STANDARD OPERATING PROCEDURE TEST PROCEDURE FOR BENDING TEST FOR RUNGS, STEPS AND PLATFORMS [Decks SAa4S0207 [it [eee eam [ries | 10 20 30 40 50 5A 82 53 Purpose Establish and maintain a procedure for bending test for rungs of the ladders as per the applicable standards ‘Scope This procedure is appicable to all types of portable and fixed ladders viz., Wind ladders, Domestic and Commercial Ladders. Responsibilities Conducting the tests ~ Quality Supervisors! Quality Head ‘Approval of Test Results - Quality Head Terms and Definitions Ladder - Device incorporating steps or rungs on which a person may ascend or descend, (Note: Step stools are explcty excluded from this definition. (Ref: DIN EN 131-1) Inside With - 1 clear width between the stiles is termed as Inside Width. Fig 1: Inside Width Dimension (as per EN 131-1) Reference Standards EN ISO 14122-4: Safety of Machinery, permanent means of access machinery Part 4 —Fixed Ladder DINEN 131-2 : Ladders ~ Requirements, testing, marking DINEN 131-1 : Ladders — Terminology, types, functional sizes omits eowity (_— Date: 24.1un.2016 Date:24-Jun-2016 CONTROLLED COPYSTANDARD OPERATING PROCEDURE TEST PROCEDURE FOR BENDING TEST FOR RUNGS, STEPS AND PLATFORM: Doc No: SA.OA-SOP.O7 Revision No:02 | Effective date: 24Jun 2016 Pago 2of4 60 Test Equipment Required 61 TestFixture 62 Hydraulic Pack 63 Load Cell 64 Dial gauge! Feeler Gauge 6.5 Measuring tape / Stee! scale 6.6 Plunger Connector with a base of 100mm length and 5Omm width. 67 Stop watch 7.0 Test Frequency TA One in 1000 ladders 8.0 Methodology 8.1 Before stating the tests, ensure that the measuring gauges to be used have valid calibration and don't have any errors. 82 Uncertainty of Measurement shall be ensured as below: +1 mm for longitudinal measurements; + 5mm for the measurement of the distance between the supports and the overhanging length; +1" forthe measurement of angles; £1 % for static foroes and torque 83 The tests conducted as per DIN EN 131-2 standard shall be performed on one ladder and in the order as listed below: Test 1 ~ Strength testo stiles Test 2- Bending test of sles Test 3 - Lateral deflection test of the ladder Test 4 ~ Bottom sie end test Test §~ Vertical load on rungs, steps and platforms Test 6 Torsion test for rungs and stops 8.4 Ensure that before conducting the bending test for rungs, strength test, bending test, lateral deflection test ‘and bottom stile ends test must nave been conducted on the test sample in thet order: 85 Vertical load on rungs ,stops and platforms 8.5.1 The ladder shall be placed in standing/ vertical position or positioned as in use as given in fg 2 below. 85.2 Test shall be conducted on weakest rung of the ladder of any design. 85.3 Plunger connector should be 100mm wide. The loading block shall placed in the center of the rung, uniformly over a width of 100mm. roms Ay rae (Od Date: 24 Jun 2016 Date: 24-Jun-2016 J CONTROLLED COPYa STANDARD OPERATING PROCEDURE | TEST PROCEDURE FOR BENDING TEST FOR RUNGS, STEPS AND PLATFORMS Revision No:02 | fective date: 2.1un-2016 | Pove3or4 oc Ho: SAA-SOP.A7 854 Place the cial gauge at te center of rung on the boom potion ofthe rung or undemeath the rung fo measure the deformation, {nine position of use ofthe ladder atest load F of 2600 N (see Figure 15) shall be applied vertically on the midpoint ofthe weakest rung or step of any design evenly distributed over a width of 100 mm ane.» depth equal to the rung/step and for the duration of one min The maximum permanent deformation after removal ofthe test-load shall be less than or equal to 0,5 % of the inner width b: (see EN 131-1), measured underneath the tested step. Fig 2: Test Method for Bending Test for Rungs 855 A preload of 200N shall be applied for duration of one minute. Remove the load and wait for one minute ‘and note the reading inthe dial gauge, The postion ofthe ung! step / platform after removal ofthe preload isthe datum for measurement. 856 With the ladder position as in use, apply atest load of 2500 N (or 260K) shall be applied vertically atthe midpoint ofthe weakest rung or step of any design evenly dstbuted over a width of 100 mm and a depth {equal tothe rung/step and for the duration of one min. Walt for one minute ater removal of load and note the reading inthe dial gauge. 86 Acceptable Limits: 86.1 The maximum permanent deformation after removal ofthe test-load shall be less than or equal to 0,5 % of the inner width 61 (see EN 131-1), measured underneath the tested step 87 Platform 8.7.4 The platform shall be tested at two positions, in the centre and at a corner ofthe front edge (see Figure 4 With the ladder positioned as in use, atestload F of 2600 N, uniformly distributed over an area of 100 mm 100 mm shall be applied forthe duration of one min 87.2 The maximum permanent deformation after removal ofeach test load shal be les than or equal to 0,5 % of the inner width bt (see EN 131-1), measured from above the platform parallel to the rungs or steps athe point where the load has been applied. The requirement after the second test shall be that no permanent deformation greater than 0,6 % of bt is visible atthe connection between platform and stile measured from ‘the underside. Peomesor Co Approved Re Date: 24-jun 2018 = Date:24-Jun-2016 | CONTROLLED COPYA STANDARD OPERATING PROCEDURE aYesia TEST PROCEDURE FOR BENDING TEST FOR RUNGS, STEPS AND PLATFORMS Doe No: SA.QA-SOP-O7 Revision No:02 | Effective dat: 24.1un2016, Page dol Fig 3: Test Method for Bending Test for platforms 88 Reporting of Test Results: 88.1 Update the test details in addr testing log book. 88.2 Report the test results in the Ladder Test Report 8.8.3 respective of test results, test report shall have the actual loads applied, time and deflection observed as Per the test procedure mentioned above, 9.0 Records 91 Ladder Testing Log Book 92 Ladder Test Report Prepared by: ae Approved by: He —— | Date: 24sun-2016 Date:24-Jun-2016 | CONTROLLED COPY