Temporary Works Design
Temporary Works Design
JULY 2014
Part 1
Contents
1
Foreword ....................................................................................................... 2
1.2
Scope ............................................................................................................ 2
1.3
Background ................................................................................................... 3
1.3.1
1.3.2
1.3.3 BS 5975: Code of practice for Temporary Works procedures and the
permissible stress design of falsework ................................................................ 5
1.3.4
1.3.5
1.3.6
1.3.7
1.4
1.4.1
Procedures.............................................................................................. 8
1.4.2
1.4.3
1.4.4
1.4.5
Loading ................................................................................................. 10
Falsework ............................................................................................. 14
1.5.2
Formwork .............................................................................................. 14
1.5.3
Access Scaffolding................................................................................ 15
1.5.4
1.5.5
1.6.2
British Standards................................................................................... 23
1.6.3
1.7
1 Part 1: Introduction
1.1 Foreword
This document has been written by the Temporary Works Forum in response to the
limited information available regarding the application of European Standards (ENs)
to Temporary Works.
The majority of the European structural design standards and all of the Eurocodes
are aimed at the design of Permanent works. Because of the differences between
Temporary Works and Permanent Works the straight application of the European
Standards to the design of Temporary Works may not be appropriate and could lead
to unacceptably low factors of safety. The Temporary Works Designer must consider
these differences and apply the European Standards appropriately.
In comparison to Permanent Works, Temporary Works:
1.2 Scope
The purpose of this document is to provide authoritative guidance to the Temporary
Works designer, and others such as; Clients, CDM-Cs and Contractors on the
application of ENs to Temporary Works. It is produced in two parts consisting of:
Part 1
Part 2
This document assumes a general competence in the use of limit state design and
relevant Eurocodes.
Parts 1 & 2 are issued as separate documents
1.3 Background
1.3.1 European Standards
European harmonization of structural design codes for construction was initiated by
the European Commission in 1975 and by 2010 was substantially complete, with
design codes covering most aspects of Permanent Works and some aspects of
Temporary Works.
The core advice for all structural design, including Temporary Works, is contained
within the Eurocode suite (BS EN1990-1999). These documents are supplemented
by product standards, design guidance for particular applications and execution
standards. All European Standards are given the designation EN, the Eurocodes
suite being a subset of them.
It is the responsibility of the National Standard Bodies (e.g. the BSI in the UK) to
implement the ENs. They must contain, without alteration, the full text of the EN
and its annexes as published by CEN (European Committee for Standardization).
This can be preceded by a National Title Page and Foreword, and followed by
a National Annex, which may be a separate document. All ENs use limit state
principles and, as they are published, any conflicting national standards are
obliged to be withdrawn.
Eurocodes provide the basis for all Temporary Works design but may be modified
by specific guidance given in product standards.
There are several issues which effect the application of the ENs to Temporary
Works:
i.
There are only a few ENs which specifically relate to Temporary Works and
these dont cover the full range. The designer therefore has to extract or
extrapolate relevant information from a range of different standards.
ii.
Because of the way some of the Temporary Works standards have been
drafted, it is difficult to interpret what the requirements are, which standards
should be referred to and how the Eurocodes suite should be used.
iii.
iv.
v.
The application of limit state principles to the design of Temporary Works has
to date been very limited, with the vast majority of schemes being designed
using permissible stress methods.
That for stability the design must consider a minimum horizontal destabilizing
force equivalent to 3% of the total vertical load. This was reduced in BS 5975 to
2.5%
A suitably qualified Temporary Works coordinator should be appointed to ensure
that procedures are followed and relevant designs/checks have been carried out.
The final Bragg report was published in 1976 during a period of high construction
activity that was also marked by a number of bridge collapses during construction.
Since the publication of BS 5975 and its adoption throughout the industry there have
been no falsework or excavation failures in the UK on the scale of the failures of the
1960s and 1970s.
Minor changes were made to BS 5975 in 1996 and then in 2008 a major update was
carried out to reflect changes made over the proceeding 25 years. The principle
changes in the 2008 version are:
The design section was updated to include advice on head fixity and partially
braced structures. Both of which had become more relevant since the standard
was first drafted
EN 12812 defines two classes of falsework, A and B; Class A has no design rules
and is defined as small simple construction "which follows established good
practice which may be deemed to satisfy the design requirements". As BS 5975
provides established good practice, it was decided to retain it, with the
recommendation that in the UK, Class A falsework be designed to BS 5975 .
EN 12812 does not provide any procedural control, an area which Bragg
highlighted as being critical for the safe execution of falsework and which forms a
central part of BS 5975.
BS 5975's principal use of permissible stress design is not seen to directly conflict
with that of EN 12812 which uses a limit state approach.
Although for Falsework BS 5975 has been retained in parallel with BS EN 12812, for
tied tube and fitting access scaffolds the existing BS 5973:1993 was withdrawn on
publication of BS EN 12811-1
Unless specified by the contract, for the design of Falsework in the UK, designers are
currently free to choose either a limit state approach as set out in BS EN 12812 or
the permissible state approach in BS 5975. There is a danger that if only EN
standards are specified in contracts the procedural control will inadvertently be left
out. Regardless of the design approach adopted, the procedural controls given in
BS 5975 should be used.
1.3.5 Definitions of Temporary Works and Falsework
BS 5975:2008 has the following definitions:
3.16 falsework
temporary structure used to support a permanent structure while it is not selfsupporting
3.40 Temporary Works
parts of the works that allow or enable construction of, protect, support or
provide access to, the permanent works and which might or might not remain
in place at the completion of the works
NOTE Examples of Temporary Works are structures, supports, back-propping,
earthworks and accesses.
The introduction to BS EN 12812:2008 states:
Most falsework is used:
6
a. to carry the loads due to freshly poured concrete for permanent structures until
these structures have reached a sufficient load bearing capacity;
b. to absorb the loads from structural members, plant and equipment which arise
during the erection, maintenance, alteration or removal of buildings or other
structures;
c. additionally, to provide support for the temporary storage of building materials,
structural members and equipment.
Definitions of Falsework can be applied equally to a cofferdam or facade retention as
the more conventional applications of vertical support. However the majority of the
design advice in BS 5975 and BS EN 12812 applies most directly to support of
concrete and building materials. This does not mean that BS 5975 and BS EN
12812 should not be applied to other forms but that the designer must decide which
aspects of the design advice is relevant.
1.3.6 Summary of EN Requirements given in Temporary Works Standards
The following table summarizes the requirements given in the Temporary Works
suite of BS ENs 12810 12813.
Design Approach:
Limit state
Actions:
Load Combinations:
Partial Factors:
Imperfections:
Calculation of
internal forces:
Equilibrium:
Section 6 of the Health and Safety at Work etc. Act (HASWA) places duties on
those who supply articles e.g. proprietary Temporary Works equipment, to
ensure it is accompanied by adequate information for its safe use.
The Provision and Use of Work Equipment Regulations (PUWER) and the
Lifting Operations and Lifting Equipment Regulations (LOLER)- if relevant to a
particular case- place similar obligations on suppliers.
It is clearly essential that any load quoted by a supplier (or required capacity quoted
by a contractor) is unambiguously stated. The consequences of confusion between
Serviceability (working) loads (SLS), and Ultimate (failure) loads (ULS), or in adopted
units, or in the use of alternative terms, are obvious.
In addition to knowing the SLS or ULS it is necessary to know how it is derived. For
example, where proprietary products are quoted with a Working Load, it will be
necessary to understand how this relates to the ultimate capacity and where tested
the test conditions.
The user has a parallel responsibility (under section 2 and 3 of HASWA and the
Regulations). Hence, if the equipment lacks the necessary data, the users must
satisfy themselves as to its fitness, either by insisting on its provision, or by their own
determination.
The expected data might include:
Aspect required
Data required
Comment
Ultimate capacity
Characteristic strength
Serviceability capacity
do
Accuracy of erection
and use
PUWER/LOLER
General
End conditions
Whether it is assumed
the ends of relevant
component s are
pinned or fixed.
1.4.5 Loading
Loadings should be taken from an appropriate EN. BS EN 12811-1 provides access
loads for working areas, BS EN 12812 provides loads relevant to Falsework and
BS EN1997 should be referred to for geotechnical loadings.
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11
Group 1
Falsework
Formwork
Propping
Soffits
Sloping
Faade Retention
Advancing Falsework/Formwork
Needling
Flying Shores
Gantries/cantilever
Advancing/Launching Formwork
Service Bridges
Jacking
Structures providing stability
construction or demolition
during
Moving of structures
12
Access
Protection
Tied Scaffolds
Crash Decks
Freestanding Scaffolds
Hoardings
Gantries
Group 2
Group 3
Geotechnical
Trench Support
Temporary bridges
Retaining Walls
Slope Stability
Foundations
Cofferdams
Horizontal Propping
Group 4
Shafts
Underground
Underpinning
Tunnels
Shafts
Chambers
Tunnelling thrust pits
Group 5
Group 6
Cofferdams
Temporary grandstands
Dolphins
Access Jetties
Floating Plant
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1.5.1 Falsework
Unlike many other forms of Temporary Works there is a specific EN relating to the
design of Falsework, BS EN 12812. Because of the way it has been drafted its
requirements are not always easily understood.
An overview of the basic
requirements have been set out in the background section above.
From the title of the standard; Falsework Performance requirements and general
design, it can be seen that the standard does not give detailed design advice and the
designer will be required to get this from elsewhere. In particular the standard does
not give advice on:
A design to BS EN 12812 will give a comparable result to BS 5975 but the designer
would need a thorough understanding of falsework design as the EN only provides
general advice and does not layout all the checks that are required
1.5.2 Formwork
In September 2008 the European Standards Committee CEN/TC 53 for Temporary
Works Equipment ruled not to continue work on preparation of a European Standard
on Vertical Formwork.
In the UK, the Concrete Society published, in May 2012, a third edition of "Formwork
a guide to good practice" (the Formwork Guide"). This publication was informed
by the Eurocodes and is the authoritative guidance on all formwork matters in the
UK. The Formwork Guide covers the philosophy of design of formwork for walls,
columns, and for soffits. Information is presented in permissible stress terms, with
information on limit state included in an appendix.
1.5.2.1 Formwork Loads
Concrete pressure should be calculated using CIRIA Report R108. Advice on its
application to modern concrete types and classifications is given in the Formwork
Guide.
Imposed service loads should be taken from the relevant EN as discussed in the
loading section above.
1.5.2.2 Properties of Timber and wood-based products
Timber and wood-based products have many different modification factors for
varying conditions. Timber stresses can change depending on exposure, duration of
load etc. Timber is often used in Temporary Works, and the design process and
common rules for limit state design are covered in BS EN 1995-1-1 . Separate ENs
give section sizes, stresses, methods of testing etc. Appendix E to the Formwork
Guide gives recommendations for the relevant modification factors, to be applied to
basic stresses, for use by the designer in limit state design.
14
The recommended permissible stresses and moduli of elasticity for formwork timbers
are given in the Formwork Guide for various conditions of use. The values, which
are based on the characteristic strengths stated in BS EN1995, are published as
grade stresses in BS 5268-2.
The European Standards Committee failed in their attempt to produce a product
standard for the various wood-based sheet materials currently available. They have,
though, produced a method of testing to determine the characteristic strengths and
properties of wood-based materials and it is the responsibility of the supplier/importer
to provide the relevant properties, using the relevant testing standard. The
modification factors for various plywoods and Oriented Strand Board (OSB) are given
in BS EN1995.
To assist design to limit state, recommendations on relevant factors are given in
Appendix E of the Formwork Guide and to further assist designers, the Concrete
Society obtained approval, from trade associations and from supply organisations, to
publish their characteristic values for commonly used wood-based sheet materials.
These, also, are given in Appendix E of the Formwork Guide.
The recommended safe structural properties of these materials, based on the
characteristic values stated, are given in Appendix D of the Formwork Guide.
Where only the characteristic values of Plywood, Particleboard or OSB are available
from the supplier and the designer wishes to use permissible stress design, the
Formwork Guide gives numerical factors to enable the formwork designer to
establish both the grade stress and the elastic moduli for wall and for general soffit
use of the materials.
1.5.2.3 Factors of Safety
The recommendation in the Formwork Guide, for permissible stress design, is that a
minimum factor of safety of 2.0, against failure, should be used. Deflections at
serviceability state should be considered and may control.
There is no guidance in the ENs on appropriate partial factors for use in limit state
design for formwork. The use of the global (or combined) safety factor of 1.65
(based on the product of a material factor of 1.1 and load factor of 1.5), might be
suitable for steel or aluminium products, but might not suit fabricated components, or
plastic or timber products.
When considering static equilibrium (overturning) the Eurocodes state partial safety
factors of 0.9 for stabilizing loads and 1.5 for destabilising loads, giving a combined
value of 1.66. This is first stated in BS EN 1990 and repeated in BS EN 12812. This
compares with a value of 1.2 given in BS 5975 and the Formwork Guide. Although
this reduced value has been used for many years in the UK in order to comply with
the ENs the higher value should be used.
1.5.3 Access Scaffolding
In June 2004 the European Standard BS EN 12811-1 was published as the
performance requirements and general design for all UK scaffolds, it replaced the
permissible stress code BS 5973. Further ENs are published covering prefabricated
15
scaffolds (BS EN 12810), towers (BS EN 1004), edge protection systems (BS EN
13374), components, scaffold tube (BS EN 39) and scaffold fittings (BS EN 74).
BS EN 12811-1 is in limit state terms and uses a partial load factor of 1.5 on all actions
and a partial material partial safety factor for steel and aluminium of 1.1. This
combined gives a global safety factor of 1.65.
The NASC document TG20 was first published in 2005 as "Technical guidance on use
of BS EN 12811-1" and gives safe height tables, working values etc for basic tube and
fitting scaffolds
The safe working load for scaffold tube in compression and for scaffold fittings are
calculated in TG20 using the global combined limit state factor of 1.65 on characteristic
strength. The safe strut buckling capacities for different effective lengths presented in
TG20 are calculated using BS EN1993, the steel code, with the 1.65 factor applied.
There is little information in the ENs on establishing the effective lengths of members
to be used, and industry user guidance, such as TG20 and BS 5975 remains a
valuable source.
One anomaly is the consideration of the working wind load, stated in BS EN 12811-1
as the standard wind velocity pressure of 200 N/m. For mobile access towers of
prefabricated materials, e.g. an aluminium tower, the horizontal design load to simulate
wind is reduced to only 100 N/m. This is based on the assumption that the mobile
access tower can be quickly dismantled or tied to another structure if high winds are
forecast. The use of a working wind less than 200 N/m2 should not be extended to
other forms of Temporary Works.
There is also an anomaly when considering temporary edge protection systems. BS
EN 13374 introduces three classes of edge protection depending on roof angle and
gives different testing requirements. If though the edge protection is made of tube and
fittings, the design is more onerous to BS EN 12811-1 with different load values and,
importantly, the introduction of an upward load on the handrail. There is no upwards
loading requirement on system handrails in BS EN 13374.
Scaffold boards are not considered under BS EN1995, but BS 2482 gives the
recommended working moment of resistance of boards complying to the standard.
Based on the minimum ultimate moment of any board tested the minimum factor of
safety is about 1.54, but considering the lower fifth-percentile increases to a minimum
1.8 factor.
1.5.4 Geotechnical Design
The relevant European Standard is BS EN 1997-1: 2004 Geotechnical Design
(referred to as Eurocode 7 or EC7) which outlines the engineering principles to be
used whilst giving considerable scope to use a variety of analytical techniques.
Clause 2.4.1 states that design should be by calculation and that the calculation
model may consist of any of the following:
An analytical model
A semi-empirical model
A numerical model
16
BS EN1997 introduces the limit state design concept to geotechnical design and, in
the UK, it is necessary to analyse two load cases referred to as Design Approach 1
Combination 1 and Design Approach 1 Combination 2. In these loadcases, factors
are applied to loads and material properties; the factors vary depending on whether
the load is permanent (dead load) or variable (live load). The factors also vary
depending on whether a load is unfavourable (destabilising) or favourable
(stabilising).
BS EN1997 outlines the engineering principles to be used for design but does not
prescribe a particular method. The UK National Annex (NA) to BS EN 1997-1 guides
the designer elsewhere for more definitive design guidance (NCCI). Several sources
of NCCI are listed, however, all of them are, at least partially, in conflict with the
principles of BS EN 1997-1:2004 and the Eurocode takes precedence in these
cases.
1.5.4.1 Temporary Foundations
It is imperative that the designer of any temporary works supported by the ground
understands the principles of geotechnical analysis and the inherent
approximations/uncertainties in it to enable the designer to allocate appropriate
factors to the temporary works.
Typical examples of temporary foundations are:
Crane bases
Crane outrigger foundations
Foundations to falsework
17
Traditionally in the UK, foundation design has adopted a factor of safety of 2.5 or 3.0
and the resultant allowable bearing pressure is deemed to satisfy settlement criteria.
However, BS EN1997 uses lower partial factors for the verification of bearing
capacity but requires the designer to do separate calculations for settlement. To
comply, both are required.
1.5.4.2 Slope Stability
For permanent slope stability it is rarely appropriate to use the undrained strength of
a fine grained soil in the analysis. However, for Temporary Works of short duration
the use of undrained strength can greatly enhance the calculated stability of a slope.
However, this needs to be used with caution; fine grained soil does soften with time
and a slope that initially appears stable can fail after an indeterminate time.
Once appropriate soil parameters, water levels or pore pressure ratios and
surcharges have been selected, analysis of a temporary slope can proceed as for an
analysis of a permanent slope. Moderately conservative soil parameters should be
selected for Eurocode designs or parameters derived from analytical methods
prescribed in EC7 which allows for adequacy of site investigation and complexity of
soils, consequence of failure etc. Previously these variables were considered in
BS6031 by allowing the designer to select an overall FOS between 1.2-1.4.
1.5.4.3 Granular Working Platforms
Granular working platforms are currently designed in accordance with BRE Report
470 which is not compatible with Eurocodes. The TWf has a Working Group
investigating working platforms and aims to produce relevant design guidance which
will be the subject of a separate guidance note. BRE Report 470 only considers
tracked plant.
1.5.4.4 Retaining structures, cofferdams and trenching
Eurocode 7 refers to CIRIA Report C580 as NCCI (non-contradictory complementary
information). The current version of CIRIA C580 is not compatible with Eurocodes but
it is understood (February 2014) that CIRIA have started preparation of a fullycompatible revision).
In order to determine the capacity of the equipment used for trench support two main
standards are available:
BS EN 13331:2002 Trench Lining Systems Part 1: Product Specifications and Part
2: Assessment by calculation or test.
BS EN 14653:2005 Manually operated hydraulic shoring systems for groundwork
support Part 1: Product Specifications and Part 2: Assessment by calculation or test.
Both of the above standards state that if assessment by calculation is used then EN
1993-1-1 should be used together with a partial material factor m of 1.1 for steel
and aluminium and a load factor m of a t l e a s t 1.5. This concurs with the other
temporary works European standards, however, it does differs from the factors used
in both the main Eurocodes and the earlier Limit State British Standards.
18
Proprietary sheet pile design software generally now includes Eurocode compliant
designs and considers DA-1 & DA-2.
Although it is possible to calculate pressures on proprietary trench sheet & boxes to
the Eurocode, currently supplier only state SWL capacities. Further development
from the suppliers is required to state Eurocode compliant capacities.
1.5.5 Tower Crane Foundations
In 2006 CIRIA published C654 Tower crane stability. The report provides an
understanding of the issues relating to the safe use of tower cranes and also
provides specific guidance for designers of Temporary Works involving tower cranes.
This is currently being updated.
1.5.5.1 Loading data supplied by tower crane manufacturers/suppliers
Tower Cranes produced in the past few year have been designed to the European
Harmonised Standards for tower cranes BS EN14439:2006 which refers to the
standards to be used for the design of tower cranes. The Construction Plant-hire
Association have published a Tower Crane Technical Information Note, TIN 027
Tower Crane - Out of Service Wind Speeds which provides additional information
regarding the wind loading in the UK.
At present the crane manufacturers supply characteristic (working) foundation loads/
actions with no separation of permanent and variable loads/actions. It is anticipated
that in the future manufacturers will be able to supply a split in loads.
1.5.5.2 Designing tower crane foundations to Eurocodes
CIRIA C654 Appendix 2 provides examples of foundation design calculations using
traditional allowable ground bearing stress design and BS EN 1997-1:2004.
Since the split in the loads between permanent and variable actions are not currently
available, the report gives guidance on the appropriate partial factors to be used for
stability, geotechnical capacity and structural design.
It is worth noting that if an element of the foundation, e.g. the pile design, is to be
designed by a specialist designer, then the loading data supplied to the designer
needs to clearly state if the loads are characteristic or design actions/loads and for
clarity state the design actions/loads for both combination 1 and 2 for Design
Approach 1.
1.5.6 Temporary Vehicle and Pedestrian bridges
1.5.6.1 Public Highway Bridges
Eurocode 1 refers to variable actions (live loads). These are radically different to the
Highways Agency BD37 and the superseded BS5400.
19
The effects on shear and bending of main members are significantly different (usually
higher) on short and medium span bridges, ie up to 30 metres. Concentrated loads
and local deck loads are considerably higher.
It is not possible to make general assumptions on a percentage change as
differences are highly dependent on span.
Partial Factors on Actions
Self-weight factor (permanent actions):Eurocodes: 1.20
The changes to highway loading present no significant risk providing that the actions
are understood. Many of those specifying are currently making fundamental errors
such as requesting HA loading to Eurocodes or specifying Load Models LM1 &
LM2 instead of Load Group 3, 4 etc.
1.5.6.2 Site Access Bridges
The use of public highway loading is unusual for site access bridges as it is usually
overly conservative. Single vehicles or a combination of single vehicles is common.
Many clients choose to specify the design of site access bridges to Eurocodes. This
does usually lead to confusion.
The Eurocodes allows: Agree with approving body. Here, the approving body can
agree load factors. (Ref BS EN 1990 part2 (bridges) Appx. A notes under table)
Typical examples of risks for site access bridges if adopting Eurocodes:
Using a load factor 1.35 for a single vehicle. The 1.35 factor is intended for the
conservative public highway notional load patterns and not an actual vehicle.
Impact factors are often much lower for public highway bridges and/or built into
the notional highway load. Appropriate impact factors that are commonly applied
to site vehicles range from 1.25 up to 1.50 depending on specific circumstances.
Factors of safety equivalent to traditional working stress methods such as 1.7 are
recommended.
1.5.6.3 Footbridges
20
By using the EN suite, it is assumes that BS EN 1090 has been considered in full.
This is unlikely to be the case for structures made up of proprietary systems or
previously used steelwork. For example:Tolerances of proprietary systems are usually less stringent than EN 1090.
Connection details are usually different to a typical permanent design detail. Eg
the use of welded end plates or pins is common.
Minor damage to parts is normally accepted (and accounted for in suppliers
data).
There are numerous situations where the global factor of safety when applying
Eurocodes (without reference to EN 12812) could be significantly lower than if
applying BS5975 to the same scheme.
For example, a propping system supporting the self-weight only of a bridge deck:Using BS5975 would result in a minimum global FoS against yield of around 1.60.
Whereas using the Eurocodes could result in a minimum global FoS against yield
of around 1.35.
Analysis: Interaction between Permanent and Temporary supports:Risks are present with temporary heavy propping design at this design interface,
for example:The accuracy of data on existing structures is often less reliable than with the
design of new structures. Also, the accuracy of the analysis of existing structures
is often lower than for new structures.
Such aspects must be taken into consideration in the design process.
21
Title
(BS.)
EN 39:2001
Loose steel tubes for tube and coupler scaffolds. Technical delivery
conditions
EN 74-1:2005
Couplers, spigot pins and base plates for use in falsework and
scaffolds Couplers for tubes. Requirements and test procedures
EN 74-2:2008
EN 74-3:2007
EN 1004:2004
EN 1058:2009
EN 1065:1999
EN 10901:2009+A1:2011
EN 10902:2008+A1:2011
EN 1090-3:2008
EN 1263-1:2002
EN 1263-2:2002
EN 1298:1996
Mobile access and working towers. Rules and guidelines for the
preparation of an instruction manual
Execution of special geotechnical work. Sheet pile walls
Wood-based panels. Characteristic values for structural design
OSB, particleboards and fireboards
BS EN 12063:1999
EN 12369-1:2001
EN 12810-1:2003
EN 12810-2:2003
22
EN 12811-1:2003
EN 12811-2:2004
EN 12811-3:2002
EN 12811-4:2013
EN 12812:2008
EN 12813:2004
EN 13331-1:2002
EN 13331-2:2002
EN 13374:2013
EN 13377:2002
EN 14653-1:2005
EN 14653-2:2005
EN 16031:2012
Title
BS 2482:2009
23
BS 5975:2008+A1:2011
24