1、raising standards worldwideNO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBSI Standards PublicationBS 7121-2-3:2012Code of practice for the safeuse of cranesPart 2-3: Inspection, maintenanceand thorough examination Mobile cranesPublishing and copyright informationThe BSI copyr
2、ight notice displayed in this document indicates when the documentwas last issued. The British Standards Institution 2012Published by BSI Standards Limited 2012ISBN 978 0 580 78194 0ICS 53.020.20The following BSI references relate to the work on this standard:Committee reference MHE/3/11Draft for co
3、mment 12/30259753 DCPublication historyFirst published November 2012Amendments issued since publicationDate Text affectedBS 7121-2-3:2012 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 26 Pre-use checks and in service inspections 27 Maintenance of mobile cranes 48 Thorough examination of mobile cranes 89 Overload testing of mobile cranes 1310 Non-destructive testing (NDT) of mobile cranes 1711 Stability testing of mobile cranes mounted o
5、n water-borne craft 1712 Overload test for jib arrangements 1913 Assessment of wire rope condition and discard criteria 22AnnexesAnnex A (informative) Examples of checklists for pre-use checking and in-serviceinspections of mobile cranes 23Bibliography 25List of tablesTable1Testconfigurations for te
6、lescopic jib arrangements 20Table2Testconfigurations for strut jib arrangements 21Table3Testconfigurations for mast/tower and jib arrangements 21Summary of pagesThis document comprises a front cover, an inside front cover, pages i to iv,pages 1 to 26, an inside back cover and a back cover.BRITISH ST
7、ANDARD BS 7121-2-3:2012 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 effect on30 November 2012. It was prepared by Subcommittee MHE/3/11, Crane
8、 safetyand testing, under the authority of Technical Committee MHE/3, Cranes andderricks. A list of organizations represented on these committees can beobtained on request to their secretary.SupersessionTogether with BS 7121-2-1, BS 7121-2-4, BS 7121-2-5 and BS 7121-2-7, thissub-part of BS 7121-2 su
9、persedes BS 7121-2:2003, which will be withdrawn whenall these sub-parts have been published.Relationship with other publicationsThe BS 7121 series is being revised.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 are in preparation. Part 2-1: Inspection, maintenance and thorough exam
10、ination 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 Towercranes; Part 2-7: Inspection, maintenance and thorough examination Overhe
11、adtravelling 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 have been published, it is intended that CP 3010will be withdrawn and BS
12、 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 the use of this British Standardto those who have duties under the Heal
13、th 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 representing theconsensus of opinion based on practical experience for safety
14、 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 from legal obligationsrelating to health and safety at any stage.BRITISH
15、 STANDARDBS 7121-2-3:2012ii 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 specification andparticular care should be taken to ensure that claims of com
16、pliance 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 British Standard that theexecution of its provisions will be entrusted to
17、 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 in which the principal auxiliaryverb is “should”.Commentary, explanat
18、ion 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 acontract. Users are responsible for its correct application.Complianc
19、e 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 Regulations (LOLER) 1998 2; Provision and Use of Work Equipment Regulations
20、(PUWER) 1998 3; Supply of Machinery (Safety) Regulations 2008 (as amended) 4; Merchant Shipping and Fishing Vessels (Health and Safety at Work)Regulations 1997 5; Merchant Shipping and Fishing Vessels (Lifting Operations and LiftingEquipment) Regulations (MCA LOLER) 2006 6; Merchant Shipping and Fis
21、hing Vessels (Provision and Use of WorkEquipment) Regulations (MCA PUWER) 2006 7; Road Vehicles (Construction and Use) Regulations 1986 (as amended) 8; Road Traffic Act 1991 9.NOTE 1 Details of the Lifting Operations and Lifting Equipment Regulations 19982 and the Provision and Use of Work Equipment
22、 Regulations 1998 3, togetherwith an HSE Approved Code of Practice and HSE Guidance, are given in HSEpublications Safe use of lifting equipment 10 and Safe use of work equipment 11.NOTE 2 Details of the Merchant Shipping and Fishing Vessels Regulations 5, 6and 7 are given in Maritime and Coastguard
23、Agency Marine Guidance NotesMGN 20 (M+F) The Merchant Shipping and Fishing Vessels (Health and Safety atWork) Regulations 1997 12, MGN 331 (M+F) The Merchant Shipping and FishingVessels (Provision and Use of Work Equipment) Regulations 2006 13 and MGN 332(M+F) The Merchant Shipping and Fishing Vesse
24、ls (Lifting Operations and LiftingEquipment) Regulations 2006 14.BRITISH STANDARD BS 7121-2-3:2012 The British Standards Institution 2012 iiiBRITISH STANDARDBS 7121-2-3:2012This page deliberately left blankiv The British Standards Institution 20121 ScopeThis sub-part of BS 7121-2 gives recommendatio
25、ns for the pre-use checks,in-service inspection, maintenance, thorough examination (in service andfollowing exceptional circumstances) and supplementary testing of mobilecranes, including truck cranes, wheeled rough terrain cranes, wheeled yardcranes, crawler mounted cranes, mini-cranes and vehicle
26、mounted self erectingtower cranes.2 Normative referencesThe following documents, 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
27、 document (including any amendments) applies.BS 7121-2-1:2012, Code of practice 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 s
28、ub-part of BS 7121-2, the terms and definitions given inBS 7121-2-1:2012 apply.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 follo
29、ws. Pre-use checks are visual checks which are carried out to ensure that 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 woul
30、d become unsafe. Thorough examinations are carried out at specified intervals, 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 thoro
31、ugh examinationand the extent and nature of any testing are specified by the competentperson carrying out the thorough examination.BRITISH STANDARD BS 7121-2-3:2012 The British Standards Institution 2012 15 Personnel carrying out pre-use checks, in-serviceinspections, maintenance and thoroughexamina
32、tionsAttributes, competencies, competency assessment, training plans and trainingrecords of personnel should be in accordance with BS 7121-2-1:2012, Clause 5.6 Pre-use checks and in service inspectionsNOTE The inspection required by MCA LOLER 2006 6 Regulation 12(1) is addressedin Clause 8.6.1 Gener
33、alPre-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), LOLER 1998 2 Regulation 9(3)(b) and MCA LOLER2006 6 Regulation 12(2)(b), to ensure that the crane is safe to use
34、 and that anydeterioration is detected and rectified before the crane becomes unsafe.Examples of checklists for pre-use checking and in-service inspections are givenin Annex A.Pre-use checks and in-service inspections should only be carried out by personnelwho have been adequately trained and assess
35、ed as competent to carry out therequired tasks (see Clause 5). LOLER 1998 2 and MCA LOLER 2006 6 requirethat results of all in-service inspections are recorded in writing. It isrecommended that the results of all pre-use checks are also recorded in writing.The crane user should ensure that sufficien
36、t 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-use checksPre-use checks should be carried out at the
37、 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 regular in-service inspection should be made to identif
38、y 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 guidance isgiven in HSE document L113 10 and MCA docu
39、ment MGN 332 14. It might beconvenient to schedule the inspections concurrently with planned preventivemaintenance (see BS 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, cracks can cause serious fai
40、lure 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 of the duty ofthe crane and the environmental conditions and might need to vary between1 we
41、ek and 6 months. The period should be kept under review and adjustedaccording to the results of the inspections.BRITISH STANDARDBS 7121-2-3:20122 The British Standards Institution 20126.4 Reporting of defectsLOLER 1998 2 and MCA LOLER 6 require that defects be reported immediatelythey are identified
42、. There should be provision for the personnel carrying outpre-use checks or in 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 cra
43、ne owner/site manager. The writtenreport should be to a pre-defined format, (a 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 operat
44、or 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 representative), who shou
45、ldarrange for any necessary action to be taken on the basis of the report. A copyof the original report should be retained by the crane user.Once the defect/observation has been dealt with and cleared this should then berecorded, with supporting information, on the original defect report.The “cleare
46、d” reports should be securely lodged in the crane owning companysmaintenance management system and should be made available on demand tothe users of the crane as well as other authorized bodies.6.5 Records of pre-use checks and in-service inspections6.5.1 GeneralWritten records of all pre-use checks
47、 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 inspection; result of the check, i.e. whether or not the crane passed; name and signature of person carrying out the check.Th
48、is may be recorded by, for example, completing a standard pro-forma record.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; description and unique iden
49、tification 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 the mobile cranes historical records and madeavailable to the competent person responsible for the thorough examination(see Clause 8).BRITISH STANDARD BS 7121-2-3:2012 The British Standards
