SIST EN 1804-1:2021
(Main)Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 1: Support units and general requirements
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 or the manufacturer's authorized representative. 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.
COMMENT 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.
This document applies for all support units that have been placed on the market for the first time after the issue date of this standard.
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 oder seinem bevollmächtigten Vertreter 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. Dieser Teil der Norm schließt Anschlagelemente am Förderer, Gewinnungseinrichtungen, Stempel und Zylinder, Ventile, hydraulische und elektrohydraulische Steuerungseinrichtungen, Beleuchtungs und Signaleinrichtungen sowie sonstige Hilfseinrichtungen aus.
ANMERKUNG Einige Komponenten werden in anderen Teilen dieser Normenreihe behandelt.
Diese Norm 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.
Diese Norm beschreibt Verfahren zur Reduzierung dieser Gefährdungen.
Abschnitt 4 enthält eine Liste der behandelten Gefährdungen.
Diese Europäische Norm spezifiziert keine zusätzlichen Anforderungen für:
- besonders korrosive Umgebung;
- Risiken bei Herstellung, Transport und Außerbetriebnahme;
- Erdbeben.
Diese Norm gilt für alle Ausbaugestelle, die nach dem Ausgabedatum dieser Norm erstmalig in Verkehr gebracht 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 ou son mandataire. 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.
COMMENTAIRE 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.
Le présent document s’applique à toutes les unités de soutènement commercialisées pour la première fois après la date de publication de la présente norme.
Stroji za podzemne rudnike - Varnostne zahteve za hidravlično podporje - 1. del: Podporne enote in splošne zahteve
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 1804-1:2021
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
SIST EN 1804-1:2021 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST EN 1804-1:2021
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SIST EN 1804-1:2021
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.
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SIST EN 1804-1:2021
EN 1804-1:2020 (E)
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
2
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SIST EN 1804-1:2021
EN 1804-1:2020 (E)
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
3
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SIST EN 1804-1:2021
EN 1804-1:2020 (E)
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.
4
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SIST EN 1804-1:2021
EN 1804-1:2020 (E)
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.
5
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SIST EN 1804-1:2021
EN 1804-1:2020 (E)
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
6
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SIST EN 1804-1:2021
EN 1804-1:2020 (E)
1
EN 1993-1-1:2005, Eurocode 3: Design of steel structures — Part 1-1: General rules and rules for buildings
2
EN 1993-1-8:2005, Eurocode 3: Design of steel structures — Part 1-8: Design of joints
3
EN 1993-1-9:2005, Eurocode 3: Design of steel structures — Part 1-9: Fatigue
4
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)
5
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)
1
As impacted by EN 1993-1-1:2005/AC:2009 and EN 1993-1-1:2005/A1:2014.
2
As impacted by EN 1993-1-8:2005/AC:2009.
3
As impacted by EN 1993-1-9:2005/AC:2009.
4
As impacted by EN 1993-1-10:2005/AC:2009.
5
As impacted by EN ISO 15614-1:2017/A1:2019.
7
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SIST EN 1804-1:2021
EN 1804-1:2020 (E)
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
8
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SIST EN 1804-1:2021
EN 1804-1:2020 (E)
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
...
SLOVENSKI STANDARD
oSIST prEN 1804-1:2019
01-april-2019
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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: prEN 1804-1
ICS:
73.100.10 Oprema za gradnjo predorov Tunnelling and tubbing
in podzemnih železnic equipment
oSIST prEN 1804-1:2019 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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oSIST prEN 1804-1:2019
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oSIST prEN 1804-1:2019
DRAFT
EUROPEAN STANDARD
prEN 1804-1
NORME EUROPÉENNE
EUROPÄISCHE NORM
February 2019
ICS 73.100.10 Will supersede 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 draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee
CEN/TC 196.
If this draft becomes a European Standard, 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.
This draft European Standard was established by CEN 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, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland,
Turkey and United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2019 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 1804-1:2019 E
worldwide for CEN national Members.
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Contents Page
European foreword . 5
Introduction . 6
1 Scope . 7
2 Normative references . 7
3 Terms . 9
4 List of significant hazards . 11
5 Safety requirements . 12
5.1 General requirements . 12
5.1.1 Travel way . 13
5.1.2 Protection against dust . 13
5.1.3 Protection against ejected fluids . 13
5.1.4 Protection against face material spalling . 13
5.1.5 Lifting and pulling points . 13
5.1.6 Forepoling devices . 13
5.1.7 Correct installation . 13
5.2 Stability and alignment requirements . 14
5.2.1 Tilt-resistance . 14
5.2.2 Alignment . 14
5.3 Design requirements . 14
5.3.1 Yield capability . 14
5.3.2 Behaviour when overloaded . 14
5.3.3 Eccentric loading . 14
5.3.4 Loading resulting from caving or stowing . 14
5.3.5 Horizontal loading . 14
5.3.6 Fatigue strength . 14
5.3.7 Force transmission points of legs and cylinders . 15
5.4 Materials . 15
5.4.1 Steel . 15
5.4.2 Light metal . 16
5.4.3 Other materials . 16
5.5 Permissible stresses. 16
5.5.1 General . 16
5.5.2 Calculated axial stresses . 16
5.5.3 Calculated shear stresses . 16
5.5.4 Calculated combined stresses . 16
5.5.5 Calculated weld stresses . 16
5.6 Hinge joints. 17
5.7 Welding . 17
6 Verification of the safety requirements . 17
6.1 Type testing . 17
6.2 Series tests . 18
7 User information . 19
7.1 General requirements . 19
7.2 Handling, transport, and storage . 19
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7.2.1 Introduction. 19
7.2.2 Handling and transport . 19
7.2.3 Storage . 19
7.3 Installation and commissioning . 20
7.3.1 General . 20
7.3.2 Installation . 20
7.3.3 Commissioning . 20
7.4 Operation . 20
7.5 Maintenance . 20
7.5.1 Introduction. 20
7.5.2 Technical description . 20
7.5.3 Maintenance instructions . 21
7.5.4 Fault diagnosis and correction . 21
7.5.5 Maintenance schedules . 21
7.6 Parts identification lists . 21
7.7 Marking . 21
7.8 Residual hazards . 22
Annex A (normative) Tests for verification of the safety requirements and calculation . 23
A.1 Load tests . 23
A.1.1 General . 23
A.1.1.1 Introduction. 23
A.1.1.2 Loading conditions . 23
A.1.2 Single loading tests . 23
A.1.2.1 Bending test . 23
A.1.2.2 Tensile and compressive test . 24
A.1.2.3 Tensile and compressive test for the force introduction points of legs and rams . 24
A.1.2.4 Convergence test . 24
A.1.2.5 Test with horizontal loading of chock supports . 24
A.1.3 Cyclic fatigue test . 24
A.1.3.1 General . 24
A.1.3.2 Bending test . 26
A.1.3.3 Torsion test . 26
A.1.3.4 Testing with eccentric load . 26
A.1.3.5 Test with horizontal loading of shield supports. 26
A.2 Testing in case of a gradient and over tipped face (caving and stowing) . 26
A.3 Testing in the case of gradients of more than 30° . 27
A.4 Testing of lifting and pulling points . 27
A.5 Testing of forepoling devices . 27
A.6 Testing of power set legs, rams and hydraulic control systems for integration within
the support unit . 27
A.7 Testing the material properties . 27
A.7.1 General . 27
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A.7.2 Welding suitability . 27
A.7.3 Yield point or 0,2 % proof stress, tensile strength, elongation at fracture . 27
A.7.4 Impact value . 27
A.8 Static calculations . 28
A.8.1 General . 28
A.8.2 Load cases . 28
A.8.2.1 Central loading . 28
A.8.2.2 Eccentric loading . 28
A.8.2.3 Horizontal loading . 28
A.8.2.4 Superimpositions . 28
Annex B (normative) Structural testing requirements for longwall shields . 42
B.1 Structural measurements . 42
B.2 Acceptance criteria . 47
B.2.1 Plastic deformation . 47
Annex ZA (informative) Relationship between this European Standard and the essential
requirements of Directive 2006/42/EC aimed to be covered . 49
Bibliography . 50
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European foreword
This document (prEN 1804-1:2019) has been prepared by Technical Committee CEN/TC 196 “Mining
machinery and equipment - Safety”, the secretariat of which is held by DIN.
This document is currently submitted to the CEN Enquiry.
This document will supersede EN 1804-1:2001+A1:2010.
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.
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);
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).
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Introduction
This European standard 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:
a) have been constructed in accordance with generally accepted engineering practice and generally
accepted calculation methods;
b) have been well manufactured mechanically;
c) 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.
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1 Scope
This document stipulates the safety requirements for the use of support units intended by the
manufacturer or the manufacturer's authorized representative. 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.
COMMENT 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.
This document applies for all support units that have been placed on the market for the first time after
the issue date of this standard.
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, Execution of steel structures and aluminium structures — Part 1: Requirements for conformity
assessment of structural components
EN 1804-2, Machines for underground mines — Safety requirements for hydraulic powered roof
supports — Part 2: Power set legs and rams
EN 1804-3, 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
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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, Hot rolled products of structural steels — Part 1: General technical delivery conditions
EN 10025-2, Hot rolled products of structural steels — Part 2: Technical delivery conditions for non-alloy
structural steels
EN 10025-3, Hot rolled products of structural steels — Part 3: Technical delivery conditions for
normalized/normalized rolled weldable fine grain structural steels
EN 10025-4, Hot rolled products of structural steels — Part 4: Technical delivery conditions for
thermomechanical rolled weldable fine grain structural steels
EN 10025-5, Hot rolled products of structural steels — Part 5: Technical delivery conditions for structural
steels with improved atmospheric corrosion resistance
EN 10025-6, 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, Metallic materials-Charpy pendulum impact test — Part 1: Test method (ISO 148-1:2016)
EN ISO 643:2012, Micrographic determination of the apparent grain size (ISO 643:2012)
EN ISO 3834-3:2005, Quality requirements for fusion welding of metallic materials — Part 3: Standard
quality requirements (ISO 3834-3:2005)
EN ISO 6892-1:2016, Metallic materials — Tensile testing — Part 1: Method of test at room temperature
(ISO 6892-1:2016)
EN ISO 9606-1:2017, Qualification testing of welders — Fusion welding — Part 1: Steels (ISO 9606-1:2012
including Cor 1:2012 and Cor 2:2013)
EN ISO 12100:2010, Safety of machinery — General principles for design — Risk assessment and risk
reduction (ISO 12100:2010)
EN ISO 14732:2013, Welding personnel — Qualification testing of welding operators and weld setters for
mechanized and automatic welding of metallic materials (ISO 14732:2013)
EN ISO 15607:2003, Specification and qualification of welding procedures for metallic materials — General
rules (ISO 15067:2003)
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)
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3 Terms
For the purposes of this document, the terms and definitions given in EN ISO 12100:2010 and EN 1804-2,
EN 1804-3 and the following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— IEC Electropedia: available at http://www.electropedia.org/
...
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