EN13000

Cranes, Safety of
Mobile Cranes

Klaus Meissner
Director Product Integrity Terex Cranes

© Klaus Meissner Terex Cranes 2009

Terex Demag CC2200

© Terex Cranes 2009 - Klaus Meissner 2

EN13000

- Why are Standards in Europe different?

- History of European Machinery Directive
- History of European Crane Standards (Afnor, BSI, DIN, …)
- Actual Status
- Content of Standard (Overview)
- Amendment 2008
- Discussion for worldwide Standard
- Requirements of EN13000 Amendment
- Override Key
- Data Logger
- Future Development of EN13000
- Revisions as planned
- Introduction EN13849

© Terex Cranes 2009 - Klaus Meissner 3

EN13000

- Why are Standards in Europe different?

- History of European Machinery Directive
- History of European Crane Standards (Afnor, BSI, DIN, …)
- Actual Status
- Content of Standard (Overview)
- Amendment 2008
- Discussion for worldwide Standard
- Requirements of EN13000 Amendment
- Override Key
- Data Logger
- Future Development of EN13000
- Revisions as planned
- Introduction EN13849

© Terex Cranes 2009 - Klaus Meissner 4

History of European
Machinery Directive

© Terex Cranes 2009 - Klaus Meissner Source: /www.wikipedia.org/ 5

Hierachy

EC-Machinery Directive Vienna Agreement

CEN/CENELEC
ISO
(CEN TC 147 Cranes)

A B C Develop Standards
CEN/CENELEC
with representatives
(CEN TC 147 WGP1 of all parties plus
Mobile Cranes) VETO right in voting
(safeguard clause)
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What
What can
can‘tbe
bedone
doneby
bysystems
systems

Automatic System „substituting“ Operator

vs.
System as Operator‘s Aid

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Additional Influences

typical jobs with higher

risks, which have to be
compensated by safe
systems of work:
 demolition work,
 tandem lifts (multi
crane lifts)

CC12600 Tandem Lift USA

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Additional Influences

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Additional Influences

Ground Deficiency

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Additional Influences

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EN13000

- Why are Standards in Europe different?

- History of European Machinery Directive
- History of European Crane Standards (Afnor, BSI, DIN, …)
- Actual Status
- Content of Standard (Overview)
- Amendment 2008
- Discussion for worldwide Standard
- Requirements of EN13000 Amendment
- Override Key
- Data Logger
- Future Development of EN13000
- Revisions as planned
- Introduction EN13849

© Terex Cranes 2009 - Klaus Meissner 12

Definition Mobile Crane

Selfpowered jib crane capable of travelling loaded or unloaded

without the need for fixed runways and relying on gravity for
stability.
Mobile cranes can operate on tyres, crawlers or with other
mobile arrangements. In fixed positions they can be supported
by outriggers or other accessories increasing their stability.
The superstructure of mobile cranes can be of the type of full
circle slewing, of limited slewing or non slewing. It is normally
equipped with one or more hoists and/or hydraulic cylinders for
lifting and lowering the jib and the load.
Mobile cranes can be equipped either with telescopic jibs,
with articulated jibs, with lattice jibs – or a combination of
these – of such a design that they can readily be lowered… 13
© Terex Cranes 2009 - Klaus Meissner
CC8800-1TWIN

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EN13000
Reference Documents

EN 13000 is part of the „family“ of EN standards

and makes reference to
• 40 ISO standards (including EN ISO standards),
• 35 EN standards and
• FEM rules 5.004 and 1.001

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Scope of Standard
Requirements for:
• Design,
• Manufacturing,
• Installation of Safety Devices,
• Information for Use,
• Information for Maintenance
• Information for Checks
• No Requirements for Loader Cranes
• No Lifting of Persons
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Importance

The standard EN 13000 is the first international

standard to cover all requirements for calculation
and design of the entire mobile crane based on
the current „state-of-the-art“.

As such it defines the current level of safety for

all mobile cranes put onto the European market.

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Calculation

no fatigue analysis for load bearing structure, if:

• Nstress Cycles =< NOperating Cycles
• Critical notch conditions are avoided by design
and manufacturing
• No predominant alternating stresses
Application of the methods of permissible
stresses and partial safety coefficients and
limiting stresses is foreseen, besides that the
experimental proof of competence according to
ISO 11662-2 is possible
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Calculation

Structure of calculation is according to EN 13001

(Load Effects/Limit States/Proof of Competence):
• Load bearing structures (made from steel),
Load effects to be determined according to
FEM 5.004
• Limit states of load bearing structure to be
determined according to FEM 5.004
Components (Parts or assemblies subjected to
load effects, e.g. mechanisms, ropes, chains,...),
calculation in accordance to FEM 1.001 or by the
supplier – see specification sheets
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Calculation Stability
(according to ISO4305)

• Sudden release of the load is calculated as

10% of permitted load acting upwards on the
unloaded crane
• Stability for erection/dismantling is a special
loading condition, dead loads and additional
loads increasing tipping are amplified with a
safety coefficient  1,1.
• Accelerations due to abrupt starting/stopping
are considered, sufficient potential energy is
needed. Requires detailed calculated or
simplified procedure using “tipping angle”
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Calculation Stability

Tipping Angle

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EN13000

- Why are Standards in Europe different?

- History of European Machinery Directive
- History of European Crane Standards (Afnor, BSI, DIN, …)
- Actual Status
- Content of Standard (Overview)
- Amendment 2008
- Discussion for worldwide Standard
- Requirements of EN13000 Amendment
- Override Key
- Data Logger
- Future Development of EN13000
- Revisions as planned
- Introduction EN13849

© Terex Cranes 2009 - Klaus Meissner 22

Loading Control

© Terex Cranes 2009 - Klaus Meissner 23

Loading Control

The rated capacity limiter shall operate to override the

controls of the crane:
c) to prevent any motion that will lead to an overload
condition, and
d) to prevent dangerous movements of the load.
For a mobile crane the motions that shall normally be over-
ridden by the rated capacity limiter when triggered are:
i) derricking out;
ii) derricking in;
iii) hoisting;
iv) telescoping out.
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Control System

Data of loading control to be displayed

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Rated Capacity Limiter

4 cases are relevant:

Normal operation
Rigging/De-Rigging
Emergency operation
Misuse of the bridging device to use the crane
beyond the capacity chart

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Amendment on
Rated capacity Limiter
4.2.6.3.2 Rated capacity limiter
In all working areas of the crane, for which load charts are available, the
crane control system shall ensure that it is not possible to override the
rated capacity limiter. The following is permissible:

a) For rigging-/de-rigging procedures and for special operating

conditions, such as self blockage of the rated capacity limiter
(deadlock), a set-up button may be provided:

b) In case of a failure of components of the rated capacity limiter/the

load moment limiter, emergency operation may be necessary. For this
case, a bypass device may be provided.

If the mobile crane is equipped with a set-up button and/or a bridging

device, then a data recorder shall be available which meets the
following criteria…
© Terex Cranes 2009 - Klaus Meissner 27
Rigging/De-Rigging
Set Up Button
a) For rigging-/de-rigging procedures and for special operating
conditions, such as self blockage of the rated capacity limiter (deadlock), a
set-up button may be provided:
1) For rigging/de-rigging procedures, where no load charts provided by the
manufacturer are available, it is admissible to override the rated capacity
limiter using the set-up button. These rigging/de-rigging procedures shall be
described in the crane operator instructions.
2) For special operating conditions (e. g. deadlock), the shut-off limits of
the rated capacity limiter shall not exceed 110 % of the set load chart when
the set-up button is actuated. Here, the speeds of all movements shall be
only max. 15 % of the permissible working speed for the corresponding load
case.
For mobile cranes where an actuating device controls the hydraulic
pressure, this speed reduction may be provided by a central control
pressure reduction. All speeds must be hereby reduced to max. 25 %.
This set-up button shall not allow any movement which can lead to
component failure or loss of stability.
The increase of the shut off limits by the set-up button shall automatically
reset
© Terex when the- Klaus
Cranes 2009 master switch is in neutral position, or at engine stop, with28a
Meissner
delay of 10 seconds being permissible.
Emergency Operation

b) In case of a failure of components of the rated capacity limiter/the

load moment limiter, emergency operation may be necessary. For this
case, a bypass device may be provided, if
• the bridging device is located outside of the crane operator’s cab and if
it can be locked, and
• the overriding of the rated capacity limiter in emergency operation
resets automatically:
• when the master switch is in neutral position, with a delay of 10 s
being admissible;
• at engine stop;
• not later than after 30 min. and
• upon actuation of the bridging device, the speeds of all movements are
only max. 15 % of the permissible working speed for the corresponding
load case.
For mobile cranes where an actuating device controls the hydraulic
pilot pressure, this speed reduction may be provided by a central
control pressure reduction. This shall reduce all speeds to max. 25 %.
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Data Recorder

If the mobile crane is equipped with a set-up button and/or a bridging

device, then a data recorder shall be available which meets the following
criteria:
• the data shall be recorded automatically, independent of the crane
operator;
• each actuation of the set-up button or the bridging device, which leads
to an overloading of the crane (>100 % of the set load chart), shall be
recorded. Here, the size of the overloading shall be recorded;
• in addition, if the set-up button, or the bridging device, is activated, all
data shall be recorded which are relevant to reconstruct the last load
case;
• a suitable interface to read out the data shall be available;
• suitable measures shall prevent the manipulation of the recorded data;
• the function of the data recorder shall be automatically checked each
time the crane is put into operation.
A data recorder malfunction shall be indicated to the crane operator.
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Amendment of EN 13000

The Amendment of EN 13000 (amending clause 4.2.6.2.3 only)

will become into force in Europe beginning 2010, summary:

The rated capacity limiter will be equipped with:

A set up button located in the operators cab, required for rigging and
derigging, to get out of dead lock situations
A bypass device located outside the operators cab, required for
emergency operation
A data logger for recording all data if the set up button or the bypass
device is activated

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EN13000

- Why are Standards in Europe different?

- History of European Machinery Directive
- History of European Crane Standards (Afnor, BSI, DIN, …)
- Actual Status
- Content of Standard (Overview)
- Amendment 2008
- Discussion for worldwide Standard
- Requirements of EN13000 Amendment
- Override Key
- Data Logger
- Future Development of EN13000
- Revisions as planned
- Introduction EN13849

© Terex Cranes 2009 - Klaus Meissner 32

Future

ISO SC96 TC6 (mobile cranes) is working on a

frame work standard – Europe is pushing for
taking over of EN 13000

USA OSHA seems to be ready to accept in future

EN 13000 as reference document

EN13000 will serve as a „shopping list“ for

technical requirements in particular for the so
called grey imports
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EN954  EN13849

EN 954-1 Categorie
[describes Redundancy, Testing]
+
EN13849 Component Quality (MTTFd)
+
Diagnostic Coverage (DCavg)
+
Common Cause Failures (CCF)

Probability of Failure 1/h (typically better than 3*10-6)

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Timeline EN13000

2004 Veto 2008 1.1.2010 2011

EN 13000:2004 Amendment
+ Amendment „fulfilled“ (EEA
only)

USA and RoW vs. CE-Declaration

EN 954-1

EN 13000:2004 + Amendment
Still includes reference to EN 954-1

EN 13849

EN 13000:xxxx
Reference to EN 13849
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