tower cranes commisioning[1]

8/13/2019 Tower Cranes Commisioning[1]

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16. Inspecting, testing, maintaining and repairing tower cranes

16.1 'Competent person' for inspecting tower cranes

16.2 Requirements for non-destructive testing16.3 Pre-erection inspections and tests (on ground inspection)

16. Commissioning inspections and tests

16.! Pre-operationa" inspection16.6 Routine inspection and maintenance

16.# $nnua" inspections

16.% 1&-ear maor inspection

16. Records of inspections and maintenance

16.1& *ower crane maintenance

16.11 *ower crane repair

16.12 +econd-,and imported tower cranes

ai"ure to carr out appropriate p"anned inspections tests and preventative maintenance

programs ma "ead to decreased safet and efficienc in t,e operation of t,e tower

crane.

/nspection and appropriate testing must 0e carried out at sufficient" frequent interva"s toensure

a. t,e parts of t,e crane su0ect to deterioration t,roug, corrosion damage wear

and a0rasion are rep"aced 0efore t,e 0ecome unservicea0"e and

0. t,e crane is maintained in a safe and servicea0"e condition.

*,e inspection and testing regime for tower cranes consists of t,e fo""owing

a. pre-erection inspection and tests0. commissioning inspection and tests

c. pre-operationa" inspection

d. routine inspection and maintenance

e. annua" inspection and

f. 1&-ear maor inspection.

16.1 'Competent person' for inspecting tower cranes

*,e Workplace Health and Safety Act 1995(P #66 45) inc"udes o0"igations for persons

conducting a 0usiness or undertaing owners and supp"iers of p"ant. $n o0"igation ,o"der

w,o owns a crane ma engage a competent person to inspect t,e crane to determine

w,et,er t,e condition of t,e crane poses a ris to safet.

$ competent person can 0e

a. t,e owner of t,e crane0. a person emp"oed 0 t,e owner of t,e crane (i.e. w,ere t,e owner is a"so an

emp"oer) or

c. an independent consu"tant or t,ird part.

16.1.1 Inspecting specific parts of a crane
http://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/competent/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/non-destructive/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/pre-erection/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/commissioning/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/pre-operational/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/routine/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/annual/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/records/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/maintenance/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/repair/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/second-hand/index.htmhttp://www.legislation.qld.gov.au/LEGISLTN/CURRENT/W/WorkplHSaA95.pdfhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/competent/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/non-destructive/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/pre-erection/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/commissioning/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/pre-operational/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/routine/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/annual/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/records/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/maintenance/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/repair/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/second-hand/index.htmhttp://www.legislation.qld.gov.au/LEGISLTN/CURRENT/W/WorkplHSaA95.pdf


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$ competent person w,o ,as 0een engaged to inspect a specific part of a crane s,ou"d

,ave suita0"e e7perience and now"edge in t,e inspection of t,at part of t,e crane. *,is

person ma not necessari" need e7perience in inspecting t,e comp"ete crane.

or e7amp"e

a. $ competent person inspecting we"ding on a crane s,ou"d ,ave suita0"enow"edge and e7perience in t,e inspection and testing of we"ds inc"uding

now"edge of non-destructive testing met,ods and $+89:+ 1!! Structural

steel welding(non-;ueens"and


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=,ere an a"teration ,as 0een made to t,e design of a crane t,e competent person must

0e an engineer wit, suita0"e now"edge and e7perience. /t is "ie" t,at t,e competent

person wi"" need to perform engineering ca"cu"ations on t,e crane design to determinet,at it comp"ies wit, re"evant tec,nica" standards.

16.2 Requirements for non-destructie testing

9on-destructive testing (9*) is t,e testing of materia"s to detect interna" surface and

concea"ed defects or discontinuities using met,ods w,ic, do not damage or destro t,e

materia" under test. 9* of specific tower crane components must tae p"ace at set

interva"s (e.g. pre-erection tests and maor inspection). *a0"e 1 specifies t,e minimum

frequenc of 9* for particu"ar crane components.

$"" 9* must 0e carried out 0 a competent person w,o ,as 0een accredited 0 t,e

9$*$. *,e resu"ts of 9* must 0e avai"a0"e at t,e worp"ace w,ere t,e crane is erected.

=,en using 9* for t,e detection of cracs in meta"s t,e paint must 0e removed from

t,e meta" surface.

Component tested !"# description !"# frequenc$

5oom c"evises Crac test Pre-erection

Counterweig,t s,eave0racet we"ds - moving

counterweig,ts on"

Crac test Pre-erection

Cruciform we"ds ("uffing

cranes on")


5utt ,ea" 0osses ("uffingcranes on")


5and 0rae we"ds Crac test Pre-erection

+"ew ring 0o"ts (w,ere s"ew

ring ,as to 0e sp"it atdisassem0")

Crac test minimum

1& > 0o"ts

Pre-erection

*ower 0o"ts Crac test minimum

1& > 0o"ts

Pre-erection


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$"uminium s,eaves Crac test Pre-erection

+"ew ring 0o"ts (a"" s"ew

rings)

Crac test a"" 0o"ts ! ears

5oom c,ord t,icness ?ateria" t,icnesstesting

1& ears

+"ew ring Crac test 1& ears

@drau"ic "uffing c"inder

g"and nut

Crac test 1& ears

@drau"ic "uffing c"inder

and ram (rod ends andcaps)

Crac test 1& ears

5oom "acing we"ds Crac test minimum

1&>

1& ears

$-frame (a"" connector

we"ds on primar c,ords)

Crac test 1& ears

$-frame "acing we"ds Crac test minimum

1&>

1& ears

@oo Crac test 1& ears

=e"ds on ,oo tro""e Crac test 1& ears

*a0"e 1 requenc of 9* testing for specific tower crane components

16.2.1 Crac% testing of &ooms and counterweigt seae &rac%et welds

5ooms on non-se"f-erecting tower cranes are connected 0 pins t,at pass t,roug, ma"e

and fema"e c"evises on t,e ends of eac, 0oom section. $"" we"ds on ma"e and fema"e

c"evises on t,e ends of ever 0oom section s,ou"d undergo 9* prior to eac, crane

erection for non-se"f-erecting cranes. ?agnetic partic"e testing is t,e usua" met,od used

for performing t,ese tests.


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/n addition to carring out crac testing of connection c"evises "uffing crane 0ooms ,ave

a ,istor of cracing in t,e fo""owing areas

a. counterweig,t s,eave 0racet we"ds0. we"ds in cruciform area and

c. 0utt ,ea" 0osses.

*,ese areas s,ou"d a"so 0e crac tested 0 9* prior to eac, crane erection.

16.2.2 Crac% testing of &and &ra%es

A"der designed avco tower cranes are provided wit, 0and 0raes. An some of t,ese

cranes t,e stee" 0and is we"ded to an end fitting t,at ,as a pin passing t,roug, it. *,ese

we"ds ,ave 0een nown to crac.

$"" avco tower cranes fitted wit, 0and 0raes must ,ave t,e we"d 0etween t,e 0and and

t,e end fitting crac tested 0 9* prior to eac, erection. 9ote t,at t,ere ma not 0e a

we"d on some 0rae 0ands.

16.2.3 Crac% testing of slew ring &olts

*,e integrit of s"ew ring 0o"ts is critica" for ensuring 0ot, t,e mac,ine dec and 0oom

remain attac,ed to t,e tower. +"ew ring 0o"ts ma 0ecome damaged and t,eir effective

"ife reduced if 0o"ts are eit,er under or over-torqued.

or tower cranes w,ere t,e s"ew ring must 0e sp"it eac, time t,e crane is moved (e.g.

avco 1!&&) 1&> of s"ew ring 0o"ts must undergo 9*. 5o"ts to 0e tested are to 0ese"ected from t,e s"ew ring 0 a competent person. /f an cracs are detected a"" 0o"ts

must 0e tested.

$"" s"ew ring 0o"ts on tower cranes inc"uding se"f-erecting tower cranes must undergo

9* at "east ever five ears. *,e preferred sstem of testing is to comp"ete" removet,e 0o"ts from t,e s"ew ring and e7amine t,em 0 magnetic partic"e testing.

16.2.( Crac% testing of tower &olts

*ower 0o"ts are a critica" part of t,e crane and permit t,e effective transfer of "oad from

t,e crane 0oom to t,e crane 0ase. *ower 0o"ts ma 0ecome damaged from o0 to o0.

*,eir effective "ife ma a"so 0e reduced if t,e 0o"ts are eit,er under or over-torqued.

=,i"e a"" tower 0o"ts are ,ig, tensi"e 0o"ts some are made from e7treme" ,ig, grade

stee" and ma 0e more suscepti0"e to cracing.

$ minimum of 1&> of tower 0o"ts must 0e crac tested 0 9* prior to eac, crane

erection. /f an cracs are found a"" tower 0o"ts must 0e crac tested.

$ sstem t,at ensures a"" tower 0o"ts are tested over time is preferred ,owever a

random sstem of testing ma a"so 0e used. $ crane owner ma decide to test more t,an

1&> of 0o"ts w,ere deemed necessar (e.g. due to a ,istor of cracing). *,e tested

0o"ts s,ou"d 0e identified 0 a met,od t,at does not damage t,e 0o"t.

16.2.) Cord tic%ness testing


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Battice-tpe tower crane 0ooms are constructed from stee". *,e components of t,ese

ma 0e prone to interna" and e7terna" corrosion affecting t,e t,icness of t,e 0oom. *,e

t,icness of t,e c,ord wa"" ma a"so 0e reduced t,roug, a0rasive 0"asting of t,e 0oom.

$"" main c,ord sections on tower crane 0ooms s,ou"d undergo t,icness testing at

interva"s not e7ceeding ten ears. "trasonic t,icness testing is one met,od of verifing

w,et,er t,ere is adequate strengt, in t,e c,ords of t,e 0oom.

C,ord sections must 0e reviewed for structura" adequac w,en t,e t,icness is s,own 0

testing to 0e &> or "ess t,an &> of t,e origina" t,icness.

16.3 *re-erection inspections and tests +on ground inspection

*ower crane components must 0e inspected and tested 0 a competent person prior to

0eing de"ivered to t,e worp"ace.

=,ere a tower crane owner is aware a crane wi"" 0e erected w,en t,e sc,edu"ed annua"

inspection is due (refer to section 16.# of t,is code) t,en t,e owner ma consider

carring out an annua" inspection during t,e pre-erection inspection.

*,ese inspections and tests must inc"ude t,e fo""owing

a. 9* of we"ds on vita" components suc, as 0oom c"evises 0utt ,ea" 0osses

counterweig,t rope s,eave 0racets

0. 9* of tower crane 0o"ts

c. 9* of s"ew ring 0o"ts

d. 9* of a"uminium s,eaves

e. t,e condition of t,e power supp" ca0"e w,ere usedf. t,e condition of motor 0raes

g. t,e condition of t,e s"ew ring gear and pinions

,. air contro"s and associated va"ves

i. t,e condition of ropes and s,eaves (e.g. erection ,oisting counterweig,t andtro""e) and correct rope tracing

. t,e condition of "imit switc,es and "imiting devices

. t,e condition of counterweig,ts

". t,e condition and fitment of mac,iner guardingm. 0rae sstems w,ic, must 0e dismant"ed and inspected for wear and damage

according to t,e fo""owing criteria

i. dr 0raesDprior to eac, erection or more frequent" if directed 0 t,e

manufacturer

ii. wet 0raesDprior to eac, erection after ! &&& ,ours of crane operation or

as directed 0 t,e manufacturer

n. a"" norma" service items inc"uding items supp"ied 0 t,e crane manufacturer (e.g.

temperature contro" units and adequate seating) 0eing maintained in a

servicea0"e condition according to t,e crane manufacturer's instructions and

o. ot,er tests specified 0 t,e manufacturer.

Ance t,e tower crane components ,ave 0een de"ivered to t,e worp"ace t,e must 0e

inspected for an possi0"e damage and wear during transport.

/nspections must a"so 0e made of

a. t,e crane 0ase design and engineer's report


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0. crane ties and structure to support t,em w,ere used and

c. t,e power supp" and eart,ing.

Crane owners s,ou"d deve"op t,eir own pre-erection inspection and test report t,atsatisfies t,e requirements of t,is code and re"evant $ustra"ian +tandards. /t s,ou"d a"so

ref"ect t,e specific tpe and mode" of crane and reference a"" re"evant design drawings

and test certificates.

16.( Commissioning inspections and tests

Commissioning inspections and tests must 0e carried out 0 a competent person once t,e

crane ,as 0een erected and 0efore it is put into service. Ance t,e performance of t,e

crane ,as 0een satisfactori" verified 0 t,e commissioning inspections and tests t,ecrane ma 0e p"aced into service.

Commissioning inspections and tests must inc"ude

a. crane e"ectricit supp" w,ere used

0. crane 0ase weig,ts or 0a""ast w,ere used

c. tower section identification and accessd. tower 0o"ts to correct tensione. c"im0ing frame and connection

f. i0 connection pins and retainers

g. $-frame connections and retainers

,. i0 and dec pendant pins and retainers w,ere used

i. mac,iner guarding

. "eaage in "ines tans va"ves pumps and ot,er parts of air or ,drau"ic

sstems

. t,e condition of t,e ropes and s,eaves (e.g. erection ,oisting tro""e andcounterweig,t) and correct rope tracing

". iso"ating switc,es

m. t,e condition and p,ase of t,e power supp" ca0"e

n. verification t,at t,e crane wiring comp"ies wit, $+89:+ 3&&& Electricalinstallations (known as the Australian/New ealand Wiring !ules"(non-;ueens"and


8/15

$ visua" inspection and functiona" test of t,e crane must 0e carried out 0 t,e crane

operator 0efore t,e commencement of eac, wor s,ift. *,is s,ou"d inc"ude inspection and

testing of t,e fo""owing

a. a"" re"evant items indicated in t,e operations manua"

0. operating and emergenc contro"s

c. 0raesd. safet switc,es and inter"ocs inc"uding "imiting and indicating devices

e. visua" inspection of t,e structure

f. wire ropes to ensure t,e are on t,e drum and correct" reeved on t,e s,eave

and

g. wire ropes for o0vious damage.

*,e resu"ts of t,e inspection must 0e entered into a "og0oo and ept wit, t,e crane.

$"" persona" protective equipment s,ou"d 0e inspected to ensure it is functioning

correct". $"" safet-re"ated pro0"ems s,ou"d 0e recorded and rectified prior to crane use.

16.6 Routine inspection and maintenance

$ program of routine inspection and maintenance s,ou"d 0e carried out 0 a competentperson in accordance wit, t,e crane manufacturer's instructions. /t s,ou"d inc"ude a

visua" inspection of t,ose re"evant items t,at can 0e safe" done w,i"e t,e crane is

erected.

Routine inspection and maintenance s,ou"d inc"ude t,e fo""owing

a. a"" functions and t,eir contro"s for speed smoot,ness of operation and "imits of

motion0. a"" emergenc and safet switc,es and inter"ocs inc"uding "imiting and indicating

devices

c. "u0rication of a"" moving parts and inspection of fi"ter e"ements and f"uid "eve"s

d. visua" inspection and measurements as necessar of structura" mem0ers and

ot,er critica" components suc, as 0raes gears fasteners pins s,afts wire

ropes s,eaves "ocing devices and e"ectrica" contactors

e. signage inc"uding warning signs and contro" marings

f. wear on w,ee"s and rai"s andg. additiona" items nominated in t,e crane manufacturer's instructions.

$"" rep"acement parts and components must 0e identica" or equiva"ent to t,e origina"

parts or components. $ written report must 0e provided upon comp"etion of t,e

inspection.

16. Annual inspections

$n annua" inspection 0 a competent person is required as part of re-registrationrequirements of t,e crane. Refer to section 6.3of t,is code for furt,er detai".

=,ere a tower crane owner is aware a crane wi"" 0e erected w,en t,e sc,edu"ed annua"

inspection fa""s due t,e owner ma consider carring out an annua" inspection prior to

crane erection or during t,e pre-erection inspection (refer to section 16.3of t,is code).
http://www.deir.qld.gov.au/workplace/law/codes/towercrane/design/index.htm#annualhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/pre-erection/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/design/index.htm#annualhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/pre-erection/index.htm


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$n annua" inspection s,ou"d inc"ude a"" items specified 0 t,e crane manufacturer for

annua" inspection as we"" as re"evant items inc"uded in t,e routine inspection and

maintenance programs.

$nnua" inspections inc"ude

a. a"" re"evant items in t,e pre-erection inspection and tests t,at can 0e safe"comp"eted w,i"e t,e crane is erected

0. t,e effective functioning and ca"i0ration of a"" "imiting and indicating devices

c. detai"ed visua" inspection and to"erance c,ecing of a"" critica" structura" and wear

componentsd. c,ecing of to"erances for wear "imit

e. a detai"ed visua" c,ec for corrosion and

f. a detai"ed visua" e7amination of critica" areas for evidence of cracing.

$ written report must 0e provided upon comp"etion of t,e inspection.

$n e7amp"e of an $nnua" crane safet certificate is provided in appendi7 . *,is

document ma 0e used as evidence t,at t,e crane ,as received an annua" safet

inspection 0 a competent person.

16. 1/-$ear ma0or inspection

AS #55$%& ' ranes) hoists and winches * Safe use * +ower cranes (non,-ueensland

.oern0ent link" specifies t,at tower cranes are to undergo a maor inspection 0 a

competent person to assess t,eir suita0i"it for continued operation. $ competent person

carring out a maor inspection s,ou"d 0e supervised 0 an engineer.

*ower cranes must undergo a maor inspection ever 1& ears. nder t,is code t,e 1&-

ear maor inspection must inc"ude inspection of t,e structure as we"" as mec,anica"

components. $ separate inspection of t,e structure ma not 0e required at 2! ears.

*,e parameters of t,e 1&-ear maor inspection s,ou"d 0e considera0" more

compre,ensive t,an t,e ear" inspection due to t,e amount and severit of operation

t,at a tower crane wi"" 0e e7posed to after 1& ears. Even if t,e crane ,as not 0een

e7posed to regu"ar operation during t,e 1&-ear period t,e crane ma ,ave deteriorated

due to t,e wa it ,as 0een stored or t,e environment in w,ic, it ,as operated in (e.g.dirt or corrosive environments). *,e 1&-ear maor inspection must 0e certified 0 an

engineer w,o ,as e7perience in t,e inspection of tower cranes. *,e engineer ma use t,e

advice of ot,er competent persons w,en preparing t,e inspection report.

$n e7amp"e of a Crane safet certificate for a 1&-ear maor inspection is provided in

appendi7 !. *,is document ma 0e used as evidence t,at t,e crane ,as received its 1&-

ear maor inspection 0 an engineer.

$ 1&-ear maor inspection invo"ves t,e e7amination (usua"" stripping down un"ess

ot,erwise determined 0 an engineer) of a"" woring components of t,e crane. $"" covers

and c"adding must 0e removed w,ere necessar to ena0"e t,e maor inspection to 0e

carried out. $ 1&-ear maor inspection requires particu"ar attention to 0e given to t,e

fo""owing

a. structura" mec,anica" e"ectrica" instrumentation contro" and operationa"anoma"ies
http://www.deir.qld.gov.au/workplace/law/codes/towercrane/appendices/annualcertificate/index.htmhttp://www.saiglobal.com/shop/Script/Details.asp?DocN=AS815815786604http://www.deir.qld.gov.au/workplace/law/codes/towercrane/appendices/10-yearcertificate/index.htmhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/appendices/annualcertificate/index.htmhttp://www.saiglobal.com/shop/Script/Details.asp?DocN=AS815815786604http://www.deir.qld.gov.au/workplace/law/codes/towercrane/appendices/10-yearcertificate/index.htm


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0. non-destructive testing e7amination to an appropriate standard

c. contro"s and emergenc stop

d. 0raing sstemse. manufacturer's safet upgrades

f. adequac of safet instructions and manua"s and

g. t,e capacit and via0i"it of upgrading t,e crane to t,e requirements of t,e "atest

re"evant tec,nica" standard.

16..1 e$ inspection items for a 1/-$ear ma0or inspection

*,e fo""owing items w,ere appropriate must 0e inc"uded in a 1&-ear maor inspectionfor tower cranes

a. s"ew ring

0. ,drau"ic motors

c. ,drau"ic pumps

d. va"ve 0"ocs (0odies)

e. ,oist and "uff drums

f. 0raing sstems

g. rope s,eaves,. ,drau"ic "uffing c"inder

i. gear 0o7es and drive s,afts

. 0oom

. $-frame

". pins wit, moving parts (e.g. 0oom ,ee" pins ram pins)

m. static pins

n. stee" wire ropes

o. e"ectrica" sstemsp. contro" sstems

q. e"ectric motors

r. ,oo tro""e (non-"uffing cranes) and

s. ,oo assem0".

9ote t,at t,is "ist on" specifies some of t,e generic items requiring inspection. +ome of

t,e items ma not 0e app"ica0"e to some tpes of tower cranes 0ecause t,e feature wi""

not e7ist on t,e crane. *,e fu"" "ist of items to 0e inspected must 0e determined 0 t,e

competent person.

/t must not 0e assumed t,at t,e items inc"uded in t,e "ist on" require inspection at 1&-ear" interva"s. $"" items wi"" require some tpe of inspection and maintenance at more

frequent interva"s (i.e. at annua" and ot,er inspection interva"s) in accordance wit, t,e

crane manufacturer's instructions. +ection 16.2.3a"so requires s"ew ring 0o"ts to 0e crac

tested 0 9* or rep"aced 0 new 0o"ts ever five ears.

=,ere t,ere is documented evidence t,at t,e appropriate inspecting and testing ,as

0een carried out on a certain item wit,in t,e preceding two ears t,is item does not,ave to 0e stripped down in t,e 1&-ear maor inspection. @owever t,e competent

person must sti"" inspect t,e safe operation of t,e item to certif t,at it is operatingsafe". *,is requirement app"ies to t,e fo""owing items

a. s"ew ring

0. ,drau"ic motors

c. ,drau"ic pumps

d. va"ve 0"ocs
http://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#a%23ahttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#b%23bhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#c%23chttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#d%23dhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#e%23ehttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#f%23fhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#g%23ghttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#h%23hhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#i%23ihttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#j%23jhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#k%23khttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#l%23lhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#m%23mhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#n%23nhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#o%23ohttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#p%23phttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#q%23qhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#r%23rhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#s%23shttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/non-destructive/index.htm#1623http://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#a%23ahttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#b%23bhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#c%23chttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#d%23dhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#e%23ehttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#f%23fhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#g%23ghttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#h%23hhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#i%23ihttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#j%23jhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#k%23khttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#l%23lhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#m%23mhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#n%23nhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#o%23ohttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#p%23phttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#q%23qhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#r%23rhttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/10-year/index.htm#s%23shttp://www.deir.qld.gov.au/workplace/law/codes/towercrane/inspecting/non-destructive/index.htm#1623


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e. ,oist and "uff drums and

f. pins wit, moving parts.

lew Ring

a. Remove t,e s"ew ring 0o"ts and sp"it t,e s"ew ring.

0. ?easure t,e wear in t,e s"ew ring.c. Rep"ace worn 0earings and spacers.

d. Carr out 9* and repair of 0earing race.

e. ?easure t,e 0ac"as, and teet, widt, in t,e pinion drives and ring drive to ensure

t,e are wit,in t,e manufacturer's specifications.f. Ensure a"" s"ew ring 0o"ts are crac tested 0 9* or rep"aced wit, new 0o"ts.

$draulic motors

a. Remove strip down and inspect a"" ,drau"ic motors.

0. Rep"ace a"" worn va"ves and ot,er components.

c. Ensure to"erances comp" wit, manufacturer's specifications prior to reassem0".

d. Ensure motors are pressure and performance tested prior to re-entering service.

$draulic pumpsa. Remove strip down and inspect a"" ,drau"ic pumps.

0. Rep"ace a"" worn va"ves and ot,er components.

c. Ensure to"erances comp" wit, manufacturer's specifications prior to reassem0".

d. Ensure pumps are pressure and performance tested prior to re-entering service.

4ale &loc%s +&odies

a. Remove strip down and inspect a"" va"ve 0"ocs.

0. Rep"ace a"" worn va"ves and ot,er components.c. Ensure to"erances comp" wit, crane manufacturer's specifications prior to

reassem0".

d. Ensure va"ves are pressure and performance tested prior to re-entering service.

oist and luff drums

a. Remove "uff drums and rep"ace drive s,aft 0earings as required.

0. /nspect grooves on t,e "uff drum.c. /nspect t,e drive pinions for wear and correct a""owa0"e 0ac"as,.

d. Rep"ace drive pinions if t,e to"erances are outside of t,e manufacturer's

specifications.

e. /nspect rope anc,or points to ensure t,e are correct for rope dimensions.

5ra%ing s$stems

a. Remove and dismant"e a"" 0raes from t,e crane.

0. C,ec pins springs and 0us,es for correct to"erance.

c. Rep"ace ru00er sea"s.d. C,ec pistons for correct operation.

e. Ensure we"ds in 0raing sstems are crac tested 0 9*.

f. /nspect ,drau"ic sstems for "eas prior to reassem0" on t,e crane.

g. /nspect wear "imits on 0rae "inings.

Rope seaes

a. Remove a"" rope s,eaves and rep"ace 0earings as necessar.

0. C,ec s,eave groove siFe and rep"ace t,e s,eave if it is outside of t,e

manufacturer's specifications.c. /nspect s,eaves for cracing a"ignment and damage.


12/15

d. Rep"ace snt,etic s,eaves if recommended to do so 0 t,e s,eave manufacturer.

$draulic luffing c$linder

a. Remove c"inder and ram from t,e crane and strip t,e c"inder and va"ve 0"ocs.0. Ensure g"and nuts are crac tested and t,reads are c,eced for wear.

c. Rep"ace sea"s and re-c,rome ram w,ere necessar.

d. Ensure t,e reassem0"ed c"inder is pressure tested and c,eced for operation and"eas.

e. Ensure we"ds on rod ends and caps are crac tested 0 9*.

ear &o7es and drie saftsa. Remove and dismant"e gear 0o7es drive s,afts and f"e7i0"e coup"ings to t,e

e7tent t,at a t,oroug, inspection is possi0"e.

0. Rep"ace worn and damaged 0earings and gears.

5oom

a. Ensure a"" 9* on 0oom components required in t,e pre-erection tests is carried

out.

0. Ensure u"trasonic c,ord t,icness of 0oom is performed.

c. Ensure a minimum of 1&> of "acing we"ds on eac, 0oom section are crac tested0 9*. /f an cracs are found ensure a"" "acing we"ds on t,e 0oom section are

tested.

A-frame

a. Remove a"" pins.

0. Ensure 9* is carried out on a"" connector we"ds on primar c,ords.

c. Ensure a minimum of 1&> of "acing we"ds are crac tested 0 9*.

*ins wit moing parts +e.g. &oom eel pins, ram pins

a. Remove and inspect a"" pins wit, moving parts.

0. ?easure t,e diameter of t,e pin and 0us, to ensure it is wit,in t,e

manufacturer's to"erance. /f not t,e pin must 0e remac,ined or rep"aced and t,e

0us, rep"aced.c. /nspect restraint sstems (i.e. c,ee p"ates) and grease nipp"es.

tatic pins

a. Remove and inspect a"" static pins.

0. Repair pins if necessar.

teel wire ropes

a. /nspect a"" ropes for wear inc"uding ,oist "uff pendant tro""e and counterweig,t

ropes to ensure t,e do not e7ceed t,e discard criteria specified in $+ 2#! '

Steel wire rope * Application guide(non-;ueens"and


13/15

;ueens"and


14/15

ocumentation stating t,at t,e crane ,as 0een inspected 0 a competent person and is

in a safe and satisfactor condition s,ou"d 0e readi" avai"a0"e.

*,e c,ecs adustments rep"acement of parts repairs and inspections performed anda"" irregu"arities or damage concerning t,e unit's safe use must 0e recorded.

/n addition a"" comp"ete routine annua" inspection and 1& ear maor inspection reportsmust 0e maintained and made avai"a0"e for e7amination as required.

16.1/ #ower crane maintenance

$ tower crane preventative maintenance program s,ou"d 0e esta0"is,ed 0ased on t,eworing environment and t,e frequenc and severit of use of t,e crane. *,e fo""owing

items s,ou"d form part of an effective maintenance program

a. rep"acement parts and components s,ou"d 0e identica" or equiva"ent to t,e

origina" equipment parts and components

0. a specific rectification program s,ou"d 0e carried out w,ere past e7perience ,as

s,own particu"ar pro0"ems wit, a crane and

c. a"" safet-re"ated ma"functions and pro0"ems s,ou"d 0e corrected 0efore t,e craneis returned to service.

*,e owner of t,e tower crane must ensure t,at

a. t,e necessar faci"ities and sstems of wor are provided and maintained so as to

minimise t,e riss to ,ea"t, and safet of persons maintaining inspecting

repairing or c"eaning t,e crane

0. inspections maintenance and c"eaning are carried out ,aving regard to

procedures recommended 0 t,e crane designer and manufacturer or t,ere"evant $ustra"ian +tandard or as deve"oped 0 a competent person

c. repair inspection and w,ere necessar testing is carried out 0 a competent

person

d. a"" safet features and warning devices of t,e crane are maintained and tested

e. w,en t,e crane ,as 0een damaged to t,e e7tent t,at its function or condition is

impaired resu"ting in increased ris to ,ea"t, or safet a competent person

assesses t,e damage and advises t,e owner of

i. t,e nature of t,e damage andii. w,et,er t,e crane is a0"e to 0e repaired and if so w,at repairs must 0e

carried out to minimise riss to ,ea"t, and safet

f. repairs to t,e crane are carried out so as to retain t,e crane wit,in its design

"imits and

g. annua" maintenance repair and inspection records are ept for t,e crane.

16.11 #ower crane repair

$"" worn or damaged parts of a crane t,at constitute a ,aFard impair t,e operation of t,e

crane or ma constitute a ,aFard 0efore t,e ne7t routine inspection are to 0e repairedor rep"aced. $"" repaired or new parts must comp" wit, t,e crane manufacturer's

recommendations or specifications. =,ere t,ese are not avai"a0"e t,e repaired or new

parts must comp" wit, t,e recommendations of a competent person taing into account

t,e design requirements of $+ 11%. ranes) hoists and winches * +ower cranes (non-

;ueens"and


15/15

16.12 econd-and imported tower cranes

*,e importance of t,e maintenance ,istor of second-,and imported tower cranes fromoverseas cannot 0e underestimated. 5efore a second-,and imported tower crane can 0e

operated for t,e first time t,e owner of t,e crane must ensure t,e crane is su0ect to an

annua" inspection or a 1&-ear maor inspection if t,e crane is at "east 1& ears o"d.

tower cranes commisioning[1]

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