Publishing and copyright information

The BSI copyright notice displayed in this document indicates when the document was last issued.

© The British Standards Institution 2025

Published by BSI Standards Limited 2025

ISBN 978 0 539 26547 7

ICS 53.020.20

The following BSI references relate to the work on this document:
Committee reference MHE/3/11
Draft for comment 24/30471992 DC

Foreword

Publishing information

This part of BS 7121‑2 is published by BSI Standards Limited, under license from the British Standards Institution, and came into effect on 31 July 2025. 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 of organizations represented on these committees can be obtained on request to the committee manager.

Supersession

This part of BS 7121‑2 supersedes BS 7121‑2‑4:2013, which is withdrawn.

Relationship with other publications

BS 7121 is published in the following parts:

Part 1: General
Part 2‑1: Inspection, maintenance and thorough examination − General
Part 2‑3: Inspection, maintenance and thorough examination − Mobile cranes
Part 2‑4: Inspection, maintenance and thorough examination of loader cranes
Part 2‑5: Inspection, maintenance and thorough examination − Tower cranes
Part 2‑7: Inspection, maintenance and thorough examination − Bridge and gantry cranes, including light crane systems
Part 2‑9: Inspection, maintenance and thorough examination − Cargo handling and container cranes
Part 3: Mobile cranes
Part 4: Lorry loaders
Part 5: Tower cranes
Part 7: Bridge and gantry cranes, including light crane systems
Part 11: Offshore cranes
Part 12: Recovery vehicles and equipment
Part 13: Hydraulic gantry lifting systems
Part 14: Side boom pipelayers

This part of BS 7121‑2 is intended to be used in conjunction with BS 7121‑2‑1.

Information about this document

This is a full revision of the document, and introduces the following principal changes:

alignment with BS 7121‑1:2016;
alignment with the content and format of other parts of BS 7121‑2;
the scope has been updated and clarified;
references have been updated throughout;
definitions have been expanded and improved, such as including timber handling and recycling cranes;
Table 1 has been added to aide understanding of the recommendations for periodic testing of lorry loaders;
provisions have been added covering facilities, services and test site conditions for thorough examinations;
provisions have been added regarding what to do if no machine history is available prior to thorough examination;
provisions have been added regarding what to do if safety systems are found deliberately overridden prior to thorough examination;
provisions have been added regarding the thorough examination of attachments;
recommended checks have been added to include the inspection and thorough examination of hydraulic rotating stabilizers throughout;
a clause has been added on running in;
a clause has been added on the functional test;
a clause has been added on the performance test;
an explanatory reason has been added for the purpose of each test clause;
the term “static” has been removed from “static overload” for improved clarity;
recommendations have been added for what to do upon the completion of testing and thorough examination;
recommendations have been added covering air suspension and lift axles during thorough examination;
clarification has been provided that non‑destructive testing (NDT) decisions can also be based on data logger information, not just crane age;
Annex A now recommends that pre‑use checklists include height warning/boom not stowed and stabilizer not stowed warnings; and
addition of recommendations from Association of Lorry Loader Manufacturers and Importers’ (ALLMI) GN010: Thorough examination and testing of loader cranes [1].

This publication can be withdrawn, revised, partially superseded or superseded. Information regarding the status of this publication can be found in the Standards Catalogue on the BSI website at knowledge.bsigroup.com, or by contacting the Customer Services team.

Where websites and webpages have been cited, they are provided for ease of reference and are correct at the time of publication. The location of a webpage or website, or its contents, cannot be guaranteed.

Hazard warnings

WARNING. — This part of BS 7121‑2 calls for the use of procedures that can be injurious to health if adequate precautions are not taken. It refers only to technical suitability and does not absolve the user from legal obligations relating to health and safety at any stage.

Use of this document

As a code of practice, this part of BS 7121‑2 takes the form of guidance and recommendations. It is not to be quoted as if it were a specification. Users are expected to ensure that claims of compliance are not misleading.

Users may substitute any of the recommendations in this part of BS 7121‑2 with practices of equivalent or better outcome. Any user claiming compliance with this part of BS 7121‑2 is expected to be able to justify any course of action that deviates from its recommendations.

It has been assumed in the preparation of this British Standard that the execution of its provisions will be entrusted to appropriately qualified and experienced people, for whose use it has been produced.

Presentational conventions

The provisions of this document are presented in roman (i.e. upright) type. Its recommendations are expressed in sentences in which the principal auxiliary verb is “should”.

Commentary, explanation and general informative material is presented in smaller italic type, and does not constitute a normative element.

The word “should” is used to express recommendations of this document. The word “may” is used in the text to express permissibility, e.g. as an alternative to the primary recommendation of the clause. The word “can” is used to express possibility, e.g. a consequence of an action or an event.

Notes and commentaries are provided throughout the text of this document. Notes give references and additional information that are important but do not form part of the recommendations. Commentaries give background information.

Where words have alternative spellings, the preferred spelling of the Shorter Oxford English Dictionary is used (e.g. “organization” rather than “organisation”).

Contractual and legal considerations

This publication has been prepared in good faith, however no representation, warranty, assurance or undertaking (express or implied) is or will be made, and no responsibility or liability is or will be accepted by BSI in relation to the adequacy, accuracy, completeness or reasonableness of this publication. All and any such responsibility and liability is expressly disclaimed to the full extent permitted by the law.

This publication is provided as is, and is to be used at the recipient’s own risk.

The recipient is advised to consider seeking professional guidance with respect to its use of this publication.

This publication is not intended to constitute a contract. Users are responsible for its correct application.

Compliance with a British Standard cannot confer immunity from legal obligations.

Particular attention is drawn to the following specific Acts and regulations:

Health and Safety at Work etc. Act 1974 [2];
Lifting Operations and Lifting Equipment Regulations (LOLER) 1998 [3];
Provision and Use of Work Equipment Regulations (PUWER) 1998 [4];
Supply of Machinery (Safety) Regulations 2008 (as amended) [5];
Road Vehicles (Construction and Use) Regulations 1986 (as amended) [6];
Road Traffic Act 1991 [7];
Work at Height Regulations 2005 (as amended) [8].
NOTE Details of LOLER 1998 [3] and PUWER 1998 [4] are provided in the HSE publications Safe use of lifting equipment. Lifting Operations and Lifting Equipment Regulations 1998. Approved code of practice [9] and Safe use of work equipment. Provision and Use of Work Equipment Regulations 1998. Approved code of practice and guidance [10].

Introduction

Loader cranes have traditionally been used to load and unload vehicles on which they are mounted and these vehicles, complete with the crane, are referred to as “lorry loaders”.

Loader cranes can be installed in a static location (e.g. on a quay, in a factory or on the roof of a building).

1 Scope

This part of BS 7121‑2 gives recommendations for the pre‑use checks, in‑service inspection, maintenance, thorough examination (in service and following exceptional circumstances) and supplementary testing of loader cranes.

This part of BS 7121‑2 also covers loader cranes fitted with attachments and interchangeable equipment that can be used in conjunction with loader cranes, such as brick grabs, muck grabs, augers, clamshells, pallet forks, wire rope hoists, fly jibs and manipulators. It does not cover detailed guidance on the pre‑use checks, in‑service inspection, maintenance, thorough examination of such attachments or interchangeable equipment.

This part of BS 7121‑2 does not cover the stability testing and certification immediately following installation of loader cranes on vehicles or in static locations.

NOTE Stability testing and certification immediately following installation of loader cranes on vehicles or in static locations is covered in BS EN 12999.

This part of BS 7121‑2 is applicable both to lorry loaders and to loader cranes used in other situations, such as static locations.

This part of BS 7121‑2 is not applicable to lorry loaders working from, or loader cranes mounted on, marine and other water‑borne vessels.

2 Normative references

3 Terms and definitions

4 General

5 Personnel carrying out pre‑use checks, in‑service inspections, maintenance and thorough examinations

6 Pre‑use checks and in‑service inspections

6.1 General

6.2 Pre‑use checks

6.3 In‑service inspection

6.4 Reporting of defects

6.5 Records of pre‑use checks and in‑service inspections

6.6 Inspection of second‑hand loader cranes

6.7 Checks when the loader crane is not in regular use

7 Maintenance of loader cranes

7.1 General

7.2 Maintenance intervals

7.3 Information for maintenance

7.4 Inspection during maintenance

7.5 Machine history files

7.6 Management review of maintenance records and procedures

7.7 Site issues for maintenance

7.8 Spare parts

7.9 Use of special materials in loader crane construction

8 Thorough examination of loader cranes

8.1 General

8.2 Selection of competent person to undertake thorough examination

8.3 Provision of facilities and services

8.4 Test site

8.5 Scope of thorough examination following installation

NOTE 1 For vehicle‑mounted loader cranes, it is industry practice for a thorough examination after installation to be completed (see 8.1).

The competent person who undertakes the thorough examination should decide the scope of the examination.

NOTE 2 Attention is drawn to Regulation 9(2)(a) of LOLER 1998 [3] in respect of safe and correct installation of the crane.

As a minimum, the examination should verify that the crane has been installed, checked and tested in accordance with the manufacturer’s instructions, including stability testing (see 8.10.6).

In the case of static mounted installations, such testing should also include verification that the foundation has been constructed to withstand the imposed loads and provide positive securement for the crane fastenings at the mounting points. The size of the foundation should not inhibit intended crane movements. The dimensions of the foundation in the ground should be designed to withstand the total imposed loads under relevant ground conditions.

8.6 Scope of periodic thorough examination

8.6.5 Scope of periodic thorough examination for cranes that remain in service beyond their design life

If a loader crane is to be used past the original design life (see 7.2.3), the defined scope of thorough examination should be reviewed and amended by the competent person, taking into account the crane service, maintenance and thorough examination history and the results of the assessment of additional life expectancy.

8.7 Periodic thorough examination interval

8.8 Thorough examination after exceptional circumstances

8.9 Preparation for thorough examination

8.10 Supplementary tests in support of thorough examination

9 Overload testing and dynamic testing of loader cranes and measurement of sink rate

9.1 Overload test

9.2 Dynamic test

9.3 Measurement of sink rate

9.4 End of testing

10 Non‑destructive testing of loader cranes to supplement thorough examination

11 Assessment of wire rope condition and discard criteria

Bibliography

BS 7121-2-4:2025

Safe use of cranes - Inspection, maintenance and thorough examination of loader cranes. Code of practice

Current

Published:

29 Jul 2025