broetje-automation company bn 10.300 … company platforms table of contents 1 scope and objective...

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BROETJE-Automation Company Standard Platforms

Table of Contents

1 Scope and Objective .................................................................................... 4

1.1 Normative References ......................................................................... 4 1.2 Design .................................................................................................. 4 1.3 Materials Used ..................................................................................... 4 1.4 Surface Coating ................................................................................... 4

2 Platforms ...................................................................................................... 5

2.1 General ................................................................................................ 5 2.2 Floor Covering ..................................................................................... 5

2.3 Foot Mounting ...................................................................................... 5 2.4 Foundation Specifications .................................................................... 6 2.5 Electrics / Pneumatics.......................................................................... 8

3 Stairs and Stepladders ................................................................................. 9

3.1 General ................................................................................................ 9

4 Guard Rails ................................................................................................ 10

4.1 General .............................................................................................. 10 4.2 Terms and Definitions ........................................................................ 10

4.3 Safety Requirements ......................................................................... 11 4.4 Guard Rail Connections ..................................................................... 12

4.5 Guard Rail Gaps ................................................................................ 12

4.6 Guard Rails for Stairs/ Stepladders ................................................... 13

4.7 Minimum distance between hand rail/ obstruction ............................. 14 4.8 Self-Closing Gate ............................................................................... 15 4.9 Flaps .................................................................................................. 15

4.10 Assessment of Compliance with Safety Requirements ...................... 16

5 Assembly Instructions / Operating Instructions .......................................... 16

6 Bibliography ............................................................................................... 16

7 Laws, Ordinances and Accident Prevention Regulations ........................... 17

Change History:

05 Change Release Otholt, S. 19 Nov.

14

04 Change Release Otholt, S. 08 Oct. 14

03 Normen Aktualisiert Baumann 20.08.12

02 Chap. 4 modified Nolting, K. 08 Oct 09

01 Creation of Standard Jürgens, S. 24 Jun. 09

Index Designation Name Date

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Released:

This company standard is valid and released only on the intranet of Broetje-automation. Prints and copies are stored locally to test. They are not subject to the amendment service. The website www.broetje-automation.de serves as an additional source for company standards for External .

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1 Scope and Objective This standard covers stationary and mobile platforms, stairs and step ladders. It also covers stationary guard rails as well as guard rails that are not permanently mounted on machines or systems or that are moveable. DIN EN ISO standards and company standards of respective customers take precedence over this BN 10.300 standard. The supplier is responsible for obtaining the corresponding information.

1.1 Normative References

This company standard includes dated and undated references to provisions from other publications. These normative references are quoted in the corresponding text passages with the corresponding publications listed below. With dated references, subsequent amendments or revisions to referenced publication are only applicable if these changes are incorporated in an amended or revised company standard. If the reference is undated the latest version of the referenced publication (including amendments) shall be applicable to the company standard.

1.2 Design

Working platforms are to be designed in such a way that all tasks can be performed safely and in an ergonomically favorable working position. All applicable ergonomics standards must be observed. Basic considerations include:

Geometry of components in the work area

type and extent of the work/task to be carried out

tools, devices, equipment, machines, etc. needed for the tasks

The following literature must always to be observed for steel structures:

“Bemessungshilfen für profilorientiertes Konstruieren“, Oberegge, Stahlbau- Verlagsgesellschaft mbH Köln [Design aids for profile-oriented design]

Please refer to para. 6 "Literature References" for further applicable standards

1.3 Materials Used

Suppliers of platforms/ladders must submit inspection certificates 3.1 (see DIN EN 10204) for S 355; test reports 2.2 are required for S 235. Materials for aluminum structures are to be selected in accordance with DIN 4113-1, table 1; test reports 2.2 must be provided for these structures.

1.4 Surface Coating

All surfaces are coated according to customer specifications after prior consultation with the project manager.

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2 Platforms

2.1 General

For reasons of cost efficiency, support structures should generally be designed using open profiles. The design for all platforms/support structures should be identical within the same order. The project manager is to be consulted on this matter. BROETJE-Automations GmbH is to receive comprehensible and verifiable calculations.

2.2 Floor Covering

The flooring should generally be covered with multi-layer resin-coated plywood (thickness: 21 cm/ approx. 8.5"). The supplier of the plywood and the exact specification must be agreed upon with the project manager.

2.3 Foot Mounting

Only chemical anchor KLS or safety bolts type B of Messrs. Liebig are to be used for mounting in concrete; mounting materials are generally included in the scope of delivery and are furnished by the supplier of the platform. Floor plates must warrant adjustability (tension and pressure screws, fixator) – refer to example: Screws should have a minimum size of M12; plates must be at least 3mm thick. Screws, anchors, safety bolts and plates must be designed for the specific application.

Fig. 1: Foot Mounting

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2.4 Foundation Specifications

Fully dimensioned drawing, specifying the load and where the load is applied (tension, pressure, shear) are required. Loads are specified in Newton; the dimensions and positions of floor plates must be specified. Standard information on drawings regarding minimum foundation requirements: POWER SUPPLY: Specification of supply voltage, frequency and power rating FUSE PROTECTION: Amperage PNEUMATICS: Specification of min. operating pressure and output per liter/hour Unlubricated and cold-dried compressed air Compressed air quality according to ISO 8573-1:

ATTENTION: Pits must have separate control and supply lines (electrical). The cover (and the appropriate pit form) is to be provided by the customer. It must not protrude above the floor's surface ("0"). Feed throughs underneath rails must be designed in such a way that the load-bearing capacity of the foundation is not compromised. Structural planning, construction and testing (acceptance test) of the foundation is not included in our scope of supplies and services. We only provide specifications regarding the foundation’s surface and recesses required (pits/ducts, etc.); we do not provide any specifications regarding the foundation block itself (length, width, depth). The dimensions and structural details (steel reinforcements...) must be determined by a qualified contractor taking into account the local ground/soil conditions and our specifications (weight, load, allowed deformation, etc.).

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ATTENTION: The following foundation requirements are a prerequisite for meeting the specified accuracy: The foundation must be properly dimensioned and, where required, be isolated from the surrounding area to ensure that adjacent machines and equipment do not have a negative impact on work results. The height of the foundation may not deviate more than ±5mm from the theoretical zero point of the overall system. The deflection of the overall system foundation may not exceed 0.1 mm, due regard given to the loads being moved. Die Tragfähigkeit des Fundaments ist gemäß den markierten Bereichen im Betriebszustand anzunehmen. The foundation’s load bearing capacity in the marked areas must be met after the concrete has been fully cured. A compression strength of at least 2857 N/cm² is mandatory. Moving loads are accepted with XXX.XXX N on rail system XX. Moving loads are accepted with XX.XXX N on rail system XX. There must not be any significant temperature differences in the vicinity of the system. The cover (and the corresponding pit form) is to be provided by the customer. It must not protrude above the floor's surface ("O"). The following requirements must also be taken into account:

- condensate drains are to be provided by the customer - foundation ground electrodes are to be provided by the customer - safety fences are to be provided by the customer

Steel reinforcements in concrete must be checked for air gaps after hardening and fusing, existing air gaps must be filled with concrete sealing compound.

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The following symbols/notes should be used on the drawing:

2.5 Electrics / Pneumatics

Switches, door locks, lighting fixtures, etc. require supply lines; paths for cables and hoses must always be provided for. Cables should be rund inside hollow profiles, when possible. All cable passages and redirections should be fitted with protective tape or flexible cable conduits to prevent damage to cable insulations. All cables should be run through cable ducts, when possible. All flexible cable conduits must be protected against dust penetration and have a min. diameter of 20mm. Installations must be easily accessible.

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3 Stairs and Stepladders

3.1 General

Steps must always be fitted with tread edges. Forge-welded gratings according to DIN 24531-1 are generally to be used. Steps are to be galvanized in accordance with DIN EN ISO 1461. Recommended suppliers are e.g. Messrs. Lichtgitter, Messrs. Goetje, etc. Analog forge-welded grating are to be used for all intermediate landings. Refer to DIN EN ISO 14122-3 for load provisions and basic design principles. Further principles regarding the design and calculation of stairs (step dimensions, clearances, etc.) can be found in DIN 18065. Stairways positioned above open spaces and traffic paths must generally be fitted with protective sheet metal plates to catch any dirt. Project-specific requirements may deviate from this company standard and must be clarified before the project is launched.

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4 Guard Rails

4.1 General

Guard rails are required for heights of 500 mm and above. Guard rails are also required when the distance between the platform and the machine or wall exceeds 200 mm or when the machine itself does not offer the same fall protection as a guard rail. Vertical toe bars are always required when the distance between the platform and the adjacent supporting structure exceeds 30 mm. The following points must be observed as a matter of principle:

1. Guard rail posts must generally be mounted to the main structure, never on flooring. 2. All joints must be welded fully circumferential; this applies in particular for joints

between posts and flooring. 3. Posts, knee rails, hand rails and foot plates must have full-depth welds or welds

with a throat thickness of a=t. 4. Vertical toe plate should be connected with an intermittent seam -> risk of distortion 5. Pipe ends must always be welded shut. 6. Only the welded seams on hand rails may be further processed mechanically. 7. Butt joints on hand rails must be connected by means of internal centering aids. 8. Angle joints must always be mitered and joined with a circumferential weld seam.

4.2 Terms and Definitions

Fig. 2: Guard Rail - Terms and Definitions

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4.3 Safety Requirements

All specified dimensions represent minimum requirements. Customer-specific requirements are to be observed.

Fig. 3: Guard Rail Dimensions

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4.4 Guard Rail Connections

The railing base should be connected on the front side of the platform, when possible. Screw connections: 4x ISO 4017 M8 8.8+ washer ISO7090-B 8, 4

Fig. 4: Example of a connection to an angle profile

4.5 Guard Rail Gaps

Guard rail gaps > 120 mm must be fitted with a self-closing gate.

Fig. 5: Guard Rail Gap

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4.6 Guard Rails for Stairs/ Stepladders

When vertical rods are used as knee guards, the horizontal distance between the rods must not exceed 180 mm.

Fig. 6: Stair Railing

Fig. 6a: Access Type 1

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Fig. 6b: Access Type 2

4.7 Minimum Distance between Hand Rail/ Obstruction

Fig. 7: Hand Rail

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4.8 Self-Closing Gate

Stairs leading down from the work space must always be equipped with additional safeguards and must never be positioned directly behind the working position. A self-closing gate is to be installed as fall protection. The guard rail must have a fixed stop to prevent it from swiveling into a hazard area.

4.9 Flaps

There are several different solutions for the design of flaps. Due to the vast variety of design solutions, we will not provide an example at this point. Flap Design The design of the flaps must be agreed upon by all persons involved in the project beforehand to ensure a uniform appearance of the overall project. All junctions, e.g. to other components, must be unobstructed, form a plane surface and must not have any gaps. Good handling of the flaps is essential (weight, size, and ergonomics). Manual forces and weights must be specified in the drawings. The operation of flaps by means of hooks is to be avoided. Flaps without stop plates must be mounted using adjustable stop bolts. (ISO 4014) The max. clearance between the component and platform or flap specified in DIN EN 349 must be complied with. The clearance between flaps and platforms must not exceed 5 mm. The clearance between adjacent flaps must not exceed 5 mm. Hinges Hinges for medium-sized and large flaps may either be screwed on or welded on. The type of mounting is to be agreed upon during the conceptual phase. Hinges must not present a tripping hazard or obstruction for roller-guided equipment (chairs, tool and material carriages, etc.). Interlock Flaps should have an automatic interlock system. Actuation Force Manually operated flaps and extensions must not exceed the limits prescribed in the applicable DIN standards. Lower values are to be applied when the posture is ergonomically unfavorable. Mechanically/electronically supported systems are to be used if the values cannot be reached. When pneumatic springs are used, it must be ensured that opening the flap all the way will not kink/bend the spring.

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4.10 Assessment of Compliance with Safety Requirements

Refer to ISO 14122-3.

5 Assembly Instructions / Operating Instructions The scope, format and structure of the documentation are to be agreed upon with the documentation department of BROETJE-Automation GmbH. Spare part lists must correspond to the format of a BA template.

6 Bibliography The following standards were consulted for this company standard:

EN ISO 14122-1- 4 Safety of machinery - Permanent means of access to machinery - Part 1: Choice of fixed means of access between two levels

DIN 18800 (Steel structures - Part 1: Design and construction)

DIN 4113 (Aluminum constructions under predominantly static loading)

DIN EN ISO 1090- 1-3 (Execution of steel structures and aluminum structures - Part 1: Requirements for conformity assessment of structural components; not yet applicable in Germany)

DIN 18065 (Stairs in buildings - Terminology, measuring rules, main dimensions)

DIN EN 10204 Metallic products - Types of inspection documents

DIN 4113-1 Aluminum constructions under predominantly static loading

Bemessungshilfen für profilorientiertes Konstruieren, Oberegge, Stahlbau- Verlagsgesellschaft mbH Köln [Design aids for profile-oriented design]

BN 10.60 Structural Steel Design

BN 10.50 Welding Guidelines

DIN EN 349 Safety of machinery - Minimum gaps to avoid crushing of parts of the human body

DIN 24531 Gratings used as stair treads

DIN 33411 Part 1 to 5 Physical strengths of man; concepts, interrelations, defining parameters Terms and definitions

DIN 33402 Part 1 and 2 Ergonomics - Body dimensions of people

Product image - Body templates - Part 1: For seats of all kinds

DIN EN ISO 12100 (2011.03) Sicherheit von Maschinen - Allgemeine Gestaltungsleitsätze - Risikobeurteilung und Risikominderung (Alt: DIN 1050 Safety of machinery - Principles for risk assessment )

DIN 1005 Parts 1 to 5 Safety of machinery - Human physical performance

DIN EN ISO 7250 Basic human body measurements for technological design

DIN EN ISO 6385 Ergonomic principles in the design of work systems

DIN EN 547 Parts 1 to 3 Safety of machinery - Human body measurements

DIN EN 842 Safety of machinery - Visual danger signals

DIN EN 894-3 Safety of machinery - Ergonomics requirements for the design of displays and control actuators - Part 3: Control actuators

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DIN EN ISO 3834-2 Quality requirements for fusion welding of metallic materials - Part 2: Comprehensive quality requirements (ISO 3834-2:2005); German version EN ISO 3834-2:2005

ISO 3864 Graphical symbols - Safety colors and safety signs - Part 2: Design principles for product safety labels (ISO 3864-2:2004)

ISO 18225 Industrial construction; traffic ways in industrial buildings

DIN EN ISO 12944 1-8 Paints and varnishes - Corrosion protection of steel structures by protective paint systems

DIN EN ISO 15536 1-2 Ergonomics - Computer manikins and body templates

DIN EN ISO 12100 Sicherheit von Maschinen - Allgemeine Gestaltungsleitsï¿½tze (Alt:DIN EN ISO 14121 Safety of machinery - Risk assessment - Part 1: Principles )

DIN EN ISO 13857 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs

DIN EN 614 Safety of machinery - Ergonomic design principles - Part 1: Terminology and general principles

DIN EN 953 Safety of machinery - Guards - General requirements for the design and construction of fixed and movable guards

DIN EN ISO 4413(2011.04) Fluidtechnik - Allgemeine Regeln und sicherheitstechnische Anforderungen an Hydraulikanlagen und deren Bauteile (Alt:DIN EN 982 Safety of machinery - Safety requirements for fluid power systems and their components - Hydraulics)

DIN EN ISO 4414 Fluidtechnik - Allgemeine Regeln und sicherheitstechnische Anforderungen an Pneumatikanlagen und deren Bauteile (Alt:DIN EN 983 Safety of machinery - Safety requirements for fluid power systems and their components – Pneumatics)

DIN EN 12464-1 Light and lighting - Lighting of work places - Part 1: I Indoor work places

7 Laws, Ordinances and Accident Prevention Regulations Workplace ordinance including workplace regulations (ASR)

ASR 7/3 Artificial lighting

ASR 12/2-3 Protection against falls and falling objects

ASR 17/1,2 Traffic ways

BGV A1 General Provision

BGI 561 Information leaflet on stairs

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