kSIST FprEN 12385-3:2020

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.åHYDQMHDrahtseile aus Stahldraht - Sicherheit - Teil 3: Informationen für Gebrauch und InstandhaltungCâbles en acier - Sécurité - Partie 3: Informations pour l'utilisation et la maintenanceSteel wire ropes - Safety - Part 3: Information for use and maintenance77.140.65Jeklene žice, jeklene vrvi in verigeSteel wire, wire ropes and link chainsICS:Ta slovenski standard je istoveten z:prEN 12385-3oSIST prEN 12385-3:2018en,fr,de01-december-2018oSIST prEN 12385-3:2018SLOVENSKI

uã Informationen für Gebrauch und Instandhaltung This draft European Standard is submitted to CEN members for enquiryä It has been drawn up by the Technical Committee

If this draft becomes a European Standardá CEN members are bounwhich stipulate the conditions for giving this European Standard the status of a national standard without any alterationä

This draft European Standard was established by CEN in three ofer language made by translation under the responsibility of a CEN member into its own language and notified to the CENæCENELEC Management Centre has the same status as the official versionsä

CEN members are the national standards bodies of Austriaá Belgiumá Bulgariaá Croatiaá Cyprusá Czech Republicá Denmarká Estoniaá Finlandá Former Yugoslav Republic of Macedoniaá Franceá Germanyá Greeceá Hungaryá Icelandá Irelandá Italyá Latviaá Lithuaniaá Luxembourgá Maltaá Netherlandsá Norwayá Polandá Portugalá Romaniaá Serbiaá Slovakiaá Sloveniaá Spainá Swedená Switzerlandá Turkey and United Kingdomä

Recipients of this draft are invited to submitá with their commentsá notification of any relevant patent rights of which they are aware and to provide supporting documentationä

Warning ã This document is not a European Standardä It is distributed for review and commentsä It is subject to change without notice and shall not be referred to as a European Standardä

EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG

t r s z CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Membersä Refä Noä prEN

prEN 12385-3:2018 (E) 2 Contents Page European foreword ....................................................................................................................................................... 3 Introduction ..................................................................................................................................................................... 4 1 Scope .................................................................................................................................................................... 5 2 Normative references .................................................................................................................................... 5 3 Terms and definitions .................................................................................................................................... 5 4 List of significant hazards ............................................................................................................................. 5 5 Safety instructions and information for use and maintenance ...................................................... 6 Annex A (informative)

Example of general information for use and maintenance .............................. 7 A.1 Limitations on use due to adverse environmental conditions ....................................................... 7 A.2 Before putting the rope into first use ....................................................................................................... 7 A.3 Handling and installing the rope ............................................................................................................... 9 A.4 Maintenance ................................................................................................................................................... 11 Annex B (informative)

Guidance on rope selection ...................................................................................... 12 B.1 Rope selection ................................................................................................................................................ 12 Annex C (informative)

Material health and safety information on steel wire rope and its component parts ........................................................................................................................................... 17 C.1 Material ............................................................................................................................................................ 17 C.2 General information .................................................................................................................................... 18 Annex ZA (informative)

Relationship between this European Standard and the essential requirements of Directive 2014/33/EU aimed to be covered ..................................................... 20 Annex ZB (informative)

Relationship between this European Standard and the essential requirements of Directive 2006/42/EC aimed to be covered ...................................................... 22 Bibliography ................................................................................................................................................................. 23

prEN 12385-3:2018 (E) 3 European foreword This document (prEN 12385-3:2018) has been prepared by Technical Committee CEN/TC 168 “Chains, ropes, webbing, slings and accessories - Safety”, the secretariat of which is held by BSI. This document is currently submitted to the CEN Enquiry. This document will supersede EN 12385-3:2004+A1:2008. 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 and Annex ZB, which are integral parts of this document. The other Parts of this European Standard are:

Part 8: Stranded hauling and carrying-hauling ropes for cableway installations designed to carry persons

Part 9: Locked coil carrying ropes for cableway installations designed to carry persons

Part 10: Spiral ropes for general structural applications oSIST prEN 12385-3:2018

prEN 12385-3:2018 (E) 4 Introduction This European Standard is a type C standard as stated in EN ISO 12100. This Part of this European Standard has been prepared to support the other Parts of this standard that concern themselves with the particular requirements for steel wire ropes to be used in specific applications. The types of ropes concerned and the extent to which hazards are covered are indicated in the scope of this document. When provisions of this type C standard are different from those which are stated in type A and B standards, the provisions of this type C standard take precedence over the provisions of the other standards, for information for use and maintenance according to the provisions of this type C standard. oSIST prEN 12385-3:2018

prEN 12385-3:2018 (E) 5 1 Scope This Part of this European Standard specifies the type of information for use and maintenance of steel wire ropes to be provided by the rope manufacturer or to be included in the manufacturer’s handbook that accompanies a machine, piece of equipment or installation of which the steel wire rope forms a part. The particular hazards covered by this European Standard are identified in Clause 4. For steel wire ropes conforming to Parts 8 and 9 used on cableway installations designed to carry persons, additional information for use and maintenance is given in EN 12927-7. For steel wire rope slings, specific information on use and maintenance is given in EN 13414-2. This document is not applicable to steel wire ropes manufactured before the date of publication of this document by CEN. 2 Normative references The following documents are referred to in the text in such a way that some or all of their content constitutes requirements of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 12385-2:2002+A1:2008, Steel wire ropes — Safety — Part 2: Definitions, designation and classification EN ISO 12100:2010, Safety of machinery — General principles for design — Risk assessment and risk reduction (ISO 12100:2010) 3 Terms and definitions For the purposes of this document, the following terms and definitions given in EN ISO 12100:2010, EN 12385-2 and the following apply. ISO and IEC maintain terminological databases for use in standardization at the following addresses:

ISO Online browsing platform: available at http://www.iso.org/obp 3.1 inspection visual check on the condition of the rope to identify obvious damage or deterioration which might affect its fitness for use 3.2 thorough examination visual examination carried out by a competent (trained and experienced) person, and where necessary, supplemented by other means, such as measurement or electro-magnetic non-destructive testing, in order to detect damage or deterioration which might affect the fitness for use of the rope 4 List of significant hazards Table 1 contains all the significant hazards, hazardous situations and events, as far as they are dealt with in this standard, identified by risk assessment and which require action to eliminate or reduce the risk. oSIST prEN 12385-3:2018

prEN 12385-3:2018 (E) 6 Table 1 — Hazards and associated requirements Hazards relevant to this standard identified by reference to EN ISO 12100:2010 Relevant clause of this standard Inadequate information for use and maintenance 5.2 Annex A Inadequate information on rope selection 5.3 Annex B Inadequate information about the effects on health and safety of the materials used in wire ropes 5.4 Annex C 5 Safety instructions and information for use and maintenance 5.1 General Information shall be provided on the subjects listed in 5.2 to 5.4. 5.2 Use and maintenance This information shall include temperature limits, use in exceptionally hazardous conditions, first use, handling and installation and maintenance. An example of such information is given in Annex A. 5.3 Rope selection For stranded ropes this information shall include guidance on rope construction in relation to abrasion and wear, type of core in relation to crushing of the rope at the drum, wire finish in relation to corrosion, direction of lay and type in relation to direction of coiling, rotational characteristics in relation to use of a swivel and fleet angle effects. An example of such information is given in Annex B. 5.4 Material health and safety information on steel wire rope and its component parts This information shall include details of all the individual materials that form part of the finished rope and general information relating to occupational protective measures, emergency medical procedures, safety (including any fire or explosion hazards) and disposal. An example of such information is given in Annex C. oSIST prEN 12385-3:2018

Example of general information for use and maintenance A.1 Limitations on use due to adverse environmental conditions A.1.1 Temperature A.1.1.1 Steel wire ropes made from carbon steel wires Account should be taken of the maximum temperature that may be reached by the wire rope in service. An underestimation of the temperature involved can lead to a dangerous situation. Stranded ropes with fibre cores or fibre centres can be used up to a maximum of 100 °C. Stranded ropes with steel cores and spiral ropes (i.e. spiral strand and locked coil) can be used up to 200 °C although some de-rating of the working load limit is necessary, the amount being dependent upon the exposure time at high temperature and the diameter of the wires. For operating temperatures between 100 °C and 200 °C the loss in strength may be assumed to be 10 %. For temperatures above 200 °C special lubricants may be necessary and greater losses in strength than stated above will need to be taken into account. The rope or machinery manufacturer should be contacted. The strength of steel wire ropes will not be adversely affected by operating temperatures as low as – 40 °C and no reduction from the working load limit is necessary; however, rope performance may be reduced, depending upon the effectiveness of the rope lubricant at low temperatures. When the rope is fitted with a termination, also refer to A.1.1.2. A.1.1.2 Terminations In addition to the limits stated above for rope, and unless otherwise specified by the rope manufacturer or the manufacturer of the machine, equipment or installation, the following operating temperatures shall not be exceeded: Turn-back eye with aluminium ferrule: 150 °C Ferrule-secured eye with steel ferrule: 200 °C Socket filled with a lead-based alloy: 80 °C Socket filled with zinc or a zinc-based alloy: 120 °C Socket filled with resin – refer to resin socketing system designer’s instructions A.1.2 Use in exceptionally hazardous conditions In cases where exceptionally hazardous conditions are known to exist, e.g. offshore activities, the lifting of persons and potentially dangerous loads such as molten metals, corrosive materials or radioactive materials a risk assessment should be carried out and the working load limit selected or adjusted accordingly. A.2 Before putting the rope into first use A.2.1 Inspecting the rope and documents The rope should be unwrapped and examined immediately after delivery in order to check its identity and condition and to ensure that the rope and its termination(s), if any, are compatible with the machinery or equipment to which they are to be attached in service. If damage to the rope or its package is observed, this should be recorded on the delivery note. oSIST prEN 12385-3:2018

prEN 12385-3:2018 (E) 8 The Certificate of conformity by the rope manufacturer should be kept in a safe place, e.g. with the crane handbook, for identification of the rope when carrying out periodic thorough examinations in service. The rope should not be used for lifting purposes without the user having a Certificate in his possession. A.2.2 Storing the rope A clean, well-ventilated, dry, dust free, undercover location should be selected. The rope should be covered with waterproof material if it cannot be stored inside. The rope should be stored and protected in such a manner that it will not be exposed to any accidental damage during the storage period or when placing the rope in, or taking it out of, storage. The rope should be stored where it is not likely to be affected by chemical fumes, steam or any other corrosive agents. If supplied on a reel, the reel should be rotated periodically during long periods of storage, particularly in warm environments, to prevent migration of the lubricant from the rope. The rope should not be stored in areas subject to elevated temperatures as this may affect its future performance. In extreme cases its original as-manufactured breaking force could be severely reduced rendering it unfit for safe use. The rope should not be allowed to make any direct contact with the floor and the reel should be so positioned that there is a flow of air under the reel. NOTE Failure to ensure the above may result in the rope becoming contaminated with foreign matter and start the onset of corrosion even before the rope is put into service. Preferably, the reel should be supported in an A-frame or cradle standing on ground which is capable of safely supporting the total mass of rope and reel. The rope should be inspected periodically and, when necessary, a suitable rope dressing, which is compatible with the manufacturing lubricant, should be applied. Any wet packaging, e.g. sackcloth, should be removed. The rope marking should be checked to verify that it is legible and relates to the certificate. When removing from store, the principle 'first in, first out' should be applied. A.2.3 Checking the condition of rope related parts of the machine, equipment or installation Before installing the new rope, the condition and dimensions of rope related parts, e.g. drums, sheaves and rope guards, should be checked to verify that they are within the operating limits as specified by the original equipment manufacturer. For ropes working on cranes, the effective groove diameter should be at least 5 % above the nominal rope diameter. The groove diameter should be checked using a sheave gauge. Sheaves should also be checked to ensure that they are free to rotate. Under no circumstances should the actual rope diameter be greater than the pitch of the drum. In the case of multi-layer coiling, the relationship between the actual rope diameter and the pitch should be assessed. When grooves become excessively worn, it may be possible to have them re-machined. Before doing so, the sheave or drum should be examined to determine if sufficient strength will remain in the underlying material supporting the rope after the machining has been carried out. NOTE When grooves become worn and the rope is pinched at it sides, strand and wire movement is restricted and the ability of the rope to bend is reduced, thus affecting rope performance. oSIST prEN 12385-3:2018

prEN 12385-3:2018 (E) 9 A.3 Handling and installing the rope A.3.1 General The procedure for installing the rope should be carried out in accordance with a detailed plan issued by the user of the steel wire rope. The rope should be checked to verify that it is not damaged when unloaded and when transported to storage compound or site. During these operations, the rope itself should not come into contact with any part of the lifting device, such as the hook of a crane or a fork of a fork lift truck. Webbing slings may be helpful. A.3.2 Rope supplied in a coil The coil of rope should be placed on the ground and rolled out straight, ensuring that it does not become contaminated with dust, grit, moisture or other harmful material. The rope should never be pulled away from a stationary coil as this will induce turn into the rope and form kinks. If the coil is too large to physically handle, it may need to be placed on a turntable which will allow the rope to be paid out as the end of the rope is pulled away from the coil. Correct methods of paying out rope from a coil are shown in Figure A.1.

Figure A.1 — Correct methods of paying out rope from a coil A.3.3 Rope supplied on a reel A shaft of adequate strength should be passed through the reel bore and the reel places in a suitable stand which allows it to rotate and be braked to avoid overrun during installation. Where multi-layer coiling is involved, the rope should be placed in equipment that has the capability of providing a back tension in the rope as it is being transferred from the supply reel to the drum. This is to ensure that the underlying laps of rope, particularly in the bottom layer, are wound tightly on the drum. The supply reel should be positioned such that the fleet angle during installation is kept to a minimum. If a loop forms in the rope it should not be allowed to tighten to form a kink. The reel stand should be mounted so as not to create a reverse bend during reeving, i.e. for a drum with an underwind rope, take the rope off the bottom of the supply reel (see Figure A.2). oSIST prEN 12385-3:2018

Figure A.2 — Transfer of wire rope from reel to drum with control of rope tension – bottom of reel to bottom of drum When releasing the outboard end of the rope from the supply reel or coil, this should be done in a controlled manner. On release of the bindings or the rope end fixing, the rope will want to straighten itself and unless controlled this could be a violent action, which could result in injury. The as-manufactured condition of the rope should be maintained during installation. If installing the new rope with the aid of the old rope, one method is to fit a wire rope sock to each of the rope ends to be attached. The open end of the sock should be securely attached to the rope by a serving or alternatively by a suitable clip. The two ends should be connected via a length of fibre rope of adequate strength in order to avoid turn being transmitted from the old rope into the new rope. If a wire rope is used, it should be a rotation-resistant type or should have the same lay type and direction as the new rope. Alternatively, a length of fibre or steel rope of adequate strength may be reeved into the system for use as a pilot/messenger line. A swivel should not be used during the installation of the rope. Monitor the rope carefully as it is being pulled into the system and ensure that it is not obstructed by any part of the structure or mechanism that may damage the rope and result in a loss of control. A.3.4 Cutting the rope If it is necessary to cut the rope, secure servings should be applied on both sides of the cut mark. The length of each serving for a stranded rope should be at least equal to two rope diameters. One serving either side of the cut mark is usually sufficient for preformed ropes (see EN 12385-2). For non-preformed ropes, rotation-resistant ropes and parallel-closed ropes a minimum of two servings each side of the cut mark is recommended. Preferably, cutting of the rope should be done using a high speed abrasive disc cutter. Other suitable mechanical or hydraulic shearing equipment may be used although not recommended when the rope end is to be welded or brazed. When cutting, ensure adequate ventilation to avoid any build-up of fumes from the rope and its constituent parts. See Annex C. NOTE 1 Some special ropes contain synthetic material which, when heated to a temperature higher than normal production processing temperatures, will decompose and may give off toxic fumes. NOTE 2 Rope produced from carbon steel wires in the form as-shipped is not considered a health hazard. During subsequent processing (e.g. cutting, welding, grinding, cleaning) dust and fumes may be produced which contain elements that may affect exposed persons. After cutting, failure to correctly secure the rope end is likely to lead to slackness or distortions in the rope. An alternative method of cutting is by fusing and tapering, a process which is designed to prevent the wires and strands from unlaying. oSIST prEN 12385-3:2018

prEN 12385-3:2018 (E) 11 A.3.5 ‘Running in’ the new rope Where possible, ‘run in’ the new rope by operating the equipment slowly, preferably with a low load for a number of cycles. This enables the new rope to adjust itself gradually to the working conditions. The rope should never 'run in' with full load or even with overload. Check that the rope is spooling correctly on the drum and that no slack occurs in the rope or cross-laps of rope develop at the drum. NOTE Irregular coiling will inevitably result in severe surface wear and rope distortion. A.4 Maintenance A.4.1 Inspecting and examining the rope Inspection and through examination intervals and discard criteria should be in accordance with the following:

Cableway ropes –EN 12927-7. A.4.2 Lubricating the rope in service The protection provided by the original manufacturing lubricant is normally adequate to prevent deterioration due to corrosion during shipment, storage and the early life of the rope; however, in order to obtain optimum performance, most ropes will benefit from the application of a service lubricant, the type of which will be dependent upon the rope application and the environmental conditions to which the rope is exposed. The service lubricant shall be compatible with the original manufacturing lubricant and in the case of a traction drive rope, not impair its frictional characteristics. Refer to the recommendations of the rope manufacturer or the original equipment manufacturer. Typical methods of applying the service lubricant are by brush, drip feed, portable pressurized spray or high pressure. This latter system is generally designed to force the service lubricant into the rope under high pressure while simultaneously cleaning the rope and removing moisture, residual lubricant and other contaminants. Failure to apply a service lubricant could result in a reduction in the performance of the rope and at worst, lead to undetectable internal corrosion. Application of too much and the wrong type of lubricant may lead to an accumulation of foreign debris on the surface of the rope. This could result in abrasive damage to the rope, the sheave and the drum. It may also make it difficult to determine the true condition of the rope for evaluation against discard criteria. oSIST prEN 12385-3:2018

Guidance on rope selection B.1 Rope selection B.1.1 Construction in relation to abrasion and wear Wire rope will become progressively weaker when subject to abrasion and wear. This occurs when a rope makes contact with another body, such as when it passes through a sheave or over a roller, coils onto a drum or is dragged through or along abrasive material. Where abrasion is known to be the primary mode of deterioration, consideration should be given to selecting a rope with as larger outer wires as possible, but also taking into account whether there is any additional need to fulfil any bending fatigue requirements. Lang lay rope (subject to both ends of the rope being fixed and prevented from rotating) and compacted strand rope can be advantageous under abrasive conditions. NOTE Although expected to occur mainly on the crowns of the wires, wear may also take place at the strand-core and strand interfaces within the rope. B.1.2 Type of core in relation to crushing of the rope at the drum Crushing can occur due to a number of reasons but more likely when the rope is subject to multi-layer coiling at the drum. Also, greater radial pressure will be experienced between the rope and a smooth or plain-faced drum than with a grooved drum. Stranded ropes containing fibre should not be used where coiling extends into multi-layers. Ropes with steel cores and compacted strand ropes are more resistant to crushing and distortion. B.1.3 Wire finish in relation to corrosion If corrosion is expected or known to be a primary mode of deterioration, it is preferable to use a rope containing zinc (or zinc alloy Zn95/Al5) coated wires. Consideration should be given to selecting a rope with as larger wires as possible, taking into account whether there is any additional need to fulfil any bending fatigue requirements. A rope with a large number of small wires is more susceptible to corrosion than a rope with a small number of large wires. B.1.4 Direction of lay and type B.1.4.1 Connecting ropes to each other (in series) or working alongside each other (in parallel) In the event that it is necessary to connect one rope to another (i.e. in series), whether during installation or in operation, it is essential that they are of the same lay direction and type, e.g. right lay ordinary (sZ) to right lay ordinary (sZ). NOTE Connecting a ‘left’ lay rope to a ‘right’ lay rope will result in rope rotation and unlaying of the strands when loaded. If the ropes are also hand spliced at the connection the splices will open up and pull apart. oSIST prEN 12385-3:2018

prEN 12385-3:2018 (E) 13 Some applications, e.g. grabs and container cranes, demand the use of a left lay rope operating alongside a right lay rope (i.e. in parallel) in order to balance out the rotational effects of the two ropes. B.1.4.2 Direction of coiling Unless specified otherwise in the original equipment manufacturer’s instructions, the direction of coiling should be in accordance with Figure B.1. The direction of coiling in Figure B.1 generally applies to both smooth and grooved drums.

Start rope at right hand flange for right hand lay rope. Start rope at left hand flange for left hand lay rope. Figure B.1 a —Right hand lay rope – underwind Figure B.1 b —Left hand lay rope – underwind

Start rope at left hand flange for right hand lay rope. Start rope at right hand flange for left hand lay rope. Figure B.1 c —Right hand lay rope – overwind Figure B.1 d —Left hand lay rope – overwind Figure B.1 — Direction of coiling oSIST prEN 12385-3:2018

prEN 12385-3:2018 (E) 14 B.1.5 Rotational characteristics and use of a swivel ‘Cabling’ of hoist ropes in a multi-part (fall) reeving arrangement due to block rotation can occur if the rope selected has inferior torsional properties for the intended height of lift, rope spacing and loading. In such cases lifting can be severely limited or even halted. Applications involving high lifts are particularly vulnerable to this condition. NOTE Cabling is a term used to describe the condition in a multi-fall reeving arrangement where