B08_Attachment_3_ANSI_E1_6-1___2021_.pdf

ANSI E1.6-1 – 2021

Entertainment Technology – Powered Hoist Systems

Approved by the ANSI Board of Standards Review on 26 January 2021

Rig/2006-2011r10

© 2021 Entertainment Services and Technology Association (ESTA)

ANSI E1.6-1 – 2021 Powered Hoist Systems

NOTICE and DISCLAIMER

ESTA does not approve, inspect, or certify any installations, procedures, equipment or materials for compliance with codes, recommended practices or standards. Compliance with an ESTA standard or an American National Standard developed by ESTA is the sole and exclusive responsibility of the manufacturer or provider and is entirely within their control and discretion. Any markings, identification or other claims of compliance do not constitute certification or approval of any type or nature whatsoever by ESTA.

ESTA neither guarantees nor warrants the accuracy or completeness of any information published herein and disclaims liability for any personal injury, property or other damage or injury of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this document. In issuing and distributing this document.

In issuing this document, ESTA does not either (a) undertake to render professional or other services for or on behalf of any person or entity, or (b) undertake any duty to any person or entity with respect to this document or its contents. Anyone using this document should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstance.

Published by:

Entertainment Services and Technology Association (ESTA) 270 Cadman Plaza, PO Box 23200 Brooklyn, NY 11202-3200

USA

Phone: 1-212-244-1505 Email: standards@esta.org

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The ESTA Technical Standards Program

The ESTA Technical Standards Program was created to serve the ESTA membership and the entertainment industry in technical standards related matters. The goal of the Program is to take a leading role regarding technology within the entertainment industry by creating recommended practices and standards, monitoring standards issues around the world on behalf of our members, and improving communications and safety within the industry. ESTA works closely with the technical standards efforts of other organizations within our industry, including USITT and VPLT, as well as representing the interests of ESTA members to ANSI, UL, and the NFPA.

The Technical Standards Program is accredited by the American National Standards Institute.

The Technical Standards Council (TSC) was established to oversee and coordinate the Technical Standards Program. Made up of individuals experienced in standards-making work from throughout our industry, the Council approves all projects undertaken and assigns them to the appropriate working group. The Technical Standards Council employs a Technical Standards Manager and Assistant to coordinate the work of the Council and its working groups as well as maintain a “Standards Watch” on behalf of members. Working groups include:

Control Protocols, Electrical Power, Event Safety, Floors, Fog and Smoke, Followspot Position, Photometrics, Rigging, and Stage Machinery.

ESTA encourages active participation in the Technical Standards Program. There are several ways to become involved. If you would like to become a member of an existing working group, as have over four hundred people, you must complete an application which is available from the ESTA office. Your application is subject to approval by the working group and you will be required to actively participate in the work of the group. This includes responding to letter ballots and attending meetings. Membership in ESTA is not a requirement. You can also become involved by requesting that the TSC develop a standard or a recommended practice in an area of concern to you.

The Rigging Working Group, which authored this Standard, consists of a cross section of entertainment industry professionals representing a diversity of interests. ESTA is committed to developing consensus-based standards and recommended practices in an open setting.

© 2021 ESTA page ii Rig/2006-2011r10

Contact Information

Technical Standards Manager Assistant Technical Standards Manager

Karl G. Ruling

ESTA

270 Cadman Plaza, PO Box 23200 Brooklyn, NY 11202-3200

USA

1-212-244-1505 x703 karl.ruling@esta.org

Richard J. Nix

ESTA

270 Cadman Plaza, PO Box 23200 Brooklyn, NY 11202-3200

USA

1-212-244-1505 x649 richard.nix@esta.org

Technical Standards Council Chairpersons

Mike Garl Mike Garl Consulting LLC 1-865-389-4371 mike@mikegarlconsulting.com

Mike Wood Mike Wood Consulting LLC 1-512-288-4916 mike@mikewoodconsulting.com

Rigging Working Group Chairpersons

Bill Sapsis Sapsis Rigging, Inc.

233 North Lansdowne Ave.

Lansdowne, PA 19050

USA

1-215-228-0888 x206 bill@sapsis-rigging.com

Christine Kaiser Syracuse Scenery & Stage Lighting Co., Inc.

101 Monarch Dr.

Liverpool, NY 13088

USA

1-315-453-8096 ckaiser@syracusescenery.com

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Investors in Innovation The Technical Standard Program (TSP) is financially supported by ESTA and by companies and individuals who make undirected donations to the TSP. Contributing companies and individuals who have helped fund the TSP are recognized as “Investors in Innovation”. The Investors in Innovation when this standard was approved by ANSI's Board of Standards Review include these companies and individuals:

VISIONARY LEADERS ($50,000 & up)

ETC PLASA

VISIONARY ($10,000 & up; >100 employees/members) Chauvet Professional Cisco Columbus McKinnon Entertainment Technology

ProSight Specialty Insurance Robe Disney Parks Live Entertainment

VISIONARY ($5,000 & up; 20–100 employees/members) Altman Lighting, Inc.

German Light Products JR Clancy McLaren Engineering Group Rose Brand

Stage Rigging Theatre Projects Theatre Safety Programs

TMB

VISIONARY ($500 & up; <20 employees/members) About the Stage B-Hive Industries, Inc.

Scott Blair Boston Illumination Group Candela Controls, Inc.

Clark Reder Engineering Tracey Cosgrove & Mark McKinney Doug Fleenor Design EGI Event Production Services Entertainment Project Services Neil Huff Interactive Technologies Jules Lauve Brian Lawlor Michael Lay

Limelight Productions, Inc.

Link John T. McGraw Mike Garl Consulting Mike Wood Consulting Reed Rigging Reliable Design Services Alan Rowe Sapsis Rigging Inc.

Steve A. Walker & Associates Dana Taylor Steve Terry Vertigo WNP Services

INVESTOR ($3,000–$9,999; >100 employees/members) Actors' Equity Association Barbizon Lighting Company Golden Sea Professional Lighting Provider IATSE Local 728 IATSE Local 891

Lex

NAMM

Rosco Laboratories Texas Scenic Company

INVESTOR ($1,500–$4,999; 20–100 employees/members) Area Four Industries American Society of Theatre Consultants BMI Supply City Theatrical Inc.

H&H Specialties, Inc.

InterAmerica Stage, Inc.

Lycian Stage Lighting Niscon Inc.

Tomcat Staging, Lighting and Support Systems

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INVESTOR ($200–$499; <20 employees/members) Bruce Darden Guangzhou Color Imagination LED Lighting Indianapolis Stage Sales & Rentals, Inc.

Kenney Drapery Associates, Inc.

L1 Inc.

Lighting Infusion LLC Scott Madaski Mediam Sp. zo.o.

Karen Miller Nanyi Audio & Lighting Enterprise Co., Ltd.

Qdot Lighting Ltd.

Sanko Device Co. Ltd.

Show Light Oy Shawn Silverman Steve Vanciel Ralph Weber

SUPPORTER ($50 - $2,999; >100 employees/members) Harlequin Floors

SUPPORTER ($50 - $1,499; 20–100 employees/members) ACT Lighting Inc./AC Power Distribution ARM Automation, Inc.

Ian Foulds, IATSE Local 873 General Lighting Electronic Co. Ltd.

Guangzhou Shenghui Electronic Technology Guangzhou YaFeng Optoelectronic Equipment Co.

Guangzhou Yilaiming Photoelectric Technology Co., Ltd.

ELECTRON SA

HAYA Light Equipment Ltd. Co.

High Output InCord Intella Systems Co., Ltd.

iWeiss LA ProPoint, Inc.

LUPO SRL

Moss LED Inc.

Nanshi Lighting Oasis Stage Werks Shenzhen Ifountain Technology Skjonberg Controls Inc.

Stage Equipment & Lighting Stagemaker Stageworks Syracuse Scenery and Stage Lighting Co., Inc.

Taurus Light Co. Ltd.

Ultratec Special Effects Vincent Lighting Systems Zhisheng Huang Zhuhai Shengchang Electronics Co.

SUPPORTER ($50 - $199; <20 employees/members) Adam Blair Alyxzander Bear Capture Visualisation AB Chip Scott Lighting Design DMX Pro Sales Emilium GmbH Peter Erskine Foshan Leiyuan Photoelectric Co. Ltd.

Jack Gallagher Tony Giovannetti Pat Grenfell John Huntington Beverly and Tom Inglesby Klik Systems

Eddie Kramer Jason Kyle David Lascaut Jason Livingston LuxBalance Lighting Tyrone Mellon, Jr.

Lizz Pittsley Michael Skinner Studio T+L TELMIC Neo Terrier Marketing Arjan van Vught Lars Wernland

Extraordinary legacy gift: Ken Vannice

All donations to the Technical Standards Program support the TSP in general, and are not directed to, or for, the benefit of any particular technical standard project, or any Working Group working on any particular standard or project. If you would like to help support the Technical Standards Program in its work, please consider becoming an Investor in Innovation by visiting our website at http://tsp.esta.org/invest or by contacting the ESTA office at 1- 212-244-1505 and selecting "TSP" from the menu.

© 2021 ESTA page v Rig/2006-2011r10

Acknowledgments The Rigging Working Group members when this document was approved by the working group on 02 September 2020 are shown below.

Voting members:

Ryan Riordan; Accurate Staging, Inc.; P; CP R. Duane Wilson; Amer. Society of Theatre Consultants; P; DE Max A. Wilson; Applied Electronics; P; MP Jon Lenard; Applied Electronics; A; MP Will Todd; Area Four Industries; P; MP Keith Bohn; Area Four Industries; A; MP Ed Leahy; Chicago Flyhouse, Inc; P; CP Jeremy Hodgson; Cirque Du Soleil, Inc.; P; U Tom Lapp; Cirque Du Soleil, Inc.; A; U Frederic Caron; Cirque Du Soleil, Inc; A; U Allen Winzler; Clark-Reder Engineering, Inc.; P; DE Ken Tilson; Columbus McKinnon Corp.; P; MP Nick Fleming; Columbus McKinnon Corp.; A; MP Mike Skinner; Contract Services Administration Trust Fund; P; U Chris Moulton; Contract Services Administration Trust Fund; A; U Don Earl; Earl Girls, Inc.; P; DR Steven Ricks; Electronic Theatre Controls, Inc.; P; MP Michael Lichter; Electronic Theatre Controls, Inc.; A; MP Eric Rouse; Entertainment Project Services, LLC; P; CP Joseph Champelli; Entertainment Project Services, LLC; A; CP Joshua “Fritz” Friedensohn; Entertainment Project Services, LLC; A; CP Ethan W Gilson; Entertainment Rigging Services, LLC; P; U John Ringelman; Freeman Companies; P; DR Chris Schmidt; Freeman Companies; A; DR Joe Golden; Gallagher Staging & Productions; P; DR Miriam Paschetto; Geiger Engineers; P; DE Reid Neslage; H & H Specialties Inc.; P; MP Pat Grenfell; Hoist Sales & Service; P; DR Edwin S. Kramer; I.A.T.S.E. Local 1; P; U Rod Haney; I.A.T.S.E. Local 891; P; U Ross Long; I.A.T.S.E. Local 891; A; U Bruce Darden; InterAmerica Stage, Inc.; P; CP Drew Becker; InterAmerica Stage, Inc.; A; CP Jonathan Deull; JSD Projects LLC; P; U William B. Gorlin; M.G. McLaren, P.C.; P; G Peter W. Batt; Mainstage Theatrical Supply, Inc; P; DR Mike Garl; Mike Garl Consulting LLC; P; DE Rick Montgomery; Motion Laboratories, Inc.; P; MP Mike Webb; Motion Laboratories, Inc.; A; MP Michael Shaw; Motion Laboratories, Inc.; A; MP Marty Wesstrom; Mountain Productions Inc.; P; DR Tim Hansen; Oasis Stage Werks; P; DR Orestes Mihaly; Production Resource Group; P; DR Ryan Roby; Production Resource Group; A; DR Carlos Ortega; PSAV Presentation Services; P; U Demian Purdy; PSAV Presentation Services; A; U Jacob Abbott; PSAV Presentation Services; A; U Jay Cid; R&M Materials Handling / Stagemaker; P; MP Bartholomew J. Mueller; Recreation Engineering Inc.; P; DE

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Bennett Brian; Reed Rigging Inc.; P; DR Elmer Veith; Reliable Design Services; P; CP Matt Panther; Reliable Design Services; A; CP Richard J. Nix; Richard J. Nix; I; G Jesse Adams; Rose Brand Wipers, Inc; P; DR Bill Sapsis; Sapsis Rigging, Inc.; P; U Joseph Jeremy; Show Distribution Group, Inc.; P; CP Bill McIntyre; Show Distribution Group, Inc.; A; CP Sanford P. Gilzow; Shur-Rig LLC; P; G Dana Bartholomew; Silver State Wire Rope and Rigging; P; DR Steve Walker; Steve A. Walker & Associates; P; G Kyle Kusmer; Steven Schaefer Associates, Inc; P; DE Mike Merz; Steven Schaefer Associates, Inc; A; DE Christine L. Kaiser; Syracuse Scenery & Stage Lighting Co., Inc.; P; DR Harold Ike Shippers; Syracuse Scenery & Stage Lighting Co., Inc.; A; DR Jason Tello; T6 Truss Designs. LLC; P; CP Tracie Allen; T6 Truss Designs. LLC; A; CP Stephan Jon Wood; Tait Towers Manufacturing LLC; P; CP David Bond; Tait Towers Manufacturing LLC; A; CP Ryan Kunkel; Tait Towers Manufacturing LLC; A; CP Tony Diemont; Texas Scenic Company; P; DR Russell Solomon; Texas Scenic Company; A; DR Steven Serafin; The Hartford Group; P; G Jim Niesel; Theatre Projects Consultants, Inc.; P; DE Jerry Gorrell; Theatre Safety Programs; P; G Sam Michael; Thern, Inc.; P; MP Jeff Wilkowski; Thern, Inc.; A; MP Paul Brunner; Thern, Inc.; A; MP Daniel H. Louis; Theta Consulting LLC; P; G Nathan Villines; Tyler Truss Systems; P; MP Bill Edwards; Tyler Truss Systems; A; MP Josh Conner ; Tyler Truss Systems; A; MP Robert Haycock; UC Berkeley; I; U Tracy Nunnally; Vertigo; P; CP John P. Moore; Vertigo; A; CP Ian Bevan; Walt Disney Company; P; DE Lee Chuong; Walt Disney Company; A; DE Peter V. Svitavsky; Wenger Corp.; P; CP Dan Culhane; Wenger Corp.; A; CP Paul Zagajeski; Wenger Corp.; A; CP Michael Wells; Xtreme Structures and Fabrication; P; MP Mark Newlin; Xtreme Structures and Fabrication; A; MP Theresa Kelley; Xtreme Structures and Fabrication; A; MP Kalen Larson; ZFX, Inc.; P; CP

Observer (non-voting) members:

Matthew Antonucci; Contract Services Administration Trust Fund; O; U Brent Armstrong; Alpine Rigging & Structural Design; O; CP William Ian Auld; Auld Entertainment; O; U Robert Barbagallo; Solotech Inc.; O; DR William Beautyman; Limelight Productions, Inc.; O; DR Justin Bennett; University of the Incarnate Word; O; U Roy Bickel; Roy Bickel; O; G Tyler Bland; Walt Disney Company; O; U

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William Bradburn; Aerial Arts, Inc.; O; U David M. Campbell; Geiger Engineers; O; G Frederic Caron; ; O; U Daniel J. Clark; Clark-Reder Engineering, Inc.; O; G Benjamin Cohen; Chicago Flyhouse Inc.; O; CP Brandon Cox; Heavyweight Solutions; O; CP David Darland; PSAV Presentation Services; O; U Robert Dean; ZFX, Inc.; O; CP Jim Digby; Event Safety Alliance; O; U Brad Dittmer; Stage Labor of the Ozarks; O; U Russ Dusek; I Weiss; O; MP Jennifer Ferguson; Kito Group; O; MP Tim Franklin; Theta Consulting LLC; O; G James M. Garner; Walt Disney Company; O; G Michael P. Gosenski; Rigging Systems LLC; O; U Phillip R. Hampton; Charcoalblue; O; DE Sean Harding; Port Lighting Systems; O; G Chris Higgs; Total Solutions Group; O; G Nick Holmberg; PSAV; O; DR Donald Hoffend_III; Avista Designs, LLC; O; G Cedric Jackson; Screen Actors Guild - American Federation of Television & Radio Artists; O; G Ted Jones; Grand Stage; O; U Jerald Kraft; JTH Lighting Alliance; O; CP Phillip Lewis; Tait Towers Manufacturing LLC; O; CP Paul “Luke” Lewkowicz; Paul E Lewkowicz PC; O; DE Jacob E. Loretto; Musson Theatrical Inc.; O; DR Wendy Manson; ; O; G Steven Michelman; Entertainment Project Services, LLC; O; CP John Neal; Rhino Staging; O; G Gregory Orth; WNP Services, Inc.; O; DR Kurt Pragman; Pragman Associates, LLC; O; G Luke Ricca; Luke Ricca; O; G Mark Riddlesperger; LA ProPoint, Inc.; O; CP Tim Salamon; PSAV Presentation Services; O; DR Peter A. Scheu; Scheu Consulting Services, Inc.; O; DE Ford Sellers; Chauvet Lighting; O; MP Monica Skjonberg; Skjonberg Controls, Inc.; O; CP Knut Skjonberg; Skjonberg Controls, Inc.; O; CP John C. Snook; Thermotex Industries Inc.; O; CP Lynn M. Snook; Thermotex Industries Inc.; O; CP Todd Spencer; PSAV Presentation Services; O; U Ross Taylor; Taylor & Taylor Associates; O; G Stephen Vanciel; IATSE Local 631; O; U Patrick Wallace; PSAV Presentation Services; O; U Charlie Weiner; Eurotruss; O; MP Drew Wending; PSAV Presentation Services; O; DR Mike Weston; PSAV Presentation Services; O; DR Greg Williams; PSAV Presentation Services; O; G Jeong Sik Yoo; Ghost LX; O; DE Andrew Young; Andrew Young; O; U

Interest category codes:

CP = custom-market producer DE = designer DR = dealer rental company G = general interest MP = mass-market producer U = user

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Table of contents 1 Scope 2 References 3 Definitions 4 Risk assessment and risk reduction 5 General design requirements 6 Mechanical design

6.1 General requirements (See Annex note.)

6.2 Power transmission components

6.3 Hoist frames and static load bearing components

6.4 Lifting media

6.5 Blocks

6.6 Load carrying devices

6.7 Guarding

7 Electrical equipment and control systems

7.1 General

7.2 Control stations

7.3 Enable devices (See Annex note.)

7.4 E-stop stations (See Annex note.)

7.5 Control system parameters

7.6 Constraining travel

7.7 Motor control panels

7.8 Multiple motor/actuator systems

7.9 E-stops (See Annex note.)

7.10 Machine stops (See Annex note.)

7.11 Normal stop

8 Manuals (See Annex note.)

8.1 General

8.2 Operation

8.3 Maintenance

9 Labeling, marking and signage 10 Installation 11 Inspection and testing

11.1 General requirements

11.2 Inspection procedures (See Annex note.)

11.3 Testing procedures

11.4 Documentation

12 Maintenance ANNEX A, Supplemental information ANNEX B, Examples of hazards and hazardous situations ANNEX C, Risk assessment and risk reduction example ANNEX D, Risk assessment publications

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1 Scope This standard establishes requirements for the design, manufacture, installation, inspection, and maintenance of powered hoist systems for lifting and suspension of loads for performance, presentation, and theatrical production.

This standard does not apply to the structure to which the hoist is attached, attachment of loads to the load carrying device, or systems for flying people. Excluded are welded link chain hoists, and manually powered hoists, including auxiliary drill operation. (See Annex note.)

The provisions of this standard are not intended to prohibit any design, materials, or methods of fabrication, provided that any such alternative is at least the equivalent of that described in this standard in quality, strength, and effectiveness. (See Annex note.)

2 References All equipment shall be manufactured to comply with this standard and any applicable codes or jurisdictional regulations where the requirements of such codes or regulations are more stringent.

The following documents are referenced. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document, including any amendments, shall apply.

Aluminum Design Manual, 2015 edition1

American Welding Society standards2

ANSI/AISC 360-16 Specification for Structural Steel Buildings

ANSI B11.TR3 2000 (R2015) Risk Assessment and Risk Reduction

ANSI E1.2 2012 Design, Manufacture and Use of Aluminum Trusses and Towers

ANSI Z535

1 - Safety Color Code-2017 2 - Environmental and Facility Safety Signs-2011 (R2017) 3 - Criteria for Safety Symbols-2011 (R2017) 4 - Product Safety Signs and Labels-2011 (R2017) 6 - Product Safety Information re Product Manuals, Instruction and Other Collateral Materials-2011 (R2017)

NFPA 70: National Electric Code, 2017 edition3

NFPA 79: Electrical Standard for Industrial Machinery, 2015 edition4

3 Definitions

3.1 characteristic load. The maximum force applied to a component of a hoist system resulting from normal intended operating conditions while the system is at rest or in motion. This includes the apportioned fractions of the working load limit (WLL), self-weight including that due to load carrying devices and lifting media, and the forces due to inertia in normal use. (See Annex note.)

3.2 competent person. A person who is capable of identifying existing and predictable hazards in the workplace and who is authorized to take prompt corrective measures to eliminate them.

1 The Aluminum Association 1525 Wilson Boulevard, Suite 600 Arlington, VA 22209, www.aluminum.org 2 American Welding Society 8669 NW 36th Street #130, Miami, FL 33166, www.aws.org 3 National Fire Protection Society 1 Batterymarch Park Quincy, MA 02169-7471, www.nfpa.org 4 National Fire Protection Society 1 Batterymarch Park Quincy, MA 02169-7471, www.nfpa.org © 2021 ESTA page 1 Rig/2006-2011r10

3.3 control station. A part of the control system that governs motion control of one or multiple hoists. The control station includes at least one motion control device (such as a “go” button, a “joystick”, an “up / down” button pair, or any other device) that, when actuated, initiates motion of a hoist.

3.4 enabling device. A manually operated control device used in conjunction with a control station, which when continuously actuated, will allow a machine to function. (See Annex note.)

3.5 fault. The state of an item characterized by inability to perform a required function.

3.6 failure. Termination of the ability of an item to perform a required function. After a failure, the item has a "fault". A "failure" is an event, as distinguished from "fault,” which is a state.

3.7 hoist. A machine used to raise or lower a suspended load.

3.8 hoist system. An arrangement of one or more hoists and associated lifting media, reeving, sheaves, and controls used for raising or lowering a suspended load.

3.9 interlock device. A switch, sensor, or interconnected logic system that permits or prevents motion.

3.10 lifting medium. The load carrying element that is driven by the hoist to move the load (e.g. wire rope, roller chain).

3.11 limit, normal (hard). A limit switch or sensor that prevents further movement in the direction of travel, i.e., end of travel, initial.

3.12 limit, software (soft). A programmed reference position that prevents further movement in the direction of travel.

3.13 limit, ultimate. A limit switch that senses over-travel in the event of failure of the normal position limit, i.e., over-travel.

3.14 limits of use. The parameters under which the system is designed to operate (e.g. working load limit, speed of movement, duty cycle, environmental conditions, user skill level, availability of maintenance).

3.15 load carrying device. The component(s) of the hoist system that connect a suspended load to the lifting media (e.g. batten, truss, hook).

3.16 load securing device. A mechanical device that prevents unintentional movement in the hoist system.

3.17 peak load. The maximum force applied to a component of a hoist system, while the system is at rest or in motion, resulting from abnormal conditions or irregular operation (e.g. effects of uncontrolled stops, stalling of the prime mover, extreme environmental conditions). (See Annex note.)

3.18 pile-on drum. Drum in which the individual lifting media winds in concentric layers, and are constrained to rest on the prior layer.

3.19 positive break operation. The achievement of contact separation as the direct result of a specified movement of the switch actuator through non-resilient members (i.e. not dependent upon springs).

3.20 power transmission system. The components within the hoist that create, transfer, support, or dissipate mechanical force and motion (e.g. motors, gears, shafts, clutches, couplings, bearings).

3.21 prime mover. A device that originates mechanical force and motion within a hoist power transmission system (e.g. electric motor, hydraulic actuator). (See Annex note.)

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3.22 qualified person. A person who, by possession of a recognized degree or certificate of professional standing, or who, by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.

3.23 reasonably foreseeable misuse. Use in a way that is predictable, but not intended (e.g. deliberate misuse of the machine to save time or materials, inadequate operator training).

3.24 risk. Combination of the probability of occurrence of harm and the severity of that harm.

3.25 risk assessment (RA). The process of identifying, evaluating, and quantifying the potentially hazardous conditions, severity, and probability of occurrence of harm.

3.26 risk reduction (RR). Mitigation of risk created by hazardous conditions.

3.27 static load. The maximum force applied to a component of a hoist system resulting from normal intended operating conditions while the system is at rest. This includes the apportioned fractions of the working load limit (WLL) and self-weight, including that due to load carrying devices and lifting media.

3.28 stop categories category 0 stop. An uncontrolled stop caused by the immediate removal of power to the machine actuators.

category 1 stop. A controlled stop with power to the machine actuators available to achieve the stop, then remove power when the stop is achieved.

category 2 stop. A controlled stop with power left available to the machine actuators.

3.29 system designer. The person or persons who specify the limits of use of the system and may also select and integrate the components of the system.

3.30 ultimate load carrying capacity. The maximum load a component may support without fracture, buckling or crushing This value may be calculated as the nominal strength using nationally recognized construction standards appropriate for the given material or by laboratory tests.

3.31 winding drum: A device used to connect the lifting media to the power transmission of a hoist; converts rotary motion of the gear shaft to linear motion of the lifting media.

3.32 working load limit (WLL). The maximum static load the user may apply.

4 Risk assessment and risk reduction

4.1 Risk assessment and risk reduction (RA/RR) for a hoist or hoist system shall be performed throughout design, fabrication, installation, and testing. Risk assessment and risk reduction shall be performed when hoists or hoist systems are modified. (See Annex note.)

4.2 It is preferable that risk assessment and risk reduction be performed by a group of two or more competent persons. When the risk assessment and risk reduction is completed by a single individual, that individual shall be a qualified person.

4.3 The group or person performing the risk assessment and risk reduction shall determine the acceptable level of residual risk.

4.4 The group or person conducting a risk assessment and risk reduction shall:

4.4.1 Identify and document the limits of use.

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4.4.2 Identify and document the tasks anticipated throughout the life of the system.

4.4.3 Identify and document the hazards associated with each task. For each identified hazard: (See Annex B.)

4.4.3.1 Estimate the severity of harm associated with exposure to the hazard.

4.4.3.2 Estimate the probability of occurrence of harm from the hazard.

4.4.3.3 Identify the risk by considering the severity and probability of harm.

4.4.3.4 Evaluate the risk associated with each hazard to determine if the risk is acceptable.

4.4.3.5 Take measures to reduce unacceptable risks.

4.4.3.6 Determine whether new or additional hazards have been introduced, or if the level of existing risks have been changed.

4.4.3.7 Repeat this process until an acceptable level of residual risk is achieved.

4.5 Documentation of the risk assessment and risk reduction shall include the mitigating actions taken for each hazard and the resulting reduction in risk.

(See Annex B.)

(See Annex C.)

(See Annex D.)

5 General design requirements

5.1 Hoist systems shall be designed by qualified persons.

5.2 Hoist systems shall incorporate all aspects of mechanical and control requirements herein (Section 6 – Mechanical design and Section 7 – Electrical equipment and control systems), unless otherwise determined by the risk assessment and risk reduction.

5.3 Hoist systems shall be designed for use in the anticipated environmental and operating conditions. The system designer shall define the limits of use.

5.4 Hoist systems shall be designed to allow for inspection, maintenance, and replacement.

5.5 All components shall be used in accordance with the manufacturer's recommendations.

5.6 The maximum number of hoists or hoist systems capable of simultaneous operation shall be determined and shall be included in the limits of use. (See Annex note.)

5.7 The distribution of loads in a multiple line hoist system, or between hoists in a multiple hoist system, shall be assessed.

5.8 Variations caused by the uneven application of load, deflections of lifted objects, deflection of supporting structure or hoist system supports, and control synchronization errors, shall be assessed.

5.9 Calculation of the peak load shall assess the maximum torque output from the prime mover in a stalling condition and the effects of uncontrolled stops. Uncontrolled stop calculations shall account for potential variations in braking torque.

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5.10 Hoist systems shall be free from vibration that threatens the integrity or functionality of the hoist under normal operating conditions.

5.11 Hoist systems shall be protected against uncontrolled speed and unintentional movements.

5.12 Hoist systems shall be designed for anticipated duty cycles and product life.

5.13 Hoist system components shall resist both unintentional sliding and detachment from the supporting structure.

5.1.14 Fasteners shall be self-locking, or secured by alternate means to prevent loosening. Fasteners shall be installed in accordance with manufacturer's instructions.

5.15 Where the supplier of any component or subassembly of the hoist system is not responsible for the entire hoist system, the system designer shall specify the safety requirements for the component or subassembly.

5.16 Design of components not specifically referenced within this document shall be reviewed according to applicable standards. In the absence of an applicable standard, the designer shall apply generally accepted engineering principles.

6 Mechanical design

6.1 General requirements (See Annex note.)

6.1.1 The hoist system shall be capable of moving the lifted load from a static condition and returning it to the static state, maintaining control throughout the operation. Fire safety curtain hoist systems operating during emergency descent in compliance with applicable standards are deemed to comply.

(See Annex note.)

6.1.2 Characteristic loads and peak loads shall be considered in determining the loads applied to the building structure. (See Annex note.)

6.1.3 Category 0 stops shall not cause permanent deformation or failure of any component or portion of the system.

6.1.4 All components shall be designed to resist unintentional loosening.

6.1.5 All welds shall comply with current American Welding Society standards.

6.2 Power transmission components

6.2.1 Design factors (See Annex note.)

6.2.1.1 For power transmission components that have a manufacturer’s recommended load rating, the characteristic load shall not exceed the mechanical load rating at a minimum Service Factor of 1.0. Power transmission components without manufacturer’s load ratings shall be designed so that stresses do not exceed the following:

6.2.1.1.1 Yield strength of the material shall be a minimum of 3X the shear stresses due to the characteristic load. (See Annex note.)

6.2.1.1.2 Yield strength of the material shall be a minimum of 1.58X the bearing (contact) stresses due to the characteristic load.

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6.2.1.2 For power transmission components for which the manufacturer has recommended load ratings, the load shall not be released upon application of the peak load. Power transmission components without a manufacturer’s peak load rating shall be selected such that the peak load is less than the yield strength of the component.

6.2.1.3 The thermally limited load rating of power transmission components shall be suitable for the limits of use of the hoist system. (See Annex note.)

6.2.2 Motors

6.2.2.1 Hoist system motors shall be sized appropriately for hoist capacity, design criteria and duty cycle.

6.2.2.2 Fixed speed hoist system motors shall have a minimum starting torque of 1.5X of the static load. Variable speed hoist system motors shall have a minimum starting torque of 1.1X of the characteristic load.

6.2.2.3 Hoist systems shall be designed to prevent loss of directional control while reversing the motor.

(See Annex note.)

6.2.3 Load securing devices

6.2.3.1 Hoists shall include at least two independently functioning load securing devices.

6.2.3.2 At least one of the load securing devices shall automatically engage when operational controls are released or drive power is removed.

6.2.3.3 Neither load securing device shall require external power to engage.

6.2.3.4 Each load securing device shall be capable of stopping and holding 1.1X the static load unless otherwise permitted by section 6.2.3.5.

6.2.3.5 A low back-driving efficiency gear reducer, or a device that slows a load without stopping it may be used in place of a load securing device only when risk assessment and risk reduction mitigates hazards associated with descent of the load as a result of release or failure of the other load securing device. Fire safety curtain hoists are deemed to comply.

6.2.3.6 It shall be possible to test the effectiveness of each load securing device separately. Single use devices shall be acceptable if they have proven reliability based upon independently verified testing.

6.2.4 Drive sprockets

6.2.4.1 This section applies to sprockets that transmit power to the lifting media.

6.2.4.2 Chain shall wrap the sprocket for sufficient distance to provide adequate tooth strength and avoid the chain rollers from disengaging the sprocket teeth.

6.2.4.3 A mechanism shall be included to prevent the chain from disengaging the sprocket teeth.

6.2.4.4 Sprockets shall be selected to mitigate the effects of chordal action.

6.2.5 Winding drums (See Annex note.)

6.2.5.1 Winding drums shall take up the media in a defined and repeatable manner.

6.2.5.2 Winding drums shall be designed to take up the lifting media in a way as to not cause damage or undue wear to the lifting media.

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6.2.5.3 Pitch diameter of a winding drum shall not cause damage or undue wear to the lifting media.

6.2.5.4 Drum material and construction shall resist tread pressures imposed by the lifting media.

6.2.5.4.1 The maximum allowable fleet angle from a grooved drum shall be two (2) degrees from perpendicular to the drum. (See Annex Note.)

6.2.5.4.2 The maximum allowable fleet angle from a smooth drum shall be one and one half (1-1/2) degrees from perpendicular to the drum.

6.2.5.4.3 Grooves on rope drums shall be sized as recommended to support the media and to prevent crushing.

6.2.5.5 When pile-on drums are used, each wire rope shall have its own winding chamber that ensures the rope is layered in such a manner that the rope centerlines are aligned. (See Annex note.)

6.2.5.6 The attachment of the lifting media to the drum shall have a strength equal to or greater than 1.33X the peak load. This shall be accomplished by end termination alone, or by including the friction from the minimum turns of lifting media on the drum.

6.2.5.7 When a clamping method is used to attach lifting media to the drum, it shall be ensured that a single failure of the attachment method (e.g. screw) does not lead to the failure of the connection. (See Annex note.)

6.2.6 Power screw drives

6.2.6.1 This section applies to power screw drives that directly support the lifted load.

6.2.6.2 The power screw shall have a greater wear resistance than the load-supporting nut.

6.2.6.3 Each power screw nut shall be provided with a means of wear indication.

6.2.6.4 The power screw nut shall have a minimum strength of 1.6X the characteristic load or 1.2X the peak load, whichever is greater.

6.2.7 Hydraulic systems

6.2.7.1 This section applies to elements of a hydraulic circuit that directly support a lifted load.

6.2.7.2 The pressure resulting from 2X the characteristic load shall not exceed the manufacturer’s recommended maximum operating pressure.

6.2.7.3 The pressure resulting from 1.2X the peak load shall not exceed the manufacturer’s recommended maximum operating pressure.

6.2.7.4 Hydraulic actuators shall be provided with local, manual valves with which each actuator can be locally disabled. Disabling an actuator shall not interfere or impede safety devices.

6.2.7.5 The operating pressure shall be limited by means of a pressure limiting device.

6.2.7.6 It shall be possible to measure the system pressure.

6.2.7.7 If the pressure is generated by means of a gaseous cushion that has a direct influence on the hydraulic fluid, all drive systems shall automatically switch off once the fluid reserve goes below the minimum level.

6.2.7.8 Accumulators shall depressurize automatically at hoist system shutdown.

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6.3 Hoist frames and static load bearing components

6.3.1 Hoist frames and static load bearing components shall be designed with a yield strength at least 2X the characteristic load. The ultimate load carrying capacity of the device shall be at least 3X the characteristic load.

6.3.2 Hoist frames and static load bearing components shall be designed with an ultimate load carrying capacity at least 2X the peak load.

6.3.3 Deflection of load bearing components shall not be detrimental to hoist operation.

6.4 Lifting media

6.4.1 General

6.4.1.1 Minimum tensile strength of lifting media shall be no less than the following:

5X the characteristic load.

8X the static load.

1.33X the peak load.

6.4.1.2 For multiline hoists, the peak load for lifting media shall not exceed 6X the characteristic load. (See Annex note.)

6.4.1.3 The minimum tensile strength shall include termination efficiency and other applicable strength reduction factors. End termination of the lifting media shall have a minimum tensile strength not less than 80% of the strength of the lifting media. (See Annex note.)

6.4.1.4 In multiple line hoist systems, lifting media shall have a method of length adjustment.

6.4.1.5 Lifting media shall not contact any part of the building structure, adjacent systems, or other equipment not intended for contact.

6.4.1.6 In cases where inspection is not possible, risk analysis and risk reduction shall address means to mitigate this additional risk.

6.4.2 Lifting media terminations

6.4.2.1 Termination hardware shall be load rated and shall have strength equal to or greater than 1.33X the peak load.

6.4.2.2 Shackles, wire rope clips, eyebolts, eye nuts, and turnbuckles shall be of forged steel or equivalent construction. Malleable wire rope clips shall not be permitted.

6.4.2.3 Turnbuckles shall be secured after adjustment to prevent turnbuckle body rotation.

6.4.2.4 Screw pin shackles and turnbuckles with screw pin jaws shall be secured to prevent disconnection.

6.4.2.5 Thimbles shall be sized in accordance with the wire rope diameter.

6.4.3 Wire rope

6.4.3.1 The grade and construction of wire rope shall be appropriate for the intended use.

6.4.3.2 Anticipated duty cycle and detrimental conditions such as reverse bending shall be factored into the selection of wire rope.

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6.4.4 Roller chain

6.4.4.1 Where roller chains are used in combination with wire rope, provisions shall be made to prevent torsion induced by the wire rope twisting the roller chain beyond the roller chain manufacturer’s recommended limits.

6.4.4.2 Roller chain connections shall distribute the load evenly to the link plates on both sides of the chain. A connection that pivots freely about an axis perpendicular to that of the chain pins shall be permitted.

6.4.5 Other lifting media

6.4.5.1 Other lifting media shall be permitted provided the lifting media manufacturer approves it for this use.

(See Annex note.)

6.4.5.2 Terminations shall be made by a competent person.

6.4.5.3 The individual terminating synthetic rope shall require third party or rope manufacturer's certification.

6.5 Blocks

6.5.1 The working load limit for the block shall meet the following criteria:

6.5.1.1 For failure modes that result in yield of ductile materials, the yield strength of the material shall be at least 4X the characteristic load stresses.

6.5.1.2 For failure modes that result in collapse or fracture, the yield strength of the material shall be at least 6X the characteristic load stresses.

6.5.1.3 For bearing contact stress failure modes, application of the characteristic load shall not result in stresses greater than the yield strength of the material.

6.5.1.4 For rolling element bearings, application of the characteristic load shall result in a calculated L10 life of at least 2000 hours at maximum system design speed.

6.5.2 Blocks shall be selected so that the characteristic load does not exceed its working load limit.

6.5.3 Blocks shall be selected so that the block’s ultimate load carrying capacity is at least 1.33X the peak load.

6.5.4 For single line blocks within multiline systems, the peak load for blocks shall not exceed 6X the characteristic load. (See Annex note.)

6.5.5 Blocks and other reeving components shall be mounted in a manner that permits inspection, maintenance, and replacement.

6.5.6 Shafts shall be installed so that no thread contacts the bearing or sheave housing. Shafts shall be locked against rotation within the block housing, unless specifically designed to rotate. Shafts shall not move axially.

6.5.7 The maximum allowable fleet angle for lifting media through a block shall not cause damage to the sheave or the lifting media.

6.5.8 Lifting media shall be prevented from unintentionally disengaging from sheaves or sprockets.

6.5.9 Sheave diameter, sheave material, lifting media, and anticipated duty cycle shall be factored into the selection of the block.

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6.6 Load carrying devices

6.6.1 The yield strength of the device shall be at least 2X the characteristic load. The ultimate load bearing capacity of the device shall be at least 3X the characteristic load.

6.6.2 The ultimate load bearing capacity of the device shall be at least 1.5X the peak load.

6.6.3 Battens or their equivalents shall be designed so that the maximum deflection for a uniformly distributed or concentrated point load shall not exceed 1/180 of the span distance between adjacent lift lines. Where there is not a specific load distribution pattern, the load shall be assumed to be uniformly distributed along the entire length of the batten.

6.6.4 Aluminum trussing shall meet the requirements of ANSI E1.2-2012, and deflection shall be calculated based on the characteristic load designated in the system designer’s limits of use. Forces generated by the calculated deflection shall not exceed the maximum allowable component forces.

6.7 Guarding

6.7.1 Exposed moving parts within 2.13 m (7 ft) of a walking/working surface or that otherwise constitute a hazard shall be guarded.

6.7.2 Equipment located in technical spaces shall be guarded in accordance with this section, except that the lifting media, sheaves, drums used for lifting media, sprockets, and shaft assemblies turning at the same speed as the drums need not be guarded when the following requirements are met:

6.7.2.1 Access to the technical space is limited to authorized persons only.

6.7.2.2 Clearances shall be provided around machines such that people need not contact unguarded components to access any part of the technical space. Contact with lifting media shall be permitted.

6.7.3 When guards are located underfoot, or in such a manner that they could serve as a step, they shall be capable of supporting, without permanent distortion, the weight of a 140 kg (310 lb) person.

6.7.4 Guards shall be secured.

6.7.5 Guards shall not create a hazard.

6.7.6 Guards shall be removable for service.

7 Electrical equipment and control systems

7.1 General

7.1.1 Hoist systems shall incorporate all aspects of control requirements herein, unless otherwise determined by the risk assessment and risk reduction.

7.1.2 Electrical equipment and control systems shall conform to NFPA 79 Electrical Standard for Industrial Machinery, 2018.

7.1.2.1 The following sections address additional requirements or exceptions to the referenced standards. In the case of conflicts between the referenced standards and this document, this document shall take precedence.

7.1.2.2 The indicator color assignment on control panels and in HMI screens shall be exempt from those in chapter 10 of NFPA 79.

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7.1.3 The electrical equipment covered by this standard commences at the point of connection of the power supply to the hoist system.

7.1.4 Interconnection wiring

Cables and wiring between control equipment shall be installed as required by the applicable electrical code.

7.1.5 Hoist disconnect (See Annex note.)

A means shall be provided to disconnect the hoist machinery from the power source. The disconnect method shall not create a hazard.

7.1.5.1 All line voltage motor leads and brake leads shall be disconnected.

7.1.5.2 A multi-pole cord and plug may be used.

7.1.5.3 The disconnecting means must be lockable in the off position.

7.1.6 Limited access

Hoist motor control equipment shall be guarded against unauthorized access.

7.1.6.1 The control system shall be secured against unauthorized use.

7.1.6.2 The control system shall have the ability to limit access to critical settings by use of a password, key operated switch, or other secure means.

7.1.7 The failure or miscommunication of the control system shall not interfere with the proper operation of the safety (E-stop) system.

7.2 Control stations

7.2.1 Location

7.2.1.1 Control access

Control devices shall be protected against unintentional and unauthorized actuation.

7.2.1.2 Control devices shall be located where movement of the load may be visually monitored via direct line-of-sight.

7.2.1.3 When line-of-sight operation is not possible from a control station, a means of visual monitoring shall be provided during hoist movement. The method of monitoring shall be determined by the risk assessment.

7.2.1.3.1 Closed circuit monitoring (CCTV) may be used.

7.2.1.3.2 Enabling devices may be used.

7.2.1.3.3 Portable control stations shall be permitted.

7.2.1.4 Control operators, including pushbuttons, toggles, selectors and joysticks shall be labeled with their function.

7.2.2 E-stop

All control stations shall incorporate an E-stop button.

7.2.3 Multiple controls interlock

Where a system has multiple control stations, hardware or software interlocks shall prevent the simultaneous control of a hoist or group of hoists by more than one control station.

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7.2.4 Wireless control

Wireless control stations shall be permitted, but shall meet the same design and safety requirements as wired systems.

7.3 Enable devices (See Annex note.)

Where remote visual monitoring is not practical or sufficient, an enable device containing a momentary contact shall be provided as determined by the risk assessment. The hoist shall only move while every applicable enable device is activated.

7.4 E-stop stations (See Annex note.)

An E-Stop Station is a station that contains only an E-stop button. The necessity, location and quantity of E-stop stations shall be determined by a risk assessment.

7.5 Control system parameters

7.5.1 Ready indication

When the system is accessed, and reset, active control stations shall indicate that the system is in a ready state.

7.5.2 Control stations

Operator control stations shall contain control means and status indication as required for the operation of the hoist system.

7.5.2.1 All control stations shall be equipped with a common emergency stop system. Activation of any of the emergency stops shall stop all hoists in the system.

7.5.2.2 All movements shall be initiated and ended by means of a control device. Direction of movement shall be indicated.

7.5.2.3 Where it is possible to initiate contrary movements of multiple machines concurrently, this function shall be indicated.

7.5.2.4 All movement shall require activation of a hold-to-run device that, when activated, allows hoist operation and, when deactivated, stops movement of the hoist or hoist system.

7.5.2.5 A control station is not required for the emergency descent operation of fire safety curtain hoists. If emergency descent of a fire safety curtain is enacted, its hoist controls shall be rendered inoperative until the curtain release mechanism is reset. (See Annex note.)

7.5.3 Systems monitoring

The control system shall not permit any operation that exceeds the design parameters of an individual hoist in the system.

7.5.3.1 The control system shall not permit simultaneous movement of more than the allowable number of hoists as determined by the limits of use.

7.5.4 Resetting

Resetting the control system shall only be possible after all system faults are cleared. Removing or resetting of the emergency stop fault condition shall not restart the hoist system, but only permit restarting. Further activity is not possible until the fault is cleared and a reset button pressed.

7.5.5 Joystick control

Joystick control shall only provide motion after a hold to enable device is activated. If the joystick is moved from its neutral position prior to activating the enabling device, no movement shall initiate until the joystick enable device is activated.

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7.5.6 Faults

7.5.6.1 Faults shall not lead to hazardous operating conditions. (See Annex note.)

7.5.6.2 Faults shall not hinder stopping.

7.5.6.3 Faults shall be indicated as determined by the risk assessment.

7.5.6.4 Removal of a fault shall not automatically restart the hoist.

7.5.6.5 When a single hoist has a fault not affecting the remaining hoists, it shall be permitted to disable only the faulted hoist.

7.5.6.6 A method of temporarily overriding fault conditions shall be provided…