Bs 7121 2º INSPECTION, TESTING AND EXAMINATION-CRANES

BS 7121- 2
CODE OF PRACTICE FOR SAFE USE OF CRANE
PART 2: INSPECTION, TESTING AND EXAMINATION

BS 7121-2 CoP for SUoC
1. SCOPE 2.NORMATIVE REFERENCE
1. SCOPE
Recommendations for the pre-use checks, in-service inspection, thorough examintation
and testing of cranes, including associated equipment.
2. NORMATIVE REFERENCE
BS 1757 Specification for power-driven mobile cranes
BS 449-2 Structural for the use of structural steel in building (Part 2: Metric units)
BS 5950-1 StructuraL use of steelwork in building-Part 1:Code of practice for design-Rolled and welded sections
BS 6968 Guide for use and maintenance of non-calibrated roun steel lifting chain and chain slings
BS EN 473 Non-destructive testing-Qualification and certification of NDT personnel- General principles
BS EN 45004 General criteria for the operation of various types of bodies performing inspection
ISO 3056 Non-calibrated round steel link lifting chain and chain slings- Use and maintenance
ISO 4301 Cranes- Clasification

3. TERMS AND DEFINITIONS
Thorough examination- competent person determinate if equipment is safe to continue in use
Competent person-practical and therorical knowledge and experience of LE (assess)
Competent engineer- theorical knowledge of the design of LE
Inspection body -employer of the competent person(s) who provided examination and testing
Type A inspection body providing ―third-party‖ services-in accordance BS EN 45004, ANNEX A
Type B inspection body BS EN 45004 ANNEX B
Type C inspection body BS EN 45004 ANNEX C- see next page this annex
Testing
Functional testing- operation of each motion without a load applied
Performance testing- operation of each motion with the rated load applied
Overload testing-static- operation with a load exceeding the rated load applied without
operating the full range of motion
Overload testing-dynamic- operation with a load exceeding the rated load applied
Non-destructive testing NTD- Testing on the estructure of the appliance
User-control of LO and crane operator, responsible maintenance and thoroughly examined
Rated capacity indicator/limiter RCI/L-prevent crane from overload
Crane operator-operating crane- to position loads or erection of the crane
Load radius indicator-which the crane is operating and its rated capacity
Radius-horizontal distance between centre of rotation and the vertical centreline load (CG)
Rated capacity-maximum load-at specified position and conditions=SWL
Service conditions- In-sevice/Out-of-service
Lifting-movement of loads or persons
Lifting accessory-LE for attaching loads

INDEPENDENCE CRITERIA FOR TYPE A INSPECTION BODY
A.1 The inspection body shall be independent of the parties involved.
The inspection body, and its staff responsible for carrying out the inspection shall not be the designer, manufacturer,
supplier, installer, purchaser, owner, user or maintainer of the items which they inspect, nor the authorized
representative of any of these parties.
A.2 The inspection body and its staff shall not engage in any activities that may conflict with their independence of
judgement and integrity in relation to their inspection activities. In particular they shall not become directly involved
in the design, manufacture, supply, installation, use or maintenance of the items inspected, or similar competitive
items.
A.3 All interested parties shall have access to the services of the inspection body. There shall not be undue
financial or other conditions. The procedures under which the body operates shall be administered in a nondiscriminatory
manner.
INDEPENDENCE CRITERIA FOR TYPE B INSPECTION BODY
B.1 A clear separation of the responsibilities of the inspection personnel from those of the personnel employed in
the other functions shall be established by organizational identification and the reporting methods of the inspection
body within the parent organization.
B.2 The inspection body and its staff shall not engage in any activities that may conflict with their independence of
judgement and integrity in relation to their inspection activities. In particular they shall not become directly involved
in the design, manufacture, supply, installation, use or maintenance of the items inspected, or similar competitive
items.
B.3 Inspection services shall only be supplied to the organization of which the inspection body forms a part.
INDEPENDENCE CRITERIA FOR TYPE C INSPECTION BODY
C.1 The inspection body shall provide safeguards within the organization to ensure adequate segregation of
responsibilities and accountabilities in the provision of inspection services by organization and/or documented
Procedures.
3. TERMS AND DEFINITIONS

4.GENERAL
5. PESONNEL CARRYING OUT PRE-USE CHECKS, IN-SERVICE INSPECTIONS AND THOROUGH
EXAMINATIONS
4. GENERAL
Pre-use check are visual checks at the start of each shift
In-service inspection- weekly intervals by the crane operator
Thorough examination- by competent person at specifiec intervals, after installation, after
alteration or reparir or exceptional circumstances
Testing- is a part of thorough examination
5. PESONNEL CARRYING OUT PRE-USE CHECKS, IN-SERVICE INSPECTIONS AND
THOROUGH EXAMINATIONS
5.1 PRE-USE CHECKS AND IN-SERVICE INSPECTIONS
Should be carried out by a person who is competent.
Initial training and assessment of competence
Periodic reassessment of that competence
Crane operators-crane is out of use.
5.2 THOROUGH EXAMINATIONS
By a competent person taking account of any instruction
An engineer should be make an assessment of the desig of the crane (NO
instructions available)
Independient and imparcial to allow objective decisions to be made.

6.PERIODIC PRE-USE CHECKS AND IN-SERVICE INSPECTIONS
6.1 GENERAL – the appoined person should ensure that inspection are carried out, and there is
as system to rectify any defects
6.2 DAILY PRE-USE CHECKS At the begining of each shift or working day:
- Pre-use check required by the instructions for the crane
- Check all ropes are correctly positioned on their sheaves and drum no displaced
- Visually check no electrical equipment-by oil, grease, water or dirt
- No loss of fluids/levels-oil, coolant
- All limits switches, or cut-outs and dead man’s handle or lever function
- Hydraulic system-hose and oil
- RCI/L-manufacturer’s daily test
- Load radius scale-jib configuration
- Movement of the equipment- varying the radius no load
- Air pressure- pneumatic control system-brakes
- Lights, windscreen wiper(s) and washer operate efficiently
- Wheels and condition tyres
- All crane controls function correctly no load
- Audible warning devices
- Safety and fire prevention-areas are in tidy conditions, access and egress from cab
- No obstruction in the path of the crane, prevent collisions

6.PERIODIC PRE-USE CHECKS AND IN-SERVICE INSPECTIONS
6.3 WEEKLY IN-SERVICE INSPECTIONS -once a week
- Instructions for the crane
- RCI/L – operating instructions- cables, connectors and mounting
- All wire ropes for broken wires, flattening, basket distorsion, excesive wear, corrosion
- All rope terminations, swivels, pin and reating devices, and all sheaves –worm bushes
or seizure
- Structure- missing and bent bracings on bridges and strut jibs, bulges mark on
telescopic jib, cracked welds, and loose bolts and other fasteners
- Hook, safety catch and swivel, free movement. –shank thread
- Operation and adjustment of controllers
- Hydraulic system-rams and hoses,, creep rate
- Brakes and clutches
- Tyre pressure, damge and wear- nuts, tread
- Rails, end stops and ties if fitted
- All guards
- Slew lock if fitted
- Steering, travel brakes, lights, indicators, horn, windscreen wipers and washers
- Enter the results in the record of inspection
6.4 RECORDS OF INSPECTION- Kept by the crane owner. Include:
- DATE AND LOCATION
- NAME PERSON CARRY OUT
- TYPE OF EQUIPMENT INSPECTED
- RESULT OF INSPECTIONS

7.THOROUGH EXAMINATION
7.1 GENERAL
Loler and Merchant Shipping Act give specified period
Supplemented by: Overload testing, NDT, opening up of concealed or encased parts
7.2 RESPONSIBLILITIES OF THE CRANE USER
GENERAL-crane is taken out of use –time examination
PROVISION OF FACILITIES AND SERVICES- area cordoned off, operator, person to
remove cover or open up parts, prepararion NDT
PROVISION OF INFORMATION-rated capacities, alteratios, repair, renewals
7.3 RESPONSIBILITIES OF THE COMPETENT PERSON-Identified defects, times to rectified.
Lifting accessories or equipment-notified the user and owner
7.4 RECTIFICATION OF DEFECTS-User ensure these defects are rectified
7.5 SPECIFIED PERIOD OF THOROUGH EXAMINATION
6 MONTHLY THOROUGH EXAMINATION-crane lift person and LA
12 MONTHLY THOROUGH EXAMINATION-crane

7.THOROUGH EXAMINATION
7.6 EXAMINATION SCHEME
GENERAL-written schedule of the steps
DETAILS OF AN EXAMINATION SCHEME- contain at least :
- Name and address owner
- Name, qualificatins and address person drawing up (organization)
- Make, model and identification number of the crane
- Information references used in drawing up-instructions
- Data logging system
- The environment
- Identification parts-deterioration, corrosion
- Frecuency –parts- time, loading or duty cycles
- Methods –dismantling, NDT techniques, time replacement
- Resources required- qualified personnel, workshop facilities,…
- Changes to equipment condition, operational or environmental
- Date of drawing up
The mechanisms function correctly and are free from defect, crane is safe for use
7.7 THOROUGH EXAMINATION PRIOR TO LOAD TESTING
Free from any defect (safely handling the test load), correct configuration and condition
(instruction), equiped with sufficients falls of wire rope for the load. Ballats amount and
weight, material used, all safety switches correct operations. LA, slinging arrangements are
safe.
7.8 THOROUGH EXAMINATION AFTER LOAD TESTING
After a load testing, crane without sings of structural damage such as cracking,
permanent deformation, paint flaking, loosening of or damage to structural
connections.

8.PRE-USE CHECKS AND IN-SERVICE INSPECTIONS FOR CRANES AND
OTHER EQUIPMENT NOT IN USE FOR AN EXTENDED PERIOD OF
TIME
Special programme of pre-use checks, in-service inspections and thorough
examinations
Depends on the length of the period, and the location of the crane.
Weather and atmospheric pollution.
Pre-use checks and in-service inspections should contain:
- Checks recommended – instructions crane
- Checking all ropes for signs of corrosion, degradation and damage- lubrication
- Checking all control linkage for evidence of seizure
- Checking for correct functioning of all the safety devices
- Checking hoses or other components for evidence deterioration
- Checking for corrosion on the structure, access, control linkages, etc
- Checking for structural integrity- cracks, dents, missing components
- Testing of every motion for several minutes without load, and with load

9. TESTING AS PART OF THOROUGH EXAMINATION
9.1 GENERAL –includes testing- functional/performance/non destructive(NDT)/overload testings.
9.2 FUNCTIONAL TESTING- without load applied-Operation of all controls (brakes, safety
devices,) correctly and smoothly and free from wear/damage
9.3 PERFORMANCE TESTING-after functional testing and with the rated load applied.
9.4 LOAD TESTING- determinate whether the equipment is stable, structurally sound and fit for
the use for which is was designed (include every load-bearing part)
Extreme care, each motion singly- at the lowest possible speed.
Overload keep close ground- 100-200mm
9.5 CRANES AND OTHER EQUIPMENT WHICH HAVE BEEN ALTERED OR REPAIRED
Any alteration or repair- the testing should be carried out in accordance with the original
crane specification.
9.6 OVERLOAD TESTING AS PART OF PERIODIC CHECKS AND INSPECTIONS
To prove the continued integrity of the equipment, taking into account its age, usage,
condition and operating environment.
9.7 OVERLOAD TESTING FOLLOWING MAJOR REPAIR OR MODIFICATION
Any testing in accordance with written instruction from manufacturer
or other appropriate design authority

9.8 TESTING OF RATED CAPACITY INDICATOR/LMITER (RCI/L)
GENERAL-at least 12 months the calibration should be verified by suspension of calibrated
weights. (after any major repair or modification)
RATED CAPACITY INDICATOR/LIMITER (RCI/L) CALIBRATION CHECK
-Warning of approach to rated capacity- commence at not less than 90% of the
rated capacity and not more than 97.5%. Function until to below the value.
- Warning of overload- clear and continuous warning of overload. Commence at not
less than 102.5% and not more than 110%
Guidance on how to calibrate an RCI/L is given in BS 7262.
The crane is not loaded beyond 110%
9.9 TEST SITE CONDITIONS
Ground well consolidated and capable of withstanding the load applied to it.
No hidden dangers- cable ducts, drains, pipes,back-filled areas, cellars, other subterranean
weaknesses. No be tested in the vicinity of overhead power lines.
Sufficient area- overhead- to move crane and load (slewing, derricking, travelling)
Not test in high risk areas- public highway, railway, occupied buildings, fight path airports
Roped off areas- prohibiting unauthorized entry.

9.10 WEATHER CONDITIONS
GENERAL- Electric storms, strong wind, heavy rains, ice, snow or excessive sea state can
impose loads. Limitation s on visibility, or heavily coated with ice or snow. Not pulling against an
anchor point (can introduce side loading)
WIND SPEEDS- specified in the operating instructions. Gusting wind conditions. Beaufort scale.
See state codes Annex B-C-next tables.
9.11 TEST WEIGHTS
Weights of proven accuracy to within +-1%
Weights proven on a weighbridge- calibrated 12 moths
Weights suspended from a calibrated weighing device-12 moths

9.12 NON-DESTRUCTIVE TESTING (NDT) TECHNIQUES
Can assist in the detection of any materials cracks or defects.
BS EN 473- Guidance on qualification and certification of NDT personnel.
3 most common types of NDT:
- MAGNETIC PARTICLE EXAMINATION- examination-surface-flood with ferrous
particles liquid-cluster over the defect (See BS EN ISO 9934 and BS EN 10228-2).
Magnetic materials.
- DYE PENETRANT- flood with a liquid dye-penetrates, after time- cleaned off, and
surface sprayed-absorbent- draws the dye from any defects. Non-ferrous materials
(aluminium alloys) (See BS EN 671-1 and BS EN 10228-2)
- ULTRASONIC EXAMINATION- Pulse of high frequency sound waves are transmited
from the surface into its interior.-measure the time delay from the time of transmission-
estimate defect’s depth.
Required a skilled operator and specialist equipment. Wide range of materials.See BS
EN 583-3
9.13 REPORT OF THOROUGH EXAMINATIONS AND CERTIFICATES OF TEST
After every test a report should be prepared. Annex A next page
After a load test-a certificate should be issued. Annex D next page
Apply all possible variables- jib length, rope reeving, track width, short or long
crawlers, counterweight, blocked, free on wheels , jib locking pins.

ANNEX A (Informative)
Information to be contained in a report of a thorough examination
The following is an extract from the Lifting Operations and Lifting Equipment Regulations [1].
Schedule 1
of Regulation 10 is quoted here in full. It details information to be contained in a report of a
thorough
examination.
1) The name and address of the employer for whom the thorough examination was made.
2) The address of the premises at which the thorough examination was made.
3) Particulars sufficient to identify the equipment including where known its date of manufacture.
4) The date of the last thorough examination.
5) The safe working load of the lifting equipment or (where its safe working load depends on the
configuration of the lifting equipment) its safe working load for the last configuration in which it was
thoroughly examined.
6) In relation to the first thorough examination of lifting equipment after installation or after
assembly
at a new site or in a new location:
a) that it is such thorough examination;
b) (if such be the case) that it has been installed correctly and is safe to operate.
7) In relation to a thorough examination of lifting equipment other than a thorough examination to
which
paragraph 6 relates:
a) whether it is a thorough examination:
i) within an interval of 6 months;
ii) within an interval of 12 months;
iii) in accordance with an examination scheme;
iv) after the occurrence of exceptional circumstances;
b) (if such be the case) that the lifting equipment is safe to operate.
8) In relation to every thorough examination of lifting equipment:
a) identification of any part found to have a defect which is or could become a danger to
persons, and a
description of the defect;
b) particulars of any repair, renewal or alteration required to remedy a defect found to
be a danger to
persons;
c) in the case of a defect which is not yet but could become a danger to persons:
i) the time by which it could become such a danger;
ii) particulars of any repair, renewal or alteration required to remedy it;
iii) the latest date by which the next thorough examination must be carried
out.
9) Where the thorough examination included testing, particulars of any test:
a) the date of the thorough examination;
b) the name, address and qualifications of the person making the report; that he is self-
employed or, if
employed, the name and address of his employer.
10) The name and address of a person signing or authenticating the report on behalf of its author.
11) The date of the report.
ANNEX D (Informative)

10. DATA LOGGING
Information that data loggers can record (example):
— time, date and duration of lift;
— configuration;
— details of average and maximum load;
— radius, angle and boom length;
— number of lifts carried out;
— rated capacity exceeded and percentage;
— the number of times that manufacturer’s set limits are exceeded;
— reeving changes;
— operating mode;
— road travel or on-site working;
— distances travelled;
— start and stop times in real time;
— operator identification;
— over speeding;
— harsh braking;
— idling time.

11. ADDITIONAL RECOMMENDATIONS FOR CRANES FOR
LIFTING PERSONS AND SUSPENDED BASKETS
11.1 GENERAL-thoroughly examined at least every 6 moths-
11.2 THE CRANE- CHECK- RCI/L (1/2 rated for other load), motion control system (rest),
anemometer (no excess 7m/s ).Free fall locked out. Hydraulic cylinders fit with load hold
valves to stop movement (in case of hose rupture or pipe fracture). Smooth transition of the
carrier , not exceeds 0.5 m/s on all motions. Access/egress .Wire rope used for hoisting
and lowering the carrier at least 8mm diameter.
11.3 THE CARRIER-safety harness, lanyard, emergency egress., marked with the number
of persons, and maximum load. Doors no open outwards and securely fastened. Handrails
Attachment points. Corrosion, cracks …Floor horizontal. Unique identification mark.
11.4 BOSUN’S CHAIR-primary and secondary suspension point. Seat structure. Belt(s)
11.5 HARNESSES –correct operation (buckles, adjuster, fasteners), suspension points. The
age.
11.6 PRE-USE CHECKS
THE CRANE- hoist rope (no kinks or defects), no slack wire ropes, ropes
properly seated on drums and sheaves, lines no twised. A means detaches
from hook.
THE CARRIER- suspension system,, attachment points, motion controls.
Annex E-in next page

11. ADDITIONAL RECOMMENDATIONS FOR CRANES FOR
LIFTING PERSONS AND SUSPENDED BASKETS

12. ASSESSMENT OF WIRE ROPE CONDITION AND DISCARD CRITERIA
12.1 GENERAL- figure shows some points to be considered as part of the assessment.
Records shoul be kept of the examination and replacement of wire rope. Annex F. Pay atention
to the terminations, length run or stationary over drums, sheaves. (Details of crane wire rope-
ISO 4309)

12.2 ROKEN WIRES
RANDOMLY DISTRIBUTED BROKEN WIRES-not exceed 10 % any length of wire of 8 rope
diameters.
LOCALIZED BROKEN WIRES IN THE VICINITY OF TERMINATIONS 3 or more visible broken
wires
WIRE ROPES OPERATING IN PLASTICS SHEAVES-wire breaks can occur internally. Dryness
or denaturing of the lubrication. Crane or rope manufacturer’s advice. (or metal sheaves having
plastics lining)
12.3 WEAR- can be uniform along or around the rope.
Metal sheaves, 6 or 8 strand rope- discarded when diameter is reduced 90% nominal
diameter..
If diameter falls to 97% or rises to 105% of nominal diameter-discard might be necessary..
12.4 CORROSION AND CHEMICAL ATTACK- slight rusting- indication need lubrication.
External and internal

12.5 LOCALIZED DAMAGE OR DISTORSION-
WAVINESS-deformation in the longitudinal axis.
BASKET DISTORSION (OR BIRDCAGE)-outer layer dislocated, or longer than
inner layer.
STRAND OR CORE PROTRUSION- associated with basket distorsion. See 3
examples
WIRE EXTRUSION-usually results from shock loading-
LOCAL INCREASE IN DIAMETER OF ROPE-corrosion or to swelling of a fibre
core owing to moisture-
LOCAL DECREASE IN DIAMETER OF ROPE-fracture of the core positions.
BENDS AND KINKS-bend angular deformation/kink created by a loop in the rope-
tightened without rotation about its axis.- See 3 pics
FLATTENED PORTIONS-wire rope on a drum with insufficcient tension
DAMAGE DUE TO HEAR OR ELECTRIC ARCING-dryness or loss of lubrication,
fusion wire surfaces- and presence of weld splatters

12.6 CUMULATIVE EFFECT OF INDIVIDUAL CRITERIA- the competent person specify
period of time used, and recommend a reduction in time between inspections or thorough
examinations.
12.7 CHAINS- inspection in accordance with ISO 3056 and BS6968

13. ADDITIONAL RECOMMENDATIONS FOR MOBILE CRANES
13.2 OVERLOAD TESTING OF MOBILE CRANES
GENERAL- less 500t, overload tested every 4 years.
+500t overload tested 12 monthly calibration RCI/L
VARIATION OF MOBILE GRANES
Outriggers-intermediate extension marked, manufacturer’s certificate –capacities to the
outrigger extension. Duty charts give specified intermediate extension. RCI/L
Counterweight- manufacturer’s duty charts specify rating applicable for each counterweight
Jibs- jib configurations . The crane should be rigged in accordance with instructions
Fly jibs –be erected and use – instructions. Variation in length and /or angle o offset
Variable length jibs- identify sections- to avoid mismatch (intermediate sections)
LEVELLING- +- 0.5% slope, use a spirit level. Alterantively the hook block in the centre
of the jib (0º-90º)
LIFTING FREE ON WHEELS-higher pressure for free on wheels duties than for road travel.
LIFTING CAPACITIES- capacity charts= weight hook+sling and lifting gear+load
OVERLOAD TEST-Crane to withstand a 25% overload. 1ºfunctional test without load. Brake, re-
hoist, brake. Test load raised the crane derricked out the radius/angle 125% of the rated capacity
and lowered to between 100-200mm-10 min, and be slewed at the lowest speed-both directions-
withstand lateral loadings.
MAJOR REPAIR OR MODIFICATION-mobile cranes be thoroughly examined and overload test.
POST TEST EXAMINATION AND CERTIFICATION-appropriate certificate
13.3 NON-DESTRUCTIVE TESTING (NDT) OF MOBILE CRANES- when cracks or other structural damaged

13.1 THOROUGH EXAMINATION OF MOBILE CRANES
GENERAL- clean- to remove all spoil/dirt. Be carried out in logical sequence (top to bottom)
RATED CAPACITY INDICATOR/LIMITER(RCI/l) CALIBRATION CHECK-12 months-Guide
BS7262. Not loaded beyond 110 % of its rated capacity (radius/angle- mark)
EXAMINATION SCHEME APPROACH- In accordance with usage- condition monitoring-
Guide ISO 12482-1 cooperation manufacturer, owner and competent person. Limiting criteria
based on the crane design (number of load cycles,, critical part, exceptional circumstances.
Complete record of crane usage.
SPECIFIED PERIOD APPROACH
6 monthly thorough examination- crane -to lift persons and lifting accessories
12 montly thorough examination- crane not used to lift persons
Items to check the specified period thorough examintation-
-Tyres for wear, damage, inflamation pressure
-Crawler tracks for wear and adjustment
-Axle locking system- correct operation, no
leak/damage/corrosion/distorsion
-Crane structure, chassis, - damage/distorsion/cracking/ corrosion
-All bolts and fastening
-Slewing mechanism
-Pipework on crane- corrossion/damage/leakage/security and fretting
-Hidraulic cylinders
-Structure and jib
-Pivoting joints on the jib and attachments
-Telescopic extensions
-Wire ropes-size, reeved, end terminations- BS7166
-Pulleys/sheaves and drums turn freely
-Braking mechanism
-Any means of access- ladders, walkways, hand rails/hand holds
-Outrigger jacks and beams
-Fluid for conditions (oil)
-Operator’s seat
- Control levers are marked
-Upper and lower hoist limit switches
-Hooks, their attachment, safety catches
-Fly jib and mounted attachment- host limit switch –working
-Operator’s cabin showing the rated - capacities for all crane operting
conditions
-All controls for smoothnes of operation
- Warning signs
-All motion operate smoothly and effectively
(telescopic jib should be dismantled at leas one every 4 years to examine any
hidden mechanism parts-rope terminations, hydraulic cilinders)

13.4 MOBILE CRANES MOUNTED ON WATER-BORNE CRAFT
GENERAL- consider modification required the assembly of the crate and the vessel
INFORMATION-rated capacity, and overload conditons-Barge or pontoon
VERIFICATION- calculate angle of heel and trim of the vessel when crane is in operation/
manufacturer’s allowable rated capacity whilst working on the pontoon or barge/ Amount and
position of any ballast/ depht of water bellow the vessel’s keel/ Limiting weather and sea state.
ANCHORING-anchor the vessel to the shore, if it not possible- vessel be anchorage to a craft
alongside
RATED CAPACITY INDICATOR/LIMITER (RCI/L)- to ensure that the rated capacity reduction
THOROUGH EXAMINATION BEFORE TESTING-verification in accordance with the crane
instructions. Fuctional test with no load applied- correct operation of control, switches,
contactor… brakes, limit switches
STABILITY MARGIN- competent person, the marging should be the maximun overturning
moment of the crane does not exceed 2/3 of the restoring moment of the crane/vessel
combination
OVERLOAD TEST- jib set at its maximum working radius the rated capacity should be applied
check all motions. Raise load 100-200 mm and held on the brake, and overload should be
applied- increasing 25% capacity an again all motions, hoist and derrick brakes.Repeated with
the maximum rated capacity and then the 25%overload. Repeated with the minimum radius.
Cranes designed -BS 1757.In case of grabbing crane mounted on a vessel- contents not
exceed 75 % of the hook load and a further 25% reduction should be made- suction effect- The
weight of the grab not exceed 56.25% of the water-borne hook load rating.
POST TEST EXAMINATION AND CERTIFICATION- report- certificate

13.4 MOBILE CRANES MOUNTED ON WATER-BORNE CRAFT

13.5 OVERLOAD TEST FOR JIB ARRANGEMENTS
GENERAL- All jib and mast/tower configuration in Table3-4-5. Tested with a 25% overload, excep where the
previous test certificate specifies a lower test load. Crane has duties on outriggers, free on wheels, crawler
tracks, lift and travel- repeat test for each condition.
LONG JIB LENGTHS- 25% overload for max, radius and slew. Maximum rated-test, and be derricked in to
the minimum radius. Increased 25% held for 10 min clear of the ground. and derricked out to max radius. Load
be slewed (structure to withstand lateral loadings)
SHORT JIB LENGTHS- 25% overload for max radius and slew. Load be slewed 360º. Maximum rated
capacity be assembed at minimum radius, raised, crane all motions. Increased 25% and lowered to 100 mm to
200 mm above the ground. Test the derrick brakes with 25% overload suspended no more than 100mm
above the ground.

14. ADDITIONAL RECOMMENDATIONS FOR OVERHEAD TRAVELLING
CRANES
14.1 ITEMS TO CHECK AT THE SPECIFIED PERIOD THOROUGH EXAMINATION
Verify the identification and rated capacity marked on the crane-compabible- records-test certificates, EC,…
Any history of defects or malfunctions, repairs, alterations or additions.
All the motions operate
Crane safe by isolation power
Examine Structure- damage, cracks, wear, distorsions, corrosion or missing parts (end carriages, brigge
girders, crab, gantry rails, bolts and gastening, end stops and buffers)
Examine the long travel mechanism for damage, cracks, wear, alignment, distortion, corrosion, missing parts,
lubrications (motor, gearing, transmission machinery, bearing, brakes, wheels, gear cases, cover and guards)
Examine the cross travel mechanism (=the same before)
Examine the hoist mechanism(=)
Examine all the wire ropes/chains, anchorages and theri fittings. Bull dog grips NO used
Examine the hook/bottom/return block assembly
Examine the cab and seating
Examine controls for marking on their function and mode of operation
Functionally test all control for smoothness and freedom from damage
Examine the audible and visual warning devices
Examine all limit switches- hoist, lower, long travel, cross travel and proximity,
Examine the platforms and access ladders.
Examine fire extinguishers (date, seal intact, appropriate type, weight)
Examine the electrical system including (isolators, motors, lead and collectors, lighting, wiring, catenaries,
trailing cables)

14. ADDITIONAL RECOMMENDATIONS FOR OVERHEAD TRAVELLING
CRANES
14.2 OVERLOAD TESTING OF OVERHEAD TRAVELLING CRANES
OVERLOAD TEST
For overhead traveling cranes- gantry and supporting structure- examined,tested and certificated
Visual examination of gantry and track prior test
Before any load- functional test with no load applied
Crane be positioned – measure deflection—load raised, then lowered to 100-200 mm above the
ground, 10 min, to check the brake. Raised again and lowered (crab be traversed to mid span and
deflection), load lowered and raised, determinate the deflection remains constant.
Load should be traversed to the opposite gantry- allong the track, and returned to its original lift
position.
Maximum deflection- not exceed 1/750 of the span
Overload test- load increased by 25 % and repeated the test- the lowest speed possible for the
crane.
2 or more hoists, separete test.
POST TEST EXAMINATION AND CERTIFICATION-report like Annex D
(see point 9)
OVERLOAD TESTING OF CRANE GANTRIES
OVERLOAD TESTS -
1º test unloaded crane- be travelled the full length of the gantry
Load be lifted 100 to 200 mm above the ground-traveling the complete length
An overload of 25% in excess of the rated load- full length
Gantries built in accordance with BS 449-2 the maximum deflection not exceed 1/360 of the span.
Gantries built in accordance with BS5950-1 the maximum deflection not exceed 1/600 of the span.
POST TEST EXAMINATION AND CERTIFICATION-report like Annex D
ANNEX D (Informative)

15. ADDITIONAL RECOMMENDATIONS FOR TOWER CRANES
15.1 THOROUGH EXAMINATION OF TOWER CRANES
GENERAL- before first erection examined on the ground.Clean.Logical sequence top to bottom
RATED CAPACITY INDICATOR/LIMITE (RCI/L) CALIBRATION CHECK-within the tolerances
given, BS 7262- guidance on how to calibrate. Each 12 months. No loaded beyond 110 % of its
rated capacity.- mark radius/angle and not take load beyond that point.
EXAMINATION SCHEME APPROACH- Condition monitoring ISO 12482-1. Accordance with
usage. (condition monitoring)
SIX MONTHLY THOROUGH EXAMINATION- to lift person and lifting accessories
TWELVE MONTHLY THOROUGH EXAMINATION-not used to lift persons
ITEMS TO CHECK AT THE SPECIFIED PERIOD THOROUGH EXAMINATION
-Visual examine-Tower structure-cast-in anchors/cruciform
base/chassis/internal collar/grillage-distorsion, cracking, corrosion.
-Travelling base rail track
-Central ballast –mass and positioning
-All bolts, pins others fastenings- no loose
-Slewing mechanism- full range of movement
-All electrical cables
-All electrical enclosures
-All pipework on the crane
-All hydraulic cylinders
-Counter jib, slewing platform, a frame, trolley and jib
-Trolley rope breaks safety devices- check any bearing
and pivots freedom of action
-Counter ballast
-All pivoting joints on the jib and attachments
-All wire rope- reeved- end termination- BS7166
-All pulleys/sheaves and drums-guards
-Whole length of wire ropes
-All motors, drive coupling, gearboxes
-Braking mechanisms
-Access, ladders, hoops, walkways, rest platforms,
han rails/hand holds and safety line anchorages
-Oil and other fluid for condition
-Operator’s cab
-Fixing for the operator’s seat
-Cab windows
-All control are marked
-Upper and lower hoist limit switches
-Hook, their attachments and safety catches
-Rated capacities table showing in the cab
-Test all controls for smoothness
-Warning signs other important instructions- rating
plate for load lifting
-Checks all motions, limiters and safety devices
The minimum inspection criteria for examination of
climbing frame is given in Annex G-see next page

ANNEX G (INFORMATIVE)-CLIMBING FRAME

15.2 OVERLOAD TESTING OF TOWER CRANES
GENERAL- should be carried out after each erection, after reconfiguration (every 4 years for crane in same
site)
LEVELLING-the mast –vertical- Annex H gives typical foundation, pre-erection inspection certificate
LIFTING CAPACITIES- load ratings marked on tower crane- loads include weight of hook, not slings and lifting
gear.
OVERLOAD TEST
PREPARATION- checks withstand 25% overload/ position -level(rail-mounted-track,tyres, jacks)/ safe state and
condition
TEST PROCEDURE- functionally testd without load
-Trolley or jib at maximum radius-raise and lower load 100-200 mm above the ground-all motions
-Then load increase 25 %, hoisted and lowered 100-200mm – all motions
- Horizontal jib cranes- trolley at the maximum radius for the maximum capacity
-Travel on rail tracks- overload should be travelled the appropriate length
MAJOR REPAIR OR MODIFICATION- after-should be thoroughly examined
POST TEST EXAMINATION AND CERTIFICATION – like Annex D-report
NON-DESTRUCTIVE TESTING (NDT) OF TOWER CRANE-identification cracks or structures damaged by fatigue,
corrosion or overloading
15.3 INDICATOR TEST
GENERAL-not loaded beyond 110% of its rated capacity-Radius marked
HORIZONTAL JIBS WITH TROLLEYS- Test trolley brake, not less than 80% max rated capacity, clear the ground at
minimum radius and travelled slowly until indicator –warning. Radious between 90-97% of the rated capacity for that radius.
When radius is measured- load should be between 102.5-110% of the rated capacity
DERRICKING JIBS- 80-90% maximum rated capacity suspended at the minimum radius of the crane.The radius increase until
indicactor warning- When radius is measured- load 90-97.5%. Radius reduced slightly and the load increased until the load
cause an oveload warning-carfully hoisted from the ground. Load should be between 102.5-110%
REPEAT TEST- using weight midway between the maximum and minimum rated capacity for that
configuration of the crane.

ANNEX H (Informative)- Tower crane foundation pre-erection inspection certificate

16. ADDITIONAL RECOMMENDATIONS FOR LOADER CRANES
16.1 THOROUGH EXAMINATION OF LOADER CRANES
GENERAL-clean-an effective examination. Logical sequence, f.e. top to bottom- nothing is overlooked.
RATED CAPACITY INDICATOR/LIMITER (RCI/L) CALIBRATION CHECK- it is not part of overload testing. No
more than 12 momthly intervals. A load 10% overload at maximun extension lifted from the ground jib fully
extension and telescopic less than 90% of rated capacity. Increase radius until indicator warning-Radius
measured- load 90-97.5%, radius increase-overload warning. Load 102,5-110%. Then radius increased until
the telescopic extension fully- overload protection have operated
EXAMINATION SCHEME APPROACH-regular assessments in accordance with usage.
SIX MONTHLY THOROUGH EXAMINATION-lift persons and lifting accessories
TWELVE MONTHLY THOROUGH EXAMINATION
ITEMS TO CHECK AT THE SPECIFIED PERIOD THOROUGH EXAMINATION
-Sub frame-for damage, distortion, cracking and corrosion
-Tightness, all bolts and fastenings to attack crane to the sub frame, and sub frame to the lorry chassis
-Functional check- hand brake interlock– power disengages
-Functional check-height warning- prevention of collisions with bridges
-There is a label visible from operator’s seat displaying the travelling height
-Pipe connections between pump and crane, crane and oil tank (chafing,leakage,..)
-Level and condition of fluid in oil tank
-Visually crane control valve
-All control valve levers and marked with their function and mode of operation
-Functionally test all controls- smoothness of operation, and retur to neutral-release
-All manufacturers’ load plate(s) are firmly attached and readable-control position
-Check deploy stabilizers-cam locks and automatic latches on the beams
-Pipework on the loader crane
-Hydraulic cylinders for alignment, leakage, corrosion..
-Pivoting points. Structure.
-Telescopic extensions.
-Access.
-Operator’s seat and restraint
ADDITIONAL CHECKS FOR LOADER CRANES FITTED WITH WINCHES
-Hoist rope and reeved- instructions
-Pulleys/sheaves and drums- lubricated, damage.. And idler-all guards in place
-Entire length of the hoist rope
-Hoist limit switches
-Operate the loader crane to check all motions
- If loader crane capacity excess 1t or load moment 40.000 N·m it should be fitted with loading control, should be tested.

16.2 TESTING OF LOADER CRANES
GENERAL
Recommendations for periodic testing see Table 6
Test area.
Test the integrity of the crane and its mounting
To establish the stability of the loader crane.
Check the rated capacity quoted
Hydraulic oil be at normal operating temperature
A functinal test (no load) all controls operate correctly
LEVELLING-firm level ground, slope of no greater than +- 5%
STABILIZERS-fully extended to maximum spread, tyres correct pressure
LIFTING CAPACITIES- the weights of all additonal lifting equipment as part to the test load
LIFTING OF VEHICLE WHEELS AND STABILIZERS
TEST CONDITIONS- order overload test and after dynamic functional test
16.2.7-OVERLOAD TEST-according to the following formula
L= (KcP)+(0.1 Gb) L=test load/P=rated load/Gb=mass of the boom system point of load
attachment/Kc=test factor
Test at the following radii: max radius with special extensions/max radius attainable with hydraulic outreach/ one
intermediate radius/smallest practical radius. Each radius-should be slewed
Rated capacity indicator and overload protection system- be overriden or disconnected
16.2.8-DYNAMIC FUNCTIONAL TEST- system hidraulic and structural members to dynamic conditios and
fluctuating loads. Full range of travel. Test load rated 1.1 max. radius. Without interruption-speed range.
Decelerating valves- sudden arrest of moving suspended load. Audible and visual warnings occur-radius and load.
Temperature of the hydraulic oil. Overload protection.The main relief valve.
STRUCTURAL REPAIR OR MODIFICATION-be thoroughly examined
POST TEST EXAMINATION AND CERTIFICATION- Annex D, report
NON-DESTRUCTIVE TESTING (NDT) OF LOADER CRANES-crack or damage in structural parts.

Bs 7121 2º INSPECTION, TESTING AND EXAMINATION-CRANES

Bs 7121 2º INSPECTION, TESTING AND EXAMINATION-CRANES

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