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TRANSCRIPT
AS 2550.1—1993
Australian Standard�
Cranes—Safe use
Part 1: General requirements
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This Australian Standard was prepared by committee ME/5, Cranes. It was approved onbehalf of the Council of Standards Australia on 2 July 1993 and published on 13 September1993.
The following interests are represented on Committee ME/5:
A.C.T. Occupational Health and Safety Office
Association of Consulting Engineers, Australia
Australian Chamber of Manufactures
Australian Institute of Building
Bureau of Steel Manufacturers of Australia
Construction and Mining Equipment Association of Australia
Crane Industry Council of Australia
Department of Defence (Commonwealth)
Department of Employment, Industrial Relations and Training, Tas.
Department of Employment, Vocational Education, Training & Industrial Relations, Qld.
Department of Labour, S.A.
Department of Occupational Health, Safety and Welfare, W.A.
Electricity Supply Association of Australia
Institution of Engineers, Australia
Lift Manufacturers Association of Australia
Maritime Services Board of New South Wales
Metal Trades Industry Association of Australia
Occupational Health and Safety Authority, Vic.
Port of Melbourne Authority
Public Works Department, N.S.W.
Railways of Australia Committee
Telecom Australia
University of New South Wales
Water Board, Sydney—Illawarra—Blue Mountains
WorkCover Authority, N.S.W.
Work Health Authority, N.T.
Review of Australian Standards. To keep abreast of progress in industry, Australian Standards are subject toperiodic review and are kept up to date by the issue of amendments or new editions as necessary. It is importanttherefore that Standards users ensure that they are in possession of the latest edition, and any amendments thereto.
Full details of all Australian Standards and related publications will be found in the Standards Australia Catalogueof Publications; this information is supplemented each month by the magazine ‘The Australian Standard’, whichsubscribing members receive, and which gives details of new publications, new editions and amendments, and ofwithdrawn Standards.
Suggestions for improvements to Australian Standards, addressed to the head office of Standards Australia, arewelcomed. Notification of any inaccuracy or ambiguity found in an Australian Standard should be made withoutdelay in order that the matter may be investigated and appropriate action taken.
This Standard was issued in draft form for comment as DR 91157.
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AS 2550.1—1993
Australian Standard�
Cranes—Safe use
Part 1: General requirements
First published as part of AS CB2—1938.Second edition 1960.Revised and redesignated in part as AS 1418.1—1977.Revised and redesignated in part as AS 2550—1982.Revised and redesignated in part as AS 2550.1—1993.
Incorporating:Amdt. 1–1995
PUBLISHED BY STANDARDS AUSTRALIA(STANDARDS ASSOCIATION OF AUSTRALIA)1 THE CRESCENT, HOMEBUSH, NSW 2140
ISBN 0 7262 8388 6
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PREFACE
This Standard was prepared by the Standards Australia Committee on Cranes, to supersede, in part,AS 2550—1982, Cranes—Mobile, tower and derrick—Selection and operation.
This Part 1 of Cranes—Safe use, covers requirements which apply generally to cranes and similar liftingappliances. Specific requirements for Cranes—Safe use will be covered by subsequent parts.
It is intended to publish the following parts:
(a) General requirements
(b) Tower cranes
(c) Mobile and vehicle–loading cranes
(d) Guided storing and retrieving appliances
(e) Builders hoists and equipment
(f) Special purpose appliances
(g) Vehicle hoists
(h) Elevating work platforms
(i) Building maintenance units
(j) Concrete placing equipment
(k) Mast work platforms
� Copyright — STANDARDS AUSTRALIA
Users of Standards are reminded that copyright subsists in all Standards Australia publications and software. Except where the Copyright Act allows andexcept where provided for below no publications or software produced by Standards Australia may be reproduced, stored in a retrieval system in any formor transmitted by any means without prior permission in writing from Standards Australia. Permission may be conditional on an appropriate royaltypayment. Requests for permission and information on commercial software royalties should be directed to the head office of Standards Australia.
Standards Australia will permit up to 10 percent of the technical content pages of a Standard to be copied for use exclusively in–house bypurchasers of the Standard without payment of a royalty or advice to Standards Australia.
Standards Australia will also permit the inclusion of its copyright material in computer software programs for no royalty payment provided suchprograms are used exclusively in–house by the creators of the programs.
Care should be taken to ensure that material used is from the current edition of the Standard and that it is updated whenever the Standard is amended orrevised. The number and date of the Standard should therefore be clearly identified.
The use of material in print form or in computer software programs to be used commercially, with or without payment, or in commercial contracts is subjectto the payment of a royalty. This policy may be varied by Standards Australia at any time.
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CONTENTSPage
SECTION 1 SCOPE AND GENERAL 1.1 SCOPE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 APPLICATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REFERENCED DOCUMENTS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 DEFINITIONS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 PLANNING 2.1 GENERAL 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 MATTERS TO BE CONSIDERED 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 SELECTION 3.1 GENERAL 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 SITING 4.1 GENERAL 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 CRANE STANDING 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 PROXIMITY HAZARDS AND VISIBILITY 10. . . . . . . . . . . . . . . . . . . . . . . 4.4 ENVIRONMENTAL RESTRICTIONS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 CLEARANCES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 PERSONNEL 5.1 MANAGEMENT 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 CRANE OPERATORS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 CRANE CHASERS AND DOGMEN 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 ALCOHOL AND DRUG USAGE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 ERECTION AND DISMANTLING 6.1 IDENTIFICATION OF CRANE COMPONENTS 13. . . . . . . . . . . . . . . . . . . . 6.2 INSTRUCTIONS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 ELECTRICAL SUPPLY 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 CORRECT FUNCTION OF SAFETY DEVICES 13. . . . . . . . . . . . . . . . . . . .
SECTION 7 OPERATION 7.1 OPERATING INSTRUCTIONS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 PRE–OPERATION CHECKS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 COMMUNICATION OF IRREGULARITIES 14. . . . . . . . . . . . . . . . . . . . . . . 7.4 LEAVING THE CRANE UNATTENDED 14. . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 ABNORMAL NOISE OR MOVEMENT 15. . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 HOUSEKEEPING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 ACCESS ONTO A CRANE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 PERSONS APPROACHING THE PROXIMITY OF A CRANE 15. . . . . . . . . 7.9 CRANE OPERATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10 CONTROL OF LOAD 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 TAG LINES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Page 7.12 COMMUNICATION 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13 HANDLING LOADS OVER PUBLIC ACCESS AREAS AND
ADJACENT BUILDINGS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14 LOADS SUPPORTED BY MAGNETIC, VACUUM AND FRICTION
LIFTING ATTACHMENTS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15 RIDING ON THE CRANE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 SUSPENSION OF PERSONS BY CRANE 19. . . . . . . . . . . . . . . . . . . . . . . . . 7.17 OPERATION NEAR AERIAL CONDUCTORS (OVERHEAD POWER
LINES) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 OPERATION NEAR UNDERGROUND LIVE CONDUCTORS 23. . . . . . . . 7.19 MULTIPLE CRANE OPERATION 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20 SPECIAL DUTIES 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21 WEATHER CONDITIONS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 ACCIDENT OR DAMAGE 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 MODIFICATIONS TO CRANES 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24 NECESSARY EQUIPMENT 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25 GUARDING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26 LOAD RATING CHARTS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27 LOAD TESTING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 MAINTENANCE, INSPECTION AND REPAIR 8.1 GENERAL 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 INSPECTION 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 MAINTENANCE AND REPAIR 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 ROPES, HOOKS AND ATTACHMENTS 9.1 ROPES 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 HOOKS AND HOOK BLOCKS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 ATTACHMENTS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPENDICES A SAFE BEARING PRESSURE FOR CRANE OUTRIGGERS 32. . . . . . . . . . . . B ROUTINE CHECKS FOR CRANES 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C SAFE WORK PROCEDURES FOR THE MAINTENANCE AND
THE INSPECTION OF CRANES 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D RECOMMENDED MINIMUM SERVICE REQUIREMENTS
FOR CRANES 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E STANDARDS FOR COMPONENTS USED IN LIFTING SYSTEMS 37. . . . .
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5 AS 2550.1 — 1993
STANDARDS AUSTRALIA
Australian Standard
Cranes—Safe use
Part 1: General requirements
S E C T I O N 1 S C O P E A N D G E N E R A L
1.1 SCOPE This Standard specifies the general requirements for cranes, hoists andwinches.
Except as given in Clause 7.20.4(a), it does not include requirements for cranes, hoistsand winches mounted on waterborne vessels.
NOTE: Where this Standard uses the word ‘crane’ it shall be taken to mean ‘hoist’ or ‘winch’as applicable.
1.2 APPLICATION This Standard specifies the general requirement for the safe useof all cranes as covered by AS 1418.
Specific usage for different types of cranes is specified in the additional parts of AS 2550,except for those cranes detailed in AS 1418, Parts 2 and 3; that information is containedonly in this Standard.
1.3 REFERENCED DOCUMENTS The following documents are referred to in thisStandard:
AS1418 SAA Crane Code1418.1 Part 1: General requirements
1801 Industrial safety helmets
1891 Industrial safety belts and harnesses
2076 Wire rope grips
2549 Cranes—Glossary of terms
2759 Steel wire rope—Application guide
3000 SAA Wiring Rules
4024 Safeguarding of machinery4024.1 Part 1: General principles*
NOHSC (National Occupational Health and Safety Commission)National Standard and National Code of Practice for Noise Management andProtection of Hearing at Work
* First published as an Interim Standard.
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AS 2550.1 — 1993 6
1.4 DEFINITIONS For the purpose of this Standard, the definitions given in AS 2549and those below apply.
1.4.1 Competent person—a person who by reasons of qualifications and experience hasthe knowledge and skill necessary to perform the duties with respect to which theexpression is used.
1.4.2 Management—persons responsible for the direction of all activities associatedwith the operation of a crane.
1.4.3 Management’s instructions—shall include the manufacturer’s latest instructions,recommendations and specifications. Where any of these instructions, recommendationsand specifications are not available from the manufacturer, they shall be drawn-up by acompetent person.
1.4.4 Shall—indicates that a statement is mandatory.
1.4.5 Should—indicates a recommendation.
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7 AS 2550.1 — 1993
S E C T I O N 2 P L A N N I N G
2.1 GENERAL The planning and application of crane requirements should commenceas early as possible in the development of each project.
Where cranes are required to operate in or near new buildings or structures, craneloadings and access should be considered at the project design stage.
Wherever practicable, the planning should include consultation with the cranemanufacturer and proprietor.
2.2 MATTERS TO BE CONSIDERED At appropriate stages during planning, thefollowing matters shall be considered, where applicable:
(a) Establishment of a management plan.
(b) Selection of cranes (see Section 3).
(c) Obtaining authorizations.
(d) Requirements of regulatory authorities.
(e) Site access and crane siting.
(f) Protection and safety of public.
(g) Proximity of power lines and other services.
(h) Procedures for the setting up and dismantling of the crane and the method of lift.
(i) Make up of the crane crew, which may include—
(i) erection crew;
(ii) crane operator;
(iii) dogmen and crane chasers;
(iv) spotters;
(v) riggers;
(vi) power line observers; and
(vii) persons under training or instruction.
(j) Communication system.
(k) Weather conditions.
(l) Ground conditions.
(m) Proximity of excavations.
(n) Selection of lifting gear.
(o) Personal safety equipment.
(p) Emergency procedures.
(q) Inspection, maintenance, and repair.
(r) Lightning protection.
(s) The documentation of work procedures where the lifting operation is not of aroutine type, e.g. multiple crane lifting.
(t) Consultation and coordination with other groups working in the area.
(u) Night operations.
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AS 2550.1 — 1993 8
S E C T I O N 3 S E L E C T I O N
3.1 GENERAL Before selecting a crane for a particular operation, the followinginformation shall be ascertained:
(a) The mass of the load to be lifted.
(b) The nature of the load to be lifted.
(c) The speed and frequency of operation.
(d) The maximum load that will be imposed on the crane.
(e) The nature of the rigging or slinging to be used.
(f) The position from which the load is to be lifted.
(g) The position to which the load is to be placed.
(h) The movement limitations of the crane and the load.
(i) Other limitations of the crane.
(j) Where multiple crane lifting is involved—
(i) how the load is to be proportioned;
(ii) how the load proportioning is to be maintained;
(iii) whether the cranes have the appropriate additional capacity over theproportioned load to be lifted; and
(iv) the operating characteristics of the crane, e.g. speed of hoisting.
(k) The environmental factors.
The danger of instability due to loss of inflation of a tyre should be considered. Forexample, foam-filled tyres should be used for rough terrain.
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9 AS 2550.1 — 1993
S E C T I O N 4 S I T I N G
4.1 GENERAL Where applicable, particular attention shall be given to the followingfactors:
(a) Crane standing (see Clause 4.2).
(b) Proximity hazards and visibility (see Clause 4.3).
(c) Environmental factors, e.g. noise and noxious fumes (see Clause 4.4).
(d) Clearances (see Clause 4.5).
4.2 CRANE STANDING
4.2.1 General The analysis of the forces imposed by a crane on the crane standing is avitally important factor. The crane standing shall conform to the crane manufacturer’srecommendations and shall be of sufficient strength to withstand both the in-serviceconditions and the out-of-service conditions.
Where a crane is to be supported on, or tied to, a permanent or temporary structure, thedesign of the structure shall be checked to confirm that it is capable of withstanding theforces likely to be imposed by the crane. In the assessment of the surface-bearingcapacity, seasonal variations shall be considered.
NOTE: Guidance on outrigger safe-bearing capacity on soils is given in Appendix A.
4.2.2 Wind force The wind forces on cranes may have a considerable influence on thestability and strength requirements of the supports and foundations. Therefore, care isnecessary in the installation of holding-down devices, rail clamps, temporary connectionsand anchorages.
Where there is a likelihood of the maximum wind speed specified by the manufacturerbeing exceeded, the management’s operating instructions shall include positive directionsto ensure that the crane is stowed in a safe position, and not operated during the periodwhen the wind speed exceeds the manufacturer’s specifications.
4.2.3 In-service conditions During in-service conditions, the loads imposed on thecrane standing are usually due to the combined effects of the following:
(a) Mass of the crane including the counterweight.
(b) Mass of the load and attachments.
(c) Dynamic forces caused by the crane and load movements during operation.
(d) Wind forces, resulting from operation in wind speed up to the maximum permittedfor in-service conditions, acting in any direction on the crane and load.
4.2.4 Out-of-service conditions When the crane is in an out-of-service condition, theloads expected to be imposed on the crane standing are usually due to the combinedeffects of the following:
(a) Mass of the crane including the counterweight.
(b) Wind forces, acting in any direction on the crane, due to the maximum wind speedsexpected on the particular site.
4.2.5 Underground services Where a check reveals the existence of undergroundservices, adequate precautions shall be taken to ensure the stability of the crane.
4.2.6 Stability on crane standing Where a crane is required to work in the vicinity ofan excavation or an embankment, particular care and appropriate precautions shall betaken. The mass of the crane and the load may affect the excavation or the embankment,and a slip may occur causing the crane to tip.
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AS 2550.1 — 1993 10
4.3 PROXIMITY HAZARDS AND VISIBILITY
4.3.1 Proximity hazards Consideration shall be given to the presence of proximityhazards such as—
(a) overhead power lines;
(b) nearby built structures or other cranes; and
(c) public access areas including roadways, railways, rivers and aircraft flight paths.
In some situations, aircraft warning lights are required to be fitted to the top of cranes andthe jib and the boom sections are required to be painted specific colours. Therecommended colours for maximum visibility are alternating bands of international orangeand white.
4.3.2 Visibility The crane should be sited in such a way that the crane driver alwayshas optimum visibility.
4.4 ENVIRONMENTAL RESTRICTIONS Precautions should be taken against theeffects of noise and exhaust gases emitted by cranes sited in a building or other enclosedspace, as well as other environmental factors.
4.4.1 Noise
4.4.1.1 Noise managementThe National Standard and National Code of Practice forNoise Management and Protection of Hearing at Work provides a framework formanagement of noise in the workplace. This document should be referred to whenplanning a noise management strategy in a workplace.
In addition to the general principles of hazard control, the recognition and understandingof the effects of noise are an important part of strategy for noise control. This becomesmore important when personal protective measures are required.
4.4.1.2 Noise exposure criteria The maximum allowable exposure to noise in theworkplace is the level specified in the National Occupational Health and SafetyCommission, National Standard and National Code of Practice for Noise Management andProtection of Hearing at Work, or other requirements of the regulatory authority.
4.4.1.3 Noise control A comprehensive program should be developed to plan andimplement the actions to be taken in noise control. The hierarchy of noise control shouldconsider—
(a) the elimination or reduction of noise at source;
(b) the control of noise transmission from source;
(c) job redesigning to minimize employee numbers and duration of exposure; and
(d) personal hearing protection.
4.4.2 Noxious fumes Regulations restrict both the road and site use of cranes whichproduce excessive exhaust fumes or other pollutants.
4.5 CLEARANCES When setting up a crane, the clearance for persons betweenmoving parts of the crane and fixed structures or other natural or built objects shall be asfollows:
(a) Clear width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . notless than 500 mm.
(b) Vertical clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . notless than 2000 mm.
Where these clearances cannot be maintained, then suitable provisions shall be made toexclude persons from any potential trapping spaces.
Clearance between two or more cranes working within a site, or sharing the same airspace shall be included in a procedure to ensure contact between parts of the cranes doesnot occur. Agreement shall be reached on adjoining sites.
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11 AS 2550.1 — 1993
S E C T I O N 5 P E R S O N N E L
5.1 MANAGEMENT Management’s responsibilities concerning each crane, shall beclearly understood and written down as a policy statement, which shall be readilyavailable. The policy shall enhance the effectiveness of the management’s efforts toprevent accidents.
Management’s responsibilities shall cover the following matters:
(a) The planning, selection and control of each crane.
(b) Ensuring that sufficient qualified and trained personnel and suitable equipment areavailable for the operation.
(c) The transport and setting up of the crane.
(d) The operation of cranes by competent and trained personnel.
(e) The supply and maintenance of the crane logbook.
(f) The proper maintenance of the crane and associated equipment, incorporating theuse of the logbook as necessary.
(g) The preparation and maintenance of instructions for the assembly, operation,maintenance and inspection of the crane (see Clause 7.1).
(h) Ensuring each crane to be used has been designed and installed in accordance withrelevant Standards and complies with the requirement of the regulatory authority.
(i) After those years of service covering the design life of the crane or where this isunknown, 25 years for the structure and 10 years for the mechanical components,the installation should be examined and assessed by a competent person to ensurethat the installation or plant is suitable for continued safe operation.
When assessing the suitability of the crane for future use, consideration should begiven to—
(i) the use of the manufacturer’s expertise and recommendations*;
(ii) initial design and theoretical life;
(iii) actual past usage of the crane;
(iv) the condition of the crane; and
(v) anticipated future use.
(j) Where a crane is upgraded, the complete installation or plant shall conform to therequirements of the relevant current Australian Standards.
(k) Where a fixed position crane (rail-mounted or structure-mounted) is changed inlocation, recognition should be given to the regulatory authority’s possiblerequirement to upgrade the installation to the requirements of the most recentAustralian Standards.
(l) The crane operator and the person charged with the supervision of the cranageoperation shall each be not less than 18 years of age.
(m) The selection and use of personal protective equipment.
* In all cases of complex mechanical assemblies, for example, gearboxes, the examination should be carriedout by the manufacturer wherever practicable.
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AS 2550.1 — 1993 12
5.2 CRANE OPERATORS
5.2.1 Qualifications The qualifications of crane operators shall conform to therequirements of the applicable regulatory authority.
5.2.2 Authorization Each crane operator shall be in possession of a certificate ofcompetency where applicable, and be authorized by a responsible representative of thecrane user or hiring contractor to operate the particular crane.
5.2.3 Physical and mental fitness of crane operator The crane operator shall notoperate a crane unless he or she is physically and mentally capable. In the event of acrane operator becoming unwell when in control of a crane, the operator shall render thecrane out-of-service and report the matter to the supervisor. When the operator is in thecontrol cabin of a crane and is too incapacitated to descend safely from the crane, theoperator should indicate his or her condition and wait in the crane cabin for help to arrive.
5.3 CRANE CHASERS AND DOGMEN
5.3.1 Qualifications The qualifications of the crane chasers and the dogmen shallcomply with the requirements for certification of the applicable regulatory authority.
5.3.2 Authorization Each crane chaser and dogman shall be in possession of anappropriate certificate of competency and be authorized by a responsible representative ofthe crane user or hiring contractor to work with the particular crane.
5.3.3 Identification The person directing the crane movement (crane chasers anddogmen) should be readily identifiable to the crane operator.
5.4 ALCOHOL AND DRUG USAGE Persons working with cranes shall avoid the useof alcohol and drugs which may have a detrimental effect on their performance.
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S E C T I O N 6 E R E C T I O N A N D D I S M A N T L I N G
6.1 IDENTIFICATION OF CRANE COMPONENTS Where necessary, componentsof cranes subject to frequent erection and dismantling shall be clearly marked to preventincorrect site assembly. Any component with a mass greater than 250 kg should bemarked with its mass.
The materials of construction of the major components and special fasteners involved insite assembly shall be recorded. Where practicable, this information should be marked onthe components.
6.2 INSTRUCTIONS (see Clause 7.1.) Management’s instructions shall be strictlyfollowed. Any departure from the specified procedures may impose excessive loading onstructural and mechanical parts. Adherence to the following is required:
(a) Management’s instruction book shall be available to the erection staff.
(b) The erection or dismantling operation shall be supervised by a competent person.
(c) The erection staff shall be familiar with the prescribed procedures.
(d) The prescribed procedures for the assembly of components shall be followed in thecorrect sequence, using the correct equipment and tools.
(e) Only parts and components meeting the manufacturer’s performance and strengthrequirements shall be used.
(f) It is recommended that jib or boom jointing pins be assembled so that they can beremoved by a person standing on the outside of the jib or boom. Jibs and boomsmay collapse if incorrectly assembled.
6.3 ELECTRICAL SUPPLY Installation of the electrical supply shall be inaccordance with AS 3000 and the appropriate Part, Sections and Clauses of AS 1418.
6.4 CORRECT FUNCTION OF SAFETY DEVICES During erection anddismantling operations, it is sometimes necessary to disconnect or bypass load momentsystems, overload cutouts or motion limit switches. Before the crane is put into service,the person supervising erection of the crane shall ensure that all safety devices arefunctioning correctly.
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AS 2550.1 — 1993 14
S E C T I O N 7 O P E R A T I O N
7.1 OPERATING INSTRUCTIONS The employer’s operating instructions for eachcrane shall incorporate the manufacturer’s latest recommendations and be clearlyidentified to the crane by reference to the manufacturer’s serial number, or the owner’splant number, or by a clear description which identifies the crane. Where themanufacturer’s operating instructions are not available, then suitable operating instructionsshall be compiled by a competent person. The operating instructions manual shall bereadily available to the operator.
7.2 PRE-OPERATION CHECKS Before commencing operations, the crane operatoror other authorized person shall carry out routine checks in accordance with the operatinginstructions which shall be sufficient to ensure the safe operation of the crane.
NOTE: A typical check list is given in Appendix B.
Before placing a crane in service, the crane operator shall review the logbook and besatisfied about—
(a) the absence of all unauthorized personnel on the crane, e.g. maintenance personnel;
(b) the safe working condition of the crane;
(c) the safe operation of each motion of the crane; and
(d) the satisfactory condition and inflation of tyres, where applicable.
Where any adjustments or alterations are necessary to ensure the safe operation andfunctional operation of the crane, these shall be carried out by authorized personnel.
7.3 COMMUNICATION OF IRREGULARITIES When going off duty an operatorshall communicate and enter into the logbook all pertinent details of the crane’sperformance, particularly any irregularities concerning the operation of the crane and ofall incidences concerning the safe operation of the crane in any way whatsoever.
7.4 LEAVING THE CRANE UNATTENDED A crane shall not be left unattended,even for short periods, unless the following actions have been taken:
(a) All loads have been removed from the hook.
(b) The hook shall be raised to a position where it is safely clear of other operations, orhooked back or otherwise secured.
(c) Where applicable, the electric power supply shall be switched off.
(d) Appropriate motion brakes and locks have been applied to put the crane in a safecondition.
(e) For longer periods and for out-of-service conditions, isolation shall be made morepermanent by taking both the actions noted above and the following actions:
(i) Cranes shall be positioned at their assigned parking stations and stowed intheir specific out-of-service configuration.
(ii) Power supply shall be locked off.
(iii) Storm anchors shall be engaged where applicable.
(iv) Fuel supplies shall be turned off and the engine stopped where applicable.
(v) All doors and windows giving access to machinery or control cabins shall belocked to prevent unauthorized access.
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(vi) Remote control equipment shall be isolated with locking key removed whereapplicable.
Means shall be provided and used to prevent unauthorized operation of the crane duringthe crane operator’s absence. For details of methods to safeguard particular types ofcranes, reference should be made to the operating instructions.
7.5 ABNORMAL NOISE OR MOVEMENT When any abnormal noise or movementoccurs during crane operation, the crane shall be taken out-of-service, and the incidententered into the logbook and reported to management.
7.6 HOUSEKEEPING Each crane shall be kept as clean as is practicable. Looseobjects shall not be left on moving parts of the crane. Grease and oil spills, debris andother materials which may cause a hazard shall be removed from the crane and associatedwalkways, stairways, platforms, ladders, working areas and access areas.
Hazardous substances, e.g. fuel, shall be stored safely.
NOTE: There are regulations pertaining to the safe storage of hazardous substances.
Tools or other loose objects shall be stowed in receptacles specially provided for thepurpose, or otherwise securely stowed.
7.7 ACCESS ONTO A CRANE Access to a crane shall be by the means provided,such as the crane operator access, the inspection access and the maintenance access.
Access onto a crane shall be made only when the crane is stationary.
Where the crane is under the control of a crane operator, the crane operator shall benotified before any person gains access onto the crane.
7.8 PERSONS APPROACHING THE PROXIMITY OF A CRANE No personnelshall be allowed to approach a crane when it is operating or travelling as there is a dangerthat they may be struck by the crane or load, or trapped between fixed and moving partsof the crane, e.g. between the slewing superstructure and the non-rotating structure of thecrane.
Barricades or guarding shall be provided where practicable.
7.9 CRANE OPERATION
7.9.1 General When operating a crane, the crane operator shall—
(a) not exceed the rated working load of the crane except for the express purpose of atest of the crane under the supervision of a competent person;
(b) be familiar with the location and operation of the main isolating switch;
(c) be familiar with the location and operation of the fire-fighting equipment;
(d) avoid sudden stops, jerks or other movements which may cause the load to swingunduly;
(e) not move the hook or load when the hook or load is out of sight except wheredirected to do so by an authorized person such as a dogman, crane chaser or rigger;
(f) ensure that the hook or load is sufficiently raised to avoid collision with any objectduring horizontal movement;
(g) not hoist off vertical;
(h) avoid moving the load, lifting attachment or other object horizontally other thanwhen the load is freely suspended from the crane;
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(i) when engaging the crane or part of the crane with end stops, do so with minimalimpact;
(j) follow the signals or directions given by the authorized person unless a dangeroussituation would be created by so doing in which case no movement shall beundertaken;
(k) when loads have to be handled in the vicinity of persons, be alert to the possibilityof persons being trapped and injured by the movement of the crane or load andexercise due caution. Where the person controlling the load or others may betrapped, do not move the crane or load unless their safety is assured.
(l) avoid developing slack rope when landing a load; and(m) position bridge and gantry cranes at their normal parking position when
out-of-service.When a crane is under pedestrian control (i.e. using pendant controls, radio controls orinfrared controls) the operator shall maintain a sufficiently close relationship with the loadto ensure good visibility and that safe handling takes place. A clear and defined pathwayfor the operator is critical. When using radio controls, management should make provisionfor the security of the transmitter when not in use.7.9.2 Hoisting of loads The crane shall not be required to handle any load greater thanthe safe working load applicable to the configuration of crane and manner of loading orany load which may create an unsafe situation.The crane shall not be used for any purpose other than direct hoisting and moving theload unless it is specifically designed for that purpose.The crane operator shall raise the load a short distance and test the hoisting brake systembefore continuing to raise the load in the following situations:(a) For the first load of each working shift.(b) For the first load of each working shift which is greater than 50 percent of the rated
capacity or the maximum line pull.7.9.3 Multiple hoist line operation Where the load is suspended from more than onehoist line, the load shall be handled in such a way that—(a) the rated load for each line is not exceeded;(b) the sum of the load moments does not exceed the rated load moment for the crane;
and(c) the sum of the load does not exceed the rated load of the crane.7.9.4 Balancing the load Where it is difficult to estimate the position of the centre ofgravity of the load, it is recommended that the load be hoisted just clear of the groundand stopped so that its balance can be checked and lowered for adjustment.7.9.5 Use of motion limits The crane operator shall avoid unnecessary operation ofmotion limits unless such usage is to a functional limit where a final limit is fitted.7.9.6 Interruption of electric power supply In the event of interruption to the electricpower supply for the crane while the crane is in operation, the crane operator shall, as faras is practicable, render the crane out-of-service until power has been restored (seeClause 7.3).If the crane is handling a load when the power supply is interrupted and the load is in aposition likely to cause a hazard, the load should be lowered manually to the surface orfloor level, where practicable and safe to do so.7.9.7 Crane operation in the vicinity of airfields Before operating high cranes in thevicinity of airfields, the management/operator shall ensure that the specific localrequirements for such operation are complied with.
7.10 CONTROL OF LOAD The crane chaser or the dogman shall direct the craneoperator from the time the crane load is hoisted until it is placed in position. The cranechaser and dogman shall ensure that the crane load clears all obstructions and, where
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necessary, shall guide the load by hand or by means of a tagline (see Clause 7.11). Wherethe load has to be manually handled, care should be taken to ensure the crane chaser ordogman is not in a position of danger. This would generally mean that the load should bepushed not pulled.
Where a load is being controlled by more than one crane chaser or dogman, only one ofthem shall take responsibility for the lift and issue instructions to the crane driver and tothe other crane chasers or dogmen.
Before signalling the crane operator to raise a load, the crane chaser or dogman shallensure that—
(a) the hoisting means is correctly applied to the load and to the crane hook;
(b) no part of the load is loose;
(c) the load is free from restraint and when hoisted will not foul any object;
(d) when hoisted, the load will not constitute a hazard to any personnel; and
(e) the position where the load is to be placed, is ready to receive the load.
7.11 TAG LINES When used, tag lines shall be of non-conductive material. Tag linesshall be maintained clean and dry and shall be fully assessed for deterioration of strengthbefore use.
7.12 COMMUNICATION
7.12.1 Methods of signalling A reliable and efficient method of communication shallbe established between the crane operator and the dogman and the crane chasers.
7.12.2 Hand signals Hand signals shall be as shown in Figure 7.1. Only one hand shallbe used for signals. When signalling the movement of two hoisting motions, it shall bearranged with the crane driver that one raised finger indicates one particular hoistingmotion and two raised fingers the other.
7.12.3 Bell, buzzer and whistle signals Bell, buzzer and whistle signals shall be asshown in Figure 7.1. The bell or buzzer shall be located in a position where it can bereadily heard by the crane operator while at the control position.
If two or more cranes are operating in close proximity, the tones of each bell, buzzer orwhistle employed for the cranes shall be clearly distinguishable.
7.13 HANDLING LOADS OVER PUBLIC ACCESS AREAS AND ADJACENTBUILDINGS The handling of loads over highways, railways, rivers, adjacent buildingsor other places to which the public have access shall be avoided. If this is not practicable,permission shall be obtained from the appropriate authority and the area kept clear oftraffic and persons, or suitable overhead protection shall be provided during the operation.
7.14 LOADS SUPPORTED BY MAGNETIC, VACUUM AND FRICTION LIFTINGATTACHMENTS If loads are supported by magnetic, vacuum or friction liftingattachments, personnel shall be excluded from all areas that may be affected by a fallingload.
7.15 RIDING ON THE CRANE When a crane is operating or travelling, all personnelon the crane shall be safely accommodated.
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AS 2550.1 — 1993 18
MOTION HAND SIGNAL WHISTLE,BELL ORBUZZERSIGNAL
MOTION HAND SIGNAL WHISTLE,BELL ORBUZZERSIGNAL
Hoistingraise
2 short• •
Hoistinglower
1 long———
Luffingboom up
3 short• • •
Luffingboom down
4 short• • • •
Slewingright
1 long,2 short— • • Slewing
left
1 long,1 short
— •
Jib-trolley out:telescoping
boom extend
1 long,3 short— • • • Jib-trolley in;
telescopingboom retract
1 long,4 short
— • • • •
Traveland
traverse
Notapplicable STOP
1 short•
CREEP SPEED: APPROPRIATE HAND SIGNAL FOR MOTION WITH HAND OPENING AND CLOSING
FIGURE 7.1 SIGNALS
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7.16 SUSPENSION OF PERSONS BY CRANE
7.16.1 General A person shall not ride upon the hook or the sling of a crane or uponany load while the load is being moved. A person suspended from a crane shall beaccommodated in a workbox designed for the purpose.
The use of the workbox shall be limited to those situations where it is necessary to elevatepersonnel to perform special tasks of short duration and where it is not practicable to usescaffold or a specially designed device.
7.16.2 Requirements for the workbox The workbox shall—
(a) be a unit specifically designed as a workbox;
(b) be marked on one side in a prominent position with —
(i) the tare weight of the workbox,
(ii) the maximum number of occupants,
(iii) the maximum mass which can be carried, in kilograms, and
(iv) an identification reference;
(c) contain not more than three persons, one of whom shall be a person competent incrane signals;
(d) be in a safe working condition;
(e) slings shall be permanently attached to the workbox by locked shackles or othersimilar means;
(f) have provisions for safety harness lanyards to be attached;
(g) be painted in high visibility colours;
(h) where an access door is fitted, it shall only open inwards and be provided withmeans to secure the door; and
(i) only be used to lift persons and their equipment.NOTE: Where regulatory authorities have specific requirements for the construction and use ofworkboxes, these shall be adhered to.
7.16.3 Requirements for the crane used with a workbox A crane used with aworkbox shall—
(a) be fitted with a safety hook;
(b) be equipped with controls that return to the neutral position when released and thisaction causes the motion to stop;
(c) be equipped with power lowering;
(d) be equipped with a positive lockout control so that inadvertent disengagement of thelockout is not possible, thus preventing free fall of the workbox;
(e) be fitted with an up-limit switch on the hoist motion; and
(f) be fitted with a down limit switch, if the workbox is to be lowered below the cranesupporting surface.
7.16.4 Operation of the crane with suspended personnelWhen personnel aresuspended from a crane, the crane operator shall—
(a) ensure that the workbox and lifting attachments have been inspected by a competentperson prior to use, and that the logbook has been checked;
(b) remain at the controls of the crane;
(c) ensure that all movements of the crane are carried out under power;
(d) ensure that at the maximum radius of the task to be performed, the crane has aminimum safe working load of 1000 kg;
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(e) ensure that, when the jib or boom of the crane is at its maximum radius for the task tobe performed, the safe working load for the crane in this condition, when divided by 2,is equal to or greater than the total load of the workbox and its contents;
(f) ensure that the workbox shall only be used to lift persons and their equipment;(g) have effective means of communication with any person in the workbox; and(h) ensure that mobile cranes do not travel while people are in the workbox.(i) ensure that movements of the workbox are at slow speeds with minimum acceleration
and deceleration.(j) workboxes should not be used in winds in excess of 7 m/s (25 km/h), electrical storms,
snow, ice, sleet or other adverse weather conditions which could affect the safety ofpersonnel.
It is recommended that flammable liquids, oxygen and acetylene cylinders and the like, becorrectly secured and housed in a compartment separate to the workbox and that onlyminimum quantities, sufficient to carry out the work, are carried together with a suitable fireextinguisher.Personnel suspended from a crane shall wear a general purpose safety harness complying withAS 1891, with the safety line attached to the safety harness anchorage points.Personnel shall not enter or leave the workbox when elevated except, in an emergency, unlesseach of the following conditions are met:(i) Risk analysis shows that this alternative means of access is safer than all other alternative
means.(ii) The structural adequacy of the landing area has been established and the landing area is
clear.(iii) Where the landing is at the edge of a structure, the maximum gap between the workbox
and landing shall not exceed 100 mm, the workbox shall be secured to a suitable point onthe landing and access and egress shall not take place unless a safety harness is properlyworn and attached to a suitable anchorage on the structure.
7.17 OPERATION NEAR AERIAL CONDUCTORS (OVERHEAD POWER LINES)7.17.1 Precautions When operating a crane in close proximity to aerial conductors, thefollowing precautions shall be observed by the operator and other persons working with thecrane:(a) When operating in an unfamiliar area, check for the presence of aerial conductors.(b) Consider all such conductors to be live unless it is positively known that they have been
de-energized and isolated. Documentary evidence of the continuing isolation of the powersupply shall be obtained before approaching conductors.
(c) The load and crane shall not approach any closer than the following:(i) For distribution lines on poles. . . . . . . . 2 m asshown in Figure 7.2(a).(ii) For transmission lines on towers. . . . . . 6 m unless designated otherwise by
the electricity supply authority (see Figure 7.2(b).(iii) Where power lines are dedicated to the use of public transport authorities, e.g.
tramways and railways; as for Figure 7.2(a).High visibility insulating materials may allow a reduced approach distance.
(d) Notify the power supply authority and obtain special procedures from that authoritywhen it is necessary to operate within the distances shown in Figure 7.2.
(e) Where necessary, provide ground barriers to warn operators. The recommended distanceof the barriers from the line of conductors shall be as shown in Figure 7.2(a) and (b).Consider the effects of wind and temperature on conductor movement, especially nearthe centre of large spans.
(f) Use non-conducting taglines when these are required.(g) Do not allow any person, other than the crane operator, to be in contact with any part of
the crane or the load, except with a non-conducting tagline, once the lift has commenced.(h) Ensure appropriate earthing systems are fitted and in contact with the ground.(i) High visibility bunting may be applied to the conductors as an indication of location of
the conductors.
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DIMENSIONS IN METRES
FIGURE 7.2 CLEARANCES FROM LIVE AERIAL CONDUCTORS
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7.17.2 Aerial conductor contact If the crane or load contacts aerial conductors, therelevant electricity supply authority shall be immediately notified of the situation and, untilassistance is received, a responsible person shall remain near the crane to warn of the danger ofelectrocution.
In such an event and where practicable, the crane operator should act as follows:
(a) Remain inside the cabin or on the crane.
(b) Warn all other personnel to keep away from the crane and not to touch any part of thecrane, rope or load.
(c) Without anyone approaching the crane, operate the crane in such a manner to breakcontact, where possible.
(d) When unable to move or disentangle the crane from the aerial conductors, remain insidethe cabin or on the crane and take no further action until it is confirmed that conditionsare safe.
(e) When it is essential to leave the cabin or crane because of fire or some other reasonthen, to avoid being electrocuted, jump clear as far away from the crane as possible andavoid touching the crane and the ground at the same time. When moving away from thecrane, the crane operator should shuffle or hop slowly across the affected area to avoid asimultaneous contact with areas of high potential difference (see Figure 7.3).
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Where the crane driver is immobilized, the power shall be isolated before assistance is given.
When a crane has been in contact with a live aerial conductor, a check shall be made by acompetent person for any damage to the hoisting rope and other crane components. Anyactions recommended by the competent person shall be completed before the crane is returnedto service.
NOTE: Regulatory authorities may require advice of any power line contact.
7.18 OPERATION NEAR UNDERGROUND LIVE CONDUCTORS When operating acrane in close proximity to live buried power lines, the same precautions as given inClause 7.17 shall be observed as appropriate.
7.19 MULTIPLE CRANE OPERATION
7.19.1 General Hoisting a load with two or more cranes requires greater attention toplanning and supervision than hoisting with one crane, because the effects of the relativemotion between the cranes may induce additional loadings on the cranes, the load and thelifting gear. Because of this and the difficulty in monitoring these additional loads, multiplecrane hoisting shall be used only when the physical dimensions, characteristics, mass orrequired movement of the load prevent the operation from being carried out by a single crane.
Multiple crane hoisting shall be planned with extreme care and shall include an accurateassessment of the proportion of the load to be carried by each crane. It is essential thatplanning shall ensure that the hoist ropes remain vertical.
During multiple crane hoisting operations, only one motion should be undertaken at any time,and movements should be planned so that luffing-up is used in preference to luffing-down.
7.19.2 Capacity requirements For multiple crane hoisting operations using two or morecranes, the following minimum capacity requirements for each crane shall apply:
(a) For two cranes . . . . . . . . 20percent greater than the calculated share of the load.
(b) For three cranes. . . . . . . . 33percent greater than the calculated share of the load.
(c) For four or more cranes . . . 50 percent greater than the calculated share of the load.
7.19.3 Planning for multiple crane hoisting
7.19.3.1 Mass of load The total mass of the load and its distribution shall be either knownor calculated. If the information is taken from a technical drawing, allowance should be madefor manufacturing tolerances.
7.19.3.2 Centre of gravity The position of the centre of gravity shall be assessed carefullyand allowances made for each uncertainty.
7.19.3.3 Mass of lifting gear The mass of the lifting gear shall be part of the calculated loadon the cranes and its mass distribution shall be accurately known.
7.19.3.4 Synchronization of the crane motionsThe crane motions should be synchronized;therefore, cranes of equal capacity and similar characteristics should be used wheneverpossible. In practice, there will always be some variation due to differences in response to theactivation of the motion controller and the setting and efficiency of the braking system.
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The safe working load of a crane is calculated on the assumption that the load will beraised and lowered in a vertical plane. The crane structure will have been designed towithstand any lateral loads imposed by accelerations in the various crane motions, but it isunsafe to rely on this lateral strength to withstand horizontal components of non-verticallifts. Since it is unlikely that the motions of the two cranes will be accuratelysynchronized, particularly if the cranes have dissimilar characteristics, the operation shallbe performed at slow speeds with extreme care being exercised to maintain the hoist ropesas close to vertical as possible.7.19.3.5 Pick and carry In pick and carry operations the axis of both or all cranes shallbe kept aligned in the same direction. The possibility is that once out of alignment, themovement of one crane may push or pull either the other crane or cranes and cause lossof stability.Figures 7.4(a) and 7.4(b) provide examples of stable pick and carry operations.Figure 7.4(c) is an example of unstable pick and carry operation where the movement ofeither crane, acting through the load, can adversely affect the stability of the other crane.7.19.3.6 Instrumentation Instruments are available to monitor constantly the angle ofthe load, and the verticality and force in each hoist rope throughout the lifting operation.Their use is recommended.7.19.3.7 Wind As multiple crane hoisting is sensitive to weather conditions,particularly wind speed, an adequate assessment of the prevailing conditions should bemade before commencement of a multiple hoisting operation.7.19.4 Supervision One competent person who shall not be one of the crane operators,shall be in attendance and in overall control of the multiple crane operation. Only thisperson shall give instructions to the crane operators except in an emergency, when a stopsignal may be given by any person observing a situation leading to danger. If allnecessary locations cannot be observed from one position, additional competent personnelshould be located at suitable positions to observe and report to the person in charge of theoperation.7.19.5 Communications Effective means of communications shall be provided andmaintained for the duration of the lifting operations.
7.20 SPECIAL DUTIES7.20.1 General The crane manufacturer shall be consulted for the use of the crane forall special duties, such as grabbing, pile driving, magnet lifting and demolition. Where thecrane manufacturer’s recommendations are not available then the advice of a competentperson shall be obtained.7.20.2 Grabbing and magnet crane service When cranes are used for grabbing ormagnet crane service, allowance shall be made for the following, where applicable:(a) Mass of the grab.(b) Mass of the magnet.(c) Mass of other attachments.(d) Mass of the load.(e) Loads resulting from fast slewing.(f) Grab or suction effects.(g) Impact loads.For these operations, consideration shall be given to the tear-off/break-out forces.7.20.3 Swinging-ball demolition service The use of a swinging ball for demolitionshould be restricted to cranes designed for arduous duty, such as convertible draglineexcavators.A crane which has been used for swinging-ball demolition shall not be used for generallifting until it has been thoroughly inspected by a competent person and found to be in asatisfactory condition.
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Dynamic loadings are imposed on the boom or jib structure and other parts of the craneby the movement and the impact of the ball.
When a crane is used for demolition duties, the cabin shall be fitted with a falling objectprotective structure against falling objects.
7.20.4 Lifting products of demolition Lifting products of demolition may behazardous because the loads may be greater than assessed or may impose excessivedynamic loads on the crane. Cranes used for this purpose shall have a capacity not lessthan 1.5 times the assessed load.
7.20.5 Piling service Piling service necessitates the use of special equipment. It isessential to ensure that the additional mass of the piling equipment and the loads arisingduring operation do not overload the crane, boom or jib structure or adversely affect thestability of the crane.
Particular attention should be given to the crane standing during operation to avoiddifferential settlement of crawler tracks or crane supports, which may adversely affect thestability of the crane.
Particular care should be given to the examination of ropes on sheaves and on drums, ropeterminal fittings and rope anchorages during the following operations:
(a) Pile driving When a pile is being pitched in position for driving, side loading onthe boom and side dragging of piles should be avoided.
If a drop hammer is used, the following should be avoided:
(i) Premature catching of the falling hammer.
(ii) Snatching the hammer following over-running of the rope on the hoistingdrum after the hammer has struck.
Before working below the drop hammer, the hammer shall be lowered onto thepositively-locked safety system and the crane hoist mechanism shall be locked out.
NOTE: Where a drop hammer is used on a crane mounted on a barge or other floating plant,the release of the hammer produces a reaction on the vessel which should be taken intoaccount when considering the stability of the combined unit.
(b) Pile extraction For pile extraction, an extractor, which is usually a reciprocating orvibratory type (and may be used either for driving or extraction of piles), strikes thepile upwards and breaks its adhesion. The actual force used to withdraw the pile isprovided by the crane hoist rope from which the extractor is suspended. Extractionshall be effected by a ‘smooth’ haul on the hoist rope. Under no circumstances shallthe hoist rope be jerked or the crane tipped to achieve faster results.
In assessing the required capacity of a crane for pile extraction duty, the followingshall be considered:
(i) Mass of the extractor.
(ii) Mass of the pile.
(iii) Adhesion and frictional forces occurring between the ground and the pile.
For sheet pile extraction, a further allowance is necessary for the friction between the pilebeing extracted and the adjacent pile remaining in the ground.
7.20.6 Inspection After a crane has been used in the above modes (Clauses 7.20.1 to7.20.4) it shall be subjected to a complete and meticulous inspection before being returnedto lifting duties.
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7.20.7 Recreational use Cranes shall not be used for recreational purposes. (Someregulatory authorities may vary this requirement.)
7.21 WEATHER CONDITIONS
7.21.1 Wind conditions Gusting or strong wind conditions have an adverse effect oncrane stability. Handling of loads with large wind-catching surfaces may result in loss ofcontrol of the load or overturning of the crane despite the mass of the load being withinthe safe working load of the crane. Even in relatively light wind conditions, the handlingof loads presenting large windage surfaces should be avoided.
It is advisable that an anemometer be available at the working site, and that for towercranes the anemometer be mounted at the highest point of the crane structure.
Where wind speeds exceed the manufacturer’s operating recommendations, cranes shall beplaced out-of-service.
7.21.2 Visibility conditions Where adverse weather conditions such as snow, fog anddust, have an adverse effect on visibility or the communication system, the crane shall beplaced out-of-service until conditions improve to such an extent that a dangerous situationno longer exists.
7.21.3 Wet conditions Brake or clutch units and electrical equipment on all cranesshall be protected against the ingress of water or other adverse weather conditions whichmay affect their efficiency. Following shutdown periods and before the start of hoistingoperations, all friction brakes and clutches shall be carefully tested.
7.21.4 Lightning Outdoor cranes should not be operated during a storm when lightningstrikes could reasonably be expected.
7.22 ACCIDENT OR DAMAGE When the crane is involved in any accident or thecrane or equipment sustains damage or failure, the crane operator shall report suchoccurrences to management.
The crane or equipment shall then be inspected and repaired as required and declared assatisfactory by a competent person before it is returned to service.
NOTE: Specific legislation may require notification of the accident or damage to the regulatoryauthority.
7.23 MODIFICATIONS TO CRANES Modifications to any part of a crane, includingthe addition of display signs, shall not be undertaken without the approval of themanufacturer or management after an engineering assessment.
7.24 NECESSARY EQUIPMENT A fire extinguisher appropriate to the hazardsinvolved should be provided for every crane as required.
7.25 GUARDING All guarding shall be fitted and maintained as required to complywith AS 4024.1.
7.26 LOAD RATING CHARTS Load rating charts applicable to the various specifiedoperating configurations of the crane shall be readily accessible to the operator at alltimes.
7.27 LOAD TESTING Load testing may be dangerous. Load testing is designed toprove a crane’s load carrying capacity and it shall be borne in mind that the crane maynot withstand the loading. It is necessary to ensure that all personnel, not essential to thetest, are kept away from the area. Test personnel should be positioned so that they areunlikely to be injured should there be a mishap. The test area should be roped off andnotices posted prohibiting unauthorized entry.
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AS 2550.1 — 1993 28
S E C T I O N 8 M A I N T E N A N C E , I N S P E C T I O NA N D R E P A I R
8.1 GENERAL Management’s instructions for routine maintenance and inspection ofthe crane shall be readily available. The instructions shall include the manufacturer’srecommendations for routine maintenance and inspection, and shall give specifications forconsumable items such as ropes, lubricating oils, and hydraulic fluids.
A logbook (record) shall be kept of all cranes and workboxes, giving all pertinentinformation such as hours worked, adjustments, insulation checks, renewal of parts,inspections and repairs, as detailed in Clause 8.3.3. Based on this record, a program ofplanned maintenance and repair work should be introduced to contribute towardstrouble-free and safe operation. The logbook shall be readily availabe for the crane orworkbox.
NOTE: For guidance on safe work procedures, see Appendix C.
8.2 INSPECTION Each crane shall be inspected periodically in accordance withmanagement’s instructions and with full consideration of the crane duties, to ensure that—
(a) the parts of the crane subject to deterioration through corrosion, damage, wear,abrasion and like effects are replaced before they become unserviceable; and
(b) the crane is maintained in a safe, serviceable condition.
8.2.1 Major inspection Management’s instructions shall include directions for theextent and frequency of major inspections.
The frequency of major inspections shall be in conformance with the manufacturer’srecommendations, or Clause D2.4, whichever is more frequent.
A major inspection shall have the following meaning:
(a) A comprehensive and detailed examination by a competent person sufficient toensure that the crane is safe to use.
(b) As considered necessary by a competent person, visual examination shall besupplemented by non-destructive examination to determine the condition of thecrane.
(c) As considered necessary by a competent person, parts of the crane shall bedismantled to enable the condition of the crane to be determined.
(d) As considered necessary by a competent person, such measurements of cranecomponents shall be taken to enable the condition of the crane to be determined.
NOTES:
1 The frequency and extent of inspections shall be related to the severity of the operatingconditions of the crane.
2 Inspections shall be thoroughly conducted by a competent person authorized bymanagement. All such inspections shall be appropriate to both the current crane use andfuture crane use.
3 The crane shall be maintained in a clean and accessible condition to enable inspections to bemade safely and efficiently.
4 Documentation shall be readily available stating that the crane has been inspected by acompetent person and is in a safe, serviceable condition.
Where experience has shown particular problems with a crane or hoist, then a specificprogram shall be established to alleviate the problems.
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8.3 MAINTENANCE AND REPAIR
8.3.1 General All maintenance and repair shall be carried out in accordance with themanagement’s instructions using suitable tools and any special equipment specified for thepurpose.
8.3.2 Worn or unserviceable parts Any part of a crane, or its ancillary or auxiliaryequipment, which becomes so worn or unserviceable as to constitute a hazard or impairthe operation of the crane or may constitute a hazard before the next periodic inspection,shall be repaired or replaced. The repaired or new part shall comply with themanufacturer’s recommendations or specifications and, where these are not available, tothe relevant requirements of the applicable part of AS 1418.
NOTES
1 In some States and Territories, repairs must comply with the requirements of the regulatoryauthority.
2 A recommended servicing frequency for cranes is given in Appendix D.
8.3.3 Log maintenance Prior to leaving the crane, the operator or other personresponsible shall record in the logbook the crane checks, adjustments, renewal of parts,repairs and inspections performed, the hours worked by the crane, duties performed by thecrane including maximum loading and all incidents and irregularities of loading,operation, wear, damage and the like concerning the safe use of the crane. Each log entryshall be signed by the responsible person making the entry and should contain details ofthat person’s identification and qualifications.
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S E C T I O N 9 R O P E S , H O O K SA N D A T T A C H M E N T S
9.1 ROPES
9.1.1 Replacement of ropes Only ropes of the correct size, type and constructionspecified by the crane manufacturer or the rope manufacturer shall be used and these shallbe in accordance with AS 2759 or other appropriate internationally recognized Standard.
9.1.2 Rope reeving Where it is possible to vary the number of falls of the hoist ropeor parts of rope in the luffing system, it is important to ensure that these are inaccordance with the crane manufacturer’s recommendations for boom and jib lengths andloads to be lifted. It should be noted that if a load moment system is fitted, the systemgenerally operates accurately only when its setting corresponds to the length of boom orjib fitted and the type of rope reeving adopted.
Where a crane is fitted with a load sensing device, the device may require adjustmentafter a change of reeving before the crane is placed in service.
9.1.3 Rope guards or keepers Rope guards or keepers where fitted to sheaves ordrums shall remain in their correct positions and be removed only for the purposes ofmaintenance, inspection or adjustment. This is of particular importance if, under certaincircumstances, the rope system may develop a slack rope condition. Failure to observethis may allow a rope to run off a sheave or drum and become trapped or damaged.
9.1.4 Guide rollers and sheaves Guide rollers or guide sheaves are sometimes fittedon the boom or jib so that the rope does not rub against the structure. Where these arefitted, it is essential that they be checked frequently to ensure that they are free to rotate.A seized roller or sheave may cause serious damage to a rope, leading to its prematurefailure. Boom or jib protective strips, where fitted, shall be frequently checked forsecurity and serviceability.
9.1.5 Rope drums and sheavesRope drums and sheaves shall be examined at regularintervals for wear.
Sheaves shall revolve freely on their supporting shafts and particular attention shall begiven to lubrication.
9.1.6 Rope terminal fittings Only rope terminal fittings as specified by the crane orrope manufacturer shall be used to attach a rope to a drum, anchorage, hook block orstructure of the crane. Improvised fittings shall not be used.
Attention shall be given to the assembly of wedge and socket fittings, and such fittingsshall be provided with a rope tail clip (see AS 2076).
9.1.7 Rope lengths Ropes of the correct length shall be fitted. With variable boom orjib lengths it may be necessary to fit a specific length of rope for a particular boom or jiblength and rope reeving combination. Too short a rope may result in the rope completelypaying out with all the load being taken by the anchorage. Too long a rope may exceedthe drum spooling capacity and result in the rope riding over the flanges and becomingtrapped in the machinery causing severe damage and possibly premature rope failure.
Before hoisting operations commence following installation of a new rope or a change ofconfiguration, the rope drums shall be checked in the extreme spooling conditions toensure that the rope lengths are correct.
9.1.8 Rope stretch Rope stretch may create problems with the setting of hoistinglimiting devices and the overfilling of the drum. Frequent inspections, particularly duringthe early life of the installed rope, shall be carried out and the limiting devices adjusted orthe rope cut back to the appropriate length.
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9.1.9 Examination of ropes Ropes wear and are affected by climatic andenvironmental conditions, e.g. saline, corrosive or abrasive atmospheres. A thoroughperiodic examination by a competent person for wear, damage and corrosion is necessaryfor the safety of rope systems.
Particular attention should be paid to tucked splices and those sections of rope close tothe terminal fittings. Ropes which are composed of more than one layer of strands, suchas non-rotating ropes, may deteriorate internally at the interface between the layers, and itis therefore essential that the rope be carefully and competently examined. If multi-layerdrums are used, examination is necessary of not only that part of the rope which is inconstant use, but also of the rope which may remain spooled and inoperative on the drumfor long periods.
Boom and fly-jib suspension ropes are often placed at positions remote from the basiccrane structure. Such ropes shall be carefully examined, particularly those sections lyinground sheaves.
The criteria for inspection and discard shall be in accordance with AS 2759.
9.2 HOOKS AND HOOK BLOCKS The hook or hook block shall be capable ofhandling the load. The hook shall not be loaded beyond its safe working load. To preventdisplacement of the sling or load, the hook should be provided with a safety catch orother effective device to minimize, as far as is practicable, the risk of the sling or loadbecoming detached.
The hook shall not be overcrowded. Where multiple slings are used, they should beattached to a shackle which is then placed on the hook. This prevents the danger of thehook being strained owing to the spread of the slings and also the danger of a slingfouling the safety catch or slipping over the point of the hook. All end links, rings orshackles shall ride freely on the hook.
When the crane is working with a single fall of rope and the load is set down, thusrelieving the tension in the hoist rope, the hook may spin. Personnel should alwaysexercise care in approaching the hook to disconnect the sling.
9.3 ATTACHMENTS
9.3.1 General Lifting attachments used with cranes, shall comply with AS 1418.1 orany Standard listed in Appendix E, or any equivalent international or national Standard.
9.3.2 Identification and marking Each lifting attachment should be clearly andpermanently marked with its tare mass, the safe working load and an identificationreference.
9.3.3 Workboxes Design and construction of workboxes shall be in conformance withthe requirements of the applicable regulatory authority.
9.3.4 Inspection All lifting attachments shall be inspected regularly and the extent ofeach inspection shall be consistent with the design and usage of the attachment.
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AS 2550.1 — 1993 32
APPENDIX A
SAFE BEARING PRESSURE FOR CRANE OUTRIGGERS
(Informative)
Soil description
Safe bearing pressurefor crane outriggers
kPatonnes (f )per square
metre
tons (f ) persquare foot
Hard clay 700 70 6.5
Medium dense to dense gravel/coarsesand
800 80 7.5
Loose medium and coarse sand/densefine sand
500 50 4.7
Stiff clay 350 35 3.3
Loose fine sand 400 40 3.7
Soft clay 80 8 0.7
Loose fill Not rated Not rated Not rated
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APPENDIX B
ROUTINE CHECKS FOR CRANES
(Informative)
It is recommended that the following routine checks of the crane be carried out by theoperator or other authorized person, where applicable at frequencies to suit theapplication:
(a) Check the oil levels, fuel level and lubrication.
(b) Check the ropes, rope terminal fittings and anchorages, rope drums and sheaves forany damage and wear.
(c) Check the condition and inflation pressures of tyres.
(d) Check that all water is drained from air reservoirs.
(e) Check the crane for any loose or damaged structural component including supportsand outriggers where fitted. Loose joints may be readily noticed by flaking ormarking on the paint surface or by rust marks. Similarly, cracks may often bedetected by rust runs.
(f) Check the security of the counterweight. Where this is in the form of removableweights, check that the weights correspond to those shown on the counterweightchart for the operating condition in use.
(g) Check that the load moment system where fitted is correctly set or fitted (or both)with the program appropriate to the boom or jib length, and fly-jib lengths and fallsor parts of rope.
(h) Check that the indicator appropriate to the boom, jib or fly-jib length is fitted.
(i) Check that the crane cabin is in a tidy condition and free from grease and oil, rags,tools and materials other than those for which storage provision is made.
(j) Check the pneumatic systems and hydraulic systems including their safety devices.
(k) Check the operation of the crane through all motions with particular attention tobrakes.
(l) Check the operation of all limit switches or cut-outs and safety devices. Exercisecaution in making the checks in the event of non-operation.
(m) Check that, where telephone or radio communications are being used, the callingsignal is functioning and any messages may be clearly heard.
(n) Check that fire extinguishers are in place and satisfactory for use.
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APPENDIX C
SAFE WORK PROCEDURES FOR THE MAINTENANCE AND THE
INSPECTION OF CRANES
(Informative)
C1 SCOPE This Appendix provides guidance on the safe working procedures for themaintenance and inspection of cranes.
C2 RESTRICTION OF ACCESS Personnel should not gain access to a crane orcrane superstructure except where such access is necessary for them to carry out theirduties.
C3 AUTHORIZATION FOR ACCESS Personnel should not gain access to a craneunless authorized.
C4 WARNING TO OTHER PERSONNEL The person responsible for safety withinthe area where the crane is located should ensure that all personnel within the area, andthose who may enter the area, are warned of potential hazard.
C5 WORK NEAR CRANES Where maintenance or other work needs to be performednear a crane, electric power to the crane-supply conductors or crane, where applicable,should be disconnected except where the crane, or part of the crane, needs to be energizedto effect maintenance work. Precautions shall be taken to ensure that personnel involvedin the maintenance or inspection of the crane and personnel in the vicinity of the craneare not subjected to an electrical hazard or a hazard due to movement of the crane.
C6 WORK ON CRANES Electric power to the crane should be isolated and internalcombustion engines should be stopped except where the crane, or part of the crane, needsto be energized to effect the maintenance or inspection. Where the electric power is notisolated or the internal combustion engines are not stopped, not less than two personsshould be present, one of whom should be free to take any action necessary to protectpersonnel in an emergency.
When working on a crane, the following precautions should be observed:
(a) The crane should be taken out-of-service.
(b) The crane should be moved to a position remote from the operating position, whereapplicable.
(c) The crane should be prevented from moving.
(d) Only tools suitable for the purpose should be used.
(e) All maintenance and inspection should be in accordance with management’sinstructions.
C7 LOCK-OUT OF MAIN ISOLATOR OR CRANE ISOLATOR Where the powersupply to the crane is isolated, the main isolator, shall be locked in the ‘off’ position andthe means of unlocking retained by the person responsible for the maintenance orinspection as nominated in management’s instructions.
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The person responsible for the maintenance or inspection should ensure that all tools,equipment and other loose materials have been removed from the crane and crane runwaysand that safe conditions prevail for the resumption of normal operation of the crane beforethe power is restored to the crane.
C8 OVERHEAD MAINTENANCE OR INSPECTION Where overhead maintenanceor inspection may create a hazard from falling objects, the area below should be isolatedfrom surrounding areas and hazard warning signs displayed.
C9 MAINTENANCE AND INSPECTION IN ELEVATED POSITIONS Wherepersonnel are required to work in elevated positions and there is a danger of falling, suchpersonnel shall use an industrial safety harness complying with AS 1891.
C10 HEAD PROTECTION Where personnel are subject to a danger from fallingobjects, such personnel shall wear an industrial safety helmet complying with AS 1801.
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APPENDIX D
RECOMMENDED MINIMUM SERVICE REQUIREMENTS FOR CRANES
(Informative)
D1 CONTROL POINTS
D1.1 General Test drive and general visual inspection. Check for loose objects andextraneous materials. Check mounting of components, surface treatments.
D1.2 Structural Check for corrosion, damage, deformation and wear.
D1.3 Function Check on the condition of bearings, seals couplings, bushes andsheaves.
D1.4 Measuring The measuring of electrical components such as motor windings,brake coils, insulation resistances.
D1.5 Adjustment Adjustment of brakes, limit switches and timers as necessary.
D1.6 Lubrication Lubrication and oil changes according to the manufacturer’sinstructions.
D2 CONTROL FREQUENCY
D2.1 General Table D1 gives the recommended minimum service requirements forcranes.
D2.2 Safety control Safety control comprises regularly repeated safety inspections.
D2.3 Preventative service Preventative service and preventative maintenancecomprises checking for correct operation of all functions at a frequency of every 400 shifthours.
D2.4 Major inspection A major inspection shall comprise a thorough inspection of allmechanical, electrical and structural components. Major inspections should be at a timingfrequency not exceeding 12 months.
TABLE D1
RECOMMENDED MINIMUM SERVICE REQUIREMENTS
Crane ClassificationC1 C2 C3 C4 C5 C6 C7
M1 M2 M3 M4 M5 M6 M7
Working hours per day ≥0.5 0.5–1 >1.2 >2.4 >4.8 >8.16 >16
Safety control, weeks 12 12 8 4 3 2 1
Preventative service, weeks 48 48 32 16 12 8 4
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APPENDIX E
STANDARDS FOR COMPONENTS USED IN LIFTING SYSTEMS
(Informative)
The following is a list of Standards for components that are used in lifting systems:
AS1138 Thimbles for wire rope
1353 Flat synthetic-webbing slings1353.1 Part 1: Product specification1353.2 Part 2: Care and use
1380 Fibre-rope slings (of natural or synthetic rope)
1438 Wire-coil flat slings
1504 Fibre rope—Three-strand, hawser laid
1666 Wire-rope slings
1752 Fibre-rope—Eight-strand plaited
2076 Wire rope grips
2089 Sheave blocks (including ships’ cargo blocks) of maximum lift 60 t
2317 Collared eyebolts
2318 Swivels for hoists
2319 Rigging screws and turnbuckles
2321 Short-link chain for lifting purposes (non-calibrated)
2740 Wedge-type sockets
2741 Shackles
2759 Steel wire rope—Application guide
2841 Galvanized steel wire strand
3569 Steel wire ropes
3585 End fittings for flat-webbing slings
3775 Chain slings—Grade T
3776 Lifting components for Grade T chain slings
3777 Shank hooks and large-eye hooks—Maximum 25 t
B291 Lifting rings and links
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