BS EN 13001-3-3:2014

BSI Standards Publication

Cranes - General design

Part 3-3: Limit states and proof of
competence of wheel/rail contacts
BS EN 13001-3-3:2014 BRITISH STANDARD

National foreword
This British Standard is the UK implementation of EN 13001-3-3:2014.
Together with BS EN 13001-1:2004+A1:2009, BS EN 13001-2:2014,
BS EN 13001-3-1:2012+A1:2013, BS EN 13001-3-2:2014, BS EN 13001-3-4
and DD CEN/TS 13001-3-5:2010 supersedes BS 2573-1:1983 and
BS 2573-2:1980, which will be withdrawn on publication of all parts of
the BS EN 13001 series.
Users’ attention is drawn to the fact that neither BS 2573-1:2014 nor
BS 2573-2:2014 should be used in conjunction with the EN 13001 series as
they are not complementary. The BS 2573 series will remain current until
all parts of the BS EN 13001 series cited above have been published to
ensure that a coherent package of standards remains available in the UK
during the transition to European standards.
The UK participation in its preparation was entrusted by Technical
Committee MHE/3, Cranes and derricks, to Subcommittee MHE/3/1,
Crane design.
A list of organizations represented on this subcommittee can be
obtained on request to its secretary.
This publication does not purport to include all the necessary provisions
of a contract. Users are responsible for its correct application.
© The British Standards Institution 2014.
Published by BSI Standards Limited 2014
ISBN 978 0 580 79310 3
ICS 53.020.20
Compliance with a British Standard cannot confer immunity from
legal obligations.
This British Standard was published under the authority of the Standards
Policy and Strategy Committee on 30 November 2014.
Amendments issued since publication
Date Text affected
EUROPEAN STANDARD EN 13001-3-3
NORME EUROPÉENNE
EUROPÄISCHE NORM October 2014

ICS 53.020.20

English Version

Cranes - General design - Part 3-3: Limit states and proof of

competence of wheel/rail contacts

Appareils de levage à charge suspendue - Conception Krane - Konstruktion allgemein - Teil 3-3: Grenzzustände
générale - Partie 3-3 : Etats limites et vérification d'aptitude und Sicherheitsnachweis von Laufrad/Schiene-Kontakten
des contacts galet/rail

This European Standard was approved by CEN on 16 August 2014.

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, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, 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: Avenue Marnix 17, B-1000 Brussels

© 2014 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 13001-3-3:2014 E
worldwide for CEN national Members.
BS EN 13001-3-3:2014
EN 13001-3-3:2014 (E)

Contents Page

Foreword ..............................................................................................................................................................3
Introduction .........................................................................................................................................................4
1 Scope ......................................................................................................................................................5
2 Normative references ............................................................................................................................5
3 Terms, definitions, symbols and abbreviations .................................................................................5
3.1 Terms and definitions ...........................................................................................................................5
3.2 Symbols and abbreviations ..................................................................................................................6
4 General ....................................................................................................................................................7
4.1 General principles..................................................................................................................................7
4.2 Line and point contact cases ...............................................................................................................8
4.3 Hardness profile below contact surface .............................................................................................9
4.4 Equivalent modulus of elasticity ....................................................................................................... 10
5 Proof of static strength ...................................................................................................................... 10
5.1 General ................................................................................................................................................. 10
5.2 Design contact force .......................................................................................................................... 10
5.3 Static limit design contact force ....................................................................................................... 11
5.3.1 General ................................................................................................................................................. 11
5.3.2 Calculation of the limit design force ................................................................................................. 11
5.3.3 Edge pressure in line contact ............................................................................................................ 12
5.3.4 Non-uniform pressure distribution in line contact .......................................................................... 12
6 Proof of fatigue strength .................................................................................................................... 13
6.1 General ................................................................................................................................................. 13
6.2 Design contact force .......................................................................................................................... 13
6.3 Limit design contact force ................................................................................................................. 13
6.3.1 Basic formula ...................................................................................................................................... 13
6.3.2 Reference contact force ..................................................................................................................... 14
6.3.3 Contact force history parameter ....................................................................................................... 14
6.3.4 Contact force spectrum factor .......................................................................................................... 15
6.3.5 Counting of rolling contacts .............................................................................................................. 15
6.3.6 Relative total number of rolling contacts ......................................................................................... 16
6.3.7 Classification of contact force history parameter ........................................................................... 16
6.4 Factors of further influences ............................................................................................................. 17
6.4.1 Basic formula ...................................................................................................................................... 17
6.4.2 Edge pressure for fatigue .................................................................................................................. 17
6.4.3 Non-uniform pressure distribution for fatigue ................................................................................ 17
6.4.4 Skewing ............................................................................................................................................... 17
6.4.5 Mechanical drive factor ...................................................................................................................... 18
Annex A (informative) Strength properties for a selection of wheel and rail materials .......................... 19
Annex B (informative) Conversion table of hardnesses ............................................................................. 20
Annex C (informative) Examples for wheel/rail material pairs and their wear behaviour ....................... 21
Annex D (informative) Selection of a suitable set of crane standards for a given application .............. 22
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC ....................................................................................... 23
Bibliography ..................................................................................................................................................... 24

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Foreword

This document (EN 13001-3-3:2014) has been prepared by Technical Committee CEN/TC 147 “Cranes —
Safety”, the secretariat of which is held by BSI.

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 April 2015, and conflicting national standards shall be withdrawn at the
latest by April 2015.

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.

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.

This European Standard is one part of EN 13001, Cranes — General design. The other parts are as follows:

— Part 1: General principles and requirements

— Part 2: Load actions

— Part 3-1: Limit states and proof of competence of steel structure

— Part 3-2: Limit states and proof of competence of wire ropes in reeving systems

— Part 3-4: Limit states and proof of competence of machinery

— Part 3-5: Limit states and proof of competence of forged hooks

For the relationship with other European Standards for cranes, see Annex D.

According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: 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, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom.

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Introduction

This European Standard has been prepared to provide a means for the mechanical design and theoretical
verification of cranes to conform with the essential health and safety requirements. This European Standard
also establishes interfaces between the user (purchaser) and the designer, as well as between the designer
and the component manufacturer, in order to form a basis for selecting cranes and components.

This European Standard is a type C standard as stated in EN ISO 12100.

The machinery concerned and the extent to which hazards are covered are indicated in the Scope of this
European Standard.

When provisions of this type C standard are different from those which are stated in type A or B standards, the
provisions of this type C standard take precedence over the provisions of the other standards, for machines
that have been designed and built according to the provisions of this type C standard.

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1 Scope

This European Standard is to be used together with EN 13001-1 and EN 13001-2 and as such they specify
general conditions, requirements and methods to prevent mechanical hazards of wheel/rail contacts of cranes
by design and theoretical verification. This European Standard covers requirements for steel and cast iron
wheels and is applicable for metallic wheel/rail contacts only.

Roller bearings are not in the scope of this European Standard.

Exceeding the limits of strength is a significant hazardous situation and hazardous event that could result in
risks to persons during normal use and foreseeable misuse. Clause 5 to Clause 6 of this European Standard
are necessary to reduce or eliminate the risks associated with this hazard.

This European Standard is applicable to cranes, which are manufactured after the date of approval of this
European Standard by CEN, and serves as a reference base for product standards of particular crane types.

This European Standard is for design purposes only and should not be seen as a guarantee of actual
performance.

EN 13001-3-3 deals only with limit state method in accordance with EN 13001-1.

2 Normative references

The following documents, in whole or in part, are normatively referenced in this document and are
indispensable for its application. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.

EN 13001-1, Cranes - General design - Part 1: General principles and requirements

EN 13001-2, Crane safety - General design - Part 2: Load actions

EN ISO 6506-1, Metallic materials - Brinell hardness test - Part 1: Test method (ISO 6506-1)

EN ISO 12100, Safety of machinery - General principles for design - Risk assessment and risk reduction (ISO
12100)

ISO 4306-1, Cranes — Vocabulary — Part 1: General

ISO 12488-1:2012, Cranes — Tolerances for wheels and travel and traversing tracks — Part 1: General

3 Terms, definitions, symbols and abbreviations

3.1 Terms and definitions

For the purposes of this document, the terms and definitions given in EN ISO 12100, ISO 4306-1 and the
following apply.

3.1.1
wheel
rolling component in a rolling contact enabling relative movement between two crane parts

EXAMPLE Crane travel wheels, trolley traverse wheels, guide rollers and wheels/rollers supporting slewing
structures.

Note 1 to entry: Roller elements in rolling bearings are not considered as wheels.

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3.1.2
unit-conform hardness
Brinell hardness HBW of the material given with the unit of the modulus of elasticity
2
EXAMPLE A Brinell hardness HBW of 300 results in a unit-conform hardness HB = 300 N/mm .

Note 1 to entry: Annex B provides a table of hardness conversion for different methods of hardness measurements.

3.2 Symbols and abbreviations

For the purposes of this document, the symbols and abbreviations given in Table 1 apply.

Table 1 — Symbols and abbreviations

Symbols, abbreviations Description

b Effective load-bearing width
Dw Wheel diameter
Em Equivalent modulus of elasticity
Er Modulus of elasticity of the rail material
Ew Modulus of elasticity of the wheel material
F Wheel load
FRd,s Limit design contact force
FSd,s Design contact force
FRd,f Limit design contact force for fatigue
FSd,f Maximum design contact force for fatigue
FSd,f,i Design contact force for fatigue in contact (i)
FSd0,s Non-factored design contact force (calculated with partial safety factors set to 1)
Fu Reference contact force
ff Factors of further influences in fatigue
ff1 Decreasing factor for edge pressure in fatigue
ff2 Decreasing factor for non-uniform pressure distribution in fatigue
ff3 Decreasing factor for skewing in fatigue
ff4 Decreasing factor for driven wheels in fatigue
f1 Decreasing factor for edge pressure
f2 Decreasing factor for non-uniform pressure distribution
fy Yield stress or 0,2 % proof stress of the material, prior to surface hardening
when this process is applied. In the text of the standard only the term yield stress
is used to denote either.
HBW Brinell hardness
2
HB Unit-conform hardness, [N/mm ]
i Index of a rolling contact

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Symbols, abbreviations Description

iD Number of rolling contacts at reference point
itot Total number of rolling contacts during the design life of wheel or rail
m Slope constant of log F/log N-curve for rolling contacts
kc Contact force spectrum factor
rk Radius of the crowned rail head or the second wheel radius
r3 Radius of the wheel or rail edge
sc Contact force history parameter
Sc Classes of contact force history parameter
w Width of projecting, non-contact area
zml, zmp Depth of maximum shear stress for line and point contact case, respectively
α Skew angle
αg Part of the skew angle α due to the slack of the guide
αt Part of the skew angle α due to tolerances
αw Part of the skew angle α due to wear
γcf Contact resistance factor
γm General resistance coefficient; γm = 1,1
γn Risk coefficient
γp Partial safety factors
ν Radial strain coefficient (ν = 0,3 for steel)
νc Relative total number of rolling contacts
ϕi Dynamic factors (see EN 13001-2)

4 General

4.1 General principles

The proof of competence for static strength and fatigue strength shall be fulfilled for the selection of wheel and
rail combination. In the proof of competence for static strength the material properties of the weaker party
(wheel or rail) shall be applied, whereas the proof of competence for fatigue strength (rolling contact fatigue,
RCF) shall be conducted separately to each party, applying its specific material property and number of rolling
contacts.

The proof shall be applied to all arrangements in cranes, where a wheel/rail type of rolling contact occurs, e.g.
crane travel wheels, trolley traverse wheels, guide rollers and wheels/rollers supporting slewing structures.
The term wheel is used throughout the document for the rolling party in a contact.

NOTE For recommendations on dimensions of wheel flanges, refer to EN 13135, Annex B.

The proof of competence criteria in Clause 5 and Clause 6 are based upon Hertz pressure on the contact
surface and the shear stress below the surface due to the wheel/rail contact.

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Some formulae used for calculations within this document refer to a so called “unit-conform hardness” HB
based on the Brinell hardness HBW given as a value without unit according to EN ISO 6506-1. The unit of HB
shall match with the unit of the modulus of elasticity used in the calculation. Using SI-units, the unit-conform
hardness is given by:

N
HB = HBW ⋅ (1)
mm 2

where

HB is the unit-conform hardness;

HBW is the value of the Brinell hardness.

4.2 Line and point contact cases

There are principally two different contact cases in typical designs of crane wheels and rails: a line contact
and a point contact (see Figure 1). With the crown radius rk relatively large in relation to width of the wheel
and rail, as is the case for cranes, point contact even for new installations will be rapidly transformed into line
contact. Figure 1 shows the conditions of the point contacts, which can be considered as line contacts, for the
proof of both static and fatigue strength.

a) Line contact b) Point contact

Point contact cases, where rk ≤ 5 × min [br ; bw ] are
outside the scope of this standard.
In cases, where rk > 200 × min [br ; bw ] , the
requirements given for line contact shall be applied.
The effective contact widths (bw, br) are determined by deducting from the material width of wheel/rail the
effect of corner radius equal to 2 × r3.

Figure 1 — Contact cases

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4.3 Hardness profile below contact surface

It shall be ensured that the hardness achieved extends into the material deeper than the depth of maximum
shear, preferably twice this depth. The hardness value can be obtained using the ultimate strength of the
material and appropriate conversion tables. For commonly used materials, see Annex B.

Special care shall be taken with surface hardening and the depth zone, to ensure that the hardness profile
does not drop below the shear profile (see Figure 2).

Key
z depth
zml, zmp depths of maximum shear stress for line and point contact case respectively
HB unit-conform hardness
1 hardness, the surface hardened zone
2 hardness, the natural hardness of the material
3 shear stress τ due to contact force

Figure 2 — Hardness and shear stress versus depth

The depth of maximum shear for line contact cases shall be calculated as:

zml = 0,50 × FSd0, s ×

(
π × Dw × 1 − ν 2 ) (2)
b × Em

and for point contact cases this shall be calculated as:

FSd0, s 1−ν2
zmp = 0,68 × × (3)
3 Em  2 
 + 1 
 Dw r k 

where

FSd0,s is the maximum, non-factored design contact force within the Load Combinations A to
C in accordance with EN 13001-2;

Em is the equivalent modulus of elasticity, see 4.4.

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The contact surface of the wheel rim on hardened wheels should be finished to a surface quality Ra 6,3 μm or
better in accordance with EN ISO 4287.

4.4 Equivalent modulus of elasticity

The equivalent modulus of elasticity shall be calculated by Formula (4), which covers also the case where the
elastic modulus of wheel and rail are different:

2 ⋅ Ew ⋅ Er
Em = (4)
Ew + Er

where

Em is the equivalent modulus of elasticity;

Ew is the modulus of elasticity of the wheel;

Er is the modulus of elasticity of the rail.

Values of the elastic moduli for selected materials are given in Table 2.

Table 2 — Values of elastic modulus

Wheel/rail material Modulus of elasticity

2
N/mm
Steel 210 000
Cast iron 176 000
Steel/cast iron-combination Em = 191 500

5 Proof of static strength

5.1 General

For the proof of static strength of wheel/rail contacts, it shall be proven that for all relevant load combinations
of EN 13001-2:

FSd,s ≤ FRd,s (5)

where

FSd,s is the design contact force;

FRd,s is the limit design contact force.

5.2 Design contact force

The design contact force FSd,s of wheel/rail contacts shall be calculated for all relevant load combinations of
EN 13001-2, taking into account the respective dynamic factors ϕi, partial safety factors γp and where
required the risk coefficient γn. The most unfavourable load effects from possible positions of the mass of the
hoist load and crane configurations shall be taken into account.

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5.3 Static limit design contact force

5.3.1 General

The static limit design contact force FRd,s is specified as a force to cause a permanent radial deformation of
0,02 % of the wheel radius.

The static limit design contact force depends on:

— materials properties (modulus of elasticity, yield stress and hardness) of wheel and rail;

— geometry (radii of wheel and rail);

— further influences (stiffness, edge effects).

Cases where r k ≤ 5 × min [br ; bw ] (see Figure 1) fall outside the method given in this standard. In those cases,
the calculation of the limit design force shall be calculated using general Hertzian theory.

5.3.2 Calculation of the limit design force

The static limit design contact force shall be calculated separately both for wheel and rail, using either
Formula (6) or Formula (7). For the proof of competence in accordance with Formula (5) the value taken for
FRd,s shall be the smaller of the values obtained for the wheel and the rail. The effective load-bearing width is
the same in both calculations.

Formula (6) applies for non-surface hardened materials only, e.g. materials as cast, forged, rolled or
quenched and tempered.

F Rd, s =
(7 × HB )2 ×
(
π × Dw × b × 1 − ν 2)× f1 × f 2 (6)
γm Em

Formula (7) applies for surface hardened materials, e.g. flame or induction hardened, provided surface
hardness is equal to or greater than HB = 0,6 × fy, and the depth of hardened layer meets the requirements
of 4.3.

F Rd, s =
( 4,2 × f y ) 2 × π × Dw × b × ( 1 − ν 2 ) × f × f2 (7)
1
γm Em

where

FRd,s is the static limit design contact force;

Em is the equivalent modulus of elasticity;

ν is the radial strain coefficient (ν = 0,3 for steel );

Dw is the wheel diameter;

b is the effective load-bearing width taken as b = min [br ; bw ] , see Figure 1;

HB is the unit-conform hardness (see 3.1.2) based on the natural hardness of the material, at the
depth of maximum shear, see Annex A;

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γm is the general resistance coefficient; γm = 1,1;

fy is the yield stress of the material below the hardened surface, i.e. the natural yield stress of
the material prior to the surface hardening process, see Annex A;

f1 is the decreasing factor for edge pressure. For line contact, see 5.3.3; for point contact cases
the factor f1may be set to 1,0;

f2 is the decreasing factor for non-uniform pressure distribution. For line contact, see 5.3.4; for
point contact cases the factor f2 may be set to 1,0.

5.3.3 Edge pressure in line contact

Formulae for the limit design contact force in the line contact case are derived from the case of two bodies in
contact of the same width. Factor f1 as given in Table 3 introduces a correction to the limit design contact
force for the situation when the two bodies are of unequal width (see Figure 3). Where the rail is wider than
the wheel, the radius of the edge (r3) shall be taken as that of the wheel.

Figure 3 — Edge pressure

Table 3 — Factor f1 for edge pressure in line contact

Ratio r3/w Factor f1

r3/w ≤ 0,1 0,85

0,1 < r3/w < 0,8 [0,58 + 0,15 (r3 / w)] / 0,7
r3/w ≥ 0,8 1,0

where
w is the width of the projecting non-contact area and
r3 is the radius of the edge of the non-projecting part (wheel or rail).

5.3.4 Non-uniform pressure distribution in line contact

An ideal uniform distribution across the tread of the wheel in the line contact case is dependent upon sufficient
elasticity of the rail fixing or its support and/or wheels with self-aligning suspension. Otherwise, deformation of
the crane structure (e.g. bending of main girders) or tolerances in rail alignment result in non-uniform pressure
distribution, decreasing the limit design contact force. This effect shall be taken into account by factor f2, given
in Table 4.

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Table 4 — Factor f2 for non-uniform pressure distribution in line contact

Tolerance class of ISO 12488-1

1 2 3 4
Wheels with self-aligning mounting 1,0 1,0 0,95 0,9
Non-aligning wheel mounting, rail mounted on elastic support 0,95 0,9 0,85 0,8
Non-aligning wheel mounting, rail mounted on rigid support 0,9 0,85 0,8 0,7

6 Proof of fatigue strength

6.1 General

The proof of competence for fatigue strength of wheels and rails shall be carried out in accordance with the
principles of EN 13001-1 and EN 13001-2. The wheels and the rails shall have a specified design life,
proportionate to that of the related crane or hoist. The proof covers hazards related to Rolling Contact Fatigue,
i.e. surface cracking and pitting of wheels and rails. Guidance for selection of wheel/rail materials to avoid
excessive wear is given in Annex C.

For the proof of fatigue strength of wheel/rail contacts it shall be proven that for each wheel and for all points
on the rails

FSd,f ≤ FRd,f (8)

where

FSd,f is the maximum design contact force for fatigue;

FRd,f is the limit design contact force for fatigue.

6.2 Design contact force

The design contact force FSd,f shall be calculated for the regular loads (load combinations A of EN 13001-2)
with the risk coefficient included, and with all dynamic factors ϕi = 1 and all partial safety factors γp = 1.
The skewing forces acting on guide rollers shall be considered as regular loads.

6.3 Limit design contact force

6.3.1 Basic formula

The limit design contact force FRd,f shall be calculated separately both for wheel and for rail by

Fu
FRd,f = × ff (9)
γ cf × m sc

where

Fu is the reference contact force;

sc is the contact force history parameter, calculated separately for wheel and rail;

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γcf is the contact resistance factor for fatigue γcf = 1,1;

ft is the factor of further influences;

m is the exponent for wheel/rail contacts, m = 10/3 = 3,33.

6.3.2 Reference contact force

The limit design contact force of a wheel or rail subjected to rolling contact fatigue is characterised by the
6
reference contact force Fu, which represents the fatigue strength under 6,4 × 10 rolling contacts under
constant contact force and a probability of survival of 90 % (i. e. avoiding cracks, pitting, excessive wear).

The reference contact force shall be calculated separately both for wheel and for rail. The material property
used in calculation shall be that specific for the party calculated; either wheel or rail. The effective load-bearing
width is the same in both calculations.

Formula (10) applies for non-surface hardened materials only, e.g. materials as cast, forged, rolled or
quenched and tempered.

Fu = (3,0 × HB ) 2×
(
π × Dw × b × 1 − ν 2 ) (10)
Em

Formula (11) applies for surface hardened materials, e.g. flame or induction hardened, provided surface
hardness is equal to or greater than HB = 0,6 × fy, and the depth of hardened layer meets the requirements
of 4.3.

( )
Fu = 1,8 × f y 2×
(
π × Dw × b × 1 − ν 2 ) (11)
Em

where

Em is the equivalent modulus of elasticity;

ν is the radial strain coefficient (ν = 0,3 for steel );

Dw is the wheel diameter;

b is the effective load-bearing width taken as b = min [br ; bw ] , see Figure 1;

HB is the unit-conform hardness, based on the natural hardness of the material, at the depth of
maximum shear, see Annex A;

fy is the yield stress of the material below the hardened surface, i.e. the natural yield stress of the
material prior to the surface hardening process, see Annex A.

Cases where rk ≤ 5 × min [br ; bw ] (see Figure 1) fall outside the method given in this standard. In those
cases, the calculation of the limit design force shall be calculated using general Hertzian theory.

6.3.3 Contact force history parameter

In analogy to stress history parameter (see EN 13001-1), the contact force history parameter shall be
calculated by

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sc = kc · νc (12)

where

kc is the contact force spectrum factor;

νc is the relative total number of rolling contacts.

The contact force history parameter describes the fatigue effect of the specified use in terms of rolling
contacts in a particular wheel/rail pair.

6.3.4 Contact force spectrum factor

The contact force spectrum factor kc shall be calculated by

i tot m
 FSd,f,i 
kc = 1/ itot ∑
⋅ 
F


(13)
i =1  Sd, f 

where

i is the index of a rolling contact with FSd,f,i

itot is the total number of rolling contacts during the design life of wheel or rail,

FSd,f,i is the design contact force for fatigue in a contact i;

FSd,f is the maximum of all forces FSd,f,i;

m is the exponent for wheel/rail contacts, m = 10/3 = 3,33.

NOTE Formula (13) implies that the rolling contacts are counted individually.

6.3.5 Counting of rolling contacts

The total number of rolling contacts itot shall be calculated separately for wheel and for rail. For a wheel, one
revolution is equivalent to one rolling contact, whereas for a selected point on the rail the passing over by any
wheel represents one rolling contact. In cases where the wheel is not rolling but the load is fluctuating in
cycles, one load cycle shall be considered as one rolling contact.

Formula (14) and Formula (15) show the calculation for itot for a work cycle comprising a two-way motion over
the point of the rail under consideration, i.e. a work cycle with the laden crane passing over the point in one
direction and unladen on the return part of the work cycle.

For a running wheel:

1 2⋅ x ⋅C
itot = ⋅ (14)
lw π ⋅ Dw

where

x is the average displacement of the related crane motion, see EN 13001-1;

C is the total number of working cycles during the design life of the crane, see EN 13001-1;

15
BS EN 13001-3-3:2014
EN 13001-3-3:2014 (E)

lw is the design number of wheel sets used during the design life of the crane (i.e. number of
wheel sets replacements + 1); for guidance see Table 5;

Dw is the wheel diameter.

For a point on the rail with wheels passing over:

itot = 2 · nw · C (15)

where

nw is the total number of wheels of the crane passing over the point under consideration on the
particular rail.

Table 5 — Guidance for selection of design number of wheel sets

Class U of total number of Number of wheel sets lw

working cycles (EN 13001-1)
U0 to U2 1
U3 to U6 1–2
U7 to U9 1–3

6.3.6 Relative total number of rolling contacts

The relative total number of rolling contacts νc shall be calculated by

itot
νc = (16)
iD

where

itot is the total number of rolling contacts during the design life of wheel or rail;

6
iD is the number of rolling contacts at reference point, iD = 6,4 · 10 .

6.3.7 Classification of contact force history parameter

In the proof of competence calculations for a particular use specified in accordance with EN 13001-1, the
contact force history parameter shall be determined by Formula (12).

Wheels and rails may be assigned to classified sets of values of contact force history parameters. Table 6
shows a recommended series of parameters and the symbols of the related classes. Where classification is
referred to, compatibility between the selected Sc-class and the specified use shall be shown in the proof of
competence calculations.

Table 6 — Classes Sc of contact force history parameter sc

Class Sc0 Sc1 Sc2 Sc3 Sc4 Sc5 Sc6 Sc7 Sc8 Sc9
sc 0,008 0,016 0,032 0,063 0,125 0,25 0,5 1,0 2,0 4,0

NOTE Change of wheel diameter changes the sc-parameter and might change the Sc-class.

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 BS EN 13001-3-3:2014
EN 13001-3-3:2014 (E)

6.4 Factors of further influences

6.4.1 Basic formula

The factor ff takes into account further influences on the limit design contact force and shall be calculated as
follows:

ff = ff1 · ff2 · ff3 · ff4 (17)

where

ff1 to ff4 are the factors of influences as given in 6.4.2 to 6.4.5.

6.4.2 Edge pressure for fatigue

Due to lateral movements of wheels, the edge pressure effect on the wider party (wheel or rail) may be
neglected and the factor ff1 is set to 1. For the narrower party with the edge radius r3 (see Figure 3) applies
the following:

ff1 = f1 (18)

where

f1 is the factor for edge pressure as given in 5.3.3.

6.4.3 Non-uniform pressure distribution for fatigue

For the proof of fatigue strength the non-uniform pressure distribution may be neglected and ff2 is set to 1.

6.4.4 Skewing

A skewing wheel causes wear of wheel and rail and thus shortens the useful life. The wear is increased over-
proportionally in relation to the skew angle α. This effect shall be taken into account by factor ff3.

ff3 = 1 for α ≤ 0,005 rad

0,005 for α > 0,005 rad

f f3 = 3 (19)
α
where

α = αg + αw + αt is the skew angle of the crane in radians, calculated in accordance with

EN 13001-2.

The part of the skew angle due to tolerances αt shall be chosen from the Table 7 according to the tolerance
class.

Table 7 — Design values of alignment angle of a single wheel

Tolerance class of ISO 12488-1

1 2 3 4
Angle αt [rad] 0,001 5 0,002 5 0,003 5 0,004 5

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BS EN 13001-3-3:2014
EN 13001-3-3:2014 (E)

6.4.5 Mechanical drive factor

In an unclean environment, the mechanical abrasion effects on the driven wheels shall be taken into account
by factor ff4:

ff4 = 0,95 for driven wheels in environment with abrasive particles (20)

ff4 = 1,0 for non-driven wheels or wheels in environment without abrasive particles.

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 BS EN 13001-3-3:2014
EN 13001-3-3:2014 (E)

Annex A
(informative)

Strength properties for a selection of wheel and rail materials

Table A.1 — Wheel and rail materials and their strength properties

Wheel materials
Ultimate
Designation Standard Material No. Delivery state strength fu
Design hardness
2
N/mm HBW

GE 300 EN 10293 1.0558 +N 520 155

EN-GJS 600-3 EN 1563 0.7060 as cast 600 210 (***)
EN-GJS 700-2 EN 1563 0.7070 as cast 700 245 (***)
25CrMo4 EN 10083-3 1.7218 +QT 650 190
34CrMo4 EN 10083-3 1.7220 +QT 700 210
42CrMo4 EN 10083-3 1.7225 +QT 750 225
33NiCrMoV14-5 EN 10250-3 1.6956 +QT 1 000 295
Wheel materials, surface hardened
Design yield
Minimum surface
Designation Standard Material No. Delivery state stress fy
hardness
2
N/mm HBW

+N , surface
42CrMo4 EN 10083-3 1.7225 420 252 (*)
hardened
Rail materials
Ultimate
Designation Standard Material No. Delivery state strength fu
Design hardness
2
N/mm HBW

S235 (**) EN 10025-2 – +N 360 125 (***)

S275 (**) EN 10025-2 – +N 410 145 (***)
S355 (**) EN 10025-2 – +N 520 175 (***)
S690Q EN 10025-6 1.8928 +QT 760 225
C35E EN 10083-2 1.1181 +N 520 155
C55 EN 10083-2 1.0535 +N 640 190
R260Mn EN 13674-1 1.0624 +N 870 260
Key
+N Normalized
+QT Quenched and tempered
(*) Hardness to be specified based on the hardening process and required depth.
(**) Table values are valid to any of the quality grades JR, J0, J2 and K2.
(***) The values deviate from the minimum given in the material standard due to work hardening occurring in service
from rolling contact [16].

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EN 13001-3-3:2014 (E)

Annex B
(informative)

Conversion table of hardnesses

Table B.1 — Conversion table of hardnesses

Hardness Hardness

HV HBW HRA HRB HRC HRD HV HBW HRA HRC HRD

120 114 67 350 332 68,1 35,5 51,9

130 123 71 360 342 68,7 36,6 52,8
140 133 75,1 370 351 69,2 37,7 53,8
150 142 78,8 380 361 69,8 38,8 54,4
160 152 82,1 390 370 70,3 39,8 55,2
170 161 85 400 380 70,8 40,8 56
180 171 87,3 410 389 71,4 41,8 56,8
190 180 89,6 420 399 71,8 42,7 57,5
200 190 91,8 430 409 72 43,6 58,2
210 199 93,7 440 418 72,3 44,5 58,8
220 209 95,5 450 423 73,3 45,3 59,4
230 218 460 432 73,6 46,1 60,1
240 228 60,7 20,3 40,3 470 442 74,1 46,9 60,7
250 235 61,6 22,2 41,7 480 450 74,5 47,7 61,3
260 247 62,4 24 43,1 490 456 74,9 48,4 61,6
270 256 63,1 26,6 44,3 500 466 75,3 49,1 62,2
280 266 63,8 27,1 45,3 510 475 75,7 49,8 62,9
290 275 64,5 28,5 46,5 520 483 76,1 50,5 63,5
300 285 65,2 29,8 47,5 530 492 76,4 51,1 63,9
310 294 65,8 31 48,4 540 500 76,7 51,7 64,4
320 304 66,4 32,2 49,4 550 509 77 52,3 64,8
330 313 67 33,3 50,2 560 517 77,4 53 65,4
340 323 67,6 34,4 51,1 570 526 77,8 53,6 65,8
Key
HV is the Vickers hardness;
HBW is the Brinell hardness;
HR is the Rockwell hardness as follows: HRA, HRB, HRC, HRD.
Values are based on EN ISO 18265, taken as average of those typical to crane wheel and rail materials. Specific values
based on particular delivery condition or heat treatment may be used.

20
 BS EN 13001-3-3:2014
EN 13001-3-3:2014 (E)

Annex C
(informative)

Examples for wheel/rail material pairs and their wear behaviour

Table C.1 — Material pairs and their wear behaviour

Predominantly wearing partner

and level of wear
Wheel material Rail material
wheel rail

GE 300 C55 = =

GE 300 R260Mn **

EN-GJS 700-2 S235 **

EN-GJS 700-2 S275 **

EN-GJS 700-2 S355 *

EN-GJS 700-2 S690QL *

25CrMo4+QT S355 **

34CrMo4+QT S355 **

34CrMo4+QT C35E *

34CrMo4+QT S690QL = =

42CrMo4+QT S355 **

42CrMo4+QT C55 = =

42CrMo4+QT R260Mn *

33NiCrMoV14-5
C55 **
Surface hardened
33NiCrMoV14-5
R260Mn *
Surface hardened
42CrMo4
S355 **
Surface hardened
42CrMo4
C55 ***
Surface hardened
Key
= equal wear in wheel and rail
* light wear
** moderate wear
*** heavy wear

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BS EN 13001-3-3:2014
EN 13001-3-3:2014 (E)

Annex D
(informative)

Selection of a suitable set of crane standards for a given application

Is there a product standard in the following list that suits the application?

EN 13000 Cranes — Mobile cranes

EN 14439 Cranes — Safety — Tower cranes
EN 14985 Cranes — Slewing jib cranes
EN 15011 Cranes — Bridge and gantry cranes
EN 13852-1 Cranes — Offshore cranes — Part 1: General purpose offshore cranes
EN 13852-2 Cranes — Offshore cranes — Part 2: Floating cranes
EN 14492-1 Cranes — Power driven winches and hoists — Part 1: Power driven winches
EN 14492-2 Cranes — Power driven winches and hoists — Part 2: Power driven hoists
EN 12999 Cranes — Loader cranes
EN 13157 Cranes — Safety — Hand powered cranes
EN 13155 Cranes — Non-fixed load lifting attachments
EN 14238 Cranes — Manually controlled load manipulating devices
EN 15056 Cranes — Requirements for container handling spreaders

YES NO

Use it directly, plus the standards that are referred to.

Use the following:

EN 13001-1 Cranes — General design — Part 1: General principles and requirements

EN 13001-2 Crane safety — General design — Part 2: Load actions
EN 13001-3-1 Cranes — General Design — Part 3-1: Limit states and proof of competence of steel structure
EN 13001-3-2 Cranes — General design — Part 3-2: Limit states and proof of competence of wire ropes in
reeving systems
EN 13001-3-3 Cranes — General design — Part 3-5: Limit states and proof of competence of wheel/rail
contacts
prEN 13001-3-5 Cranes — General design — Part 3-5: Limit states and proof of competence of forged hooks
EN 13135 Cranes — Safety — Design — Requirements for equipment
EN 13557 Cranes — Controls and control stations
EN 12077-2 Cranes safety — Requirements for health and safety — Part 2: Limiting and indicating devices
EN 13586 Cranes — Access
EN 14502-1 Cranes — Equipment for the lifting of persons — Part 1: Suspended baskets
EN 14502-2 Cranes — Equipment for the lifting of persons — Part 2: Elevating control stations
EN 12644-1 Cranes — Information for use and testing — Part 1: Instructions
EN 12644-2 Cranes — Information for use and testing — Part 2: Marking

22
 BS EN 13001-3-3:2014
EN 13001-3-3:2014 (E)

Annex ZA
(informative)

Relationship between this European Standard and the

Essential Requirements of EU Directive 2006/42/EC

This European Standard has been prepared under a mandate given to CEN by the European Commission
and the European Free Trade Association to provide a means of conforming to Essential Requirements of the
New Approach Directive Machinery 2006/42/EC.

Once this standard is cited in the Official Journal of the European Union under that Directive and has been
implemented as a national standard in at least one Member State, compliance with the normative clauses of
this standard confers, within the limits of the scope of this standard, a presumption of conformity with the
relevant Essential Requirements of that Directive and associated EFTA regulations.

WARNING — Other requirements and other EU Directives may be applicable to the product(s) falling within
the scope of this standard.

23
BS EN 13001-3-3:2014
EN 13001-3-3:2014 (E)

Bibliography

[1] Niemann, G.: Maschinenelemente Band I, 2. Auflage, Springer Verlag Berlin

[2] Hesse, W.: Verschleißverhalten des Laufrad-Schiene-Systems fördertechnischer Anlagen, Diss. Ruhr-
Universität Bochum 1983

[3] SCHEFFLER M. Grundlagen der Fördertechnik — Elemente und Triebwerke. Vieweg Verlag, 1994

[4] Calcul en fatigue du contact galet/rail, 1B2302 et 1B2303, J.-F. Flavenot, Cetim, Juin 2003

[5] EKBERG A., KABO E., ANDERSON H. An engineering model for prediction of rolling, contact fatigue of
railway wheels. Fatigue Fracture Engineering Materials and Structures. 2002, 25 pp. 899–909

[6] EN 1563, Founding - Spheroidal graphite cast irons

[7] EN 10025-2, Hot rolled products of structural steels - Part 2: Technical delivery conditions for non-alloy
structural steels

[8] 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

[9] EN 10083-2, Steels for quenching and tempering - Part 2: Technical delivery conditions for non alloy
steels

[10] EN 10083-3, Steels for quenching and tempering - Part 3: Technical delivery conditions for alloy steels

[11] EN 10250-3, Open die steel forgings for general engineering purposes - Part 3: Alloy special steels

[12] EN 10293, Steel castings for general engineering uses

[13] EN 13135, Cranes - Safety - Design - Requirements for equipment

[14] EN 13674-1, Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above

[15] EN ISO 18265, Metallic materials - Conversion of hardness values (ISO 18265)

[16] KOS M. Neue Gesichtspunkte für die Paarung Laufrad-Schiene. Fördern und Heben. 1974, 24
pp. 481–484

[15] EN ISO 4287, Geometrical product specifications (GPS) - Surface texture: Profile method - Terms,
definitions and surface texture parameters (ISO 4287)

24
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