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Builders' hoists for |
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Part 2: Inclined hoists with |
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ICS 53.020.99; 91.140.90 |
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NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW
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BS EN 12158-2:2000+A1:2010

National foreword

This British Standard is the UK implementation of

EN 12158-2:2000+A1:2010. It supersedes BS EN 12158-2:2000 which is
withdrawn.
The start and finish of text introduced or altered by amendment is indicated
in the text by tags. Tags indicating changes to CEN text carry the number
of the CEN amendment. For example, text altered by CEN amendment A1
is indicated by !".
The UK participation in its preparation was entrusted to Technical
Committee MHE/6, Hoists for builders types.
A list of organizations represented on this committee can be obtained
on request to its secretary.
This publication does not purport to include all the necessary provisions of
a contract. Users are responsible for its correct application.
Compliance with a British Standard cannot confer immunity from
legal obligations.

This British Standard, having Amendments/corrigenda issued since publication

been prepared under the
direction of the Engineering
Sector Committee, was published Date Comments
under the authority of the
Standards Committee and comes
into effect on 15 November 2000 31 August 2010 Implementation of CEN amendment A1:2010

© BSI 2010

ISBN 978 0 580 62903 7

EUROPEAN STANDARD EN 12158-2:2000+A1
NORME EUROPÉENNE
EUROPÄISCHE NORM July 2010

ICS 91.140.90 Supersedes EN 12158-2:2000

English Version

Builders' hoists for goods - Part 2: Inclined hoists with non-

accessible load carrying devices

Monte-matériaux - Partie 2: Monte-matériaux inclinés à Bauaufzüge für den Materialtransport - Teil 2:

dispositifs porte-charge non accessible Schrägaufzüge mit nicht betretbaren Lastaufnahmemitteln

This European Standard was approved by CEN on 9 September 2000 and includes Amendment 1 approved by CEN on 12 June 2010.

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

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

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland,
Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2010 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 12158-2:2000+A1:2010: E
worldwide for CEN national Members.
BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Contents Page

Foreword ..............................................................................................................................................................3 
Introduction .........................................................................................................................................................4
1 Scope ......................................................................................................................................................4 
2 Normative references ............................................................................................................................6 
3 Terms and definitions ...........................................................................................................................7
4 List of hazards........................................................................................................................................8 
5 Safety requirements and/or measures ............................................................................................. 10 
6 Verification .......................................................................................................................................... 25 
7 User Information ................................................................................................................................. 29 
Annex A (normative) European stormwind map ........................................................................................... 36
Annex B (informative) !Electric safety devices" .................................................................................... 37
Annex ZA (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC" .................................................................................. 38
Bibliography ..................................................................................................................................................... 39 

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 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Foreword
This document (EN 12158-2:2000+A1:2010) has been prepared by Technical Committee CEN/TC 10 "Lifts,
escalators and moving walks", the secretariat of which is held by AFNOR.

This European Standard shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by January 2011, and conflicting national standards shall be withdrawn at
the latest by January 2011.

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

This document includes Amendment 1, approved by CEN on 2010-06-12.

This document supersedes EN 12158-2:2000.

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

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

For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document.

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and United Kingdom.

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BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Introduction
This standard is one of a series of standards produced by CEN/TC 10/SC 1 as part of the CEN programme of
work to produce machinery safety standards.

The standard is a Type C standard relating to safety for builders hoists for goods.

The extent to which hazards are covered is indicated in the scope of this standard. In addition, machinery
should comply as appropriate with !EN ISO 12100:2003" for hazards which are not covered by this
standard.

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

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

1 Scope

1.1 This standard deals with power operated temporarily installed builders hoists intended for use by persons
who are permitted to enter sites of engineering and construction, serving either one upper landing or a work
area extending to the end of the guides, (e.g. a roof) having a load carrying device (lcd):

 which is intended for the transportation of goods only;

 where it is forbidden for persons to step upon it at any time;

 which is guided;

 which is designed to travel at an angle of at least 30 degrees to the vertical but may be used at any angle
between the vertical and the maximum inclination as specified by the manufacturer;

 which is sustained by steel wire rope and a positive drive system;

 which is controlled by hold-to-run controls by the operator;

 which does not benefit from the use of any counterweight;

 which has a maximum rated load of 300 kg;

 which has a maximum speed of 1,00 m/s;

and where the guides require support from separate structures.

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 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

1.2 The standard identifies hazards as listed in clause 4, which arise during the various phases in the life of
such equipment and describes methods for the elimination or reduction of these hazards when used as
intended by the manufacturer.

1.3 This European standard does not specify the additional requirements for:

 operation in severe conditions (e.g. extreme climates, strong magnetic fields);

 lightning protection;

 operation subject to special rules (e.g. potentially explosive atmospheres);

 electromagnetic compatibility (emission, immunity);

 handling of loads the nature of which could lead to dangerous situations (e.g. molten metal, acids/bases,
radiating materials, fragile loads);

 the use of combustion engines;

 the use of remote controls;

 hazards occurring during manufacture;

 hazards occurring as a result of mobility;

 hazards occurring as a result of being erected over a public road;

 earthquakes;

 noise.

1.4 This standard is not applicable to

 permanently installed lifts;

 builders hoists for persons and materials;

 builders hoists for the transport of goods with accessible platforms;

 builders hoists with an lcd driven by hydraulic jack (directly or indirectly);

 furniture hoists;

 conveyors;

 work cages suspended from lifting appliances;

 work platforms carried on the forks of fork trucks;

 work platforms;

 funiculars;

 lifts specially designed for military purposes;

 mine lifts;

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BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

 theatre elevators;

 special purpose hoists.

1.5 The safety requirements and/or measures of this standard deal with the design of the base frame, guide
rails, lcd, drive unit, electrical and/or hydraulic installation and the control of the hoist. Included is the design of
any guide rail support but not the design of the supporting structure (e.g. building or scaffold) and any ties.
Other aspects such as base enclosure, the design of any concrete, hard core, timber or other foundation
arrangement, hoistway protection and the upper landing are dealt with in the users' manual section 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."

!deleted text"

!EN 982:1996, Safety of machinery — Safety requirements for fluid power systems and their
components — Hydraulics"

EN 1088:1995, Safety of machinery — Interlocking devices associated with guards — Principles for design
and selection

!EN 60204-32:2008, Safety of machinery — Electrical equipment of machines — Part 32: Requirements for
hoisting machines (IEC 60204-32:2008)"

!EN 60529:1991, Degrees of protection provided by enclosures (IP code) (IEC 60529:1989)"

!EN 60947-5-1:2004, Low-voltage switchgear and controlgear — Part 5-1: Control circuit devices and
switching elements — Electromechanical control circuit devices (IEC 60947-5-1:2003)"

!EN ISO 4871:1996, Acoustics — Declaration and verification of noise emission values of machinery and
equipment (ISO 4871:1996)"

!EN ISO 12100-1:2003, Safety of machinery — Basic concepts, general principles for design — Part 1:
Basic terminology, methodology (ISO 12100-1:2003)"

!EN ISO 12100-2:2003, Safety of machinery — Basic concepts, general principles for design — Part 2:
Technical principles (ISO 12100-2:2003)"

!EN ISO 13850:2008, Safety of machinery — Emergency stop — Principles for design
(ISO 13850:2006)"

!EN ISO 13857:2008, Safety of machinery — Safety distances to prevent hazard zones being reached by
upper and lower limbs (ISO 13857:2008)"

!HD 22.1 S4:2002, Cables of rated voltages up to and including 450/750 V and having cross-linked
insulation — Part 1: General requirements"

!ISO 2408:2004, Steel wire ropes for general purposes — Minimum requirements"

!ISO 4302:1981, Cranes — Wind load assessment"

!ISO 4309:2004, Cranes — Wire ropes — Care, maintenance, installation, examination and discard"

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 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

3 Terms and definitions

!For the purposes of this document, the terms and definitions given in EN ISO 12100-1:2003 and the
following apply."

!3.1
working load/rated load"
maximum load which the hoist has been designed to carry in service. This load may depend on the
configuration of the hoist (i.e. inclination, length of guide rail, load carrying device)

3.2
rated speed
speed of the lcd for which the equipment has been designed

3.3
positive drive
drive using means other than friction

3.4
rope hoist
hoist which uses rope as the load suspension system

3.5
wire rope termination
adaption at the end of a wire rope permitting attachment

3.6
check valve
valve, which allows flow of hydraulic fluid in the desired direction only if a predetermined pressure is
maintained at the valve

3.7
base frame
lowest framework of the hoist, upon which all other components are mounted

3.8
chassis
chassis are base frames which enable road transport of the hoist

3.9
guide rails
rigid elements which determine the travel way of the lcd

3.10
knee section
guide rail element between two guide rail sections which changes the inclination

3.11
hoistway
total space which is travelled by the lcd and its load

3.12
guide rail section
indivisible piece of rail, between two adjacent rail joints

3.13
guide rail support
connection system between the rail and ground or any building structure, providing support for the rail

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BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

3.14
load carrying device (lcd)
part of the hoist which carries the rated load

3.15
stopping distance
distance the platform moves from the moment, when the control or safety circuit is broken until the platform
has come to a full stop

3.16
slack rope
rope, normally under tension, from which all external loads have been removed

3.17
broken rope device
device which prevents the lcd from falling in the event of the breaking of the wire rope suspension

3.18
landing
stopping level or work area for loading and unloading the lcd

3.19
safety distance
minimum distance between any moving part of a hoist and any point of access

3.20
normal operation
usual operating conditions for the equipment when in use for carrying loads but excluding routine
maintenance, erection, dismantling, etc

3.21
competent person
designated person, suitably trained, qualified by knowledge and practical experience, and provided with the
necessary instructions to enable the required procedures to be carried out

4 List of hazards
The list of hazards according to the following tables are based on !EN ISO 12100-1:2003 and
EN ISO 12100-2:2003".

Tables 1 and 2 show the hazards which have been identified and where the corresponding requirements have
been formulated in this standard, in order to limit the risk or reduce these hazards in each situation.

A hazard which is not applicable or is not significant and for which, therefore, no requirements are formulated,
is shown in the relevant clauses column as n.a. (not applicable).

Table 1 — Hazards relating to the general design and construction of inclined hoists
Hazards Relevant clauses in this
standard
1 Mechanical hazards
1.1 Crushing 5.5.2, 5.6.2, 7.1.2.8
1.2 Shearing 5.6.2, 7.1.2.8
1.3 Cutting or severing 5.5.2, 5.6.2, 7.1.2.8
1.4 Entanglement 5.6.2, 7.1.2.8
1.5 Drawing-in or trapping 5.6.2, 7.1.2.8
1.6 Impact 7.1.2.8

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 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Hazards Relevant clauses in this

standard
1.7 Stabbing or puncture n.a.
1.8 Friction or abrasion 5.6.2, 7.1.2.8
1.9 High pressure fluid ejection 5.7
1.10 Ejection of parts 5.5, 5.6.1
1.11 Loss of stability 5.2, 5.3, 5.4, 7.1.2.8
1.12 Slip, trip and fall 5.3.4, 5.5.2
2 Electrical hazards
2.1 Electrical contact 5.8
2.2 Electrostatic phenomena n.a.
2.3 Thermal radiation n.a.
2.4 External influences 5.6.2, 5.6.4.11, 5.8.2
3 Thermal hazards
3.1 Burns and scalds n.a.
3.2 Health-damaging effects n.a.
4 Hazards generated by noise
4.1 Hearing losses not dealt with, see 1.3
4.2 Interference with speech not dealt with, see 1.3
5 Hazards generated by vibration n.a.
6 Hazards generated by radiation
6.1 Electrical arcs n.a.
6.2 Lasers n.a.
6.3 Ionising radiation sources n.a.
6.4 Use of H F electromagnetic fields not dealt with
7 Hazards generated by materials and substances
processed, used or exhausted by machinery
7.1 Contact with or inhalation of harmful fluids, gases, mists, n.a.
fumes and dusts
7.2 Fire or explosion n.a.
7.3 Biological and microbiological n.a.
8 Hazards generated by neglecting ergonomic principles
in machine design
8.1 Unhealthy postures or excessive effort 5.1
8.2 Inadequate consideration of human hand/arm or foot/leg 5.5.1
anatomy
8.3 Neglected use of personal protection equipment n.a.
8.4 Inadequate area lighting 7.1.2.8.2
8.5 Mental overload or underload, stress 5.9
8.6 Human error 7.3
9 Hazard combinations not dealt with
10 Hazards caused by failure of energy supply, breaking
down of machinery parts and other functional
disorders
10.1 Failure of energy supply 5.6.4.1, 5.9.5
10.2 Unexpected ejection of machine parts or fluids 5.7.2
10.3 Failure or malfunction of control system 5.8.1, 5.9.3
10.4 Errors of fitting 5.4.3, 5.8.3, 7.1.2.8
10.5 Overturn, unexpected loss of machine stability 5.2, 7.1.2.8
11 Hazards caused by missing and / or incorrectly
positioned safety related measures / means
11.1 Guards 5.5.1, 7.1.2.8.3
11.2 Safety related (protection) devices 7.1.2.8.3
11.3 Starting and stopping devices 5.8.4, 5.9.4, 7.1.2.8
11.4 Safety signs and signals 7.2
11.5 Information or warning devices 7.2, 7.3

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BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Hazards Relevant clauses in this

standard
11.6 Energy supply disconnecting devices 5.8.1
11.7 Emergency devices 5.9.3, 5.9.4, 7.1.2.10
11.8 Feeding/removal means of work pieces n.a.
11.9 Essential equipment and accessories for safe adjusting 5.9.4.3
and/or maintaining
11.10 Equipment evacuating gases n.a., see 1.3

Table 2 — Particular hazards involving the mobility and/or load lifting ability of hoists
Hazards Relevant clauses in this
standard
Hazards due to mobility
12 Inadequate lighting of moving / working area Not dealt with, see 1.3
13 Hazards due to sudden movement instability etc. Not dealt with, see 1.3
during handling
14 Inadequate/non-ergonomic design of operating Not dealt with, see 1.3
position
15 Mechanical hazards Not dealt with, see 1.3
16 Hazards due to lifting operations
16.1 Lack of stability 5.1, 5.2, 5.3
16.2 Derailment of load carrying device 5.4
16.3 Loss of mechanical strength of machinery and lifting 5.1, 5.4, 5.6.3
accessories
16.4 Hazards caused by uncontrolled movement 5.4, 5.6.4, 5.6.5, 5.8
17 Inadequate view of trajectories of the moving parts 5.8, 7.2
18 Hazards caused by lightning Not dealt with, see 1.3
19 Hazards due to loading / overloading 5.2, 5.5.1, 7.1.2.9

5 Safety requirements and/or measures

5.1 General

The design of the hoist shall consider safe use, frequent erection and dismantling as well as maintenance and
transportation. At least an ambient temperature range between – 5 °C and + 40 °C shall be taken into account
for correct operation.

The design of all components that have to be handled during erection e.g. guide rail sections, shall have their
weight assessed against manual handling. Where the permissible weight for manual handling is exceeded,
the manufacturer shall give recommendations in the instruction handbook. !All removable and detachable
covers shall be retained by captive fastenings."

5.2 Load combinations and calculations

5.2.1 The structure of the hoist shall be designed and constructed in such a way that its strength is
satisfactory under all intended operating conditions, including erection and dismantling and e.g. low
temperature environments as intended by the manufacturer.

The design of the structure as a whole and each part of it shall be based on the effects of any possible
combination of loads as specified in this 5.2. The load combinations shall consider the least favourable
locations of the lcd and load relative to the guide rails and its support, both during the passage of the lcd and

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 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

any movement, e.g. tilting of the lcd. The whole range of possible inclinations, as intended by the
manufacturer, shall be considered. The guide rail support is considered to be part of the hoist structure.

5.2.2 When calculating the hoist structure and every related component, the following forces and loads shall
be taken into account:

5.2.2.1 All dead weights with exception of the lcd and equipment which moves together with the lcd.

5.2.2.2 Dead weights of the unladen lcd and all equipment which moves together with the lcd.

5.2.2.3 Rated load on the lcd.

The rated load shall be considered to act off centre, either side, by an amount which is equivalent to 10 % of
the width (W) of the LCD (25 %, when the lcd is intended to be used with overhanging loads) (See Figure 1).
Special arrangements for specific materials may need other load configurations.

Key

X = 10 % W or 25 % W – see 5.2.2.3

Figure 1 — Rated load acting off centre

5.2.2.4 For calculation purposes a load of at least 3 kN/m² shall be considered as being placed over the
area of the lcd, defined as the area, which supports the load at right angles to the guide rails.

5.2.2.5 Where the hoist is designed such that the lcd is driven against the end of the guide rails before the
terminal stopping switch is actuated, it shall be designed to tolerate being driven against the end of the guide
rails at rated speed with and without rated load (See also 5.5.1.8). The stalling torque and inertia of the drive
system shall be taken into account.

5.2.2.6 The effect of moving loads shall be determined by taking the weight of all actual loads (lcd, rated
load, wire ropes, etc.) and multiplying them by an impact factor µ = (1,1 + 0,264v) where v is the hoisting
speed in m/s. Alternative factors may be used if they can be proved to be more accurate.

5.2.2.7 To determine the forces produced by an operation of the broken rope device, the sum total of the
moving load shall be multiplied by the factor 2,5. Alternative factors, but not less than 1,2, may be used if they
can be verified under all conditions of loading up to 1,25 times rated load.

5.2.2.8 Design wind conditions

The aerodynamic pressure q is given by the general equation:

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BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

v 2w
q=
1,6

where

q is the pressure in N/m² and vW the wind velocity in m/s.

In all cases it shall be assumed that the wind can blow horizontally in any direction and the least favourable
direction shall be taken into account.

The calculation shall be done according to !ISO 4302:1981" with the exception of the following:

5.2.2.8.1 Action of the wind on the lcd

When calculating wind load on the lcd and its designed load (e.g. sheets of 1,2 m x 2,5 m) it shall be assumed
that this area is solid and a factor of 1,2 shall be applied. The factor 1,2 covers both the shape factor and the
shielding factor.

5.2.2.8.2 Wind pressure

Three design wind conditions shall be taken into account when calculating wind pressure on hoists:

5.2.2.8.2.1 In service wind

Irrespective of height, the minimum value for wind pressure shall be q = 100 N/m², corresponding to a wind
velocity of vW = 12,5 m/s.

5.2.2.8.2.2 Out of service wind

Out of service wind pressures depend on the height above ground and the area where the hoist is installed.

The values of out of service wind pressure are given in table 3.

The minimum design wind pressures shall be taken into account.

Table 3 — Minimum design wind pressures

Height H of parts of hoist Wind pressure q for geographical Regions
above ground level A to E[N/m²]
[m] A/B C D E
0<H≤10 544 741 968 1225
10<H≤20 627 853 1114 1410
20<H≤50 757 1031 1347 1704
50<H≤100 879 1196 1562 1977

The regions A to E are taken from the European Stormwind Map (see Annex A).

5.2.2.8.2.3 Erection and dismantling wind

Irrespective of height, the minimum value for wind pressure shall be q = 100 N/m², which corresponds to a
wind velocity of vW = 12,5 m/s.

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EN 12158-2:2000+A1:2010 (E)

5.2.2.9 The load supporting surface of the lcd shall be designed to withstand without permanent
deformation a static load of 75 kg, the load applied on the least favourable square area of 0,1 m x 0,1 m.

5.2.2.10 The calculation shall take into account errors of erection of at least 2,5 degrees in any direction.

5.2.3 Safety factors

5.2.3.1 Steel structures

a) Permissible stresses

fy
σ0 =
Sy

where
2
 fy = yield strength [N/mm ]

 Sy = safety factor

b) Calculations according to the theory of the second order

The deflection of a structure shall be taken into account when calculating stresses. This is very important
when calculating a slender design or using materials with a low modulus of elasticity. This can be done by
nd
using the theory of the 2 order.

fy fy '
σ = 0 or whichever is the least favourable
Sy Sy

where
2
 fy’ = apparent yield strength [N/mm ]

The safety factors against fy and fy’ shall be at least equal to those given in the following table 4 which is
related to table 6.

Table 4 — Safety factors for steel structures

Load case Safety factor (Sy)
A 1,5
B 1,33
C 1,25

5.2.3.2 Aluminium structures

a) Permissible stresses

fy fu
σ0 = or whichever gives the lowest value
S y Su

where

 fu = tensile strength [N/mm²]

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BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

 Su = Safety factor on tensile strength

b) Calculations according to the theory of the second order

The deflection of a structure shall be taken into account when calculating stresses. This is very important
when calculating a slender design or using materials with a low modulus of elasticity. This can be done by
nd
using the theory of the 2 order.

fy fu
σ0 = or whichever gives the lowest value
S y Su

The safety factors against fy and fu shall be at least equal to those given in the following table 5 which is
related to table 6.

Table 5 — Safety factors for aluminium structures

Load case Safety factor Sy on yield strength Safety factor Su on tensile strength
A 1,70 2,50
B 1,55 2,25
C 1,41 2,05

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EN 12158-2:2000+A1:2010 (E)

5.2.4 Load cases, the different combinations of loads and forces which are to be calculated

Table 6 — Load cases

Load Load case for: Forces and effects according Load
1) 2)
case to 5.2.2.(X) case
number
Ia Normal use: (structural parts, including guide (1), (8.2.1), A
rails, guide rail support, base frame, base (2) multiplied by (6)
frame support, buffers, and all other static (3) multiplied by (6)
parts of the structure) (5)
Ib Normal use: lcd (8.2.1) A
(2) multiplied by (6)
(3) multiplied by (6)
(5)
IIa Exceptional forces: guide rails (1), (8.2.1), C
(2) multiplied by (6)
(4) multiplied by (6)
IIb Exceptional forces: lcd (8.2.1) C
(2) multiplied by (6)
(4) multiplied by (6)
IIIa Exceptional broken rope device effects: guide (1), (8.2.1), C
rails (2) multiplied by (7)
(3) multiplied by (7)
IIIb Exceptional broken rope device effects: lcd (8.2.1) C
(2) multiplied by (7)
(3) multiplied by (7)
IIIc Exceptional broken rope device effects: (2) multiplied by (7) C
broken rope device (3) multiplied by (7)
IV Occasional out of service: guide rails (1), (8.2.2) B
V Erection (structural parts, including guide rails, (1), (8.2.3), B
base frame, base frame support and all other (2) multiplied by (6)
static parts of the structure)
1) X refers to the relevant subsection of 5.2.2. For example, for load case I b (normal use: lcd) the
following forces and loads shall be taken into account: 5.2.2.8.2.1, 5.2.2.2, 5.2.2.3 and 5.2.2.6.
These are thus referred to in the table in the abbreviated form (8.2.1), (2), (3) and (6).
2) see table 4 and table 5.

5.2.5 Stability

For hoists whilst they are in a free-standing condition during erection, the load cases and safety factors in
table 7 shall be used.

All stabilising forces have the factor = 1,0.

Table 7 — Stability safety factors So for various overturning forces

Loads or forces according to clause safety factor So
1)
5.2.2.(X)
Overturning parts of the dead loads (1), (2) 1,2
Erection and dismantling wind forces (8.2.3) 1,1
Errors of erection (10) 1,0
1) see note 1) of table 6

Σ Stabilising moments ≥ Σ Overturning moments multiplied by the corresponding So

15
BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

5.2.6 Fatigue stress analysis of drive and braking system components

5.2.6.1 A fatigue stress analysis shall be made for all load bearing components and joints which are critical
to fatigue, such as shafts and gearing. This analysis shall take into account the degree of stress fluctuation
and the number of stress cycles, which can be a multiple of the number of load cycles.

To determine the number of stress cycles, the manufacturer shall take the following into account:

 15.000 movements upwards with 75 % of the maximum rated load on the lcd;

 15.000 movements downwards with empty lcd;

 For the calculation of the drives a travel length of 10 m for each movement (acceleration from rest to
rated speed – travel at rated speed – deceleration to full stop) shall be taken into account (see also
7.1.2.11).
4
NOTE The number of movements for a goods hoist is based on: 3 x 10 - intermittent duty (e.g. 10 years, 20 weeks
per year, 25 hours per week, 6 movements per hour).

5.2.6.2 Each shaft shall possess a minimum safety factor of 2,0 against the appropriate endurance limit,
under consideration of the actual notch effects.

5.3 Hoist base: guide rail feet, base frame or chassis

5.3.1 General requirements

The hoist base shall be designed to accommodate all forces acting on it generated by the hoist and be able to
transfer them on to the supporting surface.

Components which transfer forces directly from the hoist into the ground shall be designed to prevent an
applied ground pressure of more than 0,2 MN/m².

In order to eliminate the risk of unintentional horizontal movement of the hoist base, means shall be provided
to fix the location of the hoist base.

5.3.2 Additional requirements for guide rail feet

The feet shall be free to pivot in the intended plane of inclination of the guide rails.

5.3.3 Additional requirements for base frames

Adjustable means shall be provided to transfer the forces into the ground. The feet shall be free to pivot in all
planes to an angle of at least 10° from the horizontal in order to prevent bending stresses in the structure. If
the foot does not pivot, the worst resulting bending stress shall be taken into account.

If a turntable between guide rails and base frame is used, it shall have a locking device to prevent
unintentional turning.

If there is a device to adjust the inclination of the guide rails, which is situated between the base frame and
guide rails, it has to be designed to withstand all possible loads and load cases (see 5.2).The lowering and
raising speed shall be limited to 8° / s. A device which prevents the guide rails from unintentional lowering
shall be provided (Regarding hydraulic drive systems for adjustment of the inclination see 5.7).

5.3.4 Additional requirements for chassis

Devices to transfer the forces into the supporting surface shall not rely on any elastic suspension or pneumatic
wheels.

16
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

It shall be possible to lock ground supports at the working and transport positions. Locking devices on ground
supports shall be secured against unintentional disengagement and loss.

Means shall be provided to fix the guide rail system (completely retracted and with its lowest inclination to the
horizontal) in a fixed position on the chassis.

Areas on the chassis that are intended to step on, shall be equipped with a slip resistant surface (e.g. chequer
plate).

5.4 Guide rails, guide rail supports and buffers

5.4.1 Guide rails shall guide and support the lcd and keep it on the correct path of travel. The guide rails can
consist of joint sections or telescopic elements. Tying points e.g. eye bolts shall be provided to facilitate
securing to a solid structure i.e. building.

5.4.2 Guide rails and knee-joints shall be designed so that they can withstand all load cases as described in
5.2.

In order to cover the malfunction of the upper or lower terminal stopping switch the hoist shall be designed to
be driven against the end of the guide rails with and without rated load in the lcd such that no permanent
deformation occurs.

In addition guide rails shall be designed to withstand the forces produced by the triggering of the safety device
(overspeed or rope breakage). Local permanent deformations of guide rails are permissible. The worst
condition shall be taken into account.

5.4.3 Connections between guide rail sections or the telescopic sections shall provide effective load transfer
and maintain alignment. Loosening shall only be possible with an intentional manual action.

5.4.4 Telescopic guide rail system

The design shall permit free sliding of the guide rail sections.

The design of the telescopic guide rail system shall permit easy inspection of the full length of all wire ropes of
the telescopic system.

If there is a locking device for the telescopic guide rails to avoid retraction (of the extended guide rail system)
in case of a failure of the extension wire rope, the utilisation coefficient of the wire rope as defined in 5.6.3.1.3
may be reduced to 3.

5.4.5 Attachments of drive elements (e.g. drive unit, pulleys, rope terminations) to the guide rails shall
ensure that they are kept in the correct position in order to ensure that the stipulated forces can be transferred
to the guide rails. Any loosening shall only be possible with an intentional manual action.

5.4.6 Guide rail support

The guide rail support shall limit the inflexion of the guide rails and reduce torsion. They specifically shall

 be installable and removable in a safe manner, without climbing the guide rails;

 be adjustable in length and inclination;

 have a hinged connection to the guide rails;

 be removable only by an intentional action.

17
BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

5.4.7 Buffers

5.4.7.1 The travel of the lcd shall be limited at the bottom by buffers. With rated load on the lcd and at a
speed equal to rated speed the average retardation of the lcd during action of the lower buffers shall not
exceed 2 g downwards.

5.4.7.2 Buffers shall be provided at the upper end of travel, when the hoist is designed such that the lcd is
driven against the end of the guide rails before the terminal stopping switch is actuated. Without load in the lcd
and at rated speed the average retardation of the lcd during action of the upper buffers shall not exceed 1 g
upwards.

5.5 Load Carrying Device (lcd)

5.5.1 General requirements

5.5.1.1 The hoist may be fitted with different types of load carrying devices (platforms, buckets, etc.). They
shall be suitable for the purpose for which they are intended by the manufacturer.

5.5.1.2 The lcd shall be calculated according to 5.2.

5.5.1.3 The lcd shall be designed in such a way that there is no need to step on it for maintenance,
erection and dismantling as well as for loading or unloading purposes. It is considered that 0,60 m shall be the
longest reachable distance to access the intended load from outside the lcd.

5.5.1.4 The lcd shall have rigid guiding to prevent disengagement, jamming or unintended tilting.

5.5.1.5 Each lcd shall be provided with effective devices which retain the lcd on guide rails in the event of
guide rollers failing.

5.5.1.6 Lcd guide rollers shall be guarded as far as possible in order to provide protection e.g. against
finger trapping.

5.5.1.7 Mechanical means shall prevent the lcd from running past the top and bottom end of the guide rails.

5.5.1.8 In order to cover the malfunction of the upper or lower terminal stopping switch the hoist shall be
designed to be driven against the end of the guide rails with and without rated load in the lcd such that no
permanent deformation occurs.

5.5.1.9 Lcd's except those designed for specific goods shall be provided on all sides with guards of at least
0,3 m height with maximum openings of (50 x 50) mm or slots with a width of no more than 20 mm.

5.5.1.10 Lcd's for specific goods shall be designed to safely transport the intended materials.

5.5.1.10.1 Lcd's for specific goods such as equipped with buckets for liquid, viscous or bulk materials which
can tilt or which can open at the bottom shall be designed in such a way that they can open or tilt only at
predetermined locations.

5.5.1.10.2 Hoists with tilting lcd’s shall be provided with means to prevent tilting.

18
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

5.5.1.11 Guards, gates, ramps, etc. shall only be openable by an intentional action.

5.5.2 Safety devices against falling of the lcd

5.5.2.1 A safety device is required to prevent the lcd from falling in the event of rope breakage.

5.5.2.2 Travelling at least at rated speed downwards, the safety device shall be able to stop and maintain
stopped the lcd with 1,25 times the rated load.

5.5.2.3 Suitable provision shall be made to prevent the safety device from becoming inoperative due to the
accumulation of extraneous materials or to atmospheric conditions.

5.5.2.4 A safety device designed to grip more than one guide shall operate on all guides simultaneously.

5.5.2.5 Jaws or blocks of the safety devices shall not be used for guiding the hoist under normal operating
conditions.

5.5.2.6 In safety devices where the action is achieved by means of springs, the springs shall be in the form
of compression springs, which shall be guided and in the non-loaded condition have a pitch of less than twice
the wire diameter.

5.6 Drive unit

The following subclauses apply to both the lcd drive system as well as to the drive system for telescopic guide
rails except where noted.

5.6.1 General provisions

Each hoist shall have at least one drive unit of its own.

Each drive system shall be calculated according to 5.2.6.

The drive motor shall be coupled to the drum by a positive drive system which cannot be disengaged.

The lcd and the telescopic guide rails shall during normal operation, erection and dismantling be lowered
under power at all times.

For all hoists, under normal operating conditions the speed of the empty lcd upwards or of the lcd with rated
load downwards shall not exceed the rated speeds by more than 15 %.

The extension speed of telescopic guide rails shall be limited to 15 m/min.

5.6.2 Protection and accessibility

The driving machinery (e.g. motor, gear, drum) shall be so positioned or guarded to protect persons from
injury.

Fixed guarding shall be provided to prevent the entry of any material that might cause damage to any part of
the drive system, e.g. gravel, rain, snow, ice, mortar, dust.

Effective guards shall be provided for gear wheels, belts and chain drives, revolving shafts, fly-wheels, guide
rollers, couplings and similar rotating parts unless those parts are made safe by design or by position and be
designed to permit easy access for routine inspection and maintenance work.

The size of any perforation or opening in the guard when closed related to the clearances from adjacent
moving parts shall be in accordance with !EN ISO 13857:2008".

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BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

5.6.3 Wire rope suspension system

5.6.3.1 Wire rope requirements

5.6.3.1.1 The characteristics of the wire ropes shall at least correspond to those specified in
!ISO 2408:2004".

5.6.3.1.2 The nominal diameter of the wire ropes shall be at least 5 mm.

5.6.3.1.3 The utilisation coefficient of wire ropes shall be at least 6. The utilisation coefficient is the ratio
between the minimum breaking load of one wire rope and the maximum static force in this rope.

5.6.3.1.4 The strength of the wire rope terminations shall be not less than 80 % of the minimum breaking
load of the wire ropes. In the termination on the drum, a factor of 2,5 times the calculated maximum rope force
shall be ensured; up to two dead turns may be taken into account.

Wire ropes shall be terminated using a secure method such as:

 a metal or resinfilled socket;

 an eye splice with thimble;

 a ferrule secured eye terminal with thimble;

 a wedge anchor;

 a bridge clamp with dead turns for a drum termination.

Figure 2 — Wire rope terminations

Terminations which may damage the rope like U-Bolt wire rope grips shall not be used for this purpose.

20
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

5.6.3.1.5 All wire ropes shall be galvanised.

5.6.3.1.6 The ratio between the pitch diameter of pulleys, or drums and the nominal diameter of wire ropes
shall be at least 14 for the telescopic system and 20 for the lcd drive system.

5.6.3.2 Pulley requirements

For the pulleys the following requirements shall be fulfilled:

 the grooves shall be circular with a radius not more than 7,5 % and not less than 5 % in excess of half the
nominal diameter of the wire rope. The depth shall be not less than 1,5 times the nominal diameter of the
wire rope;

 pulleys having wire ropes leading upwards shall be protected against the penetration of foreign bodies;

 effective precautions shall be taken to avoid wire ropes leaving their grooves;

 the angle of fleet between the wire rope and a plane normal to the axis of a pulley shall not exceed 2,5°;

 pulleys at the head section shall be effectively guarded.

5.6.3.3 Drum drive requirements

When the lcd rests in its lowest position at maximum extension of the guide rails, two dead turns of the wire
rope shall remain on the drum. Also, when the guide rails of a telescopic system are completely retracted, two
dead turns of the rope shall remain on the drum.

The drum shall be fitted with flanges at each end which project beyond the upper layer of rope by at least two
rope diameters.

The angle of deflection (fleet angle) of the wire ropes shall not exceed 2,5°.

5.6.4 Braking system for the lcd drive

5.6.4.1 Every hoist shall be provided with a braking system which operates automatically in the event of
loss of the supply to electric or hydraulic control circuits.

5.6.4.2 The braking system shall have at least one electro-mechanical or hydromechanical brake (friction
type), but may, in addition, have other braking means (e.g. electric or hydraulic).

5.6.4.3 Band brakes shall not be used.

5.6.4.4 The components on which the brake operates shall be positively coupled to the drum. Belts and
chains shall not be used.

5.6.4.5 The brake(s) on its own shall be capable of stopping the lcd from rated speed in down direction with
1,5 times the rated load.

5.6.4.6 Every spring of the brake(s) which takes part in the application of the braking action on the brake
drum or disc shall be constructed and installed in such a way that if a failure in one of the springs occurs,
sufficient braking effort to stop the lcd, when containing rated load, would continue to be exercised.

5.6.4.7 The action of the brake shall be exerted by compression springs. The springs shall be adequately
supported and shall not be stressed in excess of 80 % of the torsional elastic limit of the material.

21
BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

5.6.4.8 In normal operation, a continuous supply of current or hydraulic pressure shall be required to hold
off the brake.

5.6.4.9 Braking shall become effective without delay after opening of the brake release supply (the use of a
diode or capacitor connected directly to the terminals of the brake coil is not considered as a means of delay).

5.6.4.10 Brakes shall be provided with means of adjustment to account for the wear of the friction surfaces.

5.6.4.11 The brake shall be protected to IP 23 (!EN 60529:1991").

5.6.4.12 The stopping distance of the lcd with rated load and running at rated speed shall be not more than
0,2 m.

5.6.5 Telescopic system drive unit

The drive unit for the telescopic system shall have a brake system according to 5.6.4.1, 5.6.4.3, 5.6.4.4,
5.6.4.7, 5.6.4.8, 5.6.4.9 and 5.6.4.11 and additionally be equipped with a locking device to prevent sudden or
slow undesired retraction during normal operation.

5.7 Hydraulic installations and appliances

!deleted text"

5.7.1 !EN 982:1996" applies with the following additional requirements:

5.7.1.1 Rigid pipes shall be designed to withstand a pressure equal to 2,3 times the full load pressure. The
additional wall thickness is to be taken as 0,5 mm.

5.7.1.2 Flexible hoses including their terminations shall be selected with a safety factor of at least 4
between full load pressure and bursting pressure.

5.7.1.3 Any cylinder that supports the base frame or which is situated between base frame and the guide
rail system shall be equipped with a check valve situated directly at the port of the cylinder.

5.7.1.4 A filter fitted with a maintenance indicator shall be fitted in the return hose to the tank.

5.7.1.5 The hydraulic system shall be ventilated and able to be drained.

5.7.1.6 It shall be easy to check the level of the hydraulic fluid in the tank.

5.7.1.7 Calculations shall be made regarding pressure in cylinders and closed rams. The cylinder and the
ram shall be designed to withstand a pressure equal to 2,3 times the full load pressure with a safety factor of
1,7 against yield strength. In the thickness calculations an additional value of 1,0 mm for cylinder wall and
cylinder bases and of 0,5 mm for ram shall be taken into account.

When cylinders are working, the full load pressure is determined by the safety relief valve. Otherwise – with
the check valves at the cylinder bases closed - the full load pressure is determined by 5.2. The worst case
shall be taken into account.

22
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

5.7.1.8 Where reference is made to switches in this standard, hydraulic valves of equivalent safety may be
used as an alternative.

5.8 Electric installations and appliances

5.8.1 General

Electrical installations and appliances shall comply with !EN 60204-32:2008", which applies in full with
the exception that control circuits shall be supplied by transformer.

This standard deals with the electrical installation of the hoist itself, including the supply plug.

!deleted text"

The control circuit shall be designed in order to avoid a dangerous situation resulting from the hoist motor
acting as a generator (See also 5.9.5).

5.8.2 Protection against the effects of external influences

Any electrical apparatus shall be protected from the harmful or hazardous effects of external influences and
falling objects (e.g. rain, snow, mortar, dust). The degree of protection (see !EN 60529:1991") shall be at
least IP 65 for portable control devices, IP 54 for control cabinets, switches and the electrical components of
the brake, IP 44 for motors and IP 23 for external plugs and sockets.

5.8.3 Electric wiring

All cables and wiring for the hoist shall be located and installed to provide protection from mechanical
damage.

The machine shall be fitted with a plug for connection to the electric supply. Any power supply cable being
part of the hoist shall at least belong to category !H07RN-F (HD 22.1 S4:2002)".

In order to prevent incorrect insertion, plug and socket devices with mechanical coding shall be used
(!EN 60204-32:2008, 13.4.5").

5.8.4 Stopping switches

All switches used as stopping switches shall have safety contacts which comply with
!EN 60947-5-1:2004". Flexible actuating levers may be used considering the resilience to damage. The
switches shall be mounted following the requirements of EN 1088:1995.

5.9 Control and limiting devices

5.9.1 Terminal stopping switches

Terminal stopping switches shall be provided and positioned so that they stop the lcd from rated speed at the
highest and lowest limits of travel.

The switches shall be directly operated by the movement of the lcd or related parts.

5.9.2 Slack rope device on lcd drive system

A slack rope device shall be installed on the machine. The slack rope switch shall interrupt the control circuit
in down direction. It is permitted to use the slack rope device as the lower terminal stopping switch.

23
BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

5.9.3 Emergency stop

The emergency stop function shall be designed in accordance with stop !Category 0 in
EN ISO 13850:2008".

No electric equipment shall be connected in parallel with the emergency stop contact.

5.9.4 Control modes

Power operated functions of the hoist shall only be controlled by hold-to-run type push-buttons or levers, with
the direction of movement clearly indicated.

All controls except emergency stop shall be designed in such a way that they can only be actuated by an
intentional manual action.

There shall not be any controls inside the lcd.

Means shall be provided to reduce the speed of the lcd to 0,7 m/s in the lowermost 2 m of travel and in the
working area according to 7.1.2.8.3.3.2.

5.9.4.1 Normal operation

The hoist shall be controlled from the base level where full visibility of the travel of the lcd and of the inside of
the base enclosure is possible.

The control station shall be provided at the minimum with Up, Down and Emergency Stop functions.

5.9.4.2 Secondary control station

If the hoist is forseen to be used in such a way that part of the hoistway cannot readily be observed by the
operator from the base control station, e.g. beyond the edge of a roof, means shall be provided so that a
secondary control station can be provided in that part of the hoistway and the manufacturer shall make the
necessary equipment available.

The following conditions shall be observed:

 both control stations shall be provided at the minimum with Up, Down and Emergency Stop functions;

 directional control of the hoist shall be switched by the lcd from one control station to the other but, as
long as the other control station has not moved the lcd, it may be called back by the originating control
station.

5.9.4.3 Erection and dismantling control

Where an erection and dismantling control device is provided, control operations shall only be possible from
base level.

This device shall incorporate a mode selector according to !EN 60204-32:2008, 9.2.3" and shall switch
operation only to the erection and dismantling control station. The return to normal operation of the hoist shall
only be effected by this mode selector.

For hydraulic hoists directly controlled by levers the levers controlling movements of the guide rails shall be
lockable.

Where power operated movements are rope driven, the rope shall be monitored by a slack rope device.

24
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

5.9.5 The loss of the main power supply shall not lead to a dangerous situation. In particular:

 the lcd shall not be prevented from stopping if the command has already been given;

 automatic or manual stopping of the lcd shall be unimpeded;

 any protection device shall remain fully effective;

 the rated speed with rated load shall not be exceeded by more than 20 %.

6 Verification

6.1 Verification of design

Table 8 indicates the methods by which the safety requirements and measures described in clause 5 shall be
verified by the manufacturer for each new model of hoist, together with a reference to the corresponding
subclauses in this standard. Secondary subclauses which are not listed in the table, are verified as part of the
quoted subclause. For example, secondary subclause 5.2.2.8 is verified as part of subclause 5.2.2. All
verification records shall be kept by the manufacturer.

Table 8 - Means of verification of the safety requirements and / or measures

e
Subclause Safety requirements Visual Perfomance Measure- Drawing/ User info
a c
inspection check / ment Calculation
b d
test

5.1 Erection and handling 9 9 9 9

5.2 Forces and load

combinations

5.2.1 Basics 9

5.2.2 Calculation of structure 9 9

5.2.3 Safety factors 9

5.2.4 Load cases 9 9

5.2.5 Stability 9 9

5.2.6 Fatigue stress 9 9

5.3 Base frame

5.3.1 General 9 9

5.3.2 Guide rail feet 9 9

5.3.3 Base frames 9 9 9

5.3.4 Chassis 9 9 9

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BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Table 8 - Means of verification of the safety requirements and / or measures

(continued)
e
Subclause Safety requirements Visual Perfomanc Measure- Drawing/ User info
a c
inspection e check / ment Calculation
b d
test

5.4 Guide rails, guide rail

supports and buffers

5.4.1 Guide rails 9 9

5.4.2 Guide rails and knee 9 9 9 9

joints

5.4.3 Connections 9 9 9 9

5.4.4 Telescopic guide rail 9 9 9

system

5.4.5 Attachment of drive 9 9

elements

5.4.6 Guide rail support 9 9 9

5.4.7 Buffers 9 9

5.5 Load carrying device

5.5.1 General 9 9 9 9 9

5.5.2 Safety device 9 9 9 9 9

5.6 Drive unit

5.6.1 General 9 9 9 9

5.6.2 Protection and 9 9

accessibility

5.6.3 Wire rope suspension 9 9 9 9 9

system

5.6.4 Braking system 9 9 9 9 9

5.6.5 Telescopic drive locking 9 9 9

system

5.7 Hydraulics 9 9 9 9 9

5.8 Electric Installations

26
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Table 8 - Means of verification of the safety requirements and / or measures

(concluded)
e
Subclause Safety requirements Visual Perfomanc Measure- Drawing/ User info
a c
inspection e check / ment Calculation
b d
test

5.8.1 General Provisions 9 9 9 9

5.8.2 External Influences 9 9

5.8.3 Electric wiring 9 9

5.8.4 Stopping switches 9

5.9 Control and limiting

devices

5.9.1 Terminal stopping 9 9 9

switches

5.9.2 Slack rope device 9 9 9

5.9.3 Emergency Stop 9 9 9 9

5.9.4 Control modes 9 9 9 9 9

a
Visual inspection will be used to verify the features necessary for the safety requirements by visual
examination of the components supplied.
b
A performance check/test will verify that the features provided perform their function in such a way
that the requirement is met.
c
Measurement will verify by the use of instruments that requirements are met, to the specified limits.
d
Drawings/calculations will verify that the design characteristics of the components provided meet
the requirements.
e
Verify, that the relevant point is dealt with in the instruction handbook or by marking.

6.2 Verification tests of broken rope device

6.2.1 General provisions

The broken rope device shall be tested using the suspension and guide rail system employed in normal
service.

6.2.2 Method of test

The tests described in 6.2.2.1 to 6.2.2.3 shall insure that the broken rope device will function under various
conditions.

6.2.2.1 At least there shall be 5 tests in order to verify the triggering mechanism.

Setup:

 full length of wet guide rails;

 with knee section (if part of the design);

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BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

 with at least the upper part of guide rails at the lowest foreseen angle;

 lcd stationary at the upper end of the guide rails with rated load;

 rope cut at drum.

6.2.2.2 In order to verify the structural strength of the different lcd’s and broken rope device the broken
rope device shall be triggered with the following conditions:

 at maximum foreseen angle of guide rails;

 from rated speed downwards, with rated load (excentric as per 5.2.2.3);

 with all load carrying devices.

There shall be at least 10 tests with the same broken rope device.

6.2.2.3 In order to verify the structural strength of the guide rails the broken rope device shall be triggered
with the following conditions at least 3 times:

 the lcd stopping in the middle of the longest foreseen free span of guide rails;

 guide rails at minimum foreseen angle;

 from rated speed downwards;

 with rated load (excentric as per 5.2.2.3);

 with the load carrying device which excerts the highest excentric load to the guide rails.

6.2.2.4 The following shall be checked:

a) Immediate stopping of lcd;

b) Lcd held by the guide rails;

c) Load held inside lcd.

6.2.3 Test report

The report shall indicate:

a) name of tester, date of test;

b) test setup;

c) design of the broken rope device and related parts;

d) type(s) and model(s) of hoist(s).

6.3 Verification tests on each machine before first use

The manufacturer shall perform or have performed static and dynamic tests to ensure that the hoist has been
correctly manufactured and assembled in order to check that all the devices provided are present and
operating correctly. These tests may be taken at the manufacturer's premises or those of his authorised
representative or at the place of use.

28
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

In particular it shall be verified:

 proper function of all limit switches;

 proper function of all controls;

 function of the broken rope device within specified limits;

 braking distance of brake system within specified limits;

 proper functioning of the winch;

 electrical tests as specified in !EN 60204-32:2008";

 a test report detailing the static and dynamic tests carried out by or for the manufacturer or his authorised
representative (see also 7.1.2.6)."

7 User Information

7.1 Instruction handbook

7.1.1 Comprehensive information

Each hoist shall be accompanied by an instruction handbook, which shall be in accordance with
!EN ISO 12100-2:2003, 6.5".

7.1.2 Contents of the instruction handbook

The manufacturer and/or his authorised representative shall make available to the user an instruction
handbook containing at the least, information about the following topics:

7.1.2.1 General information

 manufacturers name and address or that of his authorised representative;

 country of manufacture;

 model designation;

 range of serial numbers for which the instruction handbook is valid;

 a repeat of the safety marking and warning signs on the machine and their signification;

 all compatible parts (guide rail sections, ties, control systems, etc.) designed to be used in the hoist
installation for which the declaration of conformity is valid;

 the contents of the instructions shall cover not only the intended use of the machinery but also take into
account any reasonably foreseeable misuse thereof."

29
BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

7.1.2.2 Capacity information

 !working load depending on inclination";

 description of available load carrying devices (purpose, dimensions);

 range of inclination;

 rated speed;

 maximum lifting height;

 maximum length of guide rails;

 distance of guide rail support;

 maximum allowable wind speed during erection and dismantling;

 maximum allowable wind speed in service (depending on the type of lcd);

 maximum allowable wind speed out of service; design wind region (see Annex A, deviations due to local
environment conditions may be possible!). Variations in guide rail support intervals, etc., shall be clearly
indicated for the appropriate wind regions;

 environmental restrictions as temperature range;

 sound pressure levels [dB(A)] measured at a height of 1,60 metres from the floor at the fixed control
position or at a distance of 1 metre from the drive unit, where the controls are not fixed. The position and
value of the maximum sound pressure shall be indicated. !The declaration shall be accompanied by
values for the associated uncertainty K using the dual-number form of declaration in accordance with
EN ISO 4871:1996."

!NOTE Information about noise emission should also be given in sales literature."

Sufficient information shall be given in the instruction handbook such that the owner can derive the particular
details for each configuration.

7.1.2.3 Dimensions and weights

 total unit ready for transportation;

 guide rail section;

 base / drive unit;

 minimum area required for installation.

7.1.2.4 Power supply data

7.1.2.4.1 Electrical drive

 power drive unit (kW);

 supply voltage / frequency (V/Hz);

 control voltage / frequency (V/Hz);

30
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

 maximum starting current (A);

 maximum power consumption (kW);

 minimum power supply (kW);

 main power supply fuses and type (V,A)

7.1.2.4.2 Hydraulic drive

 hydraulic pressures (MPa);

 engine power (kW).

7.1.2.5 Safety equipment

 broken rope device;

 slack rope device;

 limit switches;

 check valves;

 guide rail locks.

7.1.2.6 Additional technical information

 wire rope data;

 ground bearing pressure as a function of configuration of the hoist;

 hydraulic fluids;

 gasoline specifications;

 engine lubrication;

 guide rail section joints (bolt diameter, quality, tightening torque, criteria for replacement);

 for lifting accessories information shall be given regarding intended use, limits of use, instruction
assemblies, use and maintenance, static test coefficient used;

 a test report detailing the static and dynamic tests."

7.1.2.7 Road transport

 preparing the unit for transportation (securing any loose equipment);

 trailer loadings;

 Tyre specifications / pressures;

31
BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

 Transport procedure to and from site including maximum speed as well as the need for meeting local
traffic regulations.

7.1.2.8 Instructions for erection and dismantling

The instruction manual shall clearly indicate the various configurations foreseen by the manufacturer for
installing the hoist. Where any nonstandard configurations are required, these shall be agreed between the
manufacturer, the owner and the user, and information shall be added as addendum to the instruction
handbook.

7.1.2.8.1 Foundation

Information shall be given so that the site for the hoist can be suitably prepared in order that it is level and able
to withstand all resultant forces. The hoist base shall be supported by a foundation able to take all forces and
moments including overturning forces as described in 5.2, depending on the actual configuration of the hoist.

7.1.2.8.2 Erection and dismantling

Only competent persons may erect and dismantle the hoist. The instructions shall at least include the
following:

 recommendations for lifting of heavy parts;

 proper usage of any control devices;

 connection of the hoist to the electrical supply in accordance with local regulations;

 recommended use of a Residual Current Device;

 consideration of hazardous areas around the hoist, e.g. power lines;

 consideration of any effects which significantly increase the wind speed e.g. adjacent tall buildings;

 requirements for the appropriate use of jacks;

 restrictions for use of the turntable depending on guide rail extension and inclination;

 guide rail support arrangement and forces imposed on the supporting structure, for the appropriate wind
region (see Annex A);

 activating any locking device for the telescopic guide rails before use, where fitted;

 tying of the top end of the guide rails and any kneejoint to the supporting structure;

 two dead turns of the rope remaining on the drum when the lcd rests in its lowest position;

 installation of a secondary control station according to 5.9.4.2. The point of transferring the control shall
be at a location which can be readily observed from both control stations and has to be at least 2 m
above the base level. This lowermost part of travel shall only be controlled by the ground control station;

 illumination (a statement shall be included to the effect that if the hoist is to be used under poor lighting
conditions then adequate site lighting shall be provided to illuminate the full height of travel of the hoist.)

 test of the complete installation and all hoist functions with !working load" before use;

 dismantling procedure.

32
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

7.1.2.8.3 Hoistway Protection and Landing

The instruction manual shall give information to achieve the following level of protection:

7.1.2.8.3.1 At ground level

The base protection shall at least consist of two horizontal elements, marked in a conspicuous colour (e.g. red
/ white).

One element shall be at a height between 1,0 m and 1,2 m, the second at height of about 0,5 m.

The base protection shall protect the projected area of the widest anticipated load along the hoistway to a
safety distance of at least 1,4 m. The maximum width of the access opening shall be 1,4 m.

7.1.2.8.3.2 Other than loading and unloading zones

If the safety distance between any point of access and any adjacent travelling part of the hoist is less than
0,85 m (0,5 m if the hoist speed is not more than 0,7 m/s), the enclosure shall conform to
!EN ISO 13857:2008, Table 1".

7.1.2.8.3.3 Landing

7.1.2.8.3.3.1 One delivery point at the end of the hoist travel

If openings in the edge protection are necessary to accommodate the hoist, they shall be no wider than
necessary to allow safe movement of the lcd and loads normally carried.

7.1.2.8.3.3.2 Work areas where loading or unloading takes place throughout the length of travel of the
work area.

Where it is not possible to provide predetermined landing levels, e.g. delivery of roofing components to a roof
where the distribution up the slope demands an infinite number of stopping points within the range of the roof,
then over the whole of the sloping work area the lcd shall be operated from a position where the operator has
a full view of the travel of the lcd, and the speed in the sloping work area shall be not more than 0,7 m/s.

7.1.2.9 Operating Instructions

A separate section shall be included in the instruction handbook which gives clear information for all users of
the hoist regarding the safe operation and the minimum requirements for the training of operating personnel
as well as instructions for those persons loading and unloading.

Detailed instructions shall be given regarding:

 intended use;

 the requirement that no person shall be transported with the lcd;

 proper usage of any control devices;

 selection of the adequate lcd depending on the type of load;

 fitting of the lcd´s to the hoist;

 loading the lcd and possible restrictions regarding load position and securing of the load;

 consideration of the effects of any item which significantly increases the sensitivity to wind;

33
BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

 unimpeded vision of the hoistway or use of a secondary control station according to 5.9.4.2;

 environmental conditions e.g. maximum in service wind speed.

7.1.2.10 Breakdown procedures

A separate section shall be included which provides all the information necessary for a competent person,
regarding the handling of emergencies such as:

 special controls;

 safety devices, e.g. limit switches, broken rope device (after triggering of the broken rope device the
braking surfaces shall be examined for any deformations detrimental to its continued safe use);

 reacting to failures;

 circuit diagram.

7.1.2.11 Regular Inspection and Maintenance

The instruction handbook shall state the frequency of periodic examinations, tests and maintenance
depending on manufacturer's requirements, operating conditions and frequency of use. Detailed information
regarding the items to be checked and suitability for use shall be given.

The instruction handbook shall also state the contents of the logbook, if that is not delivered with the
machinery.

It shall be stated which parts are subject to wear and the criteria for replacement, e.g. !ISO 4309:2004"
for replacement of steel wire ropes. The handbook shall also include a section dealing with thorough
examination with regard to fatigue life (see also 5.2.6.1).

7.2 Markings

The manufacturer shall provide the following information on one or more durable labels fixed in a prominent
place on the hoist, in accordance with !EN ISO 12100-2:2003, 6.4".

7.2.1 Rating plate

 name and address of the manufacturer or his authorised representative;

 type designation;

 serial number;

 year of construction;

 !working load [kg]";

 lifting height;

 rope data (e.g. diameter, design, minimum breaking load);

 weight of base unit;

 rated speed of lcd.

34
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

7.2.2 Guide rail identification label

Each individual guide rail section shall be marked with an identification or serial number enabling the date of
manufacture to be determined.

7.2.3 Basic user information label

 guide rail length;

 sketch of guide rail supports;

 distance of guide rail support;

 bolted rail joints (bolt diameter, quality, tightening torque);

 power supply;

 safety clearances;

 !maximum working load depending on inclination";

 out of service position of the lcd;

 observation of operating instructions;

 hoist may only be used by authorised personnel.

7.2.4 Label on the lcd

 !maximum working load";

 no access of persons allowed.

7.2.5 Drive motor label

 name and address of manufacturer;

 type designation;

 year of construction and serial number;

 power consumption.

7.3 Marking of control elements

All control elements have to be clearly marked. The use of pictograms is recommended.

35
BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Annex A
(normative)

European stormwind map

Figure A.1 — European stormwind map"

The regions A to E are taken from the European Stormwind Map.

36
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Annex B
(informative)

!Electric safety devices

Table B.1 — List of electric safety devices

Clause Devices checked
5.9.2 slack rope/chain in drive unit
5.9.3 emergency stop
5.9.4.3 slack rope/erection and dismantling
5.9.4.3 erecting mode selector
"

37
BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Annex ZA
(informative)

!Relationship between this European Standard and the Essential

Requirements of EU Directive 2006/42/EC

This European Standard has been prepared under a mandate given to CEN by the European Commission
and the European Free Trade Association to provide a means of conforming to Essential Requirements of the
New Approach Directive Machinery 2006/42/EC.

Once this standard is cited in the Official Journal of the European Union under that Directive and has been
implemented as a national standard in at least one Member State, compliance with the normative clauses of
this standard confers, within the limits of the scope of this standard, a presumption of conformity with the
relevant Essential Requirements except those of chapter 3 of Annex I of that Directive and associated EFTA
regulations, except ESR 1.5.8, of that Directive and associated EFTA regulations.

WARNING — Other requirements and other EU Directives may be applicable to the product(s) falling within
the scope of this standard."

38
 BS EN 12158-2:2000+A1:2010
EN 12158-2:2000+A1:2010 (E)

Bibliography

[1] !EN 349:1993, Safety of machinery — Minimum gaps to avoid crushing of parts of the human
body"

[2] !EN 60947-4-1:2001, Low-voltage switchgear and controlgear — Part 4-1: Contactors and motor-
starters; Electromechanical contactors and motor-starters (IEC 60947-4-1:2000)"

[3] !ISO 6336-1:2006, Calculation of load capacity of spur and helical gears — Part 1: Basic principles,
introduction and general influence factors"

[4] !ISO 6336-2:2006, Calculation of load capacity of spur and helical gears — Part 2: Calculation of
surface durability (pitting)"

[5] !ISO 6336-3:2006, Calculation of load capacity of spur and helical gears — Part 3: Calculation of
tooth bending strength"

[6] !ISO 6336-5:2003, Calculation of load capacity of spur and helical gears — Part 5: Strength and
quality of materials"

39
BS EN
12158-2:2000
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