(t) = 1,0 + z hl · ωl / g · [( 1 - q2 ) · p · sin ( p ωl t ) – (1 – p2) · q · sin (q ωl t)]/ (p² - q²)
- z0 · ωl² / g · [cos (q ωl t) – cos (p ωl t)] / (p² - q²)

•
- z cr · ωl / g · [p · sin (p ωl t) – q · sin (q ωl t)] / (p² - q²)
[4]
This equation represents the dynamic behaviour of the crane model shown in figure A.2
cg
m0 z0
.
z h1
c r , 1r
m h1
.
z h1 , z h1
Figure A.2 — Crane model bridge crane
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prEN 15011:2004 (E)
Whereby the following calculation and auxiliary factors apply:
Total mass of the crane girders mg kg

Mass of the crab mtr kg
substitution mass (crane and 17 kg [5]
crab) me = mg + mtr
35
4
total second moment of cross- Iy m
section area of crane girders
2
Modulus of elasticity of steel E N/m
Span of the crane girder lcr m
Rigidity of the girders in the 48 ⋅ E ⋅ I y N /m [6]
middle cg = 3
lcr
tensional stiffness of a rope = crm = "EA" N
rigidity of the 1 m rope length
length of a rope fall lr m
number of rope falls n
Rigidity of the rope n • crm N/m [7]
cr =
lr
rigidity ratio cg [8]
γ=
cr
hoist load mhl kg
acceleration due to gravity g = 9.81 m/s²
mass ratio me [9]
µ=
mhl
angular velocity 1/s [10]
cr
ωl =
mhl
frequency parameter
γ +1
pD =
µ
hoist speed • m/s
z hl
Lift-off time (rigid) g [11]
τa rig = •
z hl ⋅ ω l
lift-off time τa solved acc. to equation [12] by iteration or graphically
γ +1 sin ( pD ⋅τ aj ) [12]
τa j+1 = τa rig −
γ pD ⋅ γ
lift-off coordinate (crane) • m [13]
z hl  1 
zcr = ⋅ τ a − ⋅ sin ( pD ⋅τ a ) 
ω l (γ + 1)  pD 
lift-off speed (crane) • m/s [14]
• z hl
z cr = ⋅ (1 − cos ( pD ⋅ τ a ) )
γ +1
auxiliary quantity mhl ⋅ g − cg ⋅ zcr m [15]
z0 =
µ ⋅ mhl ⋅ ω l2
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prEN 15011:2004 (E)
auxiliary quantity [16]

µ + γ +1 1
p= − (µ + γ + 1)2 − 4 ⋅ µ ⋅ γ
2⋅µ 2⋅µ
auxiliary quantity [17]
µ + γ +1 1
q= + (µ + γ + 1)2
− 4⋅µ⋅ γ
2⋅µ 2⋅µ
A.4 Calculation example for coefficient φ2
Calculation for factor φ2 for a double-girder bridge crane 8,0 t x 27 m.
Travelling on the crane is a crab with the following hoist unit data:
rope reeving 2/1

hook path h = 16,0 m
main hoist speed •
z hl = 12,5 m/min
Other crane data and calculation results are presented in Table A.5 and figure A.3.
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prEN 15011:2004 (E)
Table A.5 — Input values and calculated parameters of the examle
Remarks
mg 10 130 kg (both crane girders)
mtr 1 020 kg
me 5 940 kg
-8 4
Jy 656 200 ·10 m (both crane girders)
lcr 27,0 m
12 2
E 0,21·10 N/m
lr 16,0 m
6
cg 3,36 · 10 N/m
2
n 2 (n = 4)
7
crm 1,90 ·10 N
6
cr 0,593 75 · 10 N/m
•
z hl 0,208 3 m/s
mhl 8 000 kg
γ 1,414 7
µ 0,742 54
2 2
ω1 17,23 1/s (ω1 = 296,875 1/s )
pD 1,803 3
τa rig 2,733 3
τa 4,277 2 (by iteration)
zcr 0,018 66 m
•
z cr 0,074 15 m/s
z0 0,008 95 m
p 0,713 45
q 1,934 66
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prEN 15011:2004 (E)
1.6
1.4
1.2
1.0
S r (t)
0.8
0.6
0.4
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
t (s)
Figure A.3 — Calculation of φ2 ( φ2 = S r (t) max = 1,325 )
A.5 Calculation of skewing forces for bridge cranes

NOTE This annex is based on articles referred in bibliography
A.5.1 Calculation parameters and formulae
Skewing under the skewing angle α on the leading guide elements or leading group of guide
elements (guide distance wb see figures A.5 and A.6) - flange or guide roller - in the case of
bridge cranes results in a positive force Fy depending on the travel unit and supporting structure
system and thus also forces Fx 1i , Fy 1i and Fx 2i , Fy 2i , with i = 1,2 ... n , in the support points of
the travel wheels.
The highest skewing forces are produced, when the trolley is within the approach dimension of
the trolley and the centre of gravity of the entire crane reaches its highest eccentricity.
The following travel unit and supporting structure system is based on an assumed rigid crane
structure. The crane moves in steady condition, the skewing angles of the end carriages have
the same value α (see fig A.4).
NOTE The assumption of a rigid crane supporting structure is justified by the fact that in usual cases
1) the centre of inertia lines of the crane travel units and bridge girder are virtually on one
level (level crane, level static system);
2) the rigidities EJ of the crane travel units and bridge girders are in such a ratio to each
other that the forces can be transmitted;
3) the connections between the crane travel units and bridge girders are rigidly connected
to each other forming a frame structure.
If the above-mentioned requirements are not fulfilled, the forces resulting from skewing may
also be calculated as a non-rigid model in accordance with A.6 as a special case.
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prEN 15011:2004 (E)
x 3 2
Key
1 Direction of crane
2 Direction of rail and motion
3 rigid
Figure A.4 — Rigid crane model in skewed position, topview
Dimensions and forces for bridge cranes with flange guidance and guide rollers are shown on
the example of a 4-wheel crane in figures A.5 and A.6.3. All angles α are small.
α
3
Fx Fx
R11 1
R21
d11 = 0 2 d 21 = 0
F y11 F y21
x
d12 d 22
y
z
F y22
R12 F y12
R22
4
5 6
Figure A.5 — Bridge crane with 4 travel wheels and flange guiding
Key
1 Shaft-speed connection
2 Direction of travel
3 rail
4 span l
5 Side 1
6 Side 2
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prEN 15011:2004 (E)
F y21
Fx 3 1 Fx
R11 R 21
2 d 21
x F y11
y
wb d12 d22
z
R12
F y22
F y12
R22
4
5 6
Key
1 Shaft-speed connection
3 rail
4 span l
5 Side 1
6 Side 2
Figure A.6 — Bridge crane with 4 travel wheels and guide rollers
Required calculation quantities:
Skewing angle : α = αg + αw + α t [18]
To achieve good crane travel behaviour, the skewing angle α should not exceed 0,015 rad.
The skewing angle α allows for the clearance between guide elements and rail (αg ), wear of the
rail (αw ) and possible tolerances between the crane and crane runway (αt ). These values refer
to the distance between the guide elements wb when the crane skews.
The following figures A.7and A.8 show the required parameters for different crane conditions :
α α α
Fy Fy
Fy
wb x
wb wb
y z
Figure A.7 — Points of application of guide force Fy for guide rollers and flange guiding
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prEN 15011:2004 (E)
bt
sg
bt > bh
bh
bh
Figure A.8 — Parameters bh , bt and sg
bh : rail head width

bt : travel wheel tread for flanged travel wheels
sg : track clearance for guide rollers
wb : distance between guide elements
αg : for guide rollers skewing angle resulting from track clearance
(αg = sg / wb).
For travel wheels with flanges, skewing angle resulting from 75 % of the track clearance
between travel wheel tread and rail head width, however at least from 0,010 m.
( αg = 0,75 (bt – bh) / wb )
( min αg = 0,010 / wb ).
αw : skewing angle resulting from wear.
For guide rollers at least 3 % of the rail head width
( αw = 0,03 · bh / wb ) or
for travel wheel flanges at least 10 % of the rail head width
( αw = 0,10 · bh / wb ).
αt : general 0,001 rad, skewing angle resulting from crane and crane runway tolerances.
Special tolerance classes for crane runways may specify other αt – values, e.g.:
Crane runway tolerance class 2 in accordance with ISO 12488-1:

bt =1,0 mm over a measured length of 2,0 m
⇒ αt = 0,001 / 2. = 0,0005 rad
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prEN 15011:2004 (E)
Force - slip relationship:
A guide force Fy is balanced by the longitudinal and transverse forces Fx 1i , Fy li , Fx 2i and Fy 2i

which are caused by pivoting of the crane around the given axis. With the maximum transverse
slip sy = α on the guide elements and a linear distribution of the transverse slip syi , between the
guide elements and the given axis, the empirical relationship
-250·α
f = 0,3 · [l -e ] [19]
may be employed to simplify the calculation.
This force-slip relationship can only represent the variable reality as an approximation. Neither
the friction coefficient of the wheel/rail material combination, nor the geometry and contact
pressure nor the surface characteristics of the travel wheel and rail are allowed for in this
calculation.
Reference is made to the specialist literature for more exact approximation of f.
If specific calculation of f is not possible for a certain application or if f is known from

experiments or is proven as an empirical value according to the state-of-the-art, a deviation
from the above-mentioned equation is possible.
Further parameters :
R ij : wheel load of travel wheel ij
R ij ≥ 0 i ∈ {1,2 ... m}
j ∈ {1,2 ... n }
dij = xF - xij
Distance from the leading guide element to travel wheel ij in the direction of travel. (Dij will be
negative for travel wheels which run ahead of the leading guide element.).
i ∈ {1,2 ... m}
j ∈ {1,2 ... n}
Shaft - speed connection :
If wheels of the crane are connected between the end carriages by shafts -without slip
(electrically or mechanically), this results in speed connections. These increase the forces
resulting from skewing.
Required values :
l : crane span
R 1,i : wheel load of 1st travel wheel of shaft i i ∈ { 1,2....n}
R 2,i : wheel load of 2nd travel wheel of shaft i i ∈ { 1,2....n}
R 1,i ⋅ R 2,i
Wi = [20]
R 1,i +R 2,i
W = Σ Wi [21]
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prEN 15011:2004 (E)
NOTE If there is no shaft - speed connection ⇒ Wi = W = 0.

Method for calculating the forces resulting from skewing :
* * Travel wheels which cannot transfer [22]
S = ΣR transverse forces owing to a special travel
ij
wheel bearing arrangement (see figure 8 in
* EN 13001-2, system CFM and IFM) are [23]
Sd = Σ ( R ij ⋅ d ij) given the value of R ij = 0 in the sum
values.
* 2 [24]
S dd = Σ ( R ij ⋅ d ij )
Sd [25]
b =
Sdd + W ⋅ l 2
guide force Fy = - f · (S - Sd · b) [26]

transverse forces (y- Fy ij = f · R ij · (1 – dij · b ) [27]
direction)
transverse forces (x- Fx = f · l · b · W i [28]
direction)
NOTE The above method of calculation applies in the same sense also for crabs running on rails.
A.5.2 Example for calculating the forces resulting from skewing in the case of
bridge cranes
Table A.7 presents the results of skewing force calculation for the brigde crane defined in figure
A.9 and Table A.6.
Double-girder bridge crane : 12,5 t x 22 m

Crane with guide rollers and shaft-speed connection (shaft 2)
System: CFF (see also figure 8 in EN 13001-2)
R11 R 21
d11 d 21
F y11 F y21
d22
wb d12 Fx
Fx
F y12
R12 F y22
1 2 1 R22
3
Key
1 Shaft
2 single engine
3 span l
Figure A.9 — Bridge crane with guide rollers and shaft-speed connection
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Table A.6 — Entered data

R 11 = 34,06 kN R 21 = 94,10 kN l = 22.000 m
R 12 = 29,20 kN R 22 = 86,57 kN wb = 4,400 m
d 11 = 0,200 m d 21 = 0,200 m bh = 0,050 m
d 12 = 4,200 m d 22 = 4,200 m sg = 0.005 m
Table A.7 — Results

α = 0,002476 rad f = 0.1385 S = 243,93 kN
W 2 = 21,84 kN W = 21,84 kN Sd = 511,87 kNm
2
Sdd = 2047,31 kNm
-1
b = 0,040575 m
F y = -30,92 kN Fx = 2,70 kN
F yll = 4,68 kN F y21 = 12,93 kN
F y12 = 3,36 kN F y22 = 9,95 kN
A.5.3 Estimating the forces resulting from skewing for bridge cranes with 4
crane travel wheels and flange guiding
For this crane type the transverse forces Fy11 and Fy 21 and the guiding force Fy can be estimated
from Table A.8. The crane and the actual directions of skewing forces are illustrated in Figure
A.10.
2 2
1
Fy - F y11 = F y21
R11 R21
Fy F y21
F y11
wb
F y12 =0 F y22 =0
3 3
4
Key
2 rail
3 R = optional
3 span l
Figure A.10 — Direction of the transverse forces Fy ij
NOTE No shaft-speed connection
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Table A.8 — Examples of relative skewing forces of a 4-wheel crane with flange guiding
Symbols: qRi = Ri1/(R11+R21) i = 1, 2

qy11 = Fy11/R21 assumed: R21 = Rmax
qy21 = Fy21/R21 =f
qy = Fy/R21 = -(Fy11+Fy21)/R21 = -(qy11+qy21)
Fy = guiding force against the flange of the guiding wheel 11.
qRi = 0,2 0,8 qRi = 0,4 0,6

α qy qy11 qy21 qy qy11 qy21 f
0,004 - 0,237 0,047 0,190 - 0,316 0,126 0,190 0,190
0,006 - 0,291 0,058 0,233 - 0,388 0,155 0,233 0,233
0,008 - 0,324 0,065 0,259 - 0,432 0,173 0,259 0,259
0,010 - 0,344 0,069 0,275 - 0,459 0,184 0,275 0,275
0,012 - 0,356 0,071 0,285 - 0,475 0,190 0,285 0,285
0,014 - 0,364 0,073 0,291 - 0,485 0,194 0,291 0,291
A.5.4 Estimating the forces resulting from skewing for bridge cranes with 4
crane travel wheels and guide rollers
Table A.9 gives examples of relative skewing forces for the crane type shown in Figure A.11.
Figure A.11 also illustrates the actual directions of the skewing forces. (The forces may appear
in opposite directions as well.) For intermediate values of assumed crane parameters the values
of qy21 may be interpolated.
Other ratios may be calculated by the following formulas:
d qR1
q y22 = − ⋅ q y21 , qy1j = ⋅ qy2j , qy = −∑ qyij
wb − d qR2 ij
Fy R
R
d = 150 F y11
F y21
wb
F y12 F y22
d = 150
R R
1
Key
1 span l
Figure A.11 — Direction of the transverse forces Fy ij
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Table A.9 — Examples of relative skewing forces of a 4-wheel crane with guide rollers
Symbols: qRi = Ri1/(R11+R21) assumed: Ri1 = Ri2, i = 1, 2

qy1j = Fy1j/R21 i = number of the rail
qy2j = Fy2j/R21 j = number of the wheel
qy = Fy/R21 = -(qy11+qy12+qy21+qy22)
Fy = guiding force against the guide roller adjacent to wheel 11
Fy1j = skewing force of wheel j on rail 1
Fy2j = skewing force of wheel j on rail 2
d= 150 mm, wb = 2300 mm

qRi = 0,2 0,8 qRi = 0,4 0,6
α qy qy1j qy2j qy qy1j qy2j f
0,002 - 0,127 0,0273 0,109 -0,169 0,0729 0,109 0,118
- 0,0019 - 0,008 - 0,0051 - 0,008
0,003 - 0,170 0,0366 0,147 - 0,227 0,0977 0,147 0,158
- 0,0026 - 0,010 - 0,0068 - 0,010
0,004 - 0,204 0,0439 0,176 - 0,272 0,1170 0,176 0,190
- 0,0031 - 0,012 - 0,0082 - 0,012
0,005 - 0,230 0,0495 0,198 - 0,307 0,1321 0,198 0,214
- 0,0035 - 0,014 - 0,0092 - 0,014
d= 150 mm, wb = 5300 mm

qRi = 0,2 0,8 qRi = 0,4 0,6
α qy qy1j qy2j qy qy1j qy2j f
0,002 - 0,139 0,0286 0,115 - 0,185 0,0763 0,115 0,118
- 0,0008 - 0,003 - 0,0022 - 0,003
0,003 - 0,187 0,0385 0,154 - 0,248 0,1023 0,154 0,158
- 0,0011 - 0,004 - 0,0030 - 0,004
0,004 - 0,223 0,0460 0,184 - 0,298 0,1226 0,184 0,190
- 0,0013 - 0,005 - 0,0036 - 0,005
0,005 - 0,252 0,0519 0,208 - 0,336 0,1384 0,208 0,214
- 0,0015 - 0,006 - 0,0040 - 0,006
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A.6 Calculation of skewing forces for gantry cranes
A.6.1 Crane models
The calculation of the skewing forces for bridge cranes is usually based on a rigid crane
structure. In three-dimensional supporting structures such as gantry cranes, the crane travel
units do not feature a rigid connection in most applications at all. The horizontal elasticity and
retention of the gantry girder cause both crane travel units to adopt different skewing angles.
In special cases (e.g. justifiable rigidity circumstances, low gantry height), a gantry crane may
also be represented and calculated as a rigid crane structure.
In the following, four models (see Figure A.12) are illustrated and calculation methods indicated.
Considered are the following:
Type A Rigid crane structure

(bridge crane, special case: gantry crane)
Type B Non-rigid crane structure
(gantry crane, special case: bridge crane)
Type C Articulated crane structure
(α- possible rotation according to articulation arrangement,
y – possible displacement according to articulation arrangement ; gantry crane )
Type D Articulated crane structure
(y – possible displacement according to articulation arrangement ; gantry crane )
In all models, the crane travel units are assumed to be rigid structures in the horizontal plane.
1 ∆α αΙ ∆α Ι
α αΙ
α Ι Ι Ι
α-3
2 y -4
1 y-4
y 2
r r αr
α r α
z x α
F yij X, Y, F yl X, M l
Ml F yl
Ι F ylj Ι
F ylj Ι F ylj
Fy hx,hy,hm
hx, hm
F yij X, Y,
r Fy F yr
Mr r X, Mr r F yr
x
B F yrj F yrj
x
B F yrj
Type A Type B Type C Type D
Key
1 rigid
2 non-rigid
3 α-distortion
4 y-displacement
Figure A.12 — Crane supporting structures (type A to type D) (plan view)
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Type A shows the model of a rigid crane structure in skewing position. The skewing angles of
both crane travel units have the same value α . The crane travels with the constant, positive
•
speed x.
Type B shows the model of a non-rigid crane structure in skewing position. The beginning of the
track guidance is indicated here on the right-hand crane travel unit (r). The calculated skewing
angle α is assigned to this end carriage. Owing to the eccentrically applied track guide force Fy,
the bridge will be horizontally deformed. The non-guided crane travel unit 1 (left) has a changed
skewing angle ( α + ∆α ).
The transverse, connecting and guiding forces acting on the crane travel units are combined to
result in the forces X, Y and the torque M. The point of application for force Y is specified with
− −
the arbitrarily selected coordinates x B . The optimum coordinate x B should be selected (exploit
symmetry). The horizontal elasticity parameters hx, hy and hm of the crane supporting structure
shall be calculated for these coordinates.
NOTE The horizontal elasticity of the relevant crane runway may be allowed for in these parameters
hx , hy and hm
Type C shows the model of an articulated crane supporting structure, e.g. with a pinned leg, the
characteristics of which are indicated in the level representation by an α-possible rotation and a
y-possible displacement by corresponding articulation arrangements. Virtually only friction
forces (between rails and wheels) which may be neglected in this case are transmitted. The
deformations of the crane supporting structure under these decoupling conditions show virtually
no effect on a mutual influencing of the skewing forces of both crane travel units. The crane
travel units become "independent" travel units, each with its own guide arrangement. The
skewing forces are verified on an individual basis per crane travel unit.
Type D shows the model of a non-rigid, articulated crane supporting structure, e.g. with a
pinned leg, the characteristic of which is indicated in the level representation by a y-possible
displacement by a corresponding articulation. The transverse, connecting and guiding forces
acting on the crane travel units are combined to result in the force X and the torque M. The
horizontal elasticity parameters hx and hm of the crane supporting structure shall be calculated
for these coordinates.
Designations and coordinate systems
Figure A.13 shows the designations and coordinate systems used. The angles are small. Crane
and crane runway tolerances are also allowed for by the skewing angle share αt .
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1 _
xN 2
_ Fx
y ∆α
α
_
yl
5
3 Ι F yij F y 6
Fx
_ _ α
yr
_ _ _ x
y x x ij x F
B
d ij 7
b ij
z x 8
Key
1 wheel
2 crane travel unit l
3 relating to crane
4 relating to environment
5 track guide
6 crane travel unit r
7 skewing angle
•
8 travel direction x
x B : arbitrary selected reference coordinate (x-direction)
x F : x-coordinate to track guide
x ij : x-coordinate to travel wheel
x N : x-coordinate to the point at which a force Y causes no angular deformation α of the crane
structure
Figure A.13 — Designations and coordinate systems
A.6.2 Principles for calculation
A.6.2.1 Selection of calculation method according to the model type
The following principles for calculation developed here apply to models type B and D. The crane
supporting structures according to model type A and C are calculated in accordance with A.5.
A.6.2.2 Skewing angle α
Specification for the skewing angle α applies in accordance with A.5.
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A.6.2.3 Deformation in the case of non-rigid crane structures
 the deformation of the crane structure has a negligible effect on the crane-related x, y -
coordinates of the travel wheels and no effect on speed. Thus, a displacement ∆x and ∆y
of the crane travel unit has no influence on the skewing forces.
 the influence of the change in the wheel loads resulting from the deformation/distortion of
the environment-related supporting structure may be allowed for by iteration.
 the additional skewing angle ∆α is dependent on the horizontal elasticity parameters of the
crane supporting structure:
∆α = hx · X + hy · Y + hm · M ( in Figure. A.14 M = Ml)
Strict solutions or corresponding static programs may be used to determine the parameters hx,
hy and hm . In the static calculation programs "1 " load cases are usually applied (e.g.: X = 1 kN,
Y = 1 kN, M = 1 kNm) in order to determine the corresponding deformation/distortion. The result
lists shall be checked to ensure that no travel wheel has lifted.
Figure A.14 shows an example diagram for a semi-gantry crane, the support conditions and the
load cases X , Y and M.
1 Ι
Y = "1 1
Ι
z
y x 1 1
r
a c r
1 X = "1 1
Ι Ι
MΙ = "1
1 1
r
b d
Key
1 rigid
Figure A.14 — Diagram of a semi-gantry crane a) frame diagram b,c.d) load cases X, Y
and M
x B . In the case of
The selected coordinate for the point of application of force Y is specified as
a symmetrical crane supporting structure, it may be favourable to select x B = x N , since hy then
assumes the value zero ( x B , x N see Figure A.12).
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A.6.2.4 Slip behaviour
A.6.2.4.1 General
The force-slip behaviour of a rolling wheel is of great significance for the size and direction of
the skewing forces. The values for transverse and longitudinal slip are the most important
calculation parameters in this context.
A.6.2.4.2 Transverse slip σy ij
If the travel wheels of the crane travel units are in optimum geometrical alignment, the wheel
skewing angles correspond to the skewing angle of the crane travel unit ( αij = α ).
• •
The transverse sliding angle ( y ij / x ) of a wheel is dependent on the location arrangement. It
• •
may be derived from the pivoting slip ( α / x ) of the travel unit around the non-displaceable
guide arrangement, which is not displacable in the y-direction. For this purpose, the distance
between the guide arrangement and each wheel dij = ( x F - x ij ) is required.
The transverse slip is calculated for each travel wheel according to the following equation:
•
α
σy ij = α + sij · ∆α + dij •
. [29]
x
Where :
sij = 1 for travel wheels on a crane travel unit which is not

adjacent to the guide arrangement (see Fig A.13 crane travel unit l)
sij = 0 for travel wheels on the crane travel unit which is adjacent to the guide arrangement
(see fig A.13 crane travel unit r)
• •
x : travel speed of the crane ( x > 0 )
• •
A value for x is only expected in the case of drive speed connection, otherwise set x = 1!
A.6.2.4.3 Longitudinal slip σx
A.6.2.4.3.1 Shaft speed connection
If a pair of wheels is connected to run at the same speed, e.g. by a mechanical or rigid electrical
•
shaft, compensation of the speed differences ( l · α ) of the crane travel units can only be
effected by means of mechanical slip between the wheel and rail.
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Xw
Ι 1 2
Xw
Ι. dα
dx
y
dα
x
Figure A.15— Shaft speed connection, movement from 1 to 2
• •
The entire longitudinal slip resulting from the crane pivoting slip ( α / x ) is calculated as:
•
α
σx = l • l : crane span
x
Xw = fx (σx ) · W W = ΣW i
Set W = 0 if there is no shaft speed connection. For a definition of W, see also A.5.
A.6.2.4.3.2 Drive speed connection
If a pair of wheels is connected to allow for slip, e.g. by electrical parallel connection of the
•
drives, compensation of the speed differences ( l· α ) of the crane travel units is mainly effected
by differences in the electro-magnetic slip of the drive motors.
XA
Ι 1 2
XA
.α
y
Figure A.16 — Drive speed connection movement from 1 to 2
The force from drive connection amounts to
F
• 1 •
( x =0)
XA = A ⋅ α with A = nA · l · · •
2 x
( F =0 )
nA : Number of axles with drive speed connection

Set nA = 0 if there is no drive speed connection.
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A.6.2.4.3.3 Force slip relationship
A non-linear force-slip relationship is usually assumed. Approximately the same progression

should be used for the longitudinal and transverse force. Mutual limitation may, if required, be
considered.
The specialist literature describes other force-slip laws and their application features in detail.
The calculation is made for the
− 250 • σ y ij
y-direction : fy (σ y ij ) = 0,3 · (1 – e ) ·sign (σ y ij )
(transverse slip) - 0,015 ≤ σ y ij ≤ 0.015 rad
−250 • σ x
x-direction : fx (σ x ) = 0,3 · ( 1 - e ) ·sign( σx )
(longitudinal slip) - 0,015 ≤ σ x ≤ 0,015 rad
For remarks related to the application of the above-mentioned equations, see annex A.5: force-
slip relationship.
NOTE Linearized force-slip relationships may result in incorrect results for the skewing forces in the
equations given in A.6.3.
A.6.3 Calculation models (Type B and D)
A.6.3.1 Required calculation parameters
Rzij : Wheel load of travel wheel ij
Rz ij > 0 i ∈ {1 , 2 }
j ∈ { 1 , 2, ... }
dij = ( x F - x ij )
Distance from the leading guide arrangement to travel wheel ij in the direction of travel; dij
becomes negative for travel wheels which run in front of the leading guide arrangement.
i ∈ {1 , 2 }
j ∈ {1 , 2 ,...}
bij = ( x ij - xB )
Distance travel wheel ij - reference coordinates
hx , h y , h m : Horizontal elasticity parameters of the crane supporting structure
σ y ij : Transverse slip of travel wheel ij
σx : Longitudinal slip of the travel wheel
fy( σyij ) , fx (σx ) : Force coefficients
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A.6.3.2 Speed connections
A.6.3.2.1 Shaft speed connection
Rz 1,i : Wheel load of the first travel wheel of shaft i i ∈ { 1 , 2 , ....}
Rz 2,i : Wheel load of the second travel wheel of shaft i i ∈ { 1 , 2 , ....}
R z 1,i ⋅ R z 2,i
Wi =
R z 1,i + R z 2,i
W = ∑ Wi
Xw = fx( σx ) · W
A.6.3.2.2 Drive speed connection
nA : Number of axles with drive speed connection
XA : see A.6.2.4.3.2
•
The expression F • / x (F =0) describes the characteristic curve of a drive as a function of
(x = 0 )
force and speed at the wheel circumference.
A.6.3.3 Equation system (model Type B)
• •
σy ij = α + sij · ∆α + dij α/x (transverse slip)
• •
σx =l· α/x (longitudinal slip)
F y ij = fy(σy ij ) · R z ij (transverse forces)
Fx = XW + XA (longitudinal force)
X = Fx (resulting force on the end carriage)
Y = ∑ ( sij · Fy ij ) (resulting force on the end carriage)
M = ∑ ( sij · bij · Fy ij) (resulting torque on the end carriage)
∆α = hx · X + hy · Y + hm · M (additional skewing angle)
0 = Fx · 1 + ∑ ( dij · Fy ij ) (sum of the torques on the crane)
F y = - ∑ Fy ij (guiding force)
•
The above equation system with the unknown variables F y ij , F x and α can be solved in a
numerical manner.
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A.6.3.4 Equation system (model Type D)
For this crane model the equations of A.6.2.2, A 6.2.3, A.6.2.4, A 6.3.1 and A.6.3.2 - 2.1, 2.2,
2.3, 3.1 and 3.2 apply roughly. The calculation of the transverse slip changes in:
• •
σy ij = α + s ij · ∆α + d ij α/x
where by: s ij : switch for the wheels (explanation see also A6.2.4)
Further parameters:
F y ij = fy(σy ij ) · R z ij (transverse forces, i = l or i = r )
Fx = XW + XA (longitudinal force)
X = Fx (resulting force on the end carriage)
M = ∑ ( sij · bij · Fy ij) (resulting torque on the end carriage)
∆α = hx · X + hm · M (additional skewing angle)
0 = Fx · 1 + ∑ ( dij · Fy ij ) (sum of the torques on the crane)
F yl = - ∑ Fy ij · slj (guiding force on the left end carriage)
F yr = - ∑ Fy ij · srj (guiding force on the right end carriage) [30]
•
The above equation system with the unknown variables F y ij , F x and α can be solved in a
numerical manner.
A.6.4 Calculation example 1 to determine the forces resulting from skewing on

gantry cranes (model type B)
The following calculation example applies for the semi-gantry crane as described by figure A.17,
Table A.10 and the following
 load 25 t
 span 6,000 m
 crane with guide rollers on lower travel level (crane travel unit r)
 unguided crane travel unit (1)
— crab in left-hand approach dimension
— calculation as non-rigid crane supporting structure
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d 12
Ι an2 b12 d11
b11
R z12 R z11
Ι an1
1 1
d 21
R z22 R z21
2 d 22
wb
3 4
Key
1 guide roller
2 span l
3 crane travel unit l (non-guided)
4 crane travel unit r (guided)
Figure A.17 — Semi-gantry crane ( Type B )
Table A.10 — Entered data

R z11 = 120 kN R z21 = 35 kN l = 6,000 m
R z12 = 119 kN R z22 = 27 kN wb = 3,000 m
d 11 = 0,250 m d 21 = 0,250 m bh = 0,060 m
d 12 = 2,750 m d 22 = 2,750 m sg = 0.005 m (guide rollers)
b 11 = 1,250 m b 12 = -1,250 m
Data values and results:

-α = αg +αw+αt
-α = 0,003266 rad (skewing angle, calculation according to A.5.1)
- hx = -0,000731 rad/kN (calculated using static program)
− −
- hy = 0. ( x B = x N selected)
- hm = 0,000117 rad/kNm (calculated using static program)
- Fx = 0. (no speed connections, i.e. no longitudinal slip !)
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Solving the equation system results in:
•
- α = - 0,002561 rad/s
- ∆α = 0,003988 rad (additional skewing angle)
- αres = α + ∆α = 0,007254 rad < 0,015 rad
- Guide force : Fy = 31,05 kN
- Transverse forces : Fy 11 = 29,11 kN
Fy 12 = 1,84 kN
Fy 21 = 5,05 kN
Fy 22 = -4,95 kN
Figure A.18 shows the force values fy (σy ) as a function of the transverse slip for travel wheels
11 to 22 . The figure also shows that no travel wheel has reached the limit force.
0,5
0,001638 0,006002
0,333
1
Factoryy f
0,2331
0,167
2 0,14657
3 0,01204
0
4 0,163707
-0,167
-0,333
-0,5
-0,015-0,01 -0,005 0 0,005 0,01 0,015
σy
Key
1 travel wheel 11
2 travel wheel 21
3 travel wheel 12
4 travel wheel 22
σy)
Figure A.18 — Force-slip relationship fy(σ
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A.6.5 Calculation example 2 to determine the forces resulting from skewing on

gantry cranes (model type D)
The following calculation example applies for the gantry crane as described by figure A.19,
Table A.11 and the following data
(Ι) (r)
R z11 R z12 R z13 R z14
1 d12
2 3 d13
d11 = 0
ΣFyΙ = 0 ΣFyr = 0 d14
wb
Key
1 span l
2 fixed leg
3 pinned leg
Figure A.19 — Gantry crane with fixed leg and pinned leg (Type D )
Table A.11 — Wheel loads of the crane for calculation example 2
Fixed leg (l) Pinned leg (r)

R z ll = 231 kN R z 2l = 220 kN
R z 12 = 231 kN R z 22 = 220 kN
R z 13 = 242 kN R z 23 = 243 kN
R z 14 = 242 kN R z 24 = 243 kN
capacity 60 t
span 18,8 m
d 11 = d 21 = 0,000 m
d 12 = d 22 = 1,100 m
d 13 = d 23 = 7,300 m
d 14 = d 24 = 8,400 m
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b 11 = b 21 = 4,200 m
b 12 = b 22 = 3,100 m
b 13 = b 23 = - 3,100 m
b 14 = b 24 = - 4,200 m
l = 18,8 m
wb = 8,400 m
bh = 0,075 m
bt = 0,090 m (flange guiding)
Data values and results :
α = αg +αw+αt
α = 0,003233 rad (skewing angle, calculation in accordance with A.5.1 )
Fx = 0. kN (no speed connections, i.e. no longitudinal slip!)
Table A.12 — Results of the calculation

Fixed leg ( l ) Pinned leg ( r )
Elasticity parameter: (calculated using static
program)
hm = 0,00001119 rad/kNm
hm = 0,00001121 rad/kNm
Solving the equation system results in :
• •
α = - 0,001114 rad/s α = - 0,001071 rad/s
∆α = 0,0053 rad ∆α = 0,00498 rad
α res = α + ∆α = 0,008533 rad α res = α + ∆α = 0,008213 rad
Guide force:
Fy l = 112,51 kN Fy r = 105,87 kN
Transverse forces:
Fy l1 = 61,09 kN F y r1 = 57,52 kN
Fy l2 = 58,14 kN Fy r2 = 54,62 kN
Fy l3 = 6,86 kN Fy r3 = 6,77 kN
Fy l4 =-13,58 kN Fy r4 = -13,04 kN
Fy r1 = 57,52 kN
A.7 Distribution of wheel load under rail
A.7.1 Local stress under rail
The local stresses in the rail, rail foot, flanges, fillet welds or web rivets and webs of rail bearing
beams which arise from wheel loads acting normally and transversely to the rail shall be
determined in accordance with the rail and flange system.
Unless a more accurate calculation is made, the local vertical stress in a web or in the upper
welds of girders due to a wheel load shall be calculated using the following formula
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max .F t
σ z = 0,32 × ×3 w
tc Jc
when the rail is supported immediately by the upper flange.
Where :
max. F : maximum wheel load including the amplification factors φi
tw : web thickness (see FigureA.20)
tc : thickness of upper weld or web thickness (see FigureA.20)
Jc : moment of inertia made up of cross travel rail and share of flange plate (hatched
surface, see Figure.A.21)
Jc shall normally be calculated using 90 % of the available section of the crane rail. This value
may be adjusted depending on the following conditions of use:
— number of cycles
— load spectrum
— alignment tolerances
— material of the rail.
The wear limit used in the calculations shall be specified in the operating instructions.
In the case of a clamped cross travel rail, Jc is calculated as the sum of the individual moments
of inertia from the rail and the relevant part of the flange.
max. F max. F max. F

a
tc = tw tc = 2 a tc = a
tw tw
tw
Figure A.20 — Description of t w and t c
The effective flange width bc in this case shall be calculated as follows:
bc = br + 0.8 · hc
where:
br : rail width
hr : rail height
hc : distance from top of the rail to the bottom of the flange
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max. F
hr
hc
tf
br
bc
tw
Figure A.21 — Marked area for Jc
For the web of rolled girders and /or the connection of rolled girder and web, the individual
wheel load may be distributed uniformly in the direction of the rail over a length of
(2 h + 50 mm), on condition that the rail is directly supported on the flange as illustrated in figure
A.22
The height h, related to the top of the rail, shall be entered as follows:
— the web: as the distance to the flange boss (see FigureA.22 a));
— the weld: as the distance to the centroidal axis of the weld (see FigureA.22 b));
— the web rivets: as the distance to the centre line of the rivets (see FigureA.22 c)).
NOTE The height h may be not greater than half of the depth of the web.
50 50 50
h h
h
2h +50 2h +50 2h +50
a) web b) weld c) web rivets
Dimensions are given in mm
Figure A.22 — Height h for the analysis
If the rail rests on an elastic support, the transverse and the longitudinal distribution of the
forces under the rail shall be calculated in their most unfavourable pattern in each case, for the
calculation of the rail bearing beam and of the rail.
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A.7.2 Stress condition in a solid web under rail
The local wheel load not only causes stress in the immediate rail area, but also transfers this to
the structural elements arranged below it.
Figure A.23 shows the effects of the stresses σx , σz and τ on the edges of a solid web girder
with anti-buckling stiffeners. .
The stress σ z in section x = 0 can be approximately described by the following function:
σ z1 c c1 4c z 4c (2b − z)
σ z (z) = ⋅ ( 2·arctan 1 - 2·arctan + 2 1 2 - 2 1 ).
π 2z 4 b − 2z c 1 + 4z c1 + (4b − 2z) 2
Load length c depends on coordinate z as follows:
σ z1  z
c( z ) = ⋅ c1 ⋅ 1 −  .
σ z (z)  b
c1
σ τ σ z1 σ
x1 x1
b
1
σ σ
x2 x2
Key
1 anti-buckling stiffener
Figure A.23 — Solid girder web with dimensions and stresses
A.8 Local stresses in wheel supporting flanges
A.8.1 General
When crabs travel on the girder flanges of a girder, irrespective of the girder support
arrangement, flange bending stresses occur as secondary stresses in the area of the point of
application of the wheel load F.
Formulaes and coefficients are given for two types of main girders:
1. in A.8.1 : main girder as I - beam

2. in A.8.2 : main girder as box girder.
When determining the reference stresses in accordance with table 10 of EN 13001-2 and in the
fatigue stress verification, the local stresses shall be superimposed on the global stresses. In
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the load combinations A, B and C (see Table 10 of EN 13001-2) and in the fatigue strength
verification (load combinations A ), the local stresses in the plates and full penetration welds
shall be multiplied by 0,75 before superimposing with the global stresses. In fatigue analysis,
when coefficient 0,75 is used, the combined stresses shall be compared to the tension fatigue
strength of the weld joint or the detail.
If the wheel loads F are not symmetrical, the local stresses are calculated with the maximum
wheel load and the relevant distance i. In addition to these flange bending stresses and the
main stresses, torsion stresses from the resulting non-symmetrical load application point shall
be calculated in the girder cross section.
NOTE The local stresses can be reduced by factor 0,75 because of the extra plastic bending capacity
of the flange plate or extra plastic tension capacity of the web.
In fatigue analysis the effect of local stress can be reduced, because the fatigue strength in bending of a
plate is typically 30% to 60 % higher than in tension, for the same joint or detail.
A.8.2 Local stresses in wheel supporting flanges (Main girder as I – beam)
These stresses act in the two directions x and y as σFx and σFy (see Figures A.24 a and b).
The stresses are calculated with the help of the equations
F
σ Fx = c x (λ )
t f2
F
σ Fy = c y (λ ) 2
tf
These local stresses shall be multiplied by 0.75 and combined with the global stresses both in
static and fatique analysis.
z z
s x s x
y y y y
Fi
iF x i F x Fi
tf tf
z z
0 1 2 0 1 2
b/4
b b
a) I-beam with parallel flanges b) I-beam with inclined flanges
Figure A.24—Calculation points for local stresses in I-beams
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The coefficients cx(λ) and cy(λ) are given in Table A.13 for the stresses at the lower surface of
the bottom flange in the calculation points 0, 1, and 2. The stresses at the upper surfaces of the
flange have the opposite sign.
The variables F , tf , i and λ have the following meanings :
F : represents the maximum wheel load including the amplification factors φi ;
tf : is the theoretical thickness of the flange ( without tolerances and wear ).For the girder
with inclined flanges tf is taken at the point of wheel force application, point 1,see FigureA.24 b);
i : is the distance from the girder edge to the point of load application;
b : is the width of the flange;
s : is the thickness of the web;
λ : is calculated from the formula
i
λ= .
0,5(b − s)
Table A.13 — Coefficients of the local sresses

I - beam with I - beam with
parallel flanges inclined flanges
3,015 λ 1,322 λ
longitudinal cx0 = 0,050 - 0,580 λ + 0,148 e cx0 = -0,981 - 1,479 λ + 1,120 e
bending
-18,33 λ –7,700 λ
stresses cx1 = 2,230 - 1,490 λ + 1,390 e cx1 = 1,810 - 1,150 λ + 1,060 e
-6,00 λ –4,690 λ
cx2 = 0,730 - 1,580 λ + 2,910 e cx2 = 1,990 - 2,810 λ + 0,840 e
6,53 λ –6,000 λ
transverse cy0 = -2,110 + 1,977 λ + 0,0076 e cy0 = -1,096 + 1,095 λ + 0,192 e
bending
-1,364 λ –2,675 λ
stresses cy1 = 10,108 - 7,408 λ - 10,108 e cy1 = 3,965 – 4,835 λ - 3,965 e
cy2 = 0 cy2 = 0
The indexes have the following meanings :

0 stress at the transition web/flange
1 stress at the load application point
2 stress at the edge of the girder.
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A.8.3 Local stresses of a box girder with the wheel loads on the bottom flange
z
tw
d
F
y F
h
32 i
tf
x
0 1 a
2 b
σ z3
1
σ y0
σ y1 σ x1 , σ x2
2
Key
1 crab wheel
2 global bending stress σxg
Figure A.25 — Symbols used in the calculation of local stresses in box girder
Formulae and coefficients for the calculation of the local stresses at the bottom flange of a box
girder are specified in Table A.14. The symbols used are presented in figure A.25. The formulae
and coefficients are based on the curve-fitting of the results of finite element method calculation.
So, they are approximations and do not have any direct physical basis.
The signs of the stresses at the points 0, 1, 2 are valid at the bottom surface. The upper surface
stress has the opposite sign.
Formulaes for the local stresses at the fillet weld with partial penetration follow figure A.26.
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Table A.14 — Formulas for stresses and coefficients

Point Stress formula Coefficients Symbols and
limits
0 F C x 0 = 0,123 + 0,48λ + 0,194λ2 Valid for all

σ x0 = C x0 formulas
t 2f − 0,5 arctan(5rt − 1,375)
F rt = t w / t f
σ y0 = C y0 C y 0 = −1,3067 − 1,45rt
t 2f
2a < b < 16a
+ 0,5833rt + 1,933λ
2
0,1 < i/a < 0,5
0,15 < rt < 0,8
1 F C x1 = 2.23 − 1.49λ + 2e −18,33λ (1 + 1,5rt ) + 0,4rt

2, 5
σ x1 = C x1
t 2f
F [
C y1 = 0,33(rt − 1) + (1 + 2rt ) 0,3λ + 0,4 sin(3,4λ + 0,4rt 2 ) ]
σ y1 = C y1 2
tf
2 F 4
σ x2 = C x2 2,70  0,2 
t 2f C x 2 = −0,95 + 0 , 333
+ (1,2 ⋅ (λ − 0,1) 0 , 25
− 0,76) 
(2λ + 0,5) rt  rt 
σ y2 = 0 C y2 = 0
3 Stress at web is the sum C zm = 0,4 + 1,8rt

2
h
of membrane (m) and rh =
bending (b) stress 3 b tw
C zb = (0,01 + 0,0212rt ) ⋅ (0,125 − 0,25) 0,1
a
At the σ z 3 = σ z 3 m + σ z 3b = 4mm ≤ t w ≤ 12mm
web
plate,
at the F
σ z 3 = C zm k zh = 0 50t w < h
weld (d + t f ) t w
toe
6 Fd k z0
+ k zh C zb k zh = 1 + ,
[ ] 0 ≤ h < 50t w
3
t w 1 + (2rt )
3 −3 1 + 0,0004536rh
k z 0 = 2 + 1,5 sin(1,5π (0,35 − rt ))
+ 0,45 sin(4π (rt − 0,5))
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Mb
σ z3
M bw
p qτω qτ ω
aw
q
1 Freebody diagram
Figure A26 — Symbols used in the calculation of a fillet weld
q = σ z 3m t w ; M b = σ z 3b t w2 / 6; a wp = a w + p / 2 ; e = t w / 2 + a w /(2 2 ) − 0,75 p
qσw = qτw = q / 2 ; M bw = M b − qe;
qσw 6M bw
σn =τw = ; σ bw = 2
;
a wp a wp
Stress in weld surface : σ ws = σ n + σ bw ;
Stress in weld root : σ wr = σ n − σ bw ;
The stress combination at the weld root in accordance with prCEN/TS 13001-3.1 formula 15
shall be calöculated as follows:

2
 σ x , glob − 0,75σ x 0   σ wr
 +

2
(σ − 0,75σ x 0 )σ wr  τ glob
 − x , glob
2
  τw
 +
2

 ≤1
+
 f  f  f Rd , x ⋅ f Rd , y f  f 
 Rd , x   Rd , y   Rd ,τx   Rd ,τy 
Index glob refers to the global stresses at the calculation point (longitudinal normal stress and
shear stress that goes through the weld).
The reduction factor 0,75 shall not be applied to the transverse stresses of the fillet weld. The
weld strength factor αw (see prCEN/TS 13001-3.1) shall not be applied for fRd,y, when fy < 690
MPa.
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A.9 Example on calculation of classification parameters for weld and

wheel load
A.9.1 General
This example shows how class S of the stress history parameter s is calculated for the weld
between the web plate and the top flange below the cross travel rail. Further calculations of
stress cycles on other cross-sectional points of the crane are certainly necessary, but however
will not be calculated in this example.
Calculation of the sress histories and classification is based on the procedure presented in
clause 4.3 of EN 13001-1.
A.9.2 Crane operating conditions
The automatic crane, capacity 5.0 t and span 20 m, is classified in class U6 (number of working
cycles) and operates with two different hoist loads GHi :
1. GH1 = 5.0 t at 70 % of the working cycles
2. GH2 = 3.0 t at 30 % of the working cycles.
Operation of the crane is calculated on a basis of 10 years with daily operation of 16 hours.
Before picking up the hoist load, cross travelling is entered into the calculation without hoist load.
A.9.3 Method of operation and tasks
The crane performs five indexed tasks (see figure A.27). Table A.15 shows the basic
parameters for the tasks.
d
1 c
2 3 4 5 6
a e
b
7
Key
1 automatic crane
2 runway
3 working area 1
4 working area 2
5 quality control
6 dispatch
7 parts store
Figure A.27 — Tasks r of the crane
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Table A.15 — Tasks and cycle figures

Task Crane movement Working stress cycles per
cycles per working cycle (2
day wheels)
1 from parts store to working area 1 40 2
2 from parts store to working area 2 40 2
3 from working area 1 to quality check 40 2
4 from working area 2 to quality check 40 2
5 from quality check to dispatch 80 2
Σ = 240
A.9.4 Frequency of stress cycles
In the case of this double-girder bridge crane, only the weld seam stress σz of the weld seam
between the web plate and upper flange below the crab rail is investigated. Wheel load F of the
cross travel wheel works as a load resulting from the dead load of the crab and the hoist load
(see Figure A.28).
.
vcr
F
z
z hr
tu
crab dead load z
G H2 = 3.0 t
2 wheels 2 wheels 2 wheels t
crab
G H1 = 5.0 t z tw GH1= 5.0 t dead load GH2 = 3.0 t
a) b) c)
Key:
Figure a) stress distributions due to.
a.1 crab dead load
a.2 crab dead load and GH2 = 3.0 t
a.3 crab dead load and GH1 = 5.0 t
Figure c) stress cycles as a function of time

c.1 two wheels, GH1 = 5.0 t
c.2 two wheels, crab dead load
c.3.two wheels, GH2 = 3.0 t
Figure A.28 — Local wheel load and weld seam
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Definitions of classes ij :
- Class 1 : GH1 = 5.0 t and 70 % of the working cycles
- Class 2 : GH2 = 3.0 t and 30 % of the working cycles
- Class 3 : crab dead load 100 % of the working cycles
Minimum stresses σz1i :
σz1 = σz2 = σz3 = 0.0 N/mm2 (no wheel load in the section)
Maximum stresses σzui:

2
σzu1 = 95.0 N/mm (from GH1 = 5.0 t)
2
σzu2 = 57.0 N/mm (from GH2 = 3.0 t)
2
σzu3= 9.0 N/mm (from crab dead load)
Stress amplitudes and average stresses :

2 2
σza1 = (95.0 + 9.0) / 2 = 52.0 N/mm σzm1 = 52.0 N/mm
2 2
σza2 = (57.0 + 9.0) / 2 = 33.0 N/mm σzm2 = 33.0 N/mm
2 2
σza3 = 9.0 / 2 = 4.5 N/mm σ zm3 = 4.5 N/mm
Total number C of working cycles in 10 years:
- C = 240 working cycles/day · 250 days · 10 years

- C = 600 000.
Table A16 — Number of working cycles Cr per task r
total number of
(GH1 = 5.0 t) (GH2 = 3.0 t)
Task working cycles
70% 30%
Cr per task
1 100 000 70 000 30 000

2 100 000 70 000 30 000
3 100 000 70 000 30 000
4 100 000 70 000 30 000
5 200 000 140 000 60 000
Σ = 600 000 Σ = 420 000 Σ = 180 000
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Maximum number of stress cycles:
n1 = 4 · 70 000 · 2 + 140 000 · 2 = 840 000
n2 = 4 · 30 000 · 2 + 60 000 · 2 = 360 000
n3 = 600 000 · 2 = 1 200 000
∧
n = 2 400 000
A.9.5 Classification of the stress histories
For supporting structures µ = 0 ; therefore, the following stress amplitudes apply:

2
σa1 = 52.0 N/mm
2
σa2 = 33.0 N/mm
2
σa3 = 4.5 N/mm
∧
σ a = 52.0 N/mm2
A.9.6 History parameter s of stresses and class S :
s = ν·k , m=3
2.4 ⋅ 10 6
ν = = 1.2
2.0 ⋅ 10 6
3 3 3
 52  840 000  33  360 000  4.5  1 200 000
k =   +   +   = 0.38866
 52  2 400 000  52  2 400 000  52  2 400 000
s = 1.2 · 0.38866 = 0.4664 ⇒ class S6.
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A.10 Example on classification of a bridge crane
A.10.1 General
Description of crane and the working cycles are given in figure A.29. The positions of the crane
and crab as well as the lifted load are given by coordinates x and y. These coordinates are
shown in parentheses (x,y).
1
x A3 A5
T2 (3.5 t) T4 (10 t)
T1 (2 t)
T3 (6 t) A4
A1 A2
Key
R1 and R2 rails for crane travel
x coordinate of crab traverse; position of the load
y coordinate of crane travel; position of the load
A1 to A5 working areas: the crane moves loads from one working area to another
A5 loading area
Arrows show the direction of the material flow
T1 to T4 tasks of the crane; the figures in parentheses are the average loads moved in
each task
Figure A.29 — Tasks of a bridge crane
A.10.2 Crane specification
Crane spesification is as follows:

A single girder bridge crane with two end carriages and one hoist crab. The girger is a box
construction.
Rated capacity, mQ 10 t Crab mass mc = 0,8 t v (hoist) = 10 m/min
Span, s 20 m Hook mass mh = 0,2 t v (crab) = 25 m/min
Wheelbase 4m Coefficient φ1 = 1,1 v (crane) = 40 m/min
Approach to track 1m Coefficient φ2 = 1,1 for load combinations A
Maximum lift 8m Coefficient k5 = 1,2 corresponding to coefficient φ5
No. of rope falls, nf 4 Drum diam, D = 320 mm Sheave diameter Ds = 260 mm
Crab wheel diameter Dc = 125 mm Crane wheel dia Dw = 250 mm
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A.10.3 Crane duty
The crane in this example is working in a workshopin final assembly and shipment as follows:
Task T1: Transfer of lighter components from subassembly area A1 to the subassembly area A2.
Various loads are characterized by transfer of masses m(1) 3 m(1)= 2,0 t
times per unit
Transfer from mid A1 to mid A2 would result no crab traverse. This is not
realistic.
Therefore, the characteristic movement is taken from point (17, 5) to 13, 15).
Height of lift 3 m, lowering of the load 3 m, lift and lowering of return movement 2 m.
Task T2: Transfer of medium, 3.5 t, subassembly from area A2 (4, 7) to final assembly A4 (15, 22).
Height of lift and lowering 4 m, return movement 2 m, one time per m(2)= 3,5 t
it
Task T3: Transfer of heavy subassembly, 6 t, from area A2 (15, 15) to A4 (11, 22).
Height of lift, lowering and return 2 m, one time per unit m(3) = 6,0 t
Task T4: Transfer of the finished product, 10 t, from A4 (13, 22) on the truck, area A5 (4, 18).
Height of lift 5 m, lowering 3 m, return movements 3 m in average. m(4) = 10,0 t
All mentioned loads include the weights of slings and packings where relevant.
The slings with mass 0,3 t are expected to hang in the hook all the time. mo = 0,2 t + 0,3 t = 0,5 t.
Intensity of the work The crane is specified for life: 20 a

The plant intends to deliver 6 finished products per day: 250 day/a.
The vertical forces are considered with their dynamic coefficients in the determination of the
stress histories. The horizontal forces are not considered in the determination of the stress
histories. They are assumed to act proportionally and simultaneously with the vertical forces.
They shall be included in the determination of the stress ranges.
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A.10.4 Results of the preliminary strength analysis of the girder
The preliminary analyses has given the following results for the girder:
Weight of the girder: 5,0 t. The girder is made from steel S355.
Bending stresses (MPa) at: top flange, σx bottom flange P.1, σx bottom flange P.3, σx P.3, σz
- due to dead weight, global bending - 20 16 14
- due to 10 t load, global bending - 80 65 60
- due to 10 t load, local 75 120
Total with horizontal effects - 140 196 110
NOTE For points P.1 and P.3 see annex A.8.3.
A.10.5 Classification
A.10.5.1 Classification parameters for crane use
The following classification parameters are calculated from assumed data of crane use
according to prEN 13001-1 and using the symbols defined in that standard:
Table A.17 – Calssification
cycles/unit unit/d days/a life/a

Number of work cycles, Ctot = 6 x 6 x 250 x 20 = 180 000
Ctot = 180 000 < 250 000; leads to classification: U4.
Net load spectrum factor for the hoist mechanism is obtained as follows:
Table A.18 – Frequency of loads
3
The frequency of the loads kQ = Σ kQi kQi = (Ci/C)*(m(i)/mQ)
Index Number of Ci/C m(i)/mQ relative load

Task Load m(i) kQi
i cycles Ci = qc = qm =qc*qm
T1 1 3 2 0,5000 0,2 0,004 0,100
T2 2 1 3,5 0,1667 0,35 0,007 0,058
T3 3 1 6 0,1667 0,6 0,036 0,100
T4 4 1 10 0,1667 1 0,167 0,167
C=6 mQ = 10,0 kQ = 0,214 qr = 0,425
This leads to: Class of load spectrum = Q3
Average load = qr x mQ = 4,25 t Throughput of the workshop = 6 x 250 x mQ =

15000 t/a
Total mass handled per year = 6 x 6 x 250 x 4,25 t = 38250 t/a. Each mass handled in average
2,55 times.
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A.10.5.2 Stress history of parts loaded proportionally to the hoist load
a) The stress cycles follow the number of hoisting cycles
NOTE Typically the hoist crab structure and other non-rotating, load bearing parts belong to this
group of components.
Calculation of the stress spectrum factor is presented in the following table.
Table A.19 – Stress spectrum factor

1.2
3
Task Event mo+k5 x mi ∆Fi/kN ∆Fi/∆Fmax (∆Fi/∆Fmax) Ci/C
i 1
(t) = qFi = qCi
T1 1 0,5 0,00 0 0,0000 0.8
2 2,64 21,40 0,18228 0,0061 0,1667
qF i
0.6
3 0,5 0,00 0 0,0000
4 2,64 21,40 0,18228 0,0061 0,1667 0.4
5 0,5 0,00 0 0,0000

0.2
6 2,64 21,40 0,18228 0,0061 0,1667
T2 7 0,5 0,00 0 0,0000 0
1 3 5 7 9 11 13
8 4,44 39,40 0,33560 0,0378 0,1667
NE
T3 9 0,5 0,00 0 0,0000
10 7,44 69,40 0,59114 0,2066 0,1667
T4 11 0,5 0,00 0 0,0000
12 12,24 117,40 1,0000 1,0000 0,1667
13 0,5 0,00 0 0,0000
3
∆Fmax = 117,40 kN ks = Σ(qFi ⋅ qCi) = 0,2104
6 6
Relative number of stress cycles: ν = Ctot/2e = 180000/2e = 0,090
Stress history parameter s = νxks = 0,0189 Class: S2
Key
NE Event number
qFi Relative values of stress ranges
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b) The stress cycles follow the number of revolutions of the part
*) Relative time and relative distance are same for same speed.
**) Marking (m3) means that the spectrum factor is calculated with SN-curve slope m = 3; m5
and m7 accordingly. Different components in the hoist mechanism may have different SN-curve
slope m.
Task Event Hoistload Hoisting+ Relative Fi/Fmax ki(m3) ki(m5) ki(m7)
Fi/kN lowering distance (**
i distance (*
T1 1 22 6 0,094 0,2157 0,00094 0,0004 0,00000
2 5 4 0,063 0,0490 0,00001 0,00000 0,00000
3 22 6 0,094 0,2157 0,00094 0,00004 0,00000
4 5 4 0,063 0,0490 0,00001 0,00000 0,00000
5 22 6 0,094 0,2157 0,00094 0,00004 0,00000
6 5 4 0,063 0,0490 0,00001 0,00000 0,00000
T2 7 37 8 0,125 0,3627 0,00597 0,00079 0,00010
8 5 4 0,063 0,0490 0,00001 0,00000 0,00000
T3 9 62 4 0,063 0,6078 0,01404 0,00519 0,00192
10 5 4 0,063 0,0490 0,00001 0,00000 0,00000
T4 11 102 8 0,125 1,0000 0,12500 0,12500 0,12500
12 5 6 0,094 0,0490 0,00000 0,00000

0,00001
Fmax = 102,0 kN Sum = 64 m Sum = 1 ks = 0,1478 0,1311 0,1270
1,2000
1,0000
0,8000
0,6000
0,4000
0,2000
0,0000
0 0,2 0,4 0,6 0,8 1 1,2
Key
xc Relative cumulated
travel distance in hoisting
qF Relative force in hoisting
Figure A.30 Hoist force history versus hoisting distance
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Table A.21 – drum and sheave classification
Time used for the load cycles: Class of the drum (* Class of a sheave
st
Time used for 6 reference cycles Travel distance of the rope Travel distance of the 1
drum periphery sheave periphery
Tref = 64m/10m/min = 6,4 min
Total time = 192000 min Ld = C/6x64mx4(rope falls) = Lsh = (nf-1)/nf x Ld =
3200 h 7680000 m 5760000 m
C/6 x Tref =
C = 180 000 cycles Drum rotations Sheave rotations
Number of revolutions, N: Ndrum = Ld/(πD) = 7639437 Nsheave = Lsh/(πDs) = 7051788
Relative number of stress cycles: ν = 3,82 ν = 3,53
Stress history parameters: ν x ks = s(m3) = 0,565 s(m3) = 0,521
Classification of the detail: Drumclass: S7 Sheave class: S7
NOTE 1 *)The drum classification is valid for the drum ends and those parts of the shell where the rope
is not wound. For those parts where the rope is wound over the analysis is more complicated and not
presented here.
NOTE 2 Classification in accordance with ISO 4301-1 based on the same data is as follows:
load spectrum L2, running time T4, class of mechanism M4.
A.10.5.3 Classification of the girder
Classification of the girder is based on the classification of the stress histories in 3 points of the
girder cross section, in the middle of the girder.
Without an automatic computer program it is most convenient to study the stress influences with
the aid of the influence line of the bending moment in the vertical plane.
x 10 m 20 m
0,1
0,3
0,5
0,7
0,9
T1:
2 T2:
T3:
T4:
Key
1 Influence line representing the bending moment at the middle of the girder as the function of
the trolley position (x)
2 Trolley motions during tasks T1 … T4
qm = value of the relative bending moment
T1 … T4 = the specified tasks
Figure A.31 Influence line of bending moment
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The actual bending moment at the middle is calculated by formula M = qm x F x s/4.
Table A.22 – Loads, motions and stresses
Tas Net φ1 x mc Crab Position Relative Stress on Stress Stress

load + k5 x mHL position influence moment top of girder in P1 in P3
(t) (t) x (m) qm **) σxt σx1 σz3
T1 0 1,30 17,0 0.30 0,039 -3,1 2,5 0,0
2 3,88 17,0 0,30 0,116 -9,3 7,6 0,0
2 3,88 13,0 0,70 0,272 -21,7 17,7 0,0
0 1,30 13,0 0,70 0,091 -7,3 5,9 0,0
0 1,30 17,0 0,30 0,039 -3,1 2,5 0,0
T2 0 1,30 4,0 0,40 0,052 -4,2 3,4 0,0
3,5 5,68 4,0 0,40 0,227 -18,2 14,8 0,0
3,5 4,88 9,8 0,98 0,478 -38,3 67,0 57,4
3,5 4,88 10,0 1,00 0,488 -39,0 31,7 0,0
3,5 4,88 10,2 0,98 0,478 -38,3 67,0 57,4
3,5 5,68 15,0 0,50 0,284 -22,7 18,5 0,0
0 1,30 15,0 0,50 0,065 -5,2 4,2 0,0
0 1,30 10,0 1,00 0,130 -10,4 8,5 0,0
0 1,30 4,0 0,40 0,052 -4,2 3,4 0,0
T3 0 1,30 15,0 0,50 0,065 -5,2 4,2 0,0
6 8,68 15,0 0,50 0,434 -34,7 28,2 0,0
6 8,68 11,0 0,90 0,781 -62,5 50,8 0,0
0 1,30 11,0 0,90 0,117 -9,4 7,6 0,0
0 1,30 15,0 0,50 0,065 -5,2 4,2 0,0
T4 0 1,30 13,0 0,70 0,091 -7,3 5,9 0,0
10 13,48 13,0 0,70 0,944 -75,5 61,3 0,0
10 11,38 10,2 0,98 1,115 -89,2 156,1 133,8
10 11,38 10,0 1,00 1,138 -91,0 74,0 0,0
10 11,38 9,8 0,98 1,115 -89,2 156,1 133,8
10 13,48 4,0 0,40 0,539 -43,1 35,0 0,0
0 1,30 4,0 0,40 0,052 -4,2 3,4 0,0
0 1,30 10,0 1,00 0,130 -10,4 8,5 0,0
0 1,30 13,0 0,70 0,091 -7,3 5,9 0,0
**) Relative moment means the ratio of the actual bending moment to the bending moment
caused by the rated load mQ = 10 t acting at the middle of the girder.
The constant stress due to the own weight of the girder need not be considered in the stress
range spectrum analysis of structures.
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Stress histories of the middle of the girder
200,0
150,0
100,0
Stress (MPa)
50,0 sx-top
sx1
0,0 sz3
11
23
25
37
21
33
31
15
17
35
19
27
29
7
9
1
3
5
13
-50,0
-100,0
-150,0
event
Key
NE Loading event
σ Stress scale, unit MPa
sxt Longitudinal stress in the top flange
sx1 Longitudinal stress in the bottom flange, point 1
sz3 Vertical stress in the bottom of the web, point 3
Figure A.32 Stress cycles of 3 points of the girder during 6 cycles of 4 tasks
Table A.23 – Results of estimated stress histories based on rainflow counting of stress
ranges
Point P1 Point P3
Point in consideration: Top of girder
Stress cycles per 6 work cycles: 8 10 4
Total number of stress cycles: 240000 300000 120000
Stress spectrum factor, ks: 0,177 0,128 0,539
Relative number of cycles, ν: 0,120 0,150 0,060
Stress history parameter, s: 0,021 0,019 0,032
Stress history class: S2 S2 S3
Notch class (for example): 80 125 80

limit ∆σ (MPa), γMf =1,15 : 251 406 218
As the preliminary stress level was well below the limit stress ranges due to fatigue,
the original weight estimation for the girder is still valid. That weight will be used in the
next calculations.
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A.10.5.4 Classification of an end carriage
A.10.5.4.1 Data
It is assumed that sometimes the full load 10 t is lifted at the minimum distance to the runway (1
m) even though such a task does not belong to the process duty description. This situation
gives the maximum design load of the end carriage marked as Fwmax. This value is used as
the reference for the calculation of the stress spectrum factor.
It is useful to use the force-influence line of the end carriage. The influence line for the end
carriage at x = 0 is shown in figure A.xxxx.
A constant force, Fdw = 25 kN, due to the own weight of the girder is assumed for the end
carriage. The table of force takes this into account in the relative forces.
x 10 m 20 m
0,1
0,3
0,5
0,7
0,9
T1:
2 T2:
T3:
T4:
Key
1 Relative force on the end carriage (at x = 0) due to crab and load position x, value = qf
2 Trolley motions in tasks T1 to T4
Figure A.33 Influence line of the force on the end carriage due to crab position
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Table A.24 - Loads, motions and stresses

Task mi(t) Fzi x(m) qf y(m) yc(m) qF0 qFs qc0 qcs dks0 dkss
T1 0,0 1,30 17 0.15 5 0 0,176 0,236 - - - -
2,0 3,88 17 0.15 5 0 0,201 0,379 0,000 0,000 0,000 0,0000
nt=3 2,0 3,88 13 0.35 15 10 0,252 0,328 0,228 0,354 0,0020 0,0103
0,0 1,30 13 0.35 15 10 0,193 0,219 0,000 0,000 0,0007 0,0000
0,0 1,30 17 0.15 5 20 0,176 0,236 0,185 0,227 0,0010 0,0027
T2 0,0 1,30 4 0.80 7 22 0,231 0,180 0,205 0,209 0,0005 0,0001
3,5 5,68 4 0.80 7 22 0,460 0,238 0,000 0,000 0,000 0,0000
nt=1 3,5 5,68 15 0.25 22 37 0,256 0,442 0,368 0,350 0,0050 0,0050
0,0 1,30 15 0.25 22 37 0,185 0,227 0,000 0,000 0,0008 0,0000
0,0 1,30 4 0.80 7 52 0,231 0,180 0,209 0,205 0,0010 0,0010
T3 0,0 1,30 15 0.25 15 60 0,185 0,227 0,209 0,205 0,0001 0,0005
6,0 8,68 15 0.25 15 60 0,305 0,589 0,000 0,000 0,000 0,0000
nt=1 6,0 8,68 11 0.45 22 67 0,419 0,475 0,365 0,534 0,0020 0,0083
0,0 1,30 11 0.45 22 67 0,202 0,210 0,000 0,000 0,0006 0,0000
0,0 1,30 15 0.25 15 74 0,185 0,227 0,193 0,219 0,0000 0,0006
T4 0,0 1,30 13 0.35 22 81 0,193 0,219 0,189 0,223 0,0004 0,0006
10,0 13,48 13 0.35 22 81 0,472 0,736 0,000 0,000 0,000 0,0000
nt=1 10,0 13,48 4 0.80 18 85 0,868 0,339 0,689 0,561 0,0100 0,0055
0,0 1,30 4 0.80 18 85 0,231 0,180 0,000 0,000 0,0001 0,0000
0,0 1,30 13 0.35 22 89 0,193 0,219 0,213 0,200 0,0000 0,0002
dy-tot (m) = 129 Fwmax(kN)= 153,1 153,1 ksw= 0,0253 0,0348
Key 6
mi(t)
= Mass of net load in event I Fzi = φ1xmc+k5x(mH+mi)
x(m) x-coordinate of the crab qf = Influence of crab position x

=
y-coordinate of the crab (and
y(m) crane) yc = Cumulative travel distance
=
(qfxFzi+Fdw)/Fwmax, relative
qF0 = force, x = 0 qFs = [(1-qf)xFzi+Fdw]/Fwmax, relative force, x = s
qc0 = Relative cubic mean load of qcs =

end carriage x=0, when crane Relative cubic mean load of end carriage
travelling from yi-1 to yi x=s, when crane travelling from yi-1 to yi
dks0
3 3
= nt x qc0 x abs(yi-yi-1)/dy-tot dkss = nt x qcs x abs(yi-yi-1)/dy-tot
dy- = total travel distance in

tot 3xT1+T2+T3+T4 Fwmax = {0.95x[φ1xmc+k5x(mH+mQ)]+Fdw/g}/mQ
ksw = Load spectrum of rail wheel in each end carriage
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A.10.5.4.2 Stress histories of the steel structure of the end carriage
Variation of the force on each end carriage versus load events is presented in figure A.34
NOTE Note that task T1 is presented only once.
The influence of this task has been multiplied by nt = 3.
Relative force of end carriages

1,4
1,2
1,0
Relative force
0,8 1x=0
0,6
2x=s
0,4
0,2
0,0
11
1
13
19
3
15
5
17
Event
Key
EC0 Force on end carriage x = 0
Ecs Force on end carriage x = s
NE Event number
qF Value of relative force
Figure A.34 Variation of vertical force on the end carriages during tasks T1 to T4
In the estimation of the stress spectrum factors for the bending of the end carriages the small
stress variations can be ignored as insignificant. One stress range for each task is counted (3
times for task T1).
The stress spectrum factor can be calculated in this case by the following formula.
1 (q − q F min ) 3
ks = × ∑ F max
∑ nt (1 − min[q F min ]) 3
where qFmax and qFmin are found from each task. The denominator represents the relative value
of the greatest stress range.
The stress spectrum values are obtained from the values of columns qF0 and qFs as follows:
3 3 3 3 3
ks0 = [3x(0,252-0,176) +(0,460-0,185) +(0,419-0,185) +(0,868-0,193) ]/(1-0,176) /6 = 0,102
3 3 3 3 3
kss = [3x(0,379-0,219) +(0,442-0,180) +(0,589-0,210) +(0,736-0,180) )/(1-0,180) /6 = 0,078.
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In this example the total number of the stress cycles is same as the total number of working
cycles, i.e.
)
n = C = 180000 .
Relative number of stress cycles is: ν = 180000/2000000 = 0.09.
Consequently, the stress history parameters and classifications are:
- for end carriage x = 0: s0 = ν x ks0 = 0,0092; class S1
- for end carriage x = s: ss = ν x kss = 0,0070; class S0.
Note This is the first estimation of the stress history of the end carriages based on the variation of
the bending moment in the vertical plane. There may be more stress reversals of the bending moment in
the horizontal plane due to several accelerations during one work cycle, and if those stresses are
significant, they may contribute to the stress history parameter. In any case, the maximum calculated
stress range shall include the effects of the horizontal bending moments together with the maximum and
minimum vertical moments due to extreme crab positions. This so obtained ∆σmax shall be limited with the
estimated stress history class.
A.10.5.4.3 Stress histories of the rail wheel and bending of the wheel shaft
Variation of the rail wheel force of each end carriage versus travelled distance is presented in
figure A.35. Note that task T1 is presented only once. The influence of this task has been
multiplied by nt = 3.
Relative force of a rail wheel
1,400
1,200
1,000
1 x=0
Force
0,800
0,600 2 x=s
0,400
0,200
0,000
0,0 20,0 40,0 60,0 80,0 100,0
Cumulative travel y (m)
Key
EC0 Relative wheel force of end carriage x = 0
Ecs Relative wheel force of end carriage x = s
yc cumulative travelled distance (task T1, between yc = 0 … 20 m, is presented only once)
qF Value of relative force
Figure A.35 Variation of vertical force on the end carriages during tasks T1 to T4
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The spectrum factors for the wheel forces, ksw, are calculated in the table above. The relative
cubic mean loads qc0 and qcs are calculated with the accurate integral over a linear function y
between values y1 and y2 on distance x = 0 to 1, as follows:
1/ 3
1 
qc =  ∫ y ( x) 3 dx  [( ) ]
= y 23 + y 22 y1 + y 2 y12 + y13 / 4
1/ 3
.
0 
The usual approximation ymean = (2ymax+ymin)/3 could also be used.
The total travelling distance of the crane during the specified life is
Ltot = C/6 x dy-tot = 180 000/6 x 129 m = 3 870 000 m.
The number of wheel revolutions, which is same as the number of contacts with the rail, is
nw = Ltot/(πDw) = 4927435.
Relative number of stress cycles is: ν = 4927435/2000000 = 2,46.
Stress history parameter is: sw = 2,46 x 0,0348 = 0,086, ⇒ class S4 .
Note Calculation of spectrum factor and stress history parameter in this example are based on
exponent m = 3 for the SN-curve. CEN/TC147/WG2 is preparing a standard for the limit states and proof
of competence of rail wheel contacts. If that standard is using an exponent that differs from 3, this example
shall be modified accordingly.
A.11 Guidance on recommended maximum deflection of girders

The crane design may be characterized by a Stiffness Index (SI), which is the span divided by
the maximum static deflection due to the trolley and the rated load.
Table A.18 shows the range of Stiffness Index values considered acceptable for various
operating regimes.
NOTE These values represent the current experience on crane installations.
Table A.25 — Ranges of stiffness zones

Stiffness index SI
1 500 Zone A Zone A - Characteristic of cranes, which need high

positioning accuracy
1 000 Zone B Zone B - Characteristic of normal workshop cranes

with medium positional accuracies which can use
simple control systems
750 Zone C
500 Zone C – Suitable for low positioning accuracies or

with special features such as stepless control, low
250 hoisting speeds and accelerations may be used to
achieve acceptable positioning accuracies
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A.12 Guidance on recommended minimum frequencies of girders

For usual overhead travelling cranes the vertical and horizontal natural frequency of the crane
girder can be calculated by approximation using the following equations.
a) vertical natural frequency
Here freely supported girder ends are assumed. Other supporting conditions require other
approaches for calculating f v .
1 48EJ y
fv = in Hz
2π l (mtr + mhl + 0.4857m g )
3
All dimensions shall be in kg, m, s, N.
b) horizontal natural frequency
The horizontal frequency is taken into account from the supporting conditions between main
girder and end carriages. The factors kmg and ksc take these into consideration.
1 k sc EI 2
fh = in Hz
2π l (mtr + k mg m g )
3
Where:
freely supported girder ends kmg = 0,4857 and ksc = 48

clamped girder ends kmg = 0,3714 and ksc = 192
Typical values for cranes are:

Top running single-girder cranes kmg = 0,4500 and ksc = 100
Top running double-girder cranes kmg = 0,4300 and ksc = 125
and
mtr mass of the crab kg
mhl hoist load kg
mg mass of the crane girder kg
2
E modulus of elasticity N/m
4
Jy , Jz moments of inertia m
lcr crane girder length m
If the crane does not have to meet any special requirements, the values, shown in figure A.36
may be regarded as the minimum values for the frequencies f v and f h . These values are based
on experience gained from trials and installations supplied.
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25
3.0
2.5
2.4
fv
Horizontal frequency f h in Hz
Vertical frequency f v in Hz
2.0
1.8
fh
1.5
1.0
0.5
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Crane girder length Ι cr in m
Figure A.36 — Guide values for natural frequencies fv and fh
A.13 Accelerations and dynamic factors φ5 (informative)

When the accelerations of the drives are within the typical ranges given in Table A.26, the
factors φ5 may be taken from Tables A.27 and A.28.
Table A 26 — Typical values for acceleration and deceleration

2
Drive mechanisms Acceleration and/or braking value aw,o in m/s
Cross travel * 0,10 0,50 ( 0,70 )
Long travel * 0,15 0,40 ( 0,65 )
Slewing drives at max radius 0,10 0,60 ( 1,00 )
Hoists: Dual speed ** 0,20 0,60 ( 0,90 )
Hoists: Single speed 0,80 2,50 ( 5,00 )
* The lower values apply for movements with hoist load.
** The lower values apply for lower hoist speeds.
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Table A 27 — Factor φ5 for travel and slewing mechanism

Usual control
Drive type Factor φ5
range
Servo motor 1: 200 1.1
DC motor 1: 100 1.2
Asynchronous AC motor,
squirrel-cage rotor, 1: 50 1.4
with frequency inverter
1: 4 1.6
slip-ring rotor, with resistors
squirrel-cage rotor, 1: 4 / 1: 10 1.8
Pole-changing / creep speed stage
1: 1 2.0
Squirrel-cage rotor
Table A 28 — Factor φ5 for hoists

Drive type Usual Factor φ5 Factor φ5 Factor φ5 Factor φ5
control lifting / lifting / lowering / lowering /
range switching on switching switching switching
off on off
Servo motor 1: 200 1,05 1,05 1,10 1,05

DC motor 1: 100 1,10 1,05 1,15 1,10
Asynchronous AC motor squirrel-
cage rotor, 1: 30 1,10 1,10 1,20 1,15
with frequency inverter
Asynchronous AC motor slip-ring 1: 4 /
1,15 1,10 1,20 1,15
rotor with resistors 1: 6 /1: 10
cage rotor; pole-changing / creep 1: 2 /1: 4 1,15 1,15 1,25 1,20
speed stage
1: 1 1,20 1,20 1,30 1,25
cage rotor
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Annex B
(informative)
Guide for selection of rail wheels
NOTE The wheel selection method presented in this annex is based on FEM 1.001-1987, Booklet 4,
as revised in Booklet 9 in 1998. This method is based on the group classification of mechanisms (classes
M1 to M8) that is not defined in prEN 13001-1. Clause B.2 shows a method of deriving the class of
mechanism from the classification parameters of prEN 13001-1. This annex will be withdrawn when
CEN/TC147 publishes the standard for selection of rail wheels based on classification of stress history of
the wheel.
B.1 Rail wheel size
B.1.1 General
To determine the size of a-rail wheel, the following should be checked
 that it is capable of withstanding the maximum load to which it will be subjected, and
 that it will allow the appliance to perform its normal duty without abnormal wear.
The two requirements are checked by means of the following two formulae
Pmax
≤ 1.9 PL
b⋅D
Pmean A,B
≤ PL ⋅ c1 ⋅ c 2
b⋅D
where
D the wheel diameter in mm
b the useful width of the rail in mm

2
PL a limiting pressure dependent upon the metal used for the wheel in N/mm
c1 a coefficient depending on the speed of rotation of the wheel
c2 a coefficient depending on the group of the mechanism
Pmax the maximum load on the wheel resulting from load combinations A, B or C,
including consideration of both dynamic and static test loadings (Load combinations
are defined within prEN 13001-2.)
Pmean A,B is the higher mean load value resulting from formula in B.1.2 when considering both
load combinations Aand B.
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B.1.2 Determining the mean load
To determine the mean loads, the maximum and minimum loads withstood by the wheel in the
loading cases shall be considered, i.e. with the appliance in normal duty but omitting the
dynamic coefficient φ1 to φ5 when determining Pmean A,B. The values of Pmean are determined by
the following equations in the two load combinations A and B.
Pmin A, B + 2 Pmax A, B
PmeanA, B =
3
B.1.3 Determining the useful rail width b
For rails having a flat bearing surface and a total width with rounded corners of
radius r at each side, we have :
b = l − 2r
for rails with a convex bearing surface, we have
4
b=l− r
3
NOTE For the same width of rail head, these equations give a greater useful bearing width for convex
rails than for flat rails. This allows for the superior adaptation of a slightly convex rail to the rolling motion of
the wheel.
Figure B.1 — Rail dimensions
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B.1.4 Determining the limiting pressure PL
The value of PL is specified in Table B.1 as a function of the ultimate strength of the metal of
which the rail wheel is made;
Table B.1 — Values of PL
Ultimate strength of metal used for PL Minimum strength
2 2 2
rail wheel, N/mm in N/mm for the rail, fu, N/mm
fu > 500 5,0 350
fu > 600 5,6 350
fu > 700 6,5 510
fu > 800 7,2 510
fu > 900 7,8 600
fu > 1 000 8,5 700
The qualities of metal refer to cast, forged or rolled steels, and spheroidal graphite cast iron.
The hardening of the wheel thread at the depth of 0,01D may be taken into account when
selecting the value of PL.
In the case of rail wheels with tyres, consideration should obviously be given to the quality of the
tyre, which shall be sufficiently thick not to roll itself out.
B.1.5 Determining the coefficient c1
The values of c1 depend on the speed of rotation of the wheel and are specified in TableB.2.
The same values are also given in table B.3. as a function of the wheel diameter and the speed
in m/min.
Table B.2 — Values of c1

Wheel rotation Wheel rotation Wheel rotation
speed, rpm c1 speed, rpm c1 speed, rpm c1
200 0,66 50 0,94 16 1,09
160 0,72 45 0,96 14 1,10
125 0,77 40 0,97 12,5 1,11
112 0,79 35,5 0,99 11,2 1,12
100 0,82 31,5 1 10 1,13
90 0,84 28 1,02 8 1,14
80 0,87 25 1,03 6,3 1,15
71 0,89 22 1,04 5,6 1,16
63 0,91 20 1,06 5,0 1,17
56 0,92 18 1,07
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Table B.3 — Values of c1 as a function of the wheel diameter and the speed of travel
Wheel Values of c1 for travel speeds v in m/min
diameter
D in mm
v=
10 12,5 16 20 25 31,5 40 50 63 80 100 125 160 200 250
D
200 1,09 1,06 1,03 1 0,97 0,94 0,91 0,87 0,82 0,77 0,72 0,66 - - -
250 1,11 1,09 1,06 1,03 1 0,97 0,94 0,91 0,87 0,82 0,77 0,72 0,66 - -
315 1,13 1,11 1,09 1,06 1,03 1 0,97 0,94 0,91 0,87 0,82 0,77 0,72 0,66 -
400 1,14 1,13 1,11 1,09 1,06 1,03 1 0,97 0,94 0,91 0,87 0,82 0,77 0,72 0,66
500 1,15 1,14 1,13 1,11 1,09 1,06 1,03 1 0,97 0,94 0,91 0,87 0,82 0,77 0,72
630 1,17 1,15 1,14 1,13 1,11 1,09 1,06 1,03 1 0,97 0,94 0,91 0,87 0,82 0,77
710 - 1,16 1,14 1,13 1,12 1,1 1,07 1,04 1,02 0,99 0,96 0,92 0,89 0,84 0,79
800 - 1,17 1,15 1,14 1,13 1,11 1,09 1,06 1,03 1 0,97 0,94 0,91 0,87 0,82
900 - - 1,16 1,14 1,13 1,12 1,1 1,07 1,04 1,02 0,99 0,96 0,92 0,89 0,84
1 000 - - 1,17 1,15 1,14 1,13 1,11 1,09 1,06 1,03 1 0,97 0,94 0,91 0,87
1 120 - - - 1,16 1,14 1,13 1,12 1,1 1,07 1,04 1,02 0,99 0,96 0,92 0,89
1 250 - - - 1,17 1,15 1,14 1,13 1,11 1,09 1,06 1,03 1 0,97 0,94 0,91
B.1.6 Determining the coefficient c2
The coefficient c2 depends on the group classification of the mechanism and is specified in
Table B.4
Table B.4 — Values of c2

Group classification of mechanism c2
M1 and M2 1,25
M3 and M4 1,12
M5 1,00
M6 0,90
M7 and M8 0,80
NOTE The equations apply only to wheels whose diameters do not exceed 1,25 m. For larger
diameters experience shows that the permissible pressures between the rail and the wheel should be
lowered. The use of wheels of greater diameter is not recommended.
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B.2 Determination of the class of mechanism of the travel wheel

The determination of the mechanism class of the rail wheel is made tentatively as follows:
a) The number of working cycles C is taken as the specified value or the upper limit of of the
given U-class.
b) The average displacement of the travel motion xm is taken as the specified value or the
upper limit of the given D-class.
c) The load spectrum class number Qi shall be taken as specified or to be calculated from a
given spectrum or description of work cycles.
d) Total travel distance is: L = 2Cxm.
e) Running time T = L/vt, where vt is the normal travel speed of the motion (normally max.
speed).
f) Operation time class number is calculated as Tj = 1 + Int[log(T/200,01 h)/log(2)]

Example: 1) T = 3200 h, Tj = 1 + Int[log(3200/200,01) / 0,693147] = 1 + Int(3.9999) = 4;
⇒ class T4.
Example: 2) T = 3201 h, Tj = 1 + Int[log(3201/200,01) / 0,693147] = 1 + Int(4,0004) = 5;
⇒ class T5.
g) The load spectrum class number is taken as Li = Qi – 1.
h) The mechanism class number is calculated as Mm = Li + Tj – 2.
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Annex C
(informative)
Risk assessment for the evaluation of the requirements for the
anti-collision system
C.1 Principles of risk assessment
C.1.1 General
The procedure suggested is to evaluate the factors appropriate to the conditions expected and
to add all the probability factors together. The effects factors would be similarly treated and then
both sets of factors added to produce an overall risk factor.
C.1.2 Probability of a collision
The factors to consider in assessing the probability of a collision are:
 The travel speeds of the cranes which can enter the conflict zone.
 The quality of vision afforded to the operator.
 The expected environmental conditions.
 The number of cranes which can enter the conflict zone (a space where two or more
cranes or their parts may collide).
C.1.3 Effects of a collision
The factors to be considered in assessing the effects of a collision are:
 The effects on the structures and the means of load suspension of the colliding cranes;
 The form of the load and its constituents;
 The probability of injury occurring to persons in the conflict zone;
 The type of injury expected.
C.2 Probability of a collision
C.2.1 Probability Factors
The factors to consider in assessing the probability of a collision are:
 Speed factor, Ps, depends on the travel speeds of the cranes which can enter the conflict
zone;
 Visibility factor, Pv, depends on the quality of vision afforded to the operator;
 Environment factor, Pe, depends on the expected environmental conditions;
 'Number of cranes' - factor, Pn, depends on the number of cranes which can enter the
conflict zone ;
Other factors may be applicable to the specific situation.
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C.2.2 Speed Factor
The speed factors depends on the maximum travelling speed of the fastest crane as follows:
Table C.1 — Speed factor
Speed range Speed v, m/s Speed factor, Ps

Low Speed v ≤ 0.6 1
Medium Speed 0,6 < v ≤ 1,2 2
High Speed 1,2 < v 4
C.2.3 Visibility Factor
C.2.3.1 General
This factor is introduced to take account in the assessment of the type of control system in use
and the type of cabin and its facilities. The following classes are suggested.
C.2.3.2 High visibility, Pv=1
This group is characterized by cranes having one or more of the following features:
 Cranes with cableless or pendant controllers when the load is being controlled by the
operator who is in close proximity to the load. The user also has a good view of the other
cranes which may be in the zone of potential conflict, because generally the eyeline to the
load will normally be in the direction the load is being moved in and thus the movement of
another crane into the conflict zone is easily appreciated with peripheral vision. For
example infrared controlled cranes.
 Cranes with cabins which have all glazed structures for all round visibility and the seat is so
designed that vision of crane movement towards the seat back is not impaired.
C.2.3.3 Medium visibility, Pv=2
This group is characterized by cranes having one or more of the following features
Most cabin cranes with high percentages of glazing where the driver in concentrating on the
load and lift controller generally by looking downwards does not have such a potential for good
peripheral view of the potential conflict point.
Rotating mast type cranes with fully glazed or open platforms when the load view direction and
the direction of rotation are different which leaves little peripheral vision for potential crane
interference.
Cranes having portable remote controllers where the operator is at a considerable distance from
the load and crane and where the line of sight from the operator to the load may not be
coincident with the direction of the load. For example radio controlled cranes.
Cranes which are on differing levels of runway where the top level crane may be masked by the
cabin roof or the ropes of the higher crane only enter the conflict zone.
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C.2.3.4 Low visibility, Pv=4
This group is characterized by cranes having one or more of the following features.
Cabin controlled cranes having a low proportion of glazed area because of thermal protection or
other reasons.
Cranes where the use of video screens is considered necessary for their operation.
C.2.4 Environmental factor
C.2.4.1 General
The environment in which the crane operates will affect the potential for collision avoidance by
visual means. These factors may be considered as follows.
C.2.4.2 Clear environment, Pe=1
This class is characterized by indoor use in a well lit building having lighting levels of the order
of 300 Lux.
The atmosphere would be clear of fumes or smoke.
C.2.4.3 Medium environment, Pe=2
This class is characterized by indoor use in poor or low lighting levels of the order of less than
100 Lux. Indoor cranes subject to low levels of fume or smoke which can obscure the potential
conflict zone.
In outdoor use the principal use would be during daylight hours and the use of the crane can be
stopped while the visibility is limited by rain, snow fall, fog or smoke.
C.2.4.4 Poor environment, Pe=4
Indoor cranes operating in areas subject to heavy fumes or smoke at the potential conflict zone.
Outdoor cranes operating in all weather conditions and where the visibility is subjected to fume
or smoke.
C.2.5 Number of cranes Factor
C.2.5.1 General
The number of cranes that can access the potential conflict zone will affect the potential for a
collision.
C.2.5.2 Basic condition, Pn=1
Two cranes running on the same level gantry
C.2.5.3 Medium condition, Pn=2
Two cranes running on different level gantries
Three cranes running on one level gantry
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C.2.5.4 Severe condition, Pn=4
Three or more cranes when different level gantries are involved
Four or more cranes on one gantry
C.3 Effects of a collision
C.3.1 General
The factors to be considered in assessing the effects of a collision are:
 An effects factor which considered the effect on the crane of a collision, Ee;
 A form factor related to the type of load, El;
 A probability of injury factor, EI;
 A factor reflecting the type of expected injury, Et;
C.3.2 Effects on crane factor
C.3.2.1 General
Three classes of effect of collision on cranes are envisaged:
C.3.2.2 Light damage, Ee= 1
The colliding cranes are designed to accept the probable collisions as part of the design life
history.
The load suspension means of the cranes which have collided may normally after inspection be
reused.
C.3.2.3 Medium damage, Ee= 2
The probable collision envisaged will mean that the cranes will have received damage which will
allow them to retain their loads but will require that they are taken out of service for a fuller
inspection or repair.
The load suspension means will have suffered severe damage and will need immediate
replacement.
C.3.2.4 Severe damage, Ee= 4
The probable collision envisaged will cause damage such that the structural integrity of the
crane is brought into question.
The load suspension means are likely to fail and cause dropping of the load.
C.3.3 Load form factor, El
C.3.3.1 General
The form of the load and its constituents form a set of factors to be evaluated as follows:
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C.3.3.2 Light Risk, El = 1
This risk is characterized by loads which are unit loads, which are so attached to the crane, or
suspension means that there is little or no risk of the load splitting into parts and falling from the
load suspension means.
Examples of such a load are:
 Containers and other unit loads.

 A single part securely slung.
C.3.3.3 Medium Risk, El = 2
This risk is characterized by loads which can be split or be removed from their suspension
means by collision indent. The constituents of these loads would not give rise to any significant
chemical or biological hazard. The effect of the split would also not cause significant damage to
the persons in the vicinity of the event.
Examples of such loads are loads lifted with:
 magnets;
 bulk handling with grabs;
 hooks without latches;
 clamps or tongs;
 vacuum lifters, and;
 multi-piece load wrapped on a pallet.
The above are examples where the presence of operators on the shop floor adjacent to such
operations is normally forbidden.
C.3.3.4 High Risk, El = 4
This risk is characterized by loads which are potentially dangerous to the operators when a
collision may cause the load to split and fall or pour out. The higher risk products which give rise
to chemical or biological reactions when split are also in this category.
Examples of such loads are:
 packs of oiled sheet steel either strapped or unstrapped;

 ladles with hot molten metal;
 bundles of tubular or bar products slung from the crane in such a manner that a violent
deceleration would cause the constituents of the load to fall.
These activities are assumed to take place in an area where the use of ground based persons
is normal.
The carriage of strong alkalis or acids
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C.3.4 Injury potential factor
C.3.4.1 General
This risk is characterized by the potential for injury to persons in the potential conflict zone.
C.3.4.2 Low risk, Ei = 1
This factor is appropriate if no persons are ever in the potential conflict zone and
the loads are not hazardous in terms of heat content, chemical or biological..
C.3.4.3 Medium risk, Ei = 2
This factor is appropriate if few persons i.e. 1 or 2 may be in the affected zone
The loads are unit loads and are not hazardous in terms of heat content, chemical or biological
and will not spill or fragment under collision conditions.
C.3.4.4 High risk, Ei = 4
This factor is characterized by a conflict zone in workshop or production plant in which there are
persons regularly working in the affected zone.
C.3.5 Injury type factor
C.3.5.1 General
This factor estimates the possible type of injury to be expected if a collision occurs in the
affected zone.
C.3.5.2 Low risk, Et = 1
Bruises, cuts, abrasions that may be treated in the facilities medical unit.
The injury would not lead to loss of normal working time.
C.3.5.3 Medium risk, Et = 2
Severe cuts or limb breakage’s that necessitate treatment in casualty department. The injured
person would be absent from work due to the injuries.
C.3.5.4 Severe risk, Et = 4
Severe crushing or burning leading to disablement or death.
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C.4 Action required

The Table C.2 is a suggested method of recording the evaluation of the risk.
Table C.2 — Risk assessment of collision avoidance requirements

Cranes considered in assessment: -
Conflict zone definition
Prepared by: - Date: -
Probability Risk factor Effects Risk factor

Speed factor Structural damage factor
Visibility factor Load factor
Environment factor Injury potential factor
Number of cranes factor Injury type factor
Probability sub-total Effects sub-total
Total risk factor
Table C.3 summarizes the actions required for the provision of collision avoidance systems and
the guidelines for selection of EN 954-1 category based on the overall risk factor.
Table C.3 — Guidelines for selection of anti-collision systems

Overall Risk factor Selection of category of EN 954-1 in addition
to buffers
8 – 18 None, B or 1
19 – 24 1 or 2
25 – 32 2 or 3
For each range of overall risk factor the higher category should be considered, if there are four
or more risk factors with value 4.
Examples of anti-collision systems:
 Buffer (none);
 Buffer + positive opening switch (category 1);
 Buffer + infrared sensitive device (category B);
 Buffer + positive opening switch (category 1) + infrared sensitive device (category B);
 Buffer + infrared sensitive device (category 2);

 Buffer + positive opening switch (category 1) + infrared sensitive device (category 2).
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Annex D
(informative)
Scoring system for risk assessment on load-person
interference
Table D.1 — Scoring system

Speed of operation of crane Form of Control/Drive
v ≤ 0,6 m/s 1 Variable speed drives 1

0,6 < v ≤ 1,2 m/s 2 Dual speed drives 2
1,2 m/s < v 4 Single speed drives 4
Number of Persons in Zone Number of obstructions in Zone

0 0 0 0
1 1 1 1
2 2 2 2
>2 4 >2 4
Experience skill of Driver Number of Operations/h

Low (workers operate the crane 4 Low (<5) 1
infrequently)
Medium (workers operate the 2 Medium (>5 and < 10) 2
crane frequently)
High (dedicated driver) 1 High (> 10) 4
Anti-sway Reeving or Anti-sway control Integrity of the load

System
Both, Lateral and Longitudinal 0 Single part load 0
Lateral or Longitudinal 2 Stretch wrapped pallet 1
None 4 Bulk load 2
Multi-piece bundle 4
The sum of the scoring points should not be more than 22.
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Annex E
(normative)
Noise test code
E.1 Scope
This noise test code specifies all the information necessary to carry out efficiently and under
standardized conditions the determination, declaration and verification of the noise emission
characteristics of bridge and gantry cranes.
Noise emission characteristics include emission sound pressure levels at operator's positions.
The determination of these quantities is necessary for:
 manufacturers to declare the noise emitted,

 comparing the noise emitted by machines in the family concerned,
 purposes of noise control at the source at the design stage.
The use of this noise test code ensures reproducibility of the determination of the noise
emission characteristics within specified limits determined by the grade of accuracy of the basic
noise measurement method used. Noise determination methods allowed by this standard are:
 a calculation method (E.5) to determine the overall noise emitted by the noisiest
components of the crane.
This method shall be used systematically and the value resulting from the calculation shall
be given in the instructions for use (see clause 7.2.1.2.11).
Noise caused by rail-wheel contact in travelling and noise emitted by the runway structures
as well as noise from crane power supply festoon system or conductor bars are excluded,
because they may not be fully in crane manufacturer's control.
This method underestimates the actual noise emission value of the crane when installed at
the user's place.
 a measurement method (E.6) of the sound pressure level at the operator's position once
the crane is installed at the user's place. This sound pressure level is not an emission
sound pressure level because it includes the crane, the structure to which the crane is fixed
and the acoustic characteristics of the room or surroundings. These sound pressure levels
shall also be given in the instructions for use. This method shall be used only if noise is
likely to be a significant hazard to the operator.
The measurement determines two values, one for hoisting and traversing and another for
the travelling of a crane. Both values shall be given in the instructions for use (see clause
7.2.1.2.11). For the sound pressure level at the operator's position, both values have to be
considered. The actual value may be higher than the biggest of them, when there is a
situation where hoisting, traversing and travelling occur at the same time.
The cranes that have an A-weighted emission sound pressure level at the operators position
higher than 85 dB are very large cranes. Therefore this noise test code does not include a
method for determining the sound power level.
If there is a need for determining sound power level, it shall be made according to EN ISO 3744.
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E.2 References
ISO 1680: 1999 Acoustics -- Test code for the measurement of airborne noise emitted by
rotating electrical machines
EN ISO 3744: 1995 Acoustics -- Determination of sound power levels of noise sources using
sound pressure -- Engineering method in an essentially free field over a
reflecting plane
EN ISO 4871: 1996 Acoustics - Declaration and verification of noise emission values of
machinery and equipment
EN ISO 11201: 1995 Acoustics -- Noise emitted by machinery and equipment -- Measurement of
emission sound pressure levels at a work station and at other specified
positions - Engineering method in essentially free field over a reflecting
plane
EN ISO 11202: 1995 Acoustics -- Noise emitted by machinery and equipment -- Measurement of
positions -- Survey method in situ
EN ISO 11203: 1995 Acoustics -- Noise emitted by machinery and equipment -- Determination of
positions from the sound power level
E.3 Definitions
In general, the definitions in clause 3 of this standard apply together with the definitions given in
the standards referred in clause E.2.
E.4 Description of machinery family

This annex is applicable to individual bridge or gantry crane in the scope of this standard as fully
assembled in the intended working condition including the fixed load lifting attachment.
E.5 Calculation method
E.5.1 Principle of the method
The emission sound pressure level at the operator's position is calculated as the summation of
the contributions at this position of the main noise sources present on the crane. These
contributions are derived from the sound power levels of these main noise sources as provided
by their manufacturer's.
E.5.2 Calculation
The contribution of a given noise source with sound power level LW is given by the following
formula:
S 
L p = LW − 10 lg 
 S0 
where
Lp is the A-weighted sound pressure level at the operator's position;
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LW is the A-weighted sound power level of the source, in decibels; reference: 1 pW;
2
S is 2πr , where r is the distance between the considered place and the sound source;
2
S0 is 1 m .
The sound power levels of the components shall correspond to the rated loads and speeds of
the crane.
The noise sources to be taken by the calculation are:
 hoist mechanism
 crab traverse mechanism
 crane travelling mechanisms
 fixed load lifting attachment, when power operated
The values shall include the noise of the electrical control cubicles.
These noise sources shall be located as shown in figure below. The operator is supposed to be
in a vertical plane containing the sources. For the power operated load lifting attachment the
nearest normal operating distance shall be considered.
The values of the sound power levels and the distances r used for the calculations shall be
reported.
Figure E.1 — The noise sources of a bridge crane
Sound pressure at a certain place under influence of different sound sources can be calculated
by adding of the sound pressure levels from the different sources with the following formula:
 N 0,1L 
L p ( total ) = 10 lg ∑10 pi 
 i =1 
where
Lp(total) is the total sound pressure level at the considered place resulting from i sources;
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Lpi is the sound pressure level resulting from sound source i;
N is the total number of sound sources.
The uncertanty of the calculation is that with which the sound power levels of the components
have been determined.
The calculation method does not take into account the effect of the structure-borne noise and
therefore the calculated noise levels are usually lower than the real values.
Example for the addition of 2 sound pressure levels, 70 and 72 dB(A) respectively:
[ ]
L p ( total ) = 10 lg 10 0,1⋅70 + 10 0,1⋅72 = 74,1
E.6 Sound pressure level determination at control stations by

measurement
E.6.1 Measurement points
Sound pressure level measurements shall be made according to EN ISO 11201 or EN ISO
11202.
a) The measurements shall be made in all control stations
In case of movable pendant control station, the measurement point shall be at the vertical plane
defined by the pendant controls, at the height 1.6 m and distance one quarter of the crane span
from the vertical plane of the runway rail (from the closest rail, if the rails are at different heights).
b) If there are persons working in the crane operation area and the measurement for the
pendant control is not made, the measurements shall be made at the floor or ground level, at
height 1.6 m from the level, at the distance of 1 m from the vertical plane defined by the outmost
rail wheels, at the distance of one quarter of span from the vertical plane of the runway rail (from
the closest rail, if the rails are at different heights).
This measurement covers the non-fixed operator positions like those of radio control.
During measurement of the crane travelling the measuring point shall be kept stationary.
E.6.2 Installation and mounting conditions
The crane shall be installed on its runway in the condition it is intended to be used excluding the
sound alarm signals which shall be disconnected during the noise measurements.
The mechanisms of the non-fixed load lifting attachments causing noise may be switched off
during the noise measurement cycle.
NOTE Noise caused by the non-fixed load lifting attachments is the matter of the manufacturer of the
equipment.
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E.6.3 Operating conditions
E.6.3.1 General
In all cases, the testing position of the crane for the measurements should be so selected that
the reflections and other environmental disturbances are minimized.
The load handled during the work cycles should be preferably the rated load, but in the case of
difficulty to use the rated load, a load representing the typical loads and having a mass that is at
least 50 % of the rated load mass may be used.
Measurements in enclosed cabins shall be taken with the doors and windows closed and the
air-conditioning and/or ventilating system(s) operating at midrange speed if more than two
operating speeds are available. If only two operatiing speeds are available, then the
highestspeed shall be used. If the air-conditioning and/or ventilating systems have a recirculate
and outside air position control, the control shall be set for outside air.
E.6.3.2 Hoisting and traversing
a) Work cycles of a crane without cantilevers
The work cycle during measurement should represent the normal practice. If the motions can be
made simultaneously, the working cycle should be as follows:
1) Hoist the load with maximum speed at the point one quarter of span (beside the
measuring point). Duration shall correspond one half of the total lifting height.
2) Start traversing during the hoisting (about at the mid height of hoist path) and go on to
the point 3/4 of the span.
3) Start lowering before stopping the traversing motion and go on to the ground level.
4) Make the same motions backwards in the same way with the same load.
5) If slewing of the trolley or lifting attachment is included, it shall be carried out during
traversing.
If there are limitations to make movements simultaneously, the cycle description shall be
modified accordingly.
b) Work cycles of a crane with cantilevers
The cycle is same as in a), but the hoisting is started at the mid point of the cantilever
Test cycles and measurements shall be repeated at least three times.
The test result LP1 is the arithmetic mean value.
E.6.3.3 Travelling
Noise measurement during crane travelling shall be made separately holding the load at the mid
span of the crane.
The measuring period shall start, when the reference box reaches the stationary microphone,
and it shall end, when the other side of the reference box has passed the microphone.
Test cycles and measurements shall be repeated at least three times.
The test result LP 2 is the arithmetic mean value.
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E.7 Uncertainties
No technical data on noise emission are presently available to estimate the standard deviation
of reproducibility for the family of machinery covered by this noise test code. Therefore, the
values of the standard deviation of reproducibility stated in the basic noise emission standards
may be regarded as interim upper boundaries and used for the determination of the uncertainty
K when preparing the noise declaration. Investigations requiring a joint effort of manufacturers
are necessary to determine a possibly lower value of the standard deviation of reproducibility,
which will result in a lower value of the uncertainty K. Results of such investigations will be
reflected in a future version of this standard.
E.8 Information to be recorded

Measurements shall be recorded according to clause 12 of EN ISO 11202.
The C-weighted peak emission sound pressure levels in the bridge and gantry cranes are
typically so low that they need not to be measured and reported.
For the calculation method the information to be recorded is specified in EN ISO 11203 clause 7.
E.9 Information to be reported

The reports shall include the A-weighted sound pressure levels and the positions where they
were measured or calculated.
The noise values measured during crane travelling shall be reported separately from the values
representing the specified work cycle, because such values may be more strongly effected by
the noise generated in the runways and the building.
In the calculation method the assumptions made for the calculation and the results of the
calculations shall be reported.
Furthermore the report shall comply with the clause 13 of EN ISO 11202 or clause 8 of EN ISO
11203.
E.10Declaration and verification of noise emission values

The declaration and verification of noise emission values shall be made in accordance with EN
ISO 4871:1996.
Model number, operating conditions and other identifying information:

Type, Model, rated capacity, etc.
Calculated value according to E.5 Measured values according to E.6

LP(total)
Hoisting and traversing Travelling
LP1 LP 2
Uncertainty Kc Uncertainty Km1 Uncertainty Km2

Within the range of 1.5 to 4 dB Within the range of 1.5 to 4 dB Within the range of
1.5 to 4 dB
For uncertainties K, see cl. E.7
When the noise emission values of an individual crane are verified, the measurements shall be
conducted by using the same mounting, installation and operating conditions as those used for
the initial determination of noise emission values.
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Annex F
(normative)
Particular requirements valid for the cranes during lifting of
persons
The following table gives the additional requirements for cranes in different types of use during
lifting of persons.
Table F.1 — Additional requirements for cranes during lifting of persons
Type of usage classification: Group 1 Group 2 Group 3
Coefficients applicable during the

lifting of persons
1.1 High risk coefficients 1,25 1,25 1,25

- Structures, γn =
- Hoist. mechanism, γn = 1,60 1,60 1,25
1.2 Working coefficient for ropes 2 x 10 2x5 10

and chains
Backup brake X X X
At least two separate ropes X X
Emergency stop for the lifted X X

person
Improved control system (safety X - step control for hoisting,

related parts) vh ≤ 0,12 m/s,
Cat. 2 or 3 of step control travel or
EN 954-1, or traverse, v ≤ 0,6 m/s
redundant
solutions - stepless control
6. Rated capacity limiter X X X
7. Improved maintenance program X
8. Improved test program X
9. Controls with the lifted persons X
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Annex G
(Informative)
Actions on crane supporting structures induced by cranes
NOTE By following the format of the wheel forces and buffer forces of the crane given in this annex
the manufacturer enables the designers of the crane supporting structures to create relevant load
combinations in conformance with prEN 1991-3 and ENV 1993-6.
Key
1 rail 1
2 rail 2
3 Hook approach 1
4 Hook approach 2
5 pos. c1
6 pos. c2
Figure G.1 — Crane with trolley positions
G.1 Actions induced by cranes

The forces Fx, Fy and Fz due to the load effects described in Table H.1 shall be given. The load
positions shall be selected so as to give the maximum loads for each end carriage. The
simultaneous lighter loads in the other end shall also be given where relevant.
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Table G.1 — Load actions and relevant force components
No. Load action Force Trolley Remarks

components position
1 Mass of the crane Fz - -
2 Mass of the trolley(s) Fz c1 c2
3 Mass of the hoist load Fz c1 c2
4 Acceleration of the crane without hoist Fx, Fy, (*Fz) c1 c2
load
5 Acceleration of the crane with hoist load Fx, Fy, (*Fz) c1 c2
6 Acceleration of the trolley(s) Fy, (*Fz) c1 c2
7 Skewing, guiding on rail 1 Fx, Fy, (*Fz) c1 c2 relevant cases to
be given
8 Skewing, guiding on rail 2 Fx, Fy, (*Fz) c1 c2
9 In-service wind in direction x Fx, (*Fy), (*Fz) c1 c2
10 In-service wind in direction y Fy, (*Fz) c1 c2
11 Buffer forces Fx, Fy, (*Fz) c1 c2
12 Tilting forces Fx, Fy, Fz c1 c2
13 Out-of-service wind in direction x Fx, (*Fy), (*Fz) trolley(s) in the
stowed position
14 Out-of-service wind in direction y Fy, (*Fz)
NOTE The forces indicated by (*) are in general relevant for gantry cranes only.
G.2 Dynamic factors

The dynamic factors applicable for the crane in accordance with clauses 5.2.1.2 and 5.2.1.3 of
this standard should be presented as listed in Table G.2.
Table G.2 — Dynamic factors φi
Factor Load action to be amplified

φ1 Dynamic factor for hoisting and gravity effects acting on
the mass of the crane
φ2 Dynamic factor for inertial and gravity effects by hoisting
an unrestrained grounded load
φ3 Dynamic factor for inertial and gravity effects by sudden
release of a part of the hoist load
φ4 Dynamic factor for loads caused by travelling on uneven
surface
φ5 Dynamic factor for loads caused by acceleration of all
crane drives, see Note
φ6 Dynamic factor for test loads
φ7 Dynamic factor for loads due to buffer forces
NOTE The dynamic factor φ5 in this context should be given as the ratio of maximum dynamic wheel
force to the static wheel force (vertical or horizontal) under the load effect in conditions of acceleration by
drive forces. This definition differs from the definition of φ5 in prEN 13001-2, 4.1.2.4.
Separate factors φ5 shall be given due to accelerations in hoisting, travelling and traversing.
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Annex H
(informative)
Information labels
Table H.1 presents some examples of labels that may be used in bridge and gantry cranes to
warn about hazards or inform about actuators, access, prohibitions, etc. Mark "x" is used to
indicate the typical application, but these should be understood as neither mandatory nor
sufficient. Need of information labels shall be decided by risk assessment. It should be also be
noted that too many labels may cause inflation of information.
Table H.1 —List of information labels
Type Text Floor Cabin Floor Cabin

operated operated operated operated
bridge bridge gantry gantry
cranes cranes cranes cranes
Pictorial Emergency exit (text optional) x x
Pictorial Emergency exit arrow (text optional) x x
Pictorial Emergency stop (other than operator's, if x x x x
any)
Pictorial Fire extinguisher x x
Pictorial Moving crane / trolley /cabin / ladder / x x x
.+DANGER stairs / hopper optionally together with
type of hazard: falling, crushing, shearing
Pictorial Hanging load
.+DANGER
Pictorial High voltage x x x x
.+DANGER
Pictorial Low overhead x x

.+DANGER
Pictorial Rotating machinery x
.+DANGER
Pictorial Falling material x x
.+DANGER
WARNING Text regarding requirements for repair x x x
welding
Prohibition Do not walk under crane x x
pictorial
128
prEN 15011:2004 (E)
Table H.1 —List of information labels (cont.)
Type Text Floor Cabin Floor Cabin

operated operated operated operated
bridge bridge gantry gantry
cranes cranes cranes cranes
Unauthorized persons prohibited x x x x
No access without permission of the x x x x
driver
Keep off the track x x
Pictorial ( ! ) Crane to be locked by rail clamps / pins

/ tie downs when stowed
Pictorial Ear protection shall be worn x
Jacking point, xxx kN x x
Road clearance, x.xx m x x
Crane performance table: x
loads in different configurations speeds,
operational limitations
Need for use of labels should be considered in risk assessment. Following the principles of EN
292-2 it should be noted that excessive amount of information should be avoided. Information
for dedicated crane drivers may be included in the driver's manual, but occasional crane drivers,
slingers and other persons are more effectively informed by signs, labels, and acoustic means.
129
prEN 15011:2004 (E)
Annex I
(informative)
Selection of a suitable set of crane standards for a given
application
Is there a product standard in the following list that suits the application?
prEN 13000: 2003 Cranes – Mobile cranes
prEN 14439: 2002 Cranes – Tower cranes
WI 00147 031 Cranes – Slewing jib cranes
WI 00147 032 Cranes – Bridge and gantry cranes
prEN 13852-1: 2002 Cranes – Offshore cranes – Part 1: General purpose offshore cranes
prEN 13852-2: 2000 Cranes – Offshore cranes – Part 2: Floating cranes
prEN 14492-1 Cranes – Power driven winches and hoists – Part 1: Power driven winches
prEN 14492-2:2003 Cranes – Power driven winches and hoists – Part 2: Power driven hoists
EN 12999: 2002 Cranes – Loader cranes
prEN 13157: 1998 Cranes – Hand powered cranes
EN 13155: 2003 Cranes – Non-fixed load lifting attachments
prEN 14238: 2001 Cranes – Manually controlled load manipulating devices
YES NO
Use it directly, plus the

standards that are referred to
Use the following:

Cranes — Terminology
prEN 13001-1: 2003 Cranes — General design — Part 1: General principles and
requirements
prEN 13001-2: 2003 Cranes — General design — Part 2: Load effects
CEN/TS 13001-3-1: Cranes — General design — Part 3.1: Limit states and proof of
2003 competence of steel structures
2003 competence of wire ropes
competence of wheel / rail contacts
130
prEN 15011:2004 (E)
CEN/TS 13001-3-4: Cranes — General design — Part 3.4: Limit states and proof of competence
of machinery
EN 13135-1: 2003 Cranes — Equipment — Part 1: Electrotechnical equipment
prEN 13135-32 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
prEN 13586: 1999 Cranes — Access
PrEN 14502-1:2002 Cranes — Equipment for the lifting of persons — Part 1: Suspended
baskets
Cranes — Equipment for the lifting of persons — Part 2: Moveable cabins
Cranes — Equipment for the lifting of persons — Part 3: Spreader beams
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
131
prEN 15011:2004 (E)
Annex ZA
(informative)
Relationship of this European Standard with EU Directives
This European Standard has been prepared under a mandate given to CEN by the European
Commission and the European Free Trade Association and supports essential requirements of
EU Directives:
Directive 98/37/EC amended by Directive 98/79/EC
Compliance with this standard provides one means of conforming with the specific essential
requirements of the Directive concerned.
WARNING: Other requirements and other EU Directives may be applicable to the products
falling within the scope of this standard.
132
prEN 15011:2004 (E)
Bibliography
Machinery Directive 98/37/EEC
EN 1070 Safety of machinery - Terminology
prEN 1991-3 Eurocode 1: Actions on structures - Part 3: Actions induced by cranes and
machinery
prEN 1993-6 Eurocode 3: Design of steel structures - Part 6: Crane supporting structures
EN 10002-1 Metallic materials - Tensile testing - Part 1: Method of test (at ambient temperature)
1)
prEN 13001-3.3 , Cranes - General design - Part 3-3: Limit states and proof of competence of
wheel/rail contactsEN 50082-2 Electromagnetic compatibility - Generic immunity standard -
Part 2: Industrial environment
ISO 2631-1, Mechanical vibration and shock — Evaluation of human exposure to whole-body
vibration — Part 1: General requirements
ISO 9374-1, Cranes — Information to be provided — Part 1: General
ISO 9374-5, Cranes — Information to be provided — Part 5: Overhead travelling cranes and
portal bridge cranes
133

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EUROPEAN STANDARD DRAFT

NORME EUROPÉENNE prEN 15011

Cranes - Bridge and gantry cranes

Appareils de levage à charge suspendue - Portiques et Kräne - Brücken und Portalkräne

EUROPEAN COMMITTEE FOR STANDARDIZATION

Management Centre: rue de Stassart, 36 B-1050 Brussels

A.10.2 Crane specification ............................................................................................................................. 90

Annex H (informative) Information labels.................................................................................................... 128

This document is currently submitted to the CEN Enquiry.

This European Standard is a type C standard as stated in EN 1070.

 Requirements concerning protection against hazardous environment

This standard includes requirements for the lifting of persons.

EN 1070, Safety of machinery — Terminology

prEN 13001-2, Cranes — General Design — Part 2: Load actions

prEN 13135-1, Cranes — Equipment — Part 1: Electrotechnical equipment

prEN 13135-2, Cranes — Equipment — Part 2: Non-electrotechnical equipment

EN 13202, Ergonomics of the thermal environment — Temperatures of touchable hot surfaces —

prEN 13557, Cranes — Controls and control stations

ISO 3864, Safety colours and safety signs

Table 1 — List of significant hazards and associated requirements

2 Electrical hazards due to: EN13135-1 5.1

Table 1 — List of significant hazards and associated requirements (Continued)

No. Hazard (as listed in EN 1050:1997) EN EN 292-2 Other EN- Relevant

4 Hazards generated by noise, 4.5 3.2, 3.6.3, 4

5 Hazards generated by vibration 4.6 3.2, 3.6.3

5.2 Whole body vibration, particularly 5.2.2.6

7 Processed materials and

8 Neglected ergonomic principles in 4.9 3.6

8.2 Inadequate consideration of hand- 4.9 3.6.2, 3.6.9 EN 614-1

Table 1 — List of significant hazards and associated requirements (Continued)

No. Hazard (as listed in EN 1050:1997) EN EN 292-2 Other EN- Relevant

9 Combination of hazards 4.10 EN 13001-2 5.6

Table 1 — List of significant hazards and associated requirements (Continued)

Additional hazards and hazardous events due to mobility

Table 1 — List of significant hazards and associated requirements (Continued)

Additional hazards and hazardous events due to load lifting

Table 1 — List of significant hazards and associated requirements (Continued)

5 Safety requirements and/or protective measures

5.2 Requirements for strength and stability

5.2.1 Load actions

5.2.1.1 Selection of service conditions

5.2.1.1.1 Selection of classification parameters

5.2.1.1.2 Multiple lifting points

5.2.1.2 Determination of factor φ2

 on the basis of the hoist class, HC, (see EN 13001-2),

5.2.1.2.2 Effect of lifting force limiter

Lifting force limiters act automatically by:

 limiting the force flow (direct lifting force limitation), or

φDAL : factor for direct acting lifting force limiters

mH : mass of the gross or hoist load

The factor φIAL is calculated as follows:

where φ2 is for load combination C1

5.2.1.3 Loads caused by acceleration

 switching on the lifting motion;

(see also EN 13001-2 , Subclause 4.1.2.4)

(φ5, tot = φ5 ⋅ φPo ) for scheduled positioning movements.

Using the following equation

Ŝ = S(i) + φ5 , tot ⋅ aw,o ⋅ mw,o [3]

- S(i) : initial load effect caused by F(i)

- aw,o : acceleration or braking value

- mw,o : corresponding load for which aw,o applies.

5.2.1.4 Loads caused by skewing

5.2.1.4.1 Origin of skewing effects

5.2.1.4.2 Suspension cranes