SIST EN 1804-1:2021

Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 1: Support units and general requirements

This document stipulates the safety requirements for the use of support units intended by the manufacturer. Examples of support units are: frame supports, chock supports, shield supports, paired frames and push-pull support systems including the components of advancing and anchoring devices which provide support functions. This document excludes fixing elements on the conveyor, coal-winning equipment, power set legs and rams, valves, hydraulic and electro-hydraulic control units, lighting and signalling facilities and other ancillary equipment.
NOTE   Some components are discussed in other parts of this series of standards.
This document applies for support units that are used at ambient temperatures between −10 °C and 60 °C.
This document also applies to support components and support accessories which are provided if the support unit is fitted with stowing equipment. This document identifies and takes account of:
-   the hazards that can possibly be induced through operation of the support units;
-   the hazardous areas and the operating conditions that can cause any type of hazard;
-   the situations that can result in hazards that cause an injury or impair health;
-   dangers that can be caused through mine gas and/or flammable dusts.
This document describes methods for reducing these hazards.
Clause 4 contains a list of the hazards discussed.
This document does not specify any additional requirements for:
-   a particularly corrosive environment;
-   risks associated with manufacturing, transport and decommissioning;
-   earthquake.
A complete hydraulic powered roof support consists of the support units (EN 1804-1:2020), legs and support rams (EN 1804-2:2020) and the hydraulic and electro hydraulic controls (EN 1804-3:2020). Each part of this multipart document addresses the safety requirements of the components mentioned in the scopes of the respective parts of this multipart series.
This document is not applicable to all support units manufactured before the date of its publication.

Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen für hydraulischen Schreitausbau - Teil 1: Ausbaugestelle und allgemeine Anforderungen

Diese Europäische Norm legt die Sicherheitsanforderungen für die vom Hersteller vorgesehene bestimmungsgemäße Verwendung von Ausbaugestellen fest. Beispiele für Ausbaugestelle sind: Ausbaurahmen, Ausbauböcke, Ausbauschilde, Ausbaugespanne und Ausbauzüge einschließlich der Rückeinrichtungen und der Teile von Abspannungen, welche Ausbaufunktionen haben. Dieses Dokument schließt Anschlagelemente am Förderer, Gewinnungseinrichtungen, Stempel und Zylinder, Ventile, hydraulische und elektrohydraulische Steuerungseinrichtungen, Beleuchtungs- und Signaleinrichtungen sowie sonstige Hilfseinrichtungen aus.
ANNMERKUNG Einige Komponenten werden in anderen Teilen dieser Normenreihe behandelt.
Dieses Dokument gilt für Ausbaugestelle, die bei Umgebungstemperaturen zwischen −10 °C und 60 °C eingesetzt werden.
Diese Norm gilt darüber hinaus für Ausbauteile und Ausbauzubehör, die/das vorgesehen sind/ist, wenn das Ausbaugestell mit Versatzeinrichtungen ausgerüstet wird. Diese Norm identifiziert und berücksichtigt:
- die Gefährdungen, die womöglich durch den Betrieb von Ausbaugestellen hervorgerufen werden können;
- die Gefahrenbereiche und die Betriebsbedingungen, die irgendeine Art von Gefährdung verursachen können und
- die Situationen, die zu Gefährdungen führen können, die eine Verletzung oder Gesundheitsschädigung verursachen;
- Gefahren, die durch Grubengas und/oder brennbare Stäube verursacht werden können.
Dieses Dokument beschreibt Verfahren zur Reduzierung dieser Gefährdungen.
Abschnitt 4 enthält eine Liste der behandelten Gefährdungen.
Dieses Dokument spezifiziert keine zusätzlichen Anforderungen für:
- eine besonders korrosive Umgebung;
- Risiken bei Herstellung, Transport und Außerbetriebnahme;
- Erdbeben.
Ein kompletter hydraulischer Schreitausbau besteht aus den Ausbaugestellen (EN 1804-1:2020), Stempeln und Stützzylindern (EN 1804-2:2020) sowie den hydraulischen und elektrohydraulischen Steuerungseinrichtungen (EN 1804-3:2020). Die einzelnen Teile dieses mehrteiligen Dokuments befassen sich mit den Sicherheitsanforderungen der Komponenten, die in den Anwendungsbereichen der jeweiligen Teile dieser mehrteiligen Normenreihe genannt werden.
Dieses Dokument gilt nicht für alle Ausbaugestelle, die vor dem Datum der Veröffentlichung dieses Dokuments hergestellt wurden.

Machines pour mines souterraines - Exigences de sécurité relatives aux soutènements marchants applicables aux piles - Partie 1 : Unités de soutènement et exigences générales

Le présent document stipule les exigences de sécurité relatives à l’utilisation des unités de soutènement, telle que prévue par le fabricant. Les exemples d’unités de soutènement sont les piles à flèche, piles monoblocs, piles boucliers, piles à files et systèmes de soutènement « push pull » y compris les composants de dispositifs d’avancement et d’ancrage qui assurent le soutènement du toit. Le présent document exclut les éléments de fixation sur le convoyeur, les équipements d’abattage du charbon, les étançons et vérins à pose mécanisée, les soupapes, les unités de commande hydrauliques et électro hydrauliques, les installations d’éclairage et de signalisation et les autres équipements auxiliaires.
NOTE   Certains composants sont traités dans d’autres parties de cette série de normes.
Le présent document s’applique aux unités de soutènement qui sont utilisées à des températures ambiantes comprises entre −10 °C et 60 °C.
Le présent document s’applique également aux composants et accessoires du soutènement fournis lorsque l’unité de soutènement est munie d’équipements de remblayage. Le présent document identifie et tient compte :
-   des phénomènes dangereux pouvant potentiellement être induits par l’utilisation des unités de soutènement ;
-   des zones dangereuses et des conditions de fonctionnement susceptibles d’engendrer tout type de phénomène dangereux ;
-   des situations susceptibles d’engendrer des phénomènes dangereux pouvant entraîner des blessures ou porter atteinte à la santé ;
-   des dangers pouvant être causés par le gaz de mine (grisou) et/ou les poussières inflammables.
Le présent document décrit des méthodes permettant de réduire ces phénomènes dangereux.
L’Article 4 contient une liste des phénomènes dangereux traités.
Le présent document ne définit pas d’exigences supplémentaires concernant :
-   un milieu environnant particulièrement corrosif ;
-   les risques associés à la fabrication, au transport et à la mise hors service ;
-   les tremblements de terre.
Un soutènement marchant complet est constitué des unités de soutènement (EN 1804-1:2020), des étançons et des vérins de soutènement (EN 1804-2:2020) et des systèmes de commande hydrauliques et électro hydrauliques (EN 1804-3:2020). Chaque partie du présent document multipartie traite des exigences de sécurité des composants mentionnés dans le domaine d’application de la partie concernée.
Le présent document ne s’applique pas à toutes les unités de soutènement fabriquées avant sa date de publication.

Stroji za podzemne rudnike - Varnostne zahteve za hidravlično podporje - 1. del: Podporne enote in splošne zahteve

General Information

• Status: Published
• Public Enquiry End Date: 24-Apr-2019
• Publication Date: 03-Mar-2021
• ICS: 73.100.10 - Tunnelling and tubbing equipment
• Technical Committee: VSN - Safety of machinery
• Current Stage: 6060 - National Implementation/Publication (Adopted Project)
• Start Date: 05-Jan-2021
• Due Date: 12-Mar-2021
• Completion Date: 04-Mar-2021
• Directive: 2006/42/EC - Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast)
• Mandate: M/396 - Mandate to CEN and Cenelec for standardisation in the field of machinery
• Ref Project: EN 1804-1:2020 - Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 1: Support units and general requirements

Relations

• Replaces: SIST EN 1804-1:2002+A1:2010 - Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 1: Support units and general requirements
• Effective Date: 30-Dec-2020

Overview

EN 1804-1:2020 - Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 1: Support units and general requirements.
Published by CEN, this European standard specifies safety requirements for support units intended by the manufacturer for use in underground mining. It applies to common support unit types such as frame supports, chock supports, shield supports, paired frames and push–pull support systems, including advancing and anchoring components that perform support functions. The standard is applicable for ambient temperatures between −10 °C and 60 °C and is part of a multipart series (see Related Standards).

Key topics and technical requirements

• Scope and exclusions: covers support units and certain accessories (including stowing equipment). Excludes fixing elements on conveyors, coal-winning equipment, power set legs and rams, valves, hydraulic/electro‑hydraulic control units, lighting/signalling and other ancillary equipment.
• Hazard identification: lists significant hazards and hazardous scenarios (see Clause 4 and Annex C), including hazards from operation, hazardous areas, mine gas and flammable dusts.
• Design & strength requirements: requirements for stability, alignment, yield behaviour, overload behaviour, eccentric and horizontal loading, fatigue strength and force transmission points.
• Materials & welding: criteria for steel and other materials, welding suitability and material testing (yield, tensile, impact - Annex A).
• Verification & testing: type tests and series tests, static calculations, load and cyclic fatigue tests, tests for gradients, forepoling devices and lifting/pulling points (detailed in Annex A and Annex B for longwall shields).
• User information: required instructions for handling, transport, storage, installation, commissioning, operation, maintenance, marking and residual hazards (Clause 6).
• Standards classification: identified as a Type C standard (per EN ISO 12100:2010) and mapped to EU Machinery Directive requirements (Annex ZA).

Practical applications and users

Who uses EN 1804-1:2020:

• Manufacturers of hydraulic roof support units - to design, verify and document safety compliance.
• Mine operators and safety engineers - to select compliant support units and define safe operating/maintenance procedures.
• Regulators and conformity assessors - for conformity assessment and market surveillance against EU requirements.
• Service and maintenance providers - for maintenance schedules, fault diagnosis and spare parts handling.

Practical uses:

• Designing and type-testing support units for longwall and development faces.
• Creating user manuals, maintenance instructions and marking for safe in-mine operation.
• Defining test protocols for fatigue, load, and stability assessments.

Related Standards

• EN 1804-2:2020 - Legs and support rams (hydraulic powered roof support components)
• EN 1804-3:2020 - Hydraulic and electro‑hydraulic control systems
• EN ISO 12100:2010 - General principles for risk assessment (reference for type C standards)

Keywords: EN 1804-1:2020, hydraulic powered roof supports, underground mines, safety requirements, support units, mining machinery, longwall shields.

Standards Content (Sample)

SLOVENSKI STANDARD
01-april-2021
Nadomešča:
SIST EN 1804-1:2002+A1:2010
Stroji za podzemne rudnike - Varnostne zahteve za hidravlično podporje - 1. del:
Podporne enote in splošne zahteve
Machines for underground mines - Safety requirements for hydraulic powered roof
supports - Part 1: Support units and general requirements
Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen für hydraulischen
Schreitausbau - Teil 1: Ausbaugestelle und allgemeine Anforderungen
Machines pour mines souterraines - Exigences de sécurité relatives aux soutènements
marchants applicables aux piles - Partie 1 : Unités de soutènement et exigences
générales
Ta slovenski standard je istoveten z: EN 1804-1:2020
ICS:
73.100.10 Oprema za gradnjo predorov Tunnelling and tubbing
in podzemnih železnic equipment
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

EN 1804-1
EUROPEAN STANDARD
NORME EUROPÉENNE
December 2020
EUROPÄISCHE NORM
ICS 73.100.10 Supersedes EN 1804-1:2001+A1:2010
English Version
Machines for underground mines - Safety requirements for
hydraulic powered roof supports - Part 1: Support units
and general requirements
Machines pour mines souterraines - Exigences de Maschinen für den Bergbau unter Tage -
sécurité relatives aux soutènements marchants Sicherheitsanforderungen für hydraulischen
applicables aux piles - Partie 1 : Unités de soutènement Schreitausbau - Teil 1: Ausbaugestelle und allgemeine
et exigences générales Anforderungen
This European Standard was approved by CEN on 25 October 2020.

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-CENELEC 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-CENELEC 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, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2020 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 1804-1:2020 E
worldwide for CEN national Members.

Contents Page
European foreword . 4
Introduction . 5
1 Scope . 6
2 Normative references . 6
3 Terms and definitions . 8
4 Safety requirements . 10
4.1 General requirements . 10
4.1.1 General. 10
4.1.2 Walkway . 10
4.1.3 Protection against dust . 10
4.1.4 Protection against ejected fluids . 10
4.1.5 Protection against face material spalling . 10
4.1.6 Lifting and pulling points . 11
4.1.7 Forepoling devices . 11
4.2 Stability and alignment requirements . 11
4.2.1 Tilt-resistance . 11
4.2.2 Alignment . 11
4.3 Design requirements . 11
4.3.1 Yield capability . 11
4.3.2 Behaviour when overloaded . 11
4.3.3 Eccentric loading . 11
4.3.4 Loading resulting from caving or stowing . 11
4.3.5 Horizontal loading . 12
4.3.6 Fatigue strength . 12
4.3.7 Force transmission points of legs and cylinders . 12
4.4 Materials . 12
4.4.1 Steel. 12
4.4.2 Light metal . 13
4.4.3 Materials other than steel . 13
4.5 Permissible stresses . 13
4.5.1 General. 13
4.5.2 Calculated axial stresses . 13
4.5.3 Calculated shear stresses . 13
4.5.4 Calculated combined stresses . 14
4.5.5 Calculated weld stresses . 14
4.6 Hinge joints . 14
4.7 Welding . 14
5 Verification of the safety requirements . 14
5.1 Type testing . 14
5.2 Series tests . 15
6 User information . 16
6.1 General requirements . 16
6.2 Handling, transport, and storage . 16
6.2.1 Introduction . 16
6.2.2 Handling and transport . 16
6.2.3 Storage . 16
6.3 Installation and commissioning . 17
6.3.1 General . 17
6.3.2 Installation . 17
6.3.3 Commissioning . 17
6.4 Operation . 17
6.5 Maintenance . 17
6.5.1 Introduction . 17
6.5.2 Technical description . 17
6.5.3 Maintenance instructions . 18
6.5.4 Fault diagnosis and correction . 18
6.5.5 Maintenance schedules . 18
6.6 Parts identification lists . 18
6.7 Marking . 19
6.8 Residual hazards . 19
Annex A (normative) Tests for verification of the safety requirements and calculation . 20
A.1 Load tests . 20
A.1.1 General . 20
A.1.2 Single loading tests . 21
A.1.3 Cyclic fatigue test . 21
A.2 Testing in case of a gradient and over tipped face (caving and stowing) . 23
A.3 Testing in the case of gradients of more than 30° . 24
A.4 Testing of lifting and pulling points . 24
A.5 Testing of forepoling devices . 24
A.6 Testing of power set legs, rams and hydraulic control systems for integration within
the support unit. 24
A.7 Testing the material properties . 24
A.7.1 General . 24

A.7.2 Welding suitability . 24
A.7.3 Yield point or 0,2 % proof stress, tensile strength, elongation at fracture . 24
A.7.4 Impact value . 24
A.8 Static calculations . 25
A.8.1 General . 25
A.8.2 Load cases . 25
A.9 Samples for loading tests . 26
Annex B (normative) Structural testing requirements for longwall shields . 39
B.1 Structural measurements . 39
B.2 Acceptance criteria . 44
B.2.1 Plastic deformation . 44
Annex C (informative) List of significant hazards . 46
Annex ZA (informative) Relationship between this European Standard and the essential
requirements of Directive 2006/42/EC aimed to be covered . 49

European foreword
This document (EN 1804-1:2020) has been prepared by Technical Committee CEN/TC 196 “Mining
machinery and equipment - Safety”, the secretariat of which is held by DIN.
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 June 2021, and conflicting national standards shall be
withdrawn at the latest by June 2021.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
This document supersedes EN 1804-1:2001+A1:2010.
The main differences between this document and EN 1804-1:2001+A1:2010 are as follows:
a) Normative references (updated);
b) List of significant hazards (revised) (see Annex C);
c) Requirements for prop anchorages (deleted);
d) Requirements for steel for welded components (updated/modified);
e) List of tests for confirmation (updated);
f) Acceptance criteria for test results (modified);
g) Measurement and criteria for deformation after the test (added);
h) Requirements for convergence test (modified);
i) Cyclic fatigue test for canopy side shield (added);
j) Figures and pictures (revised/added).
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 organisations 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, Republic of North
Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United
Kingdom.
Introduction
This document is a type C standard, as specified in EN ISO 12100:2010.
The machinery concerned and the extent to which hazards, hazardous situations and events are covered
are indicated in the scope of this document.
This document is of relevance, in particular, for the following stakeholder groups representing the market
players with regard to machinery safety:
— machine manufacturers (small, medium and large enterprises);
— health and safety bodies (regulators, accident prevention organizations, market surveillance, etc.).
Others can be affected by the level of machinery safety achieved with the means of the document by the
above-mentioned stakeholder groups:
— machine users/employers (small, medium and large enterprises);
— machine users/employees (e.g. trade unions, organizations for people with special needs);
— service providers, e.g. for maintenance (small, medium and large enterprises);
— consumers (in the case of machinery intended for use by consumers).
The above-mentioned stakeholder groups have been given the possibility to participate at the drafting
process of this document.
The machinery concerned and the extent to which hazards, hazardous situations or hazardous events are
covered are indicated in the Scope of this document.
When requirements of this type-C standard are different from those which are stated in type-A or type-B
standards, the requirements of this type-C standard take precedence over the requirements of the other
standards for machines that have been designed and built according to the requirements of this type-C
standard.
The extent to which hazards are covered is indicated in the scope of this document. When creating this
standard it was assumed that:
— only trained and qualified personnel would operate the machine;
— components for which no specific requirements have been formulated:
— have been constructed in accordance with generally accepted engineering practice and generally
accepted calculation methods;
— have been well manufactured mechanically;
— are free of defects;
— the components are kept in good operational condition;
— the implementation conditions and requirements imposed on the machine have been agreed
between manufacturer and user.

1 Scope
This document stipulates the safety requirements for the use of support units intended by the
manufacturer. Examples of support units are: frame supports, chock supports, shield supports, paired
frames and push-pull support systems including the components of advancing and anchoring devices
which provide support functions. This document excludes fixing elements on the conveyor, coal-winning
equipment, power set legs and rams, valves, hydraulic and electro-hydraulic control units, lighting and
signalling facilities and other ancillary equipment.
NOTE Some components are discussed in other parts of this series of standards.
This document applies for support units that are used at ambient temperatures between −10 °C and
60 °C.
This document also applies to support components and support accessories which are provided if the
support unit is fitted with stowing equipment. This document identifies and takes account of:
— the hazards that can possibly be induced through operation of the support units;
— the hazardous areas and the operating conditions that can cause any type of hazard;
— the situations that can result in hazards that cause an injury or impair health;
— dangers that can be caused through mine gas and/or flammable dusts.
This document describes methods for reducing these hazards.
Clause 4 contains a list of the hazards discussed.
This document does not specify any additional requirements for:
— a particularly corrosive environment;
— risks associated with manufacturing, transport and decommissioning;
— earthquake.
A complete hydraulic powered roof support consists of the support units (EN 1804-1:2020), legs and
support rams (EN 1804-2:2020) and the hydraulic and electro hydraulic controls (EN 1804-3:2020).
Each part of this multipart document addresses the safety requirements of the components mentioned
in the scopes of the respective parts of this multipart series.
This document is not applicable to all support units manufactured before the date of its publication.
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 1090-1:2009+A1:2011, Execution of steel structures and aluminium structures — Part 1: Requirements
for conformity assessment of structural components
EN 1804-2:2020, Machines for underground mines — Safety requirements for hydraulic powered roof
supports — Part 2: Power set legs and rams
EN 1804-3:2020, Machines for underground mines — Safety requirements for hydraulic powered roof
supports — Part 3: Hydraulic and electro hydraulic control systems
EN 1993-1-1:2005, Eurocode 3: Design of steel structures — Part 1-1: General rules and rules for buildings
EN 1993-1-8:2005, Eurocode 3: Design of steel structures — Part 1-8: Design of joints
EN 1993-1-9:2005, Eurocode 3: Design of steel structures — Part 1-9: Fatigue
EN 1993-1-10:2005, Eurocode 3: Design of steel structures — Part 1-10: Material toughness and through-
thickness properties
EN 10025-1:2004, Hot rolled products of structural steels — Part 1: General technical delivery conditions
EN 10025-2:2019, Hot rolled products of structural steels — Part 2: Technical delivery conditions for non-
alloy structural steels
EN 10025-3:2019, Hot rolled products of structural steels — Part 3: Technical delivery conditions for
normalized/normalized rolled weldable fine grain structural steels
EN 10025-4:2019, Hot rolled products of structural steels — Part 4: Technical delivery conditions for
thermomechanical rolled weldable fine grain structural steels
EN 10025-5:2019, Hot rolled products of structural steels — Part 5: Technical delivery conditions for
structural steels with improved atmospheric corrosion resistance
EN 10025-6:2019, Hot rolled products of structural steels — Part 6: Technical delivery conditions for flat
products of high yield strength structural steels in the quenched and tempered condition
EN 10204:2004, Metallic products — Types of inspection documents
EN ISO 80079-36:2016, Explosive atmospheres — Part 36: Non-electrical equipment for explosive
atmospheres — Basic method and requirements (ISO 80079-36:2016)
EN ISO 148-1:2016, Metallic materials — Charpy pendulum impact test — Part 1: Test method
(ISO 148-1:2016)
EN ISO 643:2020, Steels — Micrographic determination of the apparent grain size (ISO 643:2019,
Corrected version 2020-03)
EN ISO 6892-1:2019, Metallic materials — Tensile testing — Part 1: Method of test at room temperature
(ISO 6892-1:2019)
EN ISO 12100:2010, Safety of machinery — General principles for design — Risk assessment and risk
reduction (ISO 12100:2010)
EN ISO 15614-1:2017, Specification and qualification of welding procedures for metallic materials —
Welding procedure test — Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys
(ISO 15614-1:2017, Corrected version 2017-10-01)

As impacted by EN 1993-1-1:2005/AC:2009 and EN 1993-1-1:2005/A1:2014.
As impacted by EN 1993-1-8:2005/AC:2009.
As impacted by EN 1993-1-9:2005/AC:2009.
As impacted by EN 1993-1-10:2005/AC:2009.
As impacted by EN ISO 15614-1:2017/A1:2019.
3 Terms and definitions
For the purposes of this document, the terms and definitions given in EN ISO 12100:2010,
EN 1804-2:2020 and EN 1804-3:2020 and the following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https://www.iso.org/obp
— IEC Electropedia: available at http://www.electropedia.org/
3.1
designs of hydraulic powered roof support
3.1.1
support unit
type of hydraulic powered roof support, e.g. frame support, chock support, shield support, consisting of
support components and support accessories
3.1.2
frame support
support unit in which the canopy and the base are connected to legs arranged in a line one behind the
other to form one support unit
3.1.3
chock support
support unit in which the canopy and the base are connected to legs arranged one behind the other and
side by side to form one support unit
3.1.4
shield support
support unit in which the canopy and the base are connected additionally via a goaf shield which lies
within the flow of the support bearing force
3.1.5
paired frame
at least two support units arranged side by side moving lengthwise against each other using an advancing
mechanism
3.1.6
push-pull support
at least two support units arranged one behind the other moving lengthwise against each other using an
advancing mechanism
3.2
support components
all components which lie within the flow of the support bearing force
3.2.1
canopy
single or composite support component which transfers the support bearing force to the roof
3.2.2
base
single or composite support component which transfers the support bearing force to the floor
3.2.3
goaf shield
support component intended to absorb and transfer, fully or partially, the support bearing force and
forces parallel to the seam between canopy and base
Note 1 to entry: It is connected to the canopy and base either directly or through a linkage. It generally shields the
face area from the waste and is therefore subjected to a load from the caved material.
3.3
support accessories
all components which do not lie within the flow of the support bearing force but which are necessary for
the functioning of the powered roof support
3.3.1
advancing mechanism
device attached to the support unit for moving the support forwards
3.3.2
sprag (flipper)
device attached to the support unit for supporting the working face
3.3.3
forepoling device
device used to protect the face area from caving materials
3.4
anchoring device
device for preventing uncontrolled movements of the conveying and extracting machines
3.5
forces
3.5.1
yield force
force produced by an actuator at the yield pressure of the pressure limitating valve, neglecting friction
3.5.2
rated force
maximum force for which the support unit or support component is designed.
Note 1 to entry: It is a calculated value which is determined from the support geometry, neglecting friction.
3.5.3
support bearing force
force borne by a support unit normal to the strata, which is a function of the support height and which
occurs at the yield force
3.5.4
test force
measured force required to be applied to the support unit or support component to ensure that it is
subjected to the rated force
3.5.5
additional force
force acting on the support unit, not produced by the strata or the support components
4 Safety requirements
4.1 General requirements
4.1.1 General
Hydraulic powered roof support that is constructed in accordance with this document shall also satisfy
the requirements stipulated in the other parts of EN 1804.
Machinery shall comply with the safety requirements and/or protective/risk reduction measures of this
clause. In addition, the machine shall be designed according to the principles of EN ISO 12100:2010 for
relevant but not significant hazards which are not dealt with by this document.
4.1.2 Walkway
The walkway through the support unit shall ensure the minimum dimensions of 0,6 m in width and 0,4 m
clearance height (permissible tapering on the corners, see Figure 1).
The walkways shall be designed to minimize slipping hazards, e.g. by the use of ribbed plates.
Dimensions in millimetres
Figure 1 — Minimum walkway
4.1.3 Protection against dust
Support units shall be designed in such a manner that appropriate equipment for dust control can be
installed.
Support units should be designed in such a manner that they seal the walkway against dust ingress from
the roof and goaf.
4.1.4 Protection against ejected fluids
Support units shall be designed that no hydraulic elements are damaged when used as intended.
4.1.5 Protection against face material spalling
Support units having a maximum extended height of 2,5 m or more shall be fitted with devices to which
sprags can be attached.
The sprags shall be positively lockable when in the retracted position.
4.1.6 Lifting and pulling points
Support units shall have lifting and pulling points.
Lifting and pulling points shall be suitable for their intended purpose. They shall be designed to have a
calculated minimum factor of safety of 4 on ultimate breaking load in relation to their intended load
carrying capacity. They shall be clearly and permanently marked with their load carrying capacity, e.g. by
welding.
4.1.7 Forepoling devices
Forepoling devices shall not lead to damage to other parts of the support unit when loaded with the rated
force.
4.2 Stability and alignment requirements
4.2.1 Tilt-resistance
When handled in accordance with the manufacturer's instructions support units in a freestanding state
shall be stable over their whole adjustment range on all sides on a gradient of up to 15°.
In addition, they shall be stable in operation, e.g. with external stabilizing means.
4.2.2 Alignment
With support units for use in inclined seams with gradients of more than 30°, the alignment force (push
or pull) of a support unit which is set shall be greater than the lateral weight component of three adjacent
support units which are not set if these support units are no longer stable in the free-standing state.
4.3 Design requirements
4.3.1 Yield capability
Support units shall be designed for yielding to absorb convergence between the roof and the floor. During
convergence the rated force shall not be exceeded by more than 20 %.
Support units should be designed in such a way that their function is impaired as little as possible by
caved waste when lowering.
4.3.2 Behaviour when overloaded
Support components including face sprags shall be designed so that no failure occurs by bending, tension
and compression when they are loaded up to 1,2 times the yield force of their respective actuators.
4.3.3 Eccentric loading
Support units shall be designed in such a way that their ability to function is not impaired in the presence
of eccentric loading, e.g. if the canopy is in contact with the roof on one side only.
4.3.4 Loading resulting from caving or stowing
Support units shall be capable of withstanding the caving or stowing forces resulting from over tipping
when operated on a gradient when working an over tipped face. The forces and the gradients to be
expected are normally be provided by the user (see introduction, last paragraph).
4.3.5 Horizontal loading
Support units shall be designed to accommodate horizontal loads.
Shield supports shall withstand a horizontal force corresponding to 0,3 times the support bearing force
without any damage to the support components.
All other support units shall either withstand the forces induced by the advancing mechanism or allow
relative movement between canopy and base:
a) in the direction of the goaf, at least 80 mm per metre of support height; and
b) in the direction of the coal face, and towards both sides at least 40 mm per metre of support height.
4.3.6 Fatigue strength
The fatigue strength of the support unit shall remain unimpaired when subjected to a total of at least
26 000 load cycles with various load configurations (see A.1.3).
4.3.7 Force transmission points of legs and cylinders
The force transmission points of actuators shall be capable of withstanding 1,5 times the maximum
tensile force and the compression force which can be generated by the support hydraulics without their
function being adversely affected.
4.4 Materials
4.4.1 Steel
4.4.1.1 General
The materials of the support parts shall be specified by the manufacturer with consideration of the
following requirements. Verification of the properties shall be provided with Acceptance Certificate 3.1
in accordance with EN 10204:2004 or better.
The ultimate tensile strength of the types of steel used shall be at least 1,08 × the determined yield
strength or 0,2 % elasticity limit, if the calculated stresses are more than 90 % of the permissible stresses
(see 4.5).
The elongation prior to fracture A of the steel grades used shall not be less than 10 %, with the exception
of steel grades used for pins where the elongation shall not be less than 9 %.
For thermal cutting of the steels, the processing guidelines issued by the manufacturer of the steel shall
be complied with.
4.4.1.2 Steel for welded support components
a) The steel shall correspond to EN 10025-1:2004, EN 10025-2:2019, EN 10025-3:2019,
EN 10025-4:2019, EN 10025-5:2019 and EN 10025-6:2019.
And it shall have at least the following impact values at a temperature of −20 °C:
— 20 J for steels with a yield strength or 0,2 % elasticity limit < 620 N/mm ;
— 25 J for steels with a yield strength or 0,2 % elasticity limit > 620 N/mm .
The specified values shall be provided, regardless of the position of sample – transverse or
longitudinal to the rolling direction.
or
b) The steel shall:
1) have a ferrite grain size of 6 or finer, in accordance with EN ISO 643:2020 and
2) at a temperature of −20 °C have at least the following impact values:
— 20 J for steels with a yield strength or 0,2 % elasticity limit < 620 N/mm ;
≥ 2
— 25 J for steels with a yield strength or 0,2 % of the elasticity limit 620 N/mm .
The specified values shall be provided, regardless of the position of sample – transverse or
longitudinal to the rolling direction.
The steels shall be suitable for welding.
Preferably the requirements in accordance with a) shall be satisfied.
4.4.1.3 Steel for non-welded support components
The steels shall be killed.
The impact value of the types of steel shall be at least 25 J at room temperature (20 °C).
4.4.2 Light metal
Surfaces consisting of light metal or light metal alloys (including paints and coatings containing light
metal) of actuators intended by the manufacturer to be used in potentially gaseous mines shall meet the
requirements of EN ISO 80079-36:2016, 6.4.4.
4.4.3 Materials other than steel
When such materials are used for the manufacture of support components, equivalent performance
characteristics to those specified for steel in 4.4.1 shall be proven. Non-metallic materials shall meet the
requirements of EN ISO 80079-36:2016, 7.4.
4.5 Permissible stresses
4.5.1 General
Static load calculations shall be carried out for all support components.
Additional forces which stress a support component shall be taken into account.
The stresses in the support components determined by calculation either shall not exceed the permissible
stresses given in 4.5.2 to 4.5.5 or the manufacturer shall demonstrate by theoretical or experimental
methods that the support component performs in a safe manner.
4.5.2 Calculated axial stresses
For canopies, bases and footplates the calculated axial stresses shall not exceed the guaranteed minimum
yield point or 0,2 % proof stress values of the materials. For other support components, the calculated
axial stresses shall not exceed 85 % of these values.
4.5.3 Calculated shear stresses
The calculated shear stresses shall not exceed 80 % of the calculated axial stresses allowed for each
support unit and load case.
4.5.4 Calculated combined stresses
The calculated combined stresses shall not exceed the guaranteed minimum yield points or 0,2 % proof
stress of the materials.
4.5.5 Calculated weld stresses
The calculated weld stresses shall not exceed the following values of the permissible stresses of the
adjacent materials (see Table 1). The welded joints and combined stresses shall be calculated in
1 2 3
accordance with EN 1993-1-1:2005 , and/or EN 1993-1-8:2005 , and/or EN 1993-1-9:2005 , and/or
EN 1993-1-10:2005 , or a comparable calculation method. Execution level to be met shall be at least EXC2
according EN 1090-1:2009+A1:2011.
Table 1 — Permissible weld stresses
Weld type Axial stresses Shear stresses Combined stresses
Fillet welds 65 % 65 % 100 %
Butt welds 100 % 65 % 100 %
4.6 Hinge joints
Hinge joints which lie in the flow path of the support bearing force shall be designed so that the
permissible stresses as specified in 4.5 are not exceeded when subjected to:
a) central loading at 1,5 times the rated force;
b) horizontal loading at the rated force (see Figure A.7);
c) eccentric and central loading when combined at the rated force (see Figures A.1, A.3 and A.6).
4.7 Welding
Welding of Roof Support steel structures shall be in accordance with the requirements min. EXC2 of
EN 1090-1:2009+A1:2011.
5 Verification of the safety requirements
5.1 Type testing
One specimen of the support unit shall be type tested in accordance with Annex A. The test requirements
given in Annex A shall be met. The following documents shall be made available to the laboratory running
the type test:
— user information;
— results of the static calculation in accordance with A.8;
— manufacturing drawings;
— welding drawings;
— data relating to the material characteristics;
— qualification verification of the welding shop.
The specimen which has been tested according to Annex A shall not be put into service.
NOTE Testing will consume the intended design life.
If no provision has been made in Annex A for verification of the requirements in Clause 4 by specified
tests, they shall be verified by means of visual inspection, function test or reference to documents.
Verification of the safety requirements is shown in Table 2.
Table 2 — Tests for confirmation of the safety requirements
Safety requirements Confirmation
4.1.2 * Measurements
4.1.3 * Visual inspection/comparison with the manufacturer's drawings
4.1.4 * See A.6
4.1.5 * Visual inspection/comparison with the manufacturer's drawings
4.1.6 * See A.4
4.1.7 * See A.5
4.2.1 * Function test or calculation
4.2.2 * See A.3
4.3.1 * See A.1.1 and A.1.2.4
4.3.2 * See A.1.1, A.1.2.1, and A.1.2.2
4.3.3 * See A.1.1 and A.1.3.4
4.3.4 * See A.2
4.3.5 * See A.1.1, A.1.2.5, and A.1.3.5
4.3.6 * See A.1.1 and A.1.3
4.3.7 * See A.1.1 and A.1.2.3
4.4.1 ** See A.7
4.4.2 ** Comparison with the manufacturers material specification and see A.7.1
4.4.3 ** Comparison with the manufacturers material specification and see A.7.1
4.5 * See A.8
4.6 * See A.8
6.3.2 * Visual inspection/comparison with the manufacturer's assembly
drawings and test documentation
*    Type test.
**   Series test.
5.2 Series tests
See Table 2; column Confirmation with **.
6 User information
6.1 General requirements
The hydraulic powered roof support manufacturer shall provide user information meeting the
requirements of EN ISO 12100:2010, Clause 5 and Clause 7.
The user information shall be the primary source of information on a complete hydraulic powered roof
support operating and control methods (e.g. immediate forward support system, conventional support
advance system, adjacent control and sequential control).
The user information shall include hazards and corresponding safety precautions for each type of support
operating mode (e.g. automatic control mode) and for combined use with other operating devices.
A complete listing of all drawings, illustrations, and other documents, e.g. including information
concerning the welding shop, that are components of the user information, shall be made available
separately. The list shall include appropriate cross-references to the text of the user information.
6.2 Handling, transport, and storage
6.2.1 Introduction
This section of the user information shall include information and instructions for the safe handling,
transport and storage of the hydraulic powered roof support or its components.
6.2.2 Handling and transport
The following shall be specified:
a) instructions concerning dismantling and for protection of parts during transport to the place of
operation;
b) list of individual components and assemblies which may be required to be lifted and transported
separately, together with location of lifting points and centre of gravity;
c) weights and overall dimensions of the complete hydraulic powered roof support and individual
components and assemblies listed in b) above;
d) details of any particular precautions to be taken during handling and transportation. In addition,
indications of possible damage to the hydraulic powered roof support during handling and transport;
e) information on the number and rated load of any ancillary lifting equipment (e.g. shackles, eye bolts)
not supplied but
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