1、raising standards worldwideNO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBSI Standards PublicationBS 7121-2-5:2012Code of practice for the safeuse of cranesPart 2-5: Inspection, maintenanceand thorough examination Tower cranesPublishing and copyright informationThe BSI copyri
2、ght notice displayed in this document indicates when the documentwas last issued. The British Standards Institution 2012.Published by BSI Standards Limited 2012ISBN 978 0 580 78196 4ICS 53.020.20The following BSI references relate to the work on this standard:Committee reference MHE/3/11Draft for co
3、mment 12/30259756 DCPublication historyFirst published November 2012Amendments issued since publicationDate Text affectedBS 7121-2-5:2012 BRITISH STANDARDContentsForeword ii1 Scope 12 Normative references 13 Terms and definitions 14 General 15 Personnel carrying out pre-use checks, in-service inspec
4、tions, maintenanceand thorough examinations 16 Pre-use checks and in-service inspections 27 Maintenance of tower cranes 48 Thorough examination of tower cranes 109 Overload testing of tower cranes to supplement thoroughexamination 1710 Non-destructive testing (NDT) of tower cranes 1911 Rated capacit
5、y indicator/rated capacity limiter (RCI/RCL) test 1912 Assessment of wire rope condition and discard criteria 20AnnexesAnnex A (informative) Examples of a checklists for pre-use checking of towercranes 21Annex B (informative) Example of a tower crane base pre-erection inspectionreport form 24Annex C
6、 (informative) Example of a tower crane base approval/completioncertificate 25Annex D (informative) Example of a tower crane tie fabrication andpre-installation inspection report 26Annex E (informative) Example of a tower crane tie approval/completioncertificate 27Annex F (informative) Example of a
7、checklist for inspection duringmaintenance 28Annex G (informative) Example of procedures for thorough examinations andsupplementary testing of climbing frames 29Bibliography 31List of figuresFigure B.1 Example of a tower crane base pre-erection inspection reportform 24Figure C.1 Example of a tower c
8、rane base approval/completion certificate 25Figure D.1 Example of a tower crane tie fabrication and pre-installationinspection report form 26Figure E.1 Example of a tower crane tie approval/completion certificate 27Summary of pagesThis document comprises a front cover, an inside front cover, pages i
9、 to iv,pages 1 to 32, an inside back cover and a back cover.BRITISH STANDARD BS 7121-2-5:2012 The British Standards Institution 2012 iForewordPublishing informationThis sub-part of BS 7121-2 is published by BSI Standards Limited, under licensefrom the British Standards Institution and came into effe
10、ct on 30 November2012. It was prepared by Subcommittee MHE/3/11, Crane safety and testing,under the authority of Technical Committee 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,
11、BS 7121-2-3, BS 7121-2-4 and BS 7121-2-7, thissub-part of BS 7121-2 supersedes BS 7121-2:2003, which will be withdrawn whenall these 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 a
12、re in preparation. Part 2-1: Inspection, maintenance and thorough examination General; Part 2-3: Inspection, maintenance and thorough examination Mobilecranes; Part 2-4: Inspection, maintenance and thorough examination Loadercranes; Part 2-5: Inspection, maintenance and thorough examination Towercra
13、nes; Part 2-7: Inspection, maintenance and thorough examination Overheadtravelling cranes, including portal and semi-portal cranes, hoists, and theirsupporting structures; Part 2-9; Inspection, maintenance and thorough examination Cargohandling and container cranes.When all sub-parts of BS 7121-2 ha
14、ve been published, it is intended that CP 3010will be withdrawn and BS 5744 will be revised to cover manually operated andlight cranes 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 t
15、he use of this British Standardto those who have duties under the Health and Safety at Work etc. Act 1974 1.This standard was drawn 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 represe
16、nting theconsensus of opinion based on practical experience for safety of cranes.Hazard warningsWARNING. This British Standard calls 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 fr
17、om legal obligationsrelating to health and safety at any stage.BRITISH STANDARDBS 7121-2-5:2012ii The British Standards Institution 2012Use 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 specifi
18、cation andparticular care should be taken to ensure that claims of compliance are notmisleading.Any user claiming compliance with this 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 Bri
19、tish Standard that theexecution of its provisions will be entrusted to appropriately qualified andexperienced people, for whose use it has been produced.Presentational conventionsThe provisions of this standard are presented in roman (i.e. upright) type. Itsrecommendations are expressed in sentences
20、 in which the principal auxiliaryverb is “should”.Commentary, explanation and general informative material is presented insmaller italic type, and does not constitute a normative element.Contractual and legal considerationsThis publication does not purport to include all the necessary provisions of
21、acontract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunity from legalobligations.Particular attention is drawn to the following specific regulations: Health and Safety at Work etc. Act 1974 1; Lifting Operations and Lifting Equipment Regula
22、tions (LOLER) 1998 2; Provision and Use of Work Equipment Regulations (PUWER) 1998 3; Supply of Machinery (Safety) Regulations 2008 (as amended) 4; Work at Height Regulations 2005 (as amended) 5.NOTE Details of the Lifting Operations and Lifting Equipment Regulations 1998 2and the Provision and Use
23、of Work Equipment Regulations 1998 3, together withan HSE Approved Code of Practice and HSE Guidance, are given in HSE publicationsSafe use of lifting equipment 6 and Safe use of work equipment 7.BRITISH STANDARD BS 7121-2-5:2012 The British Standards Institution 2012 iiiBRITISH STANDARDBS 7121-2-5:
24、2012This page deliberately left blankiv The British Standards Institution 20121 ScopeThis sub-part of BS 7121-2 gives recommendations for the pre-use checks,in-service inspection, maintenance, thorough examination (in service andfollowing exceptional circumstances) and supplementary testing of tower
25、 cranes.It covers self-erecting tower cranes, with the exception of vehicle mountedself-erecting tower cranes, which are covered by BS 7121-2-3.This sub-part of BS 7121-2 is not applicable to permanently installed cranes onmarine and other water-borne vessels.2 Normative referencesThe following docu
26、ments, in whole or in part, are normatively referenced in 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 pra
27、ctice for the safe use of cranes Part 2-1:Inspection, maintenance 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 given inBS 7121-2-1:2012 a
28、pply.4 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
29、thecrane 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 interv
30、als, afterinstallation 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 t
31、he competentperson 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,
32、 Clause 5.BRITISH STANDARD BS 7121-2-5:2012 The British Standards Institution 2012 16 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
33、1974 1 Section 2(2)(a), and LOLER 1998 2 Regulation 9(3)(b) to ensurethat the crane is safe to use and that any deterioration is detected and rectifiedbefore the crane becomes unsafe.Examples of checklists for pre-use checking are given in Annex A.Pre-use checks and in-service inspections should onl
34、y be carried out by personnelwho have been adequately trained and assessed as competent to carry out therequired tasks (see Clause 5). LOLER 1998 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
35、 writing.The crane user should ensure that sufficient time is allowed for pre-use checksto be carried before the crane starts work. The user should 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-u
36、se checksPre-use checks should be carried out at the start of each shift during which thecrane is to be used. These are to test the functionality of the crane and visuallycheck for any obvious defects. It is essential that these are carried out from aposition of safety.6.3 In-service inspectionA reg
37、ular 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 is a risk of failure of the crane or injury to persons. Further g
38、uidance isgiven in HSE document L113 6. It might be convenient to schedule theinspections concurrently with planned preventive maintenance (seeBS 7121-2-1:2012, 7.2.2 and 7.2.3).Steel structures suffer from fatigue, a process which can create cracks thatpropagate over time. If left unattended, crack
39、s can cause serious failure of thecrane structure, so the in-service inspection regime should include measures todetect cracks before the safety of the crane is affected.The period between inspections should be decided on the basis the duty of thecrane and the environmental conditions and might need
40、 to vary between1 week and 6 months. The period should be kept under review and adjustedaccording to the results of the inspections.6.4 Reporting of defectsAny defects found during pre-use checks and in-service inspections should berecorded and notified to the user. LOLER 1998 2 requires that defect
41、s identifiedby in-service inspections which are, or could become, a danger to persons arenotified to the employer (user) forthwith.BRITISH STANDARDBS 7121-2-5:20122 The British Standards Institution 20126.5 Records of pre-use checks and in-service inspections6.5.1 GeneralWritten records of all pre-u
42、se checks and in-service inspections should be kept.6.5.2 Pre-use checksThe record of a pre-use check should include at least the following information: identity of the crane; date of the check; result of the check, i.e. whether or not the crane passed; name and signature of person carrying out the
43、check.This may be kept to a minimum by, for example, completing a single line of apro-forma record card.6.5.3 In-service inspectionsThe record of an in-service inspection should include at least the followinginformation: date and location of the inspection; name of person carrying out the inspection
44、; description and unique identification number of the equipment inspected; nature and extent of the inspection; results of the inspection, including details of the condition of criticalcomponents which need to be monitored, for example a wire rope showingsigns of wear.The record should be related to
45、 the cranes historical records and made availableto the competent person responsible for the thorough examination (seeClause 8).6.6 Inspection prior to reconfiguration or dismantlingBefore an erected tower crane is reconfigured or dismantled it should beinspected to determine whether there are any d
46、efects which could affect thesafety of the reconfiguration or dismantling operation. Any defects foundduring such an inspection should be recorded for inclusion in the machinehistory file and corrective action taken before the reconfiguration ordismantling operation is carried out. The details of th
47、ese defects, together withany corrective actions, should be made available to the competent person at thetime of the next thorough examination.6.7 Inspection of second-hand tower cranesWhen purchasing second-hand tower cranes their condition should be inspectedand thoroughly assessed; nothing should
48、 be taken for granted. Where possiblethis assessment should include a review of maintenance records and previousreports of thorough examination.Once the cranes condition has been fully assessed any necessary repairs shouldbe carried out and appropriate inspection and maintenance intervalsestablished
49、.BRITISH STANDARD BS 7121-2-5:2012 The British Standards Institution 2012 37 Maintenance of tower cranes7.1 GeneralUnder the Provision and Use of Work Equipment Regulations (PUWER) 1998 3employers are required to ensure that cranes are maintained in an efficientstate, in efficient working order and in good repair. To ensure adequatemaintenance an effective maintenance management system should be set up inaccordance with BS 7121-2-1:2012, 7.1.The Health and Safety at Work etc. Act 19
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