tower crane-assessment instrument

TOWER CRANES

ASSESSMENT INSTRUMENT

NATIONAL OCCUPATIONAL HEALTH AND SAFETYCERTIFICATION STANDARDS FOR USERS AND OPERATORS OF

INDUSTRIAL EQUIPMENT

[ NOHSC: 1006 (1995) ]

June 1994

Level 4, Lutwyche Shopping Village, 543 Lutwyche Road, Brisbane Qld 4030PO Box 820 Lutwyche Qld 4030. Telephone: (07) 3247 9444; Facsimile: (07) 3247 9426

Cranes

Tower Cranes

ASSESSMENT INSTRUMENT

Part 1 PerformancePart 2 Oral/WrittenPart 3 Written

June 1994

Tower Cranes Guidelines June 1994 2

Contents

Page

Assessor guidelines general guidelines for Schedule B i

Part one Performance Assessment 1

Part two Oral/Written Assessment 10

Assessment Summary 20

Note:

Part three Written Assessment for Cranes provided as a separate

document.

Tower Cranes Guidelines June 1994 i

Assessor guidelines general

1 Introduction1.1 Scope

These general guidelines apply to all theassessment instruments for the certificatesof competency prescribed by Schedule B ofthe National Occupational Health andSafety Certification Standard for Users andOperators of Industrial Equipment.

Assessors should also be familiar with thepublication Assessment guidelines forNational Occupational Health and SafetyCertification Standard for users andoperators of industrial equipment.

1.2 Additional guidelinesGuidelines which provide additional specificinformation to certificate assessors are alsoincluded in each assessment instrument. Included, where appropriate, are specificinstructions on the usefulness of trainingrecords (such as logbooks) and othercertificates with overlapping competencies.

1.3 Evidence of competenceEvidence of competence is established in anumber of ways. The methods used in thefollowing instruments involve:• assessment of practical performance• written and/or oral answers to questions

on underpinning knowledge.

2 Preparing for the assessment2.1 Study the instruments

You need to read the assessmentinstruments and specific instructionscarefully before beginning an assessment.

2.2 Confirm appointmentsPrior to an assessment, you need toconfirm the date, time and location of theassessment with the applicants and anyother relevant people.

2.3 Equipment availabilityThe availability of equipment, materials anda suitable working area must be organisedand confirmed, prior to the assessment.

2.4 Workplace factorsBecause procedures and processes varygreatly between workplaces, it is importantfor assessors to plan their approaches tomeet the requirements of the individualworkplace.

Make sure you take the timeframe intoaccount when planning the assessmentand also make applicants aware of anytime limits.

2.5 Selecting questionsQuestions for the written/oral assessmentshould be randomly selected, either byhand or using the computer system, ifapplicable.

3 Conducting the assessment3.1 Provide an explanation

Begin by explaining clearly to the applicantswhat is required of them. Check thatapplicants have provided (or have beenprovided with) the necessary tools andequipment.

3.2 Practical performanceComplete the performance checklist, asthe applicant works through the requiredtasks. Wherever possible, this should bedone in a normal working environment.

Do not ask the applicant questions while heor she is performing a task, as this can bedistracting, and may affect the time takento complete the assessment.

Tower Cranes Guidelines June 1994 ii

If, at any time, the applicant is endangeringhimself/herself or others, stop theassessment immediately. This indicatesthat the applicant is not yet competent andmay require further training, before beingreassessed.

Assessments should also be stopped, ifequipment or property are likely to bedamaged.

3.3 KnowledgeThe knowledge assessment covers bothoral and written exercises. The modelanswers provided with the knowledgeassessment instruments are notnecessarily exhaustive. Use your ownjudgement when scoring alternativeanswers.

3.4 Written assignmentAs well as providing a means to determinethe applicant's competence in solving work-related problems, the written assignmentwill clearly demonstrate whether or not theapplicant can work without directsupervision. The assessor may assist byreading out a question, but should notprompt or interpret for the applicant.

3.5 Recording responsesEach item and question on the assessmentforms you use is accompanied by a box. Assessors must complete every box asfollows:

CORRECT PERFORMANCE/ANSWER

NOT YET ACHIEVED

NOT APPLICABLE

If a box is marked incorrectly, cross out themistake, mark the correct responsealongside, and initial the change.

4 Determining competencies4.1 Assessment summary

A specific assessment summary is given foreach certificate class. This is to be filled inand signed by the assessor, andcountersigned by the applicant.

The original and duplicate are given to theapplicant. The applicant provides theoriginal to the certifying authority. Thetriplicate is retained by the assessor.

4.2 Competency requirementsIn order for you to deem an applicant competent, he or she must have completedeach section of the assessment to thestandard required. You should note anytime constraints when arriving at yourdecision.

The standard required for each instrumentis specified in the specific guidelines and/oron the summary page at the end of eachassessment.

In the case of a repeat assessment, theassessor can decide to apply the whole oronly part of the assessment.

4.3 Additional commentsWhere an applicant fails to meet thestandard of competence, you should add awritten comment on the AssessmentSummary, which briefly explains theproblem.

Advice to the applicant, on the appropriateremedial action should also be included. This will also assist the certificate assessor,in the event that the applicant undergoesfuture reassessment.

Likewise, if an applicant demonstratesoutstanding or remarkable performance,this should be noted.

Tower Cranes Guidelines June 1994 iii

4.4Further investigation

As a certificate assessor, it is your role todetermine whether or not an applicant hasachieved the standard necessary for thecertifying authority to be able to grant acertificate of competency.

Whenever you are unsure of the applicant'sperformance or knowledge or performance,ask additional questions, and obtainadditionalevidence, before making your final decision.

National OHS Certification Standard

Cranes and Hoists

Tower Cranes

Performance Assessment

May 1994

Tower Cranes – Performance June 1994 1

TOWER CRANES

Assessor Guidelines - Specific

1. The assessment comprises 15 itemscovering the following operating areas-

1) Pre-operational checks2) Start up crane3) Site/job planning4) Operate crane5) Shut down crane6) Set up and dismantle crane7) Special operations

The applicant must undertake allperformance items. All critical componentsmust be demonstrated/answered correctly. An assessor must use his/her discretion inassessing competence of non-criticalitems, at least 75% being ticked for acompetent person.

2. The answers provided are only typical ofthis type of equipment, eg. in shutdown,the sequence varies between differenttypes of crane.

3. The assessment should be conducted inan area -1) With sufficient space to operate freely,

without obstruction.2) Without undue interference from

nearby operations.

4. The applicant should provide (or beprovided with) appropriate personal,protective equipment and clothing.

5. In item 11, the assessor is to use the loadchart for the crane being used for theassessment, and to select either:1) The working conditions of the crane

including number of counterweightsand ask the applicant to determine themaximum permissible load, or,

2) the load and crane configuration andask for number of counterweights, or,

3) another load chart problem typicallyencountered,for 4 different crane configurations thatcover the scope of operations for thatcrane. The applicant should be able toidentify whether the load is limited bystructural strength.

6. Items 13 to 15 can be achieved bypresentation of adequate records oftraining/experience or by answering thequestions.


PRE-OPERATIONAL CHECKS:

1. Demonstrate checks to be madeon the base/foundation/tracksystem and tower sections.

• Foundation attachments

• Tracks are clear of obstructions

(where applicable)

• Rail travel clamps have been

removed (where applicable)

• Visually check that nomaintenance personnel are

working on or near the crane

• Main isolation switch(where applicable) - ensure

no safety tags

• Travel mechanism

(where applicable)

• Travel limits

(where applicable)

• Counterweights

• Tower bolts are secure

• Ties (where applicable)

• Structural damage to

tower section

• Access ladders and kickplates

• Slew mechanism

• Lighting (where appropriate)

2. Demonstrate checks that should be made beforeyou start the motor (walk around check oncarrier and machine deck).

• Visual check of motor

• Radiator water

• Fuel level

• All oil levels eg. motor,

gearbox, hydraulic

• Lubrication (grease)

• Battery Water

• Oil/water leaks on machinery

deck and carrier

• Communication system

• SWL and manufacturers

data plate of crane

• Load radius indicator

• Load chart

• Examine all ropes, wires,anchorages, splices and

hooks where practical

• Any structural damage of crane

• Rope drums

• Examine all brake mechanisms

• Access to machinery deck

• Controls identified and use

explained

• Fire extinguisher is present

• Cabin windows are clean

• Guard railings

• Pneumatic system


• Visual check of all mechanical

equipment

• Machinery deck drainage

• Lock to access manhole

• Electrical system

START UP CRANE:

3. What checks should be made after themotor has been started? (Critical whereapplicable.)

• Throttle control

• Check boost pressure gauge - must read 100PSI or 700 KPa or 7 BAR, ie tomanufacturer's specification

Caution:Do not move any motion until boost pressureis raised to correct pressure.Do not move anymotion until after a warm up period for hydraulic

and engine oils.

• Hoist brake

• Luff brake

• Maximum radius limit

• Minimum radius limit and

deceleration limit

• Hoist limit and deceleration limit

• Cavitation switches

• Deadman operation on all controls

• Communication system

• "Back up" signalling system

• Slew brake

• Horn/lights/drive indicator

• Travel brake (where applicable)

• Radius indicator

• Trolley brake (where applicable)

• Counterweights and attachments

• Trolley travel limits (where applicable)

SITE/JOB PLANNING:

4. On arrival to the workplacewhat pre-erection inspection mustbe made?• Check site plan for working

radii at given locations from

tower.

• Check tower crane foundationanchorages. Sight engineer's

certificate.

• Maximum free standing height

of the crane.

5. What is the function of the service

log book?It explains the service maintenancecarried out and any defects foundand repaired.

6. Produce the service log book and explaincritical entries.Log book produced and explained.

OPERATE CRANE:

7. Demonstrate all of the following signals.• Stop - hand

• Stop - whistle

• Hoist up - hand


• Hoist up - whistle

• Hoist down - hand

• Hoist down - whistle

• Luff boom down - hand

• Luff boom down - whistle

• Luff boom up - hand

• Luff boom up - whistle

• Slew left - hand

• Slew left - whistle

• Slew right - hand

• Slew right - whistle

• Jib/trolley extend - hand

• Jib/trolley extend - whistle

• Jib/trolley retract - hand

• Jib/trolley retract - whistle

• Creep - hand

Note:Whistle signal for trolley extended or retracted canbe utilised by using the boom extend or retractsignal.

8. Explain the load chart and its capabilities at thefollowing 4 boom angles or trolley positions.

LOAD

Working Radius

Angle/trolley position

LOAD

Working Radius


LOAD

Working Radius


LOAD

Working Radius


Note:An assessor can give the load and ask for the otheritems to be calculated or else give the workingradius and angle/trolley position and ask for the loadto be calculated.

9. Demonstrate all crane movements.• Secure load

• Load correctly slung

• Conduct trial lift

• Lift conforms with load chart

• Jib positioned over load correctly

• Hoist

• Move load

• Lower

• Luff up

• Luff down

• Slew load


• Trolley travel

• Travel with load

• All movements smooth/adequate speed

• Tag line used (where applicable)

• Signals interpreted correctly

• Load placed correctly on dunnage (whereapplicable)

• Load unslung

• Hook and attachment raised to safe height

SHUT DOWN CRANE:

10. Demonstrate shut down procedures.

• Hazard lights (aircraft warning)

• Slings removed

• Raise hook to maximum height

• Shut down as per manufacturers instructionsand as per site conditions

• Free slew (where applicable)

• Lock and secure crane

SET UP AND DISMANTLE CRANE:

11. Demonstrate competence either through recordof training or by answering the following:

Record of training shows erection procedurecompleted.

List the sequence of events involved in theerection procedure.

Note:Question only relates to the crane driver'sinvolvement.

Erection Sequence• Anchors

• Tower sections

• Slew ring

• Machine deck

• Cabin

• Controls

• Power pack

• Counter weight & attachments

• `A' Frame

• Boom

• Sheaves and bearings

• Ropes and attachments

• Climbing frame equipment

14. Demonstrate competence in special operationseither through record of training, bypresentation of Rigging Certificate, or byanswering the following:Record of training/Rigging Certificate internaland external climbing sequences completed.

List the sequence of events involved in theclimbing for both internal and externalclimbers.



Climbing Sequence (Internal)• Ensure climbing cylinders are full of oil and

no air is trapped in cylinders

• Safety throttling valves on both cylinders arechecked and adjusted

• Before commencement of climbing, ensure thattower will be guided at two positionsthroughout the whole operation untilcompletion

• Guides must be at least 6metres apart

• It is important to ensure the guides areaccurately placed

• It is important to ensure the crane is balanced

• It is important to ensure clearance of tower leg(at least 3mm)

Equilibrium of the crane is achieved by:• Locking the travelling counter weight

• Luff the crane into the minimum radius

• Secure the lock plates oncounter weight trolleys tospecial lugs located on the underside of thecounter weight trolley track

• Luff out slowly, the lugs will anchor the trolleyand counter weights will tay in the minimumradius position

• Luff the boom out with caution until the craneis in equilibrium

• Place a steel bearing plate under the climbingrams to distribute the load over the concretesurface.

• Connect special climbing hoses to the quickrelease connections on the climbing frame(care must be taken to prevent dust and foreignmatter entering the system)

• Set engine throttle at 1,500 Rpm

• The climbing control valve located at the frontof the winch unit can then be operated

• The crane should commence to rise slowly

• If there is no visible movement check forobstructions or an out of balance condition ofthe tower

• Raise the crane sufficiently to enable the outerclimbing support beams to be extended on thehigher floor

• Lower the crane by reversingthe climbing control valve until the load istaken on the outer support beams

• Retract the cylinders until the centre climbingsupport beam can be extended as well

• Care must be taken to equalise the retractionrate of the cylinders

• This can be achieved by the manuallycontrolled balancing valve located at the baseof the tower

• Ensure that the support beam remains in thehorizontal position


Climbing Sequence (External)• Mono rail fitted

• Tower sections placed at baseof tower ready for use in climb

• Tower section placed on the monorail

• Boom up

• Disconnect counter weight and locate close totower

• Equilibrium of crane can nowbe achieved by luffing up and having firsttower section ready on mono rail

• Lock slew ring, when in position to climb

• "Fitter" will disconnect slew hose and attachthem to the climbing rams.

• Climb the crane

• "Rigger" then pulls in tower section on monorail

• Crane is then lowered slightly, not more than15mm

• Drifts fitted

Note:Crane should only work to 50% of its rated capacitywhile on drifts

• Climb down until mount is just clear of towersection pad

• Bolts inserted and tightened to specified torque

On Completion of Climb

• Place mono rail beam onground

• Disconnect climbing hose and coil on machinedeck

• "Fitter" re-connects slew hoseto slew motor

• Re-connect counter weight trolleys; this can beachieved by luffing into minimum radius and

the lock plates release this allowing thecounter weight to travel in relation to theboom.

15. List the sequence of events involved in thedismantling process.


Dismantling Sequence(Crane driver has very little involvement in thedismantling operation)• External and internal tower crane sequence

for dismantling is identical to that of erectionand climbing procedure. But, in the reverseorder. After the slew ring is locked and the"Fitter" has disconnected the slew hose andattached the lines to the climbing reins. Thecrane is then removed from the workplace withthe assistance of another crane.

Special Operations• Covered in knowledge assessment.

Warnings• Before operating the crane in new position

always ensure that the crane is checked at twolevels of lateral support.

• Where tower passes through penetration infloor ensure tower section are checked with foxwedges to improve stability near the base.


Tower Cranes - Performance

RELATIONSHIP TO THE NATIONAL CERTIFICATION STANDARD

THE UNITS OF COMPETENCE

The items in the practical performanceassessment are intended to assess thecompetencies of the applicant in the safe useof Tower Cranes as described in Schedule Bof the National Occupational Health andSafety Certification Standard for Users andOperators of Industrial Equipment.

These are as follows:

1.0 Assess and secure equipment and workarea.

2.0 Secure and transfer load.

3.0 Set up and dismantle mobile or towercranes.

4.0 Carry out special operations withmobile or tower cranes.

Each unit of competence is subdivided intoelements of competence, for whichperformance criteria are prescribed. Thequestions in each section of the assessmentcover the following competencies.

1. Pre-operational checks

Performance Criteria 1.1.1, 1.1.3, 1.3.4.

2. Start up crane

Performance Criteria 1.3.1, 1.3.2, 1.3.3,1.3.4, 1.3.5.

3. Site/job planning

Performance Criteria 1.1.2, 1.2.1, 1.2.2,1.2.3.

4. Operate crane

Performance Criteria 1.2.1, 1.2.2, 1.2.6,1.2.7, 1.3.1, 1.3.2, 1.3.5, 2.1.1, 2.1.2,2.1.3, 2.2.1, 2.2.2, 2.2.3, 2.2.4, 2.2.5,2.3.1, 2.3.2, 2.3.3, 2.3.4, 2.3.5.

5. Shut down crane

Performance Criteria 1.4.1, 1.4.2, 1.4.3,1.4.6.

6. Set up and dismantle crane

Performance Criteria 3.1.1, 3.1.2, 3.2.3,3.4.1, 3.4.2, 3.4.3, 3.4.4.

7. Special operations

Covered in knowledge assessment.

THE RANGE STATEMENT

The performance assessment takes intoaccount factors described in the rangestatements, including relevant standards andrelevant State/Territory occupational healthand safety legislation.

Tower Cranes – Oral/Written June 1994 9

National OHS Certification Standard

Cranes and Hoists

Tower Cranes

Oral/Written Assessment

June 1994

Tower Cranes – Oral/Written June 1994 10

TOWER CRANES

Assessor Guidelines - Specific

1. The knowledge assessment consists of 70questions, with 18 compulsory questions. Thecompulsory questions are identified under eachoperational area heading.

Compulsory questions have part or all of theanswers identified as critical. All criticalcomponents must be answered correctly, and atleast 75% of other components answeredcorrectly, for the applicant to be assessed ascompetent.

2. Fifteen questions from the other 52 questionsare to be randomly selected (manually or bycomputer) with at least one question from eachof the following operational areas -

1) Pre-operational checks2) Start up crane3) Site/job planning4) Operate crane5) Shut down crane6) Set up and dismantle crane7) Special operations

3. The knowledge assessment may be given orally,or as a mixture of oral and written.

4. In the Operate Crane planning section thequestions, including compulsory questions, aregrouped in general subject areas.

Operationalarea

No.critical

questions

No. non-critical

questionsto select

Totalquestion

sselected

123457

0 2 3 8 4 1

1 1 2 8) 3)

1 3 5 16 8

Total 18 15 33

Tower Cranes - Oral/Written June 1994 11

PRE-OPERATIONAL CHECKS:

1. Explain the function of the mechanicalboom radius indicator, and how it works.Applicant shows all connections frombase of boom to final position

on control panel.

2. On checking the fuel systems, you noticea leak at one of the hose connections. What action should you take?If unable to repair report to

authorised person.

3. You noticed that one of the towerframe connection bolts was loose, whatwould you do?Immediately stop work and contact anauthorised person, who would arrangefor a competent person to inspect the

remainder of the tower bolts.

4. Why does the trap door which leads to themachine deck have to be locked with a chainand padlock if necessary?So that unauthorised persons cannot gainaccess to the machine deck and

start the crane.

START UP CRANE:

Questions 9 and 10 are compulsory

5. You are working in cold conditions, whywould you have to take special care whenstarting up?Extra time would have to be taken toallow the engine and hydraulic oils to

warm up.

6. What happens when the luff out ultimate isactuated?The limit de-energises the luff out solenoid andstops the luff out motion, the brake is

automatically applied.

7. What happens when the luff in ultimate isactuated?The luff in limit when actuated, provides acomplete shut down of the crane including

engine and all brakes are applied

8. What limits are on the hoist and how do theywork?Hoist up and hoist down limits are usually ofthe hunting tooth type. The hoist down limitshould stop the hoist hook from hitting theground and should stop the motion when thereare two full turns of rope remaining on the

drum.

Note:The hoist down limits should be adjusted afterevery climb. Hoist up limit is set with jib atmaximum radius.

• Declaration limit is set to trip atapproximately 5 metres below jib head.

• Up limit is set at approximately 2 metresbelow jib head.

• Ultimate limit is set approximately 1metre below jib head.

9. What is cavitation and what is the anti-cavitation device and why is it important?Cavitation is when the pumps are dragginghydraulic oil faster than it can be suppliedand the pumps suck air allowing a free-fall. The anti-cavitation device senses

cavitation and applies the brakes.


10. How do you check the anti-cavitation device?

Note:All limits are important but the anti-cavitationdevice is of extreme importance. Assessors mustsee the applicant crack the anti-cavitation device. There is a small pressure line which simulatescavitation if it is cracked. An air release is heardand brakes will be applied and controls willreturn to neutral

SITE/JOB PLANNING:

Questions 11, 12 and 13 are compulsory

11. What procedures should you follow inpreparing an operational plan for atower crane?Job requirements, priorities, workplace rules and procedures, identified hazards

and hazard control measures.

12. What types of hazards would you consider forincorporation into your workplan?

• Powerlines

• Trees

• Overhead service lines

• Surrounding structures

• Obstructions

• Facilities

• Other equipment

• Dangerous materials

13. What hazard control strategies would need tobe included in the plan for the craneprocedures?A hazard control strategy plan shall addressthe following areas:-

• Task being performed

• Any site hazards - filledground; power lines; obstructionsin the working radius of the boom,scaffold, ladders; access and exit

points.

• PPE required by tower crane

personnel

• Traffic controls

• Lights/lighting

• Public safety

• Hoardings

14. What is the importance of havingworkplace emergency procedures?In the case of an emergency that mayarise in the workplace (fire, collapses,serious accident to individual/s) a planshould be developed and put in placein the workplace that lays out asequence of events that should

be followed.

15. What matters should be consideredwhen developing emergency procedures?Raising of the alarm.Location of fire fighting equipment.Location of first aid facilities/equipment.Location of first aid personnel box.Location of telephones and emergenciesnumbers.

Location of evacuation muster area.


16. In the case of an emergency situation,a set of procedures should bedeveloped specifically relating toyour crane. Why?

Note:Assessor may need to give an exampleof emergency situation.

The tower crane in most cases is fixedin one position, has to a certainextent an element of isolation. The crane driver's means of escapein an emergency is in most casesby climbing down the tower to a level where the personnel hoist isoperating or all the way to theground by means of the tower.

Most workplaces have an alternateemergency escape route, due to thefact that the personnel hoist maybeaffected by the emergency situation.It is essential to notify the persondogging the load prior to leaving

the crane cabin.

17. In the case of an emergency why is itimportant to communicate with theperson dogging the load prior toleaving the crane?To find out the area or areas thatmay be unsafe for the crane driverto pass. The person dogging the loadwill inform the driver as to the natureof the emergency and also make someoneaware at ground level that you aremaking your way down.

The person dogging the load cangive instructions as to whether it may besafer to stay in the cabin until the situation

has eased.

18. Your crane is set up very close to abuilding which is next door to the sitewhere you are working. If you slew toofar, your counter weight will hit the building. What special precautions must be takenwhen you park the crane?

The crane cannot be left in free slewas is normally done when parkingtower cranes. With the long boomcrane, an engineer's permissionshould be obtained to ensure that itis safe to leave the slew locked

when parking the crane.

19. You notice that scaffolders are erecting ascaffold which is close to the crane - whatshould you do?Have them stop until you check whetherthe scaffold will be hit by the counter-weight or other part of the crane

when you slew.

20. What equipment should be provided forthe crane operations working at night or indarkened areas?There should be sufficient lighting

over the whole work area.

21. What is the importance of having anoperations plan that ensures the correctlighting for the workplace?The importance of having an operationsplan with regards to lighting is task/jobscheduling, taking environmental factorsinto account can greatly improve conditionsin the workplace.• working directly into the sun, which

includes the hottest hours of the day

• working at night using artificial lightsources

• access and exit

• limited visibility during rain

conditions etc.

22. If power failure is to be of a long term problem,what needs to be done?An authorised electrician investigates theproblem and where necessary has a danger tagplaced on the main switch board until

rectified.


OPERATE CRANE:

Questions 27, 29, 37, 43, 44, 50, 51 and 52 arecompulsory

23. When interference (tampering) isidentified, to whom should the cranedriver report any faults?

To an authorised person.

24. What warnings are indicated by theenunciator panel?Low engine oilLow coolant levelLow boost pressure

Hydraulic filter bypass warning

25. Concrete form work shutters haveto be stripped and lowered to theground. While the carpenters arereleasing a shutter, a very strong windblows up. What should you do?Lay the shutter down. If the wind isvery strong do not take it down.Inform an authorised person regarding

the wind condition.

26. What would you do if a very stronggale force wind blows up?As per manufacturers

recommendations.

27. The crane will boom up but will not boomdown. When you push the controller toboom down the motor starts to fade.What action should be taken?Cease operation. Check for cause

and take appropriate action.

28. A tower crane has been set up on anew site. Your truck unloading positionrequires you to lift from the street. People walk along that footpath, whatshould be done so that work can progress?The walkway should be covered with apedestrian hoarding which conforms torelevant standards. Do not lift over

pedestrians/public.

29. (i) What is the minimum distanceany part of the crane and load isallowed to set-up near overheadpowerlines?2 metres from distribution lines onpoles, 6 metres from transmissionlines on towers, closer if lines are

covered.

(ii) If you want to work closer than thesedistances what can you do?Must seek an exemption from

the relevant authority.

30. The crane hoist rope is 2.5 metresaway from distribution lines on poles. The load you are to pick up is steel andover 5 metres long. The load could spinand hit the power lines. What shouldbe done?The person dogging the load shouldcontrol the load with a hand held

tag line

31. The building next to your constructionsite is one of the new mirrored glassbuildings. At a certain time of day, theglare is such that you cannot see inpositions where it could be assumedthat you can see the job. What shouldyou do?Inform the person dogging the loadthat you cannot see because of the glare. Treat the job as you would normallywhen working out of sight. Wearpersonal protective equipment

(AS approved tinted glasses).

32. You have to lift an internal lift shaftformwork shutter. You know it weighstwo tonnes. The person dogging the loadslings it and you take the weight. Theweight gauge shows an increasing strainover two tonnes. What should you do?Stop hoisting immediately if the straingoes over two tonnes, the shutter could bejammed. If it freed suddenly it could be a

hazard and injure people.


33. What is the maximum wind speedthat tower cranes can work in?As per manufacturers

recommendations.

34. You have some formwork shutters,to lower from aloft. While the carpentersare freeing them a strong wind blows up. What should you do?Shutters are large in area but light inweight, therefore they could flap aroundin the wind. Inform the supervisor thatyou will bring them down when the

wind drops.

Note:Some applicants may say place them together andbring them down on the flat. This is a correctmethod if the wind is not too strong.

35. What hazard exists when accessing andegressing steel ladders in wet weather?The access ladder will be slippery, it

would be easy to slip and fall.

36. If the work takes longer thanexpected and natural lighting isfading, what steps/action shouldyou take?At the instance where natural lightinghas faded to the point where it isunsafe to operate the crane, informthe person dogging the load thatwork will cease until artificial

lighting has been set up.

37. If the boom length is lengthened, whatneeds to be done to the load radiusindicator chart?Ensure that the load chartcalibration is readjusted to

the new boom length.

38. During operation of the crane,electrical power failure/fault occurs. What would you do?Communicate with the persondogging the load and advise

of the problem for rectification.

39. If you heard abnormal noises comingfrom the machine deck, what maincomponents would you check?Hoist brake, luff brake, slew brake, main engine, hydraulic pumps ie hoist,luff, slew, gear box, hoistand luff drive, spur wheels and

drive pinions.

40. What action would you take andwhat would you look for if you hearda sudden loud noise just underneath themachine deck?Cease operation immediately andlook for any broken gears on theslew ring, report to an authorised

person.

41. What would you do if you heard a loudnoise and felt vibration coming from anarea lower down on the tower section?Cease operation immediately andcommunicate with the person doggingthe load to have an inspection carriedout to identify whether some form of heavyplant has struck the main tower andcheck for damage, report to an

authorised person.

42. You have hit the luff in limit and theengine has stopped. How do you re-start the motor?Manufacturers require that the mechanicbe called to re-start the crane if the luff-inlimit is actuated. This is to ensure thatthe luff pump is not in stroke while thecontroller is in neutral. Some ownershave fitted luff override buttons toallow the motor to be started and boomdown to take place, but manufacturers

believe that a mechanic should be called.

43. Why is it important that all motion limitsare checked for correct functioning?You could overrun and cause structural,

personnel and property damage.


44. What precautions must be taken when longtravelling?• Prior to operating, ensure that there

are no obstructions in the

tracks.

• Ensure that working radius has

being calculated prior to travelling.

• Ensure that there are no people, forexample, people fishing on wharfs, whocould be in danger of travelling

crane.

• When travelling long distances, siren

and flashing lights must be fitted.

• Ensure that load is controlled bythe person dogging the load and/or

tag lines where necessary.

• Ensure that "people pushers"

or wheel guards are in place.

• Travel at minimum speeds.

• Ensure that crane travelling ismechanically stopped prior to

reaching end stops.

Note:Some hydraulic tower cranes are put on a travellingbase which is counterweighted toengineers/manufacturers specifications, they run onrails and have end stops. When fitted as a travellingcrane, they have a separate travel motor which isnear the base, these are usually fitted so that it canbe driven from the base or the drivers cabin.

45. If you observed a defect in one ofthe main controls, who would you reportthis to for rectification and who would beresponsible for rectification work?To an authorised person, whowould then contact the mechanic

for corrective action.

46. If any signals are observed throughwarning lights, alarms or gauges, whataction would you take to have the defectrectified?Cease all operations, investigate where theproblem is and report problem to an authorised

person, for action.

47. Why do you have to have a machinedeck well and rain water storage, whichcan be drained by opening a cock?This is to ensure that oils and greaseswhich may leak are not washed down

all over the job/crane access.

48. You are driving a tower crane which isfitted on to a travelling base. Whyshould access to the travel motor in thebase be locked off?So that unauthorised personscannot gain access to the base start,the travel motor and drive the crane

along the rails.

49. What action would you take ifthe boom struck a power line?Attempt to break contact withthe power by controlling the

main boom.

50. A person dogging a load puts a handon the hook and starts to jump asthough they are getting an electricshock. What should you do?If possible, lift hook clear of theperson dogging the load to breakcontact with earth. Follow relevantfirst aid procedure as required. If

possible, get somebody to assist.

51. Are you permitted to allow a personto ride upon the lifting hook, slingattachment or suspended load?

No.

52. Explain the requirements that wouldpermit you to lift personnel using thecrane?• Any requirements specified by crane

manufacturer.


• Any requirements covered by workplaceconditions.

• Applicant to explain requirement for thework box -refer Clause 7.16.2 of AS 2550Part 1.

• Applicant to explain requirements for thecrane - refer Clause 7.16.3 of AS 2550Part 1.

• Applicant to explain the operatorrequirements - refer Clause 7.16.4

of AS 2550 Part 1.

Note:Statutory authorities may have other conditions.

53. Explain the use of packing or dunnagewhen slinging a load.

• To protect the load.

• To facilitate the

connection/disconnection.

• To prevent damage to lifting gear.

SHUT DOWN:

Questions 61, 62, 63 and 64 are compulsory

54. When shutting down the crane,what check is most importantwith the pawl to the luff drum,and how would you ensurethis procedure was done?The pawl `must' be fully engaged. Firstly by observing the light onthe control panel, then by physicallyproceeding to the luff drumand sighting that the pawl

if fully engaged.

55. On a luffing boom crane what isthe ideal radius to leave the boom induring shut down?With the head sheave on the boom,approximately level with the head

of the`A' frame.

56. If the boom cannot be left at thedesired radius because of theobstruction of surrounding buildingsetc. and must be left at the minimumradius, what procedure would you follow?Have a qualified engineer assess thesituation, taking into account theeffects on the crane caused by wind

loadings.

57. If the crane is located near aircrafttraffic zones, what must be switchedon at night?The red warning light at the uppermost

point of the crane.

58. What would you do with theplatform access hatch on shut down?Ensure that it is securely closed

and locked with a key lock.

59. What must be done to the baseof a travelling tower crane on shut down?(i) Ensure that blocks are placed at

base of wheels to prevent

movement of crane.

(ii) Make sure that the electricmotor to the travelling wheelmechanism is isolated

and locked.

60. On shutting down an electricpowered ie hammerhead type crane, whatis the most important thing to be done?Ensure that all electric circuits are

fully isolated - locked off.


61. Is it permitted for any loads includingslings to remain suspended fromthe hook following shut down?

No.

62. Why is it essential that you checkwhether the pawl is fully engagedbefore leaving the crane overnight?To ensure that the pawl is not riding

on the top of the tooth on the ratchet.

63. If the crane is to be left in free slew,why is it important that you raise thehook clear of obstructions for thefull 360o around the crane?When in free slew the crane

can paravane.

64. Why do you have to connect themachine deck water drain to asystem that can take water awayduring periods of shut down?This is to ensure that oils andgreases which may leak are notwashed down all over the

crane and job.

65. You are driving a crane which is ona travelling base. Why is it essentialthat travel locks are clipped to therails as you leave the crane?These locks stop the crane frombeing blown down the rails

by strong winds.

66. On an electric hammerhead type,why should you bring the trolleyback to near the tower for parking?So that the trolley-hook assembly

creates less wind resistance.

67. Do you leave hammerhead typecranes in free slew for parking?Yes. Or as otherwise required for site

conditions.

SET UP AND DISMANTLE CRANE:

Covered in performance assessment.

SPECIAL OPERATIONS:

Question 69 is compulsory

68. How often should the load mass (weight)indicator be calibrated?Six monthly, by picking up a knownweight, or in accordance with

manufacturer's specifications.

68. How do you lower the load in anemergency?As per manufacturers

recommendations.

Note:This operation differs from crane to crane. Operators must know their particular crane and beable to describe to the Assessor exactly how it isdone. Operators have a responsibility to ensurethat they can emergency lower on any crane thatthey operate. It is essential for the applicant toknow this. If not, then they should not be assessedas competent.

70. Is it permitted to carry out a multiple lift?

Refer to the statutory authority.


Tower Cranes - Oral/Written

RELATIONSHIP TO THE NATIONAL CERTIFICATION STANDARD

THE UNITS OF COMPETENCE

The items in this part of the knowledge assessmentare intended to assess the competencies of theapplicant in the safe use of Tower Cranes asdescribed in Schedule B of the NationalOccupational Health and Safety CertificationStandard for Users and Operators of IndustrialEquipment.

These are as follows:

1.0 Assess and secure equipment and work area.2.0 Secure and transfer load.3.0 Set up and dismantle tower cranes.4.0 Carry out special operations with tower

cranes.

Each unit of competence is subdivided into elementsof competence, for which performance criteria areprescribed. The questions in each section of theassessment cover the following competencies.

1. Pre-operation checks

Performance Criteria 1.1.1, 1.1.3.

2. Start up crane

Performance Criteria 1.3.1, 1.3.2, 1.3.3, 1.3.4.

3. Site/job planning

Performance Criteria 1.2.1, 1.2.2, 1.2.3, 1.2.4,1.2.5, 1.2.8, 1.3.4.

4. Operate crane

Performance Criteria 1.2.1, 1.2.2, 1.2.4, 1.2.6,1.2.7, 1.3.1, 1.3.2, 1.3.5, 2.1.1, 2.1.2, 2.2.1,2.2.2, 2.2.3, 2.2.5, 2.3.2, 2.3.3, 2.3.5.

5. Shut down crane

Performance Criteria 1.4.1, 1.4.2, 1.4.3, 1.4.6,3.3.1.

6. Set up and dismantle cran

Covered in performance assessment.

7. Special operations

Performance Criteria 4.3.1, 4.3.2, 4.3.3.

THE RANGE STATEMENT

This part of the knowledge assessment takes intoaccount factors described in the range statements,including relevant standards and relevantState/Territory occupational health and safetylegislation.

Tower Cranes June 1994 20

Assessment summary

! Tower Cranes

Form ofassessment

Totalnumber of

items in theassessment

Number ofitems given!!!! or NA

Number ofitems

required tomeet

standard

Were allcritical boxesgiven !!!! or

NA?

Assessmentstandard

requirementsachieved *

Performance 15 13 Yes No Yes No

Oral/Written 33 29 Yes No Yes No

Written 22 17 Yes No Yes No

Assessment completed within time allowed Yes No NA

* Performance standard = Number of items required to meet standard (including all critical boxes)Knowledge standard = Number of questions required to meet standard (including all critical boxes)

Summary

Candidate is: COMPETENT Date: ........................................(circle the result obtained)

NOT YET COMPETENT

Name of ................................................. Name ofassessor ................................................. candidate ..................................................

Signature ................................................ Signature ..................................................

Comments/feedback(assessors to make any additional comments which clarify the assessment)

..........................................................................................................................................................................

..........................................................................................................................................................................

..........................................................................................................................................................................

..........................................................................................................................................................................

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..........................................................................................................................................................................

tower crane-assessment instrument

Documents

national occupational health

service log book

safety certification standard

including relevant standards

assessor guidelines specific1

strong wind blows

cease operation immediately

operational checks start