BS 7121-2-4-2013 Code of practice for the safe use of cranes Inspection maintenance and thorough examination Loader cranes《起重机安全使用实用规程 检验 维护和全面检查 装载起重机》.pdf

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1、BSI Standards PublicationBS 7121-2-4:2013Code of practice for the safeuse of cranesPart 2-4: Inspection, maintenanceand thorough examination LoadercranesPublishing and copyright informationThe BSI copyright notice displayed in this document indicates when the documentwas last issued. The British Sta

2、ndards Institution 2013Published by BSI Standards Limited 2013ISBN 978 0 580 79129 1ICS 53.020.20The following BSI references relate to the work on this document:Committee reference MHE/3/11Draft for comment 13/30264261 DCPublication historyFirst published July 2013Amendments issued since publicatio

3、nDate Text affectedBS 7121-2-4:2013 BRITISH STANDARDContentsForeword iiIntroduction 11 Scope 12 Normative references 13 Terms and definitions 14 General 25 Personnel carrying out pre-use checks, in-service inspections, maintenanceand thorough examinations 26 Pre-use checks and in-service inspections

4、 27 Maintenance of loader cranes 58 Thorough examination of loader cranes 89 Overload testing and dynamic testing of loader cranes, and measurementof sink rate 1610 Non-destructive testing of loader cranes to supplement thoroughexamination 1811 Assessment of wire rope condition and discard criteria

5、20AnnexesAnnex A (informative) Example of a pre-use checklist for a loader crane and fora lorry loader 21Annex B (informative) In-service inspection Example of additional checks to becarried out in addition to pre-use checks, at intervals of 1 week to 1 month 22Annex C (informative) In-service inspe

6、ction Example of checklist for in-serviceinspections at intervals of 3 months to 6 months 23Annex D (informative) Example of an in-service inspection checklist for a loadercrane attachment 25Annex E (informative) Stress concentration points in loader cranes 26Bibliography 27List of figuresFigure 1 A

7、reas to be subjected to NDT 20Figure E.1 Stress concentration points on a loader crane 26Summary of pagesThis document comprises a front cover, an inside front cover, pages i to iv,pages 1 to 28, an inside back cover and a back cover.BRITISH STANDARD BS 7121-2-4:2013 The British Standards Institutio

8、n 2013 iForewordPublishing informationThis sub-part of BS 7121-2 is published by BSI Standards Limited, under licensefrom the British Standards Institution and came into effect on 31 July 2013. Itwas prepared by Subcommittee MHE/3/11, Crane safety and testing, under theauthority of Technical Committ

9、ee MHE/3, Cranes and derricks. A list oforganizations represented on these committees can be obtained on request totheir secretary.SupersessionTogether with BS 7121-2-1, BS 7121-2-3, BS 7121-2-5 and BS 7121-2-7, thissub-part of BS 7121-2 supersedes BS 7121-2:2003, which will be withdrawn whenall the

10、se sub-parts have been published.Relationship with other publicationsThe BS 7121 series is being revised. The following new sub-parts of BS 7121-2have been published or are in preparation. Part 2-1: Inspection, maintenance and thorough examination General; Part 2-3: Inspection, maintenance and thoro

11、ugh examination Mobilecranes; Part 2-4: Inspection, maintenance and thorough examination Loadercranes; Part 2-5: Inspection, maintenance and thorough examination Towercranes; Part 2-7: Inspection, maintenance and thorough examination Overheadtravelling cranes including portal and semi-portal cranes,

12、 hoists, and theirsupporting structures; Part 2-9: Inspection, maintenance and thorough examination Cargohandling and container cranes.When all sub-parts of BS 7121-2 have been published, it is intended that CP 3010will be withdrawn and BS 5744 will be revised to cover manually operated andlight cra

13、nes only.This sub-part of BS 7121-2 is intended to be used in conjunction withBS 7121-2-1.Information about this documentThe Health and Safety Executive (HSE) commends the use of this British Standardto those who have duties under the Health and Safety at Work etc. Act 1974 1.This standard was drawn

14、 up with the participation of HSE representatives and itwill be referred to in the relevant HSE publications.The BS 7121-2 series has been accepted by the HSE as representing theconsensus of opinion based on practical experience for safety of cranes.Hazard warningsWARNING. This British Standard call

15、s for the use of procedures that can beinjurious to health if adequate precautions are not taken. It refers only totechnical suitability and does not absolve the user from legal obligationsrelating to health and safety at any stage.BRITISH STANDARDBS 7121-2-4:2013ii The British Standards Institution

16、 2013Use of this documentAs a code of practice, this sub-part of BS 7121-2 takes the form of guidance andrecommendations. It should not be quoted as if it were a specification andparticular care should be taken to ensure that claims of compliance are notmisleading.Any user claiming compliance with t

17、his sub-part of BS 7121-2 is expected to beable to justify any course of action that deviates from its recommendations.It has been assumed in the preparation of this British Standard that theexecution of its provisions will be entrusted to appropriately qualified andexperienced people, for whose use

18、 it has been produced.Presentational conventionsThe provisions of this standard are presented in roman (i.e. upright) type. Itsrecommendations are expressed in sentences in which the principal auxiliaryverb is “should”.Commentary, explanation and general informative material is presented insmaller i

19、talic type, and does not constitute a normative element.Contractual and legal considerationsThis publication does not purport to include all the necessary provisions of acontract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunity from legalob

20、ligations.Particular attention is drawn to the following specific regulations: Health and Safety at Work etc. Act 1974 1; Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 2; Provision and Use of Work Equipment Regulations (PUWER) 1998 3; Supply of Machinery (Safety) Regulations 2008

21、 (as amended) 4; Road Vehicles (Construction and Use) Regulations 1986 (as amended) 5; Road Traffic Act 1991 6; Work at Height Regulations 2005 (as amended) 7.NOTE Details of the Lifting Operations and Lifting Equipment Regulations 1998 2and the Provision and Use of Work Equipment Regulations 1998 3

22、, together withan HSE Approved Code of Practice and HSE Guidance, are given in HSE publicationsSafe use of lifting equipment 8 and Safe use of work equipment 9.BRITISH STANDARD BS 7121-2-4:2013 The British Standards Institution 2013 iiiBRITISH STANDARDBS 7121-2-4:2013This page deliberately left blan

23、kiv The British Standards Institution 2013IntroductionLoader cranes have traditionally been used to load and unload vehicles on whichthey are mounted, These vehicles, complete with the crane, being referred to as“lorry loaders”. Increasingly loader cranes are being used in place of mobile oroverhead

24、 cranes.Loader cranes can be installed in a static location, for instance on a quay, in afactory or on the roof of a building.1 ScopeThis sub-part of BS 7121-2 gives recommendations for the pre-use checks,in-service inspection, maintenance, thorough examination (in service andfollowing exceptional c

25、ircumstances) and supplementary testing of loadercranes.This sub-part of BS 7121-2 also covers lifting accessories, attachments andinterchangeable equipment that may be used in conjunction with loader cranes,such as brick grabs, muck grabs, augers, clamshells, pallet forks, wire rope hoists,fly jibs

26、, magnets, vacuum lifters, manipulators, integrated man baskets andspreaders.This sub-part of BS 7121-2 is applicable both to lorry loaders and to loadercranes used in other situations.This sub-part of BS 7121-2 does not cover the stability testing and certificationimmediately following installation

27、 of loaders cranes on vehicles, or in staticlocations. This is covered by BS EN 12999.This sub-part of BS 7121-2 is not applicable to lorry loaders or loader cranes onmarine and other water-borne vessels.2 Normative referencesThe following documents, in whole or in part, are normatively referenced i

28、n thisdocument and are indispensable for its application. For dated references, onlythe edition cited applies. For undated references, the latest edition of thereferenced document (including any amendments) applies.BS 7121-2-1:2012, Code of practice for safe use of cranes Part 2-1: Inspection,mainte

29、nance and thorough examination GeneralBS ISO 4309:2010, Cranes Wire ropes Care and maintenance, inspection anddiscard3 Terms and definitionsFor the purposes of this sub-part of BS 7121-2, the terms and definitions applygiven in BS 7121-2-1:2012 and the following apply.3.1 loader cranepowered crane c

30、omprising a column which slews about a base, and a boomsystem which is attached onto the top of the column3.2 lorry loadercommercial vehicle or trailer, fitted with a loader crane, which normally has aload-carrying capabilityBRITISH STANDARD BS 7121-2-4:2013 The British Standards Institution 2013 14

31、 GeneralRegular pre-use checking, in-service inspection, maintenance and thoroughexamination of cranes are essential if cranes are to function safely and reliably.The nature of these activities can be summarized as follows. Pre-use checks are visual checks which are carried out to ensure that thecra

32、ne has not suffered any damage or failure, and is safe to use. In-service inspections and maintenance are carried out to ensure thatcomponents are repaired or replaced before they deteriorate to a point atwhich they would become unsafe. Thorough examinations are carried out at specified intervals, a

33、fterinstallation on a new site, after major alteration or repair or after theoccurrence of exceptional circumstances which could jeopardize the safetyof the crane. Supplementary testing is carried out in support of thorough examinationand the extent and nature of any testing are specified by the com

34、petentperson carrying out the thorough examination.5 Personnel carrying out pre-use checks, in-serviceinspections, maintenance and thoroughexaminationsAttributes, competencies, competency assessment, training plans and trainingrecords of personnel should be in accordance with BS 7121-2-1:2012, Claus

35、e 5.6 Pre-use checks and in-service inspections6.1 GeneralPre-use checks and in-service inspection of cranes, together with a system torectify any defects disclosed, are required by the Health and Safety at Work etc.Act 1974 1 Section 2(2)(a), and LOLER 1998 2 Regulation 9(3)(b) to ensurethat the cr

36、ane is safe to use and that any deterioration is detected and rectifiedbefore the crane becomes unsafe.Pre-use checks and in-service inspections should only be carried out by personnelwho have been adequately trained and assessed as competent to carry out therequired tasks (see Clause 5). LOLER 1998

37、 2 requires that results of all in-serviceinspections are recorded in writing. It is recommended that the results of allpre-use checks are also recorded in writing.The crane user should ensure that sufficient time is allowed for pre-use checksto be carried before the crane starts work. The user shou

38、ld also ensure that asafe system of work is in place to prevent the person who is carrying out thechecks/inspections from being exposed to danger.6.2 Pre-use checksPre-use checks should be carried out at the start of each shift during which thecrane is to be used and at each change of operator. Thes

39、e are to test thefunctionality of the crane and visually check for any obvious defects. It isessential that these are carried out from a position of safety.An example of a checklist for pre-use checking of a loader crane and of a lorryloader is given in Annex A.BRITISH STANDARDBS 7121-2-4:20132 The

40、British Standards Institution 20136.3 In-service inspectionA regular in-service inspection should be made to identify any defects whichmight not be detected by the pre-use checks. In-service inspections should becarried out at intervals which ensure that any deterioration is identified beforethere i

41、s a risk of failure of the crane or injury to persons. Further guidance isgiven in HSE document L113 8. It might be convenient to schedule theinspections concurrently with planned preventive maintenance (seeBS 7121-2-1:2012, 7.2.2 and 7.2.3).For loader cranes, two types of in-service inspection shou

42、ld usually carried out.The first, which is in addition to the pre-use checks, should be carried out atintervals of between 1 week and 1 month, depending on the application andlevel of use of the crane. An example of a checklist for this type of in-serviceinspection is given in Annex B. The second ty

43、pe of in-service inspection shouldbe carried out at intervals of between 3 months and 6 months. An example of achecklist for this type of inspection is given in Annex C.An example of an in-service inspection checklist for an attachment is given inAnnex D.Steel structures suffer from fatigue, a proce

44、ss which can create cracks thatpropagate over time. If left unattended, cracks can cause serious failure of thecrane structure. The in-service inspection regime should include measures todetect cracks before the safety of the crane is affected. Therefore, in-serviceinspections should include a struc

45、tural inspection of highly stressed areas of thecrane. Details of these areas are given in Annex E.NOTE The majority of these areas are adjacent to greasing points so a closeinspection can be made while the structure is being lubricated.If there are any indications of cracking or excessive wear in p

46、ins, bearings orstructural components, the crane should be taken out of use and a thoroughexamination should be carried out in accordance with Clause 8, with NDT ifconsidered necessary by the competent person.The period between inspections should be decided on the basis the duty of thecrane and the

47、environmental conditions. The period should be kept underreview and adjusted according to the results of the inspections.6.4 Reporting of defectsLOLER 1998 2 requires that defects be reported immediately they areidentified. There should be provision for the personnel carrying out pre-usechecks or in

48、-service inspections to make written reports of defects orobservations immediately they are identified.This facility should augment the normal verbal reporting that should routinelytake place between crane operator and crane owner/site manager. The writtenreport should be to a pre-defined format, (a

49、 company pro-forma, a section onthe daily time sheet, etc.), which requests details of the defect or observationand supporting information such as date, time, crane identification, error codesand circumstances. The operator should also fill in a written report when thereare no defects or observations to report (a “nil report”) and these should besubmitted at least weekly.All the defect reports, including the “nil reports”, should be forwarded to thecrane owner, (or the crane owners delegated