CROPS (COMPACT ROLL OVER PROTECTIVE

STRUCTURE)
1.

Organisations involved

Azienda Agricola Casale is a farm located in the countryside of Viterbo (Italy), with 10
hectares of hazelnut trees.

2.

National Institute for Occupational Safety and Prevention (ISPESL)

Description of the case

2.1. Introduction
The Directives 77/536/CEE, 79/622/CEE, 86/298/CEE and 87/402/CEE, set out methodologies,
according to tractor type, for the testing of frame and cabin rollover protection. The basic
principle is that rollover equipment guarantees an adequate safety volume around the drivers
seat in the case of a roll over. The overall vertical dimensions of these structures can prevent
the use of tractors under trees or in greenhouses and therefore foldable roll over bars are often
installed. However, according to the new Machinery Directive 2006/42/EC , Annex 1 (Essential
health and safety requirements relating to the design and construction of machinery) point 1.1.2 Letter C,
when designing and constructing machinery, the manufacturer or their authorised
representative must envisage not only the intended use of the machinery but also any
reasonably foreseeable misuse thereof. Foldable Roll Over Protective Structures (ROPS) on
tractors do not comply with this safety requirement. In fact, the use of tractors with the foldable
ROPS not in the safe position, during various working operations, is a foreseeable and quite
common misuse.

2.2. Aims
The aim was to implement an innovative safety device, Compact Roll Over Protective Structure,
(CROPS) able to reduce the risks related to the foreseeable misuse of the traditional, foldable
safety device to improve protection for workers in the case of incidents where the tractor rolls
over.

2.3. What was done, and how?

After a roll over incident involving a tractor equipped with a front mounted foldable ROPS,
which was not in the safe position, the Azienda Agricola Casale decided to install a Compact
Roll Over Protective Structure (CROPS) on one of its narrow track wheeled tractors for working
under trees or in greenhouses in a safe manner. The CROPS was designed by the Safety and
Technology Department of ISPESL (National Institute for Occupational Safety and Prevention)
(Italy) for narrow track wheeled agricultural tractors in order to avoid the misuse of foldable
ROPS and to allow safe working under trees or in greenhouses. The CROPS installed in this
case study was built at the NUNZI s.r.l. factory in Caprarola.

Safety level investigation

Before designing the CROPS, a preliminary safety level investigation on the existing two-post
front mounted ROPS was carried out. Since it is possible to equip narrow-track wheeled
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tractors both with a rear two-post ROPS, as defined in OECD code 7 , or with a front two-post
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one, as defined in OECD code 6 , a comparison of these two kinds of protective structure was
undertaken. The main difference concerns the shape and the dimensions of the operator
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clearance zones protected by each structure. This peculiarity is also reported in the field of
application of OECD code 6 which, at point 2.1.4, specifies that it refers to tractors being fitted
with roll-over protective structures of the dual-pillar type mounted in front of the drivers seat
and characterised by a reduced clearance zone attributable to the tractor silhouette, thus
rendering it inadvisable, under any circumstances, to impede access to the driving position but
worthwhile retaining these structures (fold-down or not) in view of their undoubted ease of use.
In Figure 1, these two clearance zones are shown.
Figure 1: Comparison between operator clearance zones as defined in OECD code 6 (A)
and in OECD code 7 (B)

Figure 1 shows that, the clearance zone preserved by a two-post front mounted structure has a
completely different shape, which is formed in such a way that the operator is only in a safe
position if they lean forward against the steering wheel whilst the tractor is rolling over. In fact,
the simulated ground plane, which is represented by a straight line from the top of the front
ROPS to the top of the rear hard fixture in Figure 2, does not intersect the operator clearance
zone only when shaped in this manner (see Figure 2 (B)). When the clearance zone defined in
OECD code 7 is considered, the same front ROPS does not ensure protection in the case of a
roll-over (see Figure 2 (A)), unless significantly increasing the height of the front roll-bar or of
the rear hard fixture. Thus, it seems that the safety level guaranteed by this kind of protective
structure is quite poor. This is also confirmed by recent tractor rollover accidents, which have
resulted in fatalities, despite the tractors being fitted with foldable front mounted ROPS that
were in the safe position at the time of the accident. Moreover, another issue related to this kind
of protective structure concerns the possibility of folding them down.

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Figure 2: Simulated ground plane protection ensured by a two post front mounted ROPS
with reference to OECD code 6 operator clearance zone (A) and OECD code 7 operator
clearance zone (B)

In many cases, the folding operation is achieved by simply removing a pin by hand without the
use of any specific tool. The ease of this operation can lead to the ROPS being folded even
during field operations, completely by-passing a fundamental safety device. Finally, the last
concern with respect to front mounted ROPS refers to its application on articulated tractors. The
possibility to rotate about a central pivoting axis of a tractors mainframe significantly reduces
the already poor safety zone provided by these protective structures. In fact, in the case of
rolling over or tilting of the tractor, the independent rotation of the rear part of the tractors
mainframe, where the operator is seated, with respect to the front one where the ROPS is
fitted, could laterally expose the operator to an impact with the ground.
Compact roll-over protective structure design
With the aforementioned limitations of ROPS in mind, the National Institute for Occupational
Safety and Prevention (ISPESL) designed an innovative Compact Roll-Over Protective
Structure (CROPS) to be fitted on narrow-track wheeled tractors. This structure is a four post
rigid frame made of circular steel tubes with a smooth longitudinal profile, shaped in such a way
to allow the tractor to be used beneath trees, whilst also preserving the OECD code 7 operator
clearance zone. The design criteria were to produce a non-foldable protective structure, which
would always preserve the safe zone defined in OECD code 7, whilst also minimising the
overall height of the tractor, and therefore allowing it to work under trees or in greenhouses,
and avoiding the misuse of foldable ROPS. The CROPS design can be summarized in the
following steps:
1. reverse engineering of tractor and virtual prototyping of the CROPS;
2. finite element analysis (FEA) of CROPS according to OECD code 7;
3. shape and dimensions optimization.
Reverse engineering and virtual prototyping
It was, first of all, necessary to reverse engineer the tractor in order to virtually reproduce the
position and the relative disposition of the anchorage points suitable for the CROPS. This also
allowed the OECD code 7 operator clearance zone to be superimposed onto the tractor to
ensure that the protective structure did not interfere with its operation. In Figure 3, the virtual
model of the tractor, actually fitted with a foldable front mounted protective structure, has been
reproduced. Figure 3 (A) gives an overview and Figure 3 (B), shows the OECD code 6 operator
clearance zone with a simulated ground plane related to the front mounted two-post ROPS.
Note that the actual overall height of the tractor is 2370 mm from the ground.
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Figure 3: Tractor reverse engineering

In Figure 4 (A), the front attachment points for CROPS are shown. In particular, they
correspond to the bolts and pin joint of the foldable portion of the actual two-post protective
structure. The CROPS rear mounting uses the same attachment points of the actual rear hard
fixture (Figure 4 (B)).
Figure 4: Front (A) and rear (B) mountings

According to ergonomic principles and safety requirements, a convex volume for CROPS has
been designed. This volume has been obtained as an extrusion of a smooth profile in the
middle longitudinal geometrical plain of the tractor (see Figure 5). Moreover, it has been
compared to the OECD code 7 operator clearance zone in order to verify that this is completely
included within it, as shown in Figure 5. Starting from the convex volume, the tentative shape of
the CROPS was defined and a virtual prototype created, as shown in Figure 6. Thanks to its
longitudinal smoothness, the CROPS appears more compact and suitable for work under trees
or in greenhouses than the original straight two-post front mounted ROPS.

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Figure 5: The CROPS convex volume side (A) and back (B) views

In any case, the main function of CROPS is to protect the operator clearance zone. Thus, its
size, with respect to this first prototype, has been varied according to the results of structural
simulations which lead to the optimization process.
Figure 6: The first virtual prototype of the CROPS

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Finite element analysis

The first virtual CAD prototype of CROPS was meshed in order to perform the finite element
analysis on it. The geometrical properties were modelled by means of plate elements of
variable thickness. Since the OECD code 7 test procedure specifies that the plastic energy
absorbed by the protective structure should be evaluated, it was necessary to mimic the plastic
behaviour of the material and to represent the large deformations which the structure
undergoes. For these reasons the RambergOsgood equation has been used for reproducing
the elasto-plastic features of steel. In figure 7 the FEA model has been reproduced. Mountings
of the actual two-post ROPS, on which CROPS attaches (see Figure 4), have not been
included in the model. In fact, they could be considered as significantly more rigid than the
remainder of the structure. This allowed the number of elements in the model to be reduced
and consequently the analysis process to be sped up.
Figure 7: The finite element model of the CROPS

As the CROPS is connected to the front and rear mountings by means of threaded connections
(see Figure 4), the constraints in the model are of a pinned type. Figure 7 shows how the pins
were attached to the centre of each hole.
Table 1: Test procedure and acceptance criteria according to OECD code 7

TEST DESCRIPTION

Acceptance
criteria

1st test

Loading at the rear of

the structure

Energy

3.055 J

2nd test

Rear crushing

Load

60.000 N

3rd test

Loading at the front of

the structure
Loading at the side of
the structure

Energy

2.000 J

Energy

5.250 J

Load

60.000 N

4th test
5th test

Crushing at the front

ACCEPTANCE VALUE

Table 1 summarizes the compulsory requirements specified by OECD code 7 with respect to a
tractor mass of 3000 kg.
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Figure 8: Contour diagram of Von Mises stress and deformations for the side load: first
CROPS version (A) and latest CROPS version (B)

Figure 8 shows the result of the side load test for two different versions of CROPS. In Figure 8
(A), the first version is depicted while, in Figure 8 (B), the latest version is shown. The first
version was fabricated out of S235 tubular steel with a 60 mm diameter, while the latest
version, developed as a result of the optimization process (see following section), was made
using S355 tubular steel, with a 40 mm diameter.
It is important to note that each load was applied in the sequence shown in Table 1 and that
subsequent loads were applied following any deformations and stresses sustained during the
application of the previous load(s) in the sequence. Once the required energy/load was
reached, it was necessary to verify that this was significantly less than the breaking strength of
the various structural elements and that no part of the CROPS, while deformed, lead to the
infringement of the operator clearance zone or to its invasion by the simulated ground plane.
For both side loads depicted in Figure 8, the maximum stress recovered was significantly lower
than the materials breaking strength value, and the operator clearance zone was always
protected.
Optimization
Different aspects were involved in the optimization process of the CROPS:

enhancement of mechanical strength for the critical points of the structure;

reduction of tractor overall height;
reduction of CROPS width;
simplification and retrenchment of the production phase;
use of structural members with reduced cross section to streamline the structure.

Each of the cited aspects led to a new version of CROPS for which it was necessary to carry
out a new design and finite element analysis, as previously described. The CROPS final
version was deemed the best compromise between structural and practical requirements.
Figure 9 (A) compares the original CROPS design, which used 60mm diameter S235 steel with
the latest design, which uses 40mm diameter S355 steel. Figure 9 (B) shows that one of the
effects of the optimization was the reduction of an additional 100 mm to the overall height of the
tractor, whilst continuing to ensure operator protection.

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Figure 9: Comparison between original and latest CROPS designs - top left: latest design
fabricated out of 40mm diameter S355 tubular steel; bottom left: original design
fabricated out of 60mm diameter S235 tubular steel.

Prototypes
On the basis of the experimental test which investigated structural and functional aspects, two
prototypes have been realized. The first one was made from S235 60 mm diameter tubular
steel (see Figure 10). The overall height of the tractor fitted with this CROPS was 1889 mm
from the ground.
Figure 10: Crops first prototype

The latest version of CROPS was made from S355 tubular steel with a diameter of 40 mm (see
Figure 11). The overall height of the tractor fitted with this CROPS was 1789 mm from the
ground. The overall height could be further reduced by about 100 mm by fitting the tractor with
the smallest tires authorized by the manufacturer.

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Figure 11: Crops latest version

2.4. What was achieved?

The CROPS design process resulted in a permanently fixed roll over protective structure which
should provide an adequate level of protection to tractor drivers in the case of a roll over. By
reducing the tractors overall height by 480 mm (see Figure 12), working under trees was
possible. Moreover, the particular shape of the structure renders working under trees an easier
activity and reduces the likelihood of branches being damaged. This has led to an increase in
the level of roll over protection offered to drivers of narrow track wheeled agricultural tractors.
Figure 12: Height reduction of tractor

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2.5. Success factors

The virtual prototyping process and finite element analysis allowed a significant reduction in
design costs. Furthermore, the computer aided design (CAD) virtual model helped to take the
ergonomic features of the structure into account and the finite element analysis enabled
streamlining of the structure, improving its mechanical strength and optimising the machineproduction process. Thus, the costly experimental tests have only been carried out on the
prototypes which had virtual models that successfully passed the structural analysis.
The success factors of the CROPS itself can be summarized as follows:

reduced tractor overall height;

improvement of roll-over protective structure shape, suitable for working under trees or in
greenhouses;

non-foldable roll-over protective structure;

2.6. Further information

AZIENDA AGRICOLA CASALE
01032 CAPRAROLA (VT)
Contact Person: Carlo Stelliferi
0761 646391

2.7. Transferability
Since the frame is made from commercial steel tubing, the metalwork necessary is not complex
and can easily be carried out by most metal fabricators and workshops. The CROPS can,
therefore, be easily realized and installed on narrow track wheeled agricultural tractors. The
present cost of CROPS is about 2,500 euro each but, once the production process is at full
speed, the cost will be significantly reduced. Moreover ISPESL is going to incorporate the
CROPS project into the national guideline developed, and already used, for making the old
agricultural and forestry tractors produced without a ROPS consistent with the safety
requirements of the current Italian safety consolidated act (D. Lgs. 81/08). In any case, the
advantages in its use in terms of health and safety of the operator are significantly greater than
the economical aspects.

3.

References, resources:

1. OECD code 6 OECD Standard Code for the Official Testing of Front Mounted
Protective Structures on Narrow Track Wheeled Agricultural and Forestry Tractors
2010.
2. OECD code 7 OECD Standard Code for the Official Testing of Rear Mounted
Protective Structures on Narrow Track Wheeled Agricultural and Forestry Tractors
2010.

Roll-over
February
Roll-over
February

Further reading:

http://www.oecd.org/document/10/0,3343,en_2649_33905_34735882_1_1_1_1,00.html
(accessed 29/10/10).

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