GB/T 6067.1-2010Safety rules for lifting appliances - Part 1: General (English PDF)

Foreword

SAC/TC 227 is in charge of this English translation. In case of any doubt about the contents of English translation, the Chinese original shall be considered authoritative.

The GB/T 6067 consists of the following parts, under the general title Safety rules for lifting appliances: Part 1: General; Part 2: Mobile cranes; Part 3: Tower cranes; Part 4: Jib cranes; Part 5: Bridge and gantry cranes; Part 6: Cable cranes; Part 7: Series lifting equipment.

This part is Part 1 of the GB/T 6067. This part replaces the GB/T 6067-1985 Safety rules for lifting appliances in whole.

Compared with the GB/T 6067-1985, the main revisions are as follows: the safety requirements for lifting appliances and their parts are elaborated in detail and some of the requirements concerning product technology in the former edition of standard are deleted; the safety requirements for the marking, nameplates, safety signs, limiting sizes and clearances of lifting appliances are added; the operation management requirements for lifting appliances are added; the selection, responsibilities and minimum requirements of personnel are added.

The requirements for the safety, selection, sitting, erection and dismantling, operation, inspection, test, maintenance and repair as well as the safety assessment during in-service conditions of lifting appliances are added; the requirements for "special attachments for load handling" and "simple lifting equipment for common use" are deleted; Table 1 to Table 5, Table 7 to Table 15 and Table 16 (partial content) are deleted; Table 17 is changed to Table A.1.

Annex A of this part is normative. This part was proposed by China Machinery Industry Federation. This part was prepared by SAC/TC 227 National Technical Committee on Lifting Appliances of Standardization Administration of China.

The issued edition of the standard replaced by this part is as follows: GB/T 6067-1985.

1 Scope

China's umbrella safety code for lifting appliances, the general part that the other six parts of GB/T 6067 build on. Cranes kill people in ways that are depressingly repeatable - a weld that was never inspected, a hook without a latch, a rope run onto a drum with two grips instead of five, a driver who left the controls with a load in the air, a jib swung into a live overhead line - and the answer this standard takes is to write one document that follows a crane from the drawing board to the scrapyard. It specifies the basic safety requirements for the design, manufacture, erection, refurbishment, maintenance, operation, discard and inspection of lifting appliances, and applies to bridge and gantry cranes, mobile cranes, tower cranes, jib cranes, cable cranes and series lifting equipment as general requirements, the appliance-specific rules being left to the other parts; it does not apply to floating cranes, deck cranes and manned lifting equipment, though it may be used as a reference for other appliances where no basic safety problem is involved. The nineteen clauses run from metal structures, mechanisms and parts, hydraulic systems, electrical equipment, control systems and electric protection, through the safety protective devices and the marking, nameplates, safety signs and clearances, to the management of crane operation, the duties and minimum requirements of the appointed person, driver, slinger, signaller, erector and maintenance personnel, and then to safety, selection, siting, erection and dismantling, operation, inspection, test, maintenance and repair, and the safety assessment of an appliance already in service. A normative annex tabulates which safety protective devices - load limiters, lifting and travel limiters, buffers, wind-resistant and anti-skid devices, anti-collision devices and the rest - are required on each type of crane. The 2010 edition replaced GB/T 6067-1985 in whole: it elaborated the safety requirements, dropped much of the product technology of the old edition, and added the whole operational and personnel side that the 1985 text had left out.

This part of GB/T 6067 specifies the basic safety requirements for the design, manufacture, erection, refurbishment, maintenance, operation, discard and inspection of lifting appliances.

This part is applicable to bridge and gantry cranes, mobile cranes, tower cranes, jib cranes, cable cranes and series lifting equipment as general requirements. The requirements for specific lifting appliances are provided in other parts of GB/T 6067.

This part is not applicable to floating cranes, deck cranes and manned lifting equipment. If no basic safety problems are involved, this part may be used as reference for other lifting appliances.

2 Normative references

The following normative documents contain provisions which, through reference in this text, constitute provisions of this part of GB/T 6067. For dated references, subsequent amendments (excluding corrections), or revisions, of any of these publications do not apply to this part of GB/T 6067. However parties to agreements based on this part of GB/T 6067 are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. For undated references, the latest edition of the normative document referred to applies.

GB 2893 Safety colors; GB/T 3323 Radiographic examination of fusion welded joints in metallic materials; GB/T 3811-2008 Design rules for cranes; GB/T 4842 Argon; GB/T 5117 Carbon steel covered electrodes; GB/T 5118 Low alloy steel covered electrodes.

GB 5226.2-2002 Safety of machinery - Electrical equipment of machines - Part 32: Requirements for hoisting machines; GB/T 5293 Carbon steel electrodes and fluxes for submerged arc welding; GB/T 5905 Cranes - Test code and procedures; GB/T 5972 Cranes - Wire ropes - Care, maintenance, installation, examination and discard; GB/T 8110 Welding electrodes and rods for gas shielding arc welding of carbon and low alloy steel; GB 8918 Steel wire ropes for important purposes.

GB/T 10051.1, GB/T 10051.2 and GB/T 10051.3 Lifting hooks - Mechanical properties, lifting capacities, stresses and materials, Technical conditions of shank hook, and Inspection of shank hook in service; GB/T 12470 Low-alloy steel electrodes and fluxes for submerged arc welding; GB 15052 Cranes - Safety signs and hazard pictorials - General principles.

GB/T 17908 Cranes and lifting appliances - Technical characteristics and acceptance documents; GB/T 17909.1 Cranes - Crane driving manual - Part 1: General; GB/T 18453 Cranes - Maintenance manual - Part 1: General; GB/T 18875 Cranes - Spare parts manual; GB/T 19418 Arc-welded joints in steel - Guidance on quality levels for imperfections.

GB/T 20303.1 Cranes - Cabins - Part 1: General; GB/T 20652 Chain slings of welded construction - Grades M (4), S (6) and T (8); GB/T 20947 Short-link chain for lifting purposes - Grade T (Types T, DAT and DT), fine-tolerance hoist chain; GB/T 25196.1 Cranes - Condition monitoring - Part 1: General.

GB 50054 Code for design of low voltage electrical installations; GB 50058 Electrical installations design code for explosive atmospheres and fire hazard; HG/T 2537 Carbon dioxide for welding.

JB/T 6061 Non-destructive testing - Magnetic particle testing of welds; JB/T 6062 Non-destructive testing - Penetrant testing of welds; JB/T 10559 Non-destructive testing of lifting appliances - Ultrasonic testing of steel welds; JGJ 81 Technical specification for welding of steel structure of building; JGJ 82 Code for design, construction and acceptance of high strength bolts for steel structure.

3 Metal structures

3.1 General. 3.1.1 In design of the metal structures of lifting appliances, materials, structure types and construction measures shall be selected appropriately to meet the requirements on strength (including fatigue strength), stability, rigidity, safety during the transport, erection and operation process, as well as the requirements on fire resistance and corrosion protection. 3.1.2 In the design documents of metal structure, the grade of steel and type of connecting materials shall be specified; for important load bearing members, the mechanical property, chemical composition and other important properties of steel shall also be specified. Moreover, the required weld type and weld quality level shall be stated.

3.2 Materials. The steel for load-bearing structural members of lifting appliances shall be selected according to the requirements of 5.3 in GB/T 3811-2008.

3.3 Welding requirements for structural members. Manufacturers or erection and construction companies of metal structures shall formulate their own specification for welding of steel structures according to JGJ 81 or relevant standards, and shall carry out welding procedure qualification on the combination condition of various first-adopted parameters. The covered electrode model for manual welding shall be in compliance with mechanical properties of the base metal and shall meet GB/T 5117 or GB/T 5118; the welding wire shall meet GB/T 8110 or GB/T 5293; the argon for gas shielded arc welding shall meet GB/T 4842 with the purity no lower than 99.95 %, and the carbon dioxide in use shall meet HG/T 2537.

The weld quality levels of fully-penetrated melt welding joints shall meet the level requirements of Level-1, Level-2 and Level-3 in JB/T 10559. 100 % of level-1 welds shall be tested; where ultrasonic testing is adopted the qualification level shall reach the acceptance criteria of Level-1 weld in JB/T 10559, and where radiological testing is adopted the qualification level shall meet GB/T 3323 and shall be no lower than Level II. Level-2 welds may be conducted sampling inspection according to specific circumstances, with the corresponding Level-2 and Level III criteria; Level-3 welds may be sampled with the Level-3 ultrasonic criteria and no regulation for radiographic testing.

Surface crack detection shall be carried out when there may be cracks during visual inspection, or it is required in design documents, or inspectors consider it is necessary to do so. The magnetic particle testing shall meet the requirements of JB/T 6061 while the penetrant testing shall meet those of JB/T 6062. The quality levels for defects of arc welding joints in steel shall meet Level B, Level C and Level D in GB/T 19418 for level-1, level-2 and level-3 welds respectively.

Welders shall pass the examination held by authorized departments and their certificate of qualification shall be within the period of validity, and the certificate holders shall conduct welding within the recognized scope of items. Level-1 welds shall be traceable after welding. The personnel for non-destructive testing of welds shall have the corresponding qualification; the report compiling personnel and the issuing personnel shall have Grade II (or above) qualification certificate for corresponding inspection methods. Welding quality inspectors shall receive training on the manufacturing, inspection and testing of metal structures and shall obtain corresponding qualifications.

3.4 Connection with high strength bolts. The design, construction and acceptance of high strength bolt connection shall meet the requirements of JGJ 82. The contact surfaces of connected members connected by a high strength bolt shall be treated in accordance with the design requirements, and shall be kept dry, clean and free of flash, burr, spatter, welding scar, iron scale, dirt, etc. There shall be no painting on the contact surfaces unless required in the design. The high strength bolts shall be tightened up with a torque spanner or a special tool according to the erection instructions of lifting appliances. The torque spanner shall be calibrated regularly and the calibration shall be recorded. The high strength bolts shall have tightening records.

3.5 Cabins. The crane cabins shall meet the requirements of GB/T 20303.1. When the jib luffing or the jib and load falling may affect safety of the cabin, it shall not be set right below the lifting jibs. When the cabins are threatened by potential falling loads, the top of cabins shall be provided with effective protection. Cabins of enclosed construction should be adopted to operate cranes outdoors or indoors without any heating (excluding favorable climate conditions). If cranes are operated under high temperature or environment with vapor, dust, toxic or harmful gas, well-sealed cabins of enclosed construction with clean air shall be adopted. If cranes are operated indoors with heating, or cranes are seldom operated as an auxiliary, open cabins may be adopted, which shall be fitted with a guard rail of at least 1 m high.

Unless under extreme weather conditions, the operating temperature of cabins in service should be kept between 15 degrees C and 30 degrees C. Cabins shall be equipped with the emergency exit. Where the windows of cabins are located less than 1 m above the floor, glass windows shall be installed in such way that they cannot be opened or shall be protected; the protection height shall not be lower than 1 m; glass windows shall be made of toughened glass or equivalent materials. The cabin floor shall have a slip resistant surface made of non-metal and thermal insulating material. The illuminance on the working face of cabins shall not be less than 30 lx. There shall be eye-catching display on important operation indicators.

3.6 Access and platforms. As for operation positions and positions requiring frequent inspection and maintenance (including sheaves on the top of jibs and moving parts) on cranes, the positions over 2 m above the ground shall be accessible through inclined ladders (or stairs), platforms, access or vertical ladders, and both sides of the steps shall be provided with guard rails. No matter where cranes are located, access, inclined ladders (or stairs) and platforms shall be provided with emergency exit.

3.9 Repair and discard of metal structures. Main load-bearing members that lose the overall stability shall be discarded rather than repaired. Where the main load-bearing members are affected by corrosion, inspection and measurement shall be carried out; where the corroded section of main load-bearing members reaches 10 % of the design thickness, they shall be discarded if cannot be repaired. When cracks appear on main load-bearing members, measures shall be taken based on the load and crack conditions to prevent cracks from further development; measures shall also be taken to strengthen these members or change the stress distribution in them, or stop using those load-bearing members. When working mechanisms cannot operate safely and normally due to plastic deformation of main load-bearing members, these members shall be discarded if cannot be repaired.

4 Mechanisms and parts

4.1 Mechanisms. Constitution and layout of mechanisms of lifting appliances shall meet the operation requirements and ensure safety and reliability. Selection and calculation of parts shall meet the relevant requirements of GB/T 3811. The lifting mechanism shall be capable of lifting and lowering rated loads stably in accordance with the specified operating mode; as for the lifting mechanism used for handling molten metal and other hazardous materials, each set of independent driving device shall be equipped with two support brakes, and for the lifting mechanism with extra high safety requirements a safety brake shall be installed additionally.

4.2.1 Wire ropes. Where wire ropes are connected by grips, the requirements of Table 1 shall be met and the connection strength shall be no less than 85 % of the minimum breaking force of the wire rope; Table 1 requires at least 3 grips for nominal rope diameters up to 19 mm, 4 from 19 mm to 32 mm, 5 from 32 mm to 38 mm, 6 from 38 mm to 44 mm and 7 from 44 mm to 60 mm, with the grip saddle located at the load-bearing side and the spacing between every two grips not less than 6 times the rope diameter. Where wire ropes are connected by splicing, the splicing length shall not be less than 15 times the rope diameter and no less than 300 mm, and the connection strength no less than 75 % of the minimum breaking force; the wedge and wedge socket connection also gives 75 %, the cone sleeve by casting method shall reach the minimum breaking force, and the aluminum-alloy sleeve by compression method shall reach 90 %. The care, maintenance, erection, inspection and discard of wire ropes shall meet the relevant requirements of GB/T 5972.

4.2.2 Lifting hooks, hook jackets and other lifting load attachments. The mechanical property, lifting capacity, stress and materials for forged hooks shall meet the requirements given in GB/T 10051.1. Cast hooks shall not be used in lifting appliances. When the application condition or operation approach may cause unexpected hook slippage of load, the hook with safety latch shall be adopted; when there is a risk that the hook may be caught by other objects during the lifting process, the safety hook or other effective measures shall be adopted.

4.2.4 Drums. Rope anchorage on the drum shall be safe and reliable, and shall be capable of anti-loosening or self-tightening. If the wire rope ends are fixed with press plates, the fixing strength shall not be less than 80 % of the minimum breaking force of wire ropes. It shall be clamped with at least two spaced press plates, and the press plates shall be reliably fixed with bolts. The circumferential and longitudinal butt welds on the welded drum body shall be subjected to nondestructive testing after visual inspection. The drum shall be discarded if surface defects affecting performance occur, or the wall abrasion of drum reaches 20 % of the original wall thickness.

4.2.5 Sheaves. The sheave shall be equipped with devices or structures to prevent wire ropes from detaching the sheave groove. The gap between the sheave and the side plate or the top plate of circular arc of shield shall not exceed 0.5 times the nominal diameter of wire rope. The sheave block accessible by hands shall be equipped with shield. The sheave shall be discarded if surface defects affecting performance occur, the non-uniform abrasion of sheave groove reaches 3 mm, the wall abrasion of sheave groove reaches 20 % of the original wall thickness, or the bottom diameter decrement of sheave groove reaches 50 % of the wire rope diameter due to abrasion.

4.2.6 Brakes. The lifting, luffing, travelling and slewing mechanisms of power-driven cranes shall be provided with reliable brake devices (excluding those driven by hydraulic cylinders).

4.2.8 Transmission gears. If no discard criteria are provided for the transmission gear in the maintenance instruction, it shall be discarded when the plastic deformation of gear teeth causes the peak or valley of tooth flank higher or lower than 20 % of the gear teeth modulus of theoretical tooth profile; the fracture of gear teeth is greater than or equal to 1/5 of the facewidth and the crack of gear teeth is greater than or equal to 1/8 of the facewidth; the pitting area of tooth flank reaches 50 % of the working area of gear teeth; the cementing area reaches 20 % of the working area of tooth flank and the depth of cement groove reaches modulus 0.1; or the sum of abrasion losses on both sides of the tooth roots of hoisting and unbalanced luffing mechanisms reaches modulus 0.1 and that of other mechanisms reaches modulus 0.15.