DUBAI

09-11th of November
2013

Eng. Fabrizio Mori

 TOWER CRANES
ADDITIONAL TRAINING
FOR IBs INSPECTORS
 Types of Tower Cranes
1.Rail Mounted, supported on a carriage
running on a parallel set of rails.
2.Outrigger Mounted
3.On a fixed base, supported on a concrete
base.
4.Climbing type, supported by floors during
the construction of a multi-stored building.
5.On crawler tracks. 3
4
5
 Slewing Tower & Non-Slewing Tower
Slewing: the slewing ring is situated at the
bottom of the tower and the whole of the
tower and jib assembly slews relative to
the base of the crane.
Non-Slewing: The slewing ring is situated
at or near the top of the tower and the jib
slews about the vertical axis of the tower
which itself remains stationary.
6
(should be tied to the to a fixed structure.)
7
 Types of Jib
1.Horizontal Trolley Jib
2.Inclined trolley Jib
3.Luffing Jib
4.Fixed Radius Jib

8
9
HOW TOWER CRANES ARE ERECTED

Tower cranes arrive at the

construction site in a convoy
of trucks. The crew uses a
mobile crane to assemble the
jib and the machinery
section, and places these
horizontal members on the
first of two mast sections.
The mobile crane then adds
the counterweights.

10
ERECTION OF A TOWER
CRANE
ERECTION OF A TOWER
CRANE
ERECTION OF TOWER
CRANE
 TOWER CRANES
Tower cranes are a common fixture at
any major construction site.
They often rise hundreds of feet into the
air, and can reach out just as far.
The construction crew uses the tower
crane to lift steel, concrete, large tools
and a wide variety of other materials.
15
COUNTER WEIGHT

JIB
COUNTER JIB

SLEWING RING

TOWER

BALLAST
RAILS / ..
PARTS OF THE CRANE
All tower cranes consist of the
same basic parts:
The base is bolted to a large
concrete pad that supports the
crane.
The base connects to the mast
(or tower), which gives the
tower crane its height.
Attached to the top of the mast
is the slewing unit -- the gear
and motor -- that allows the
crane to rotate:
On top of the slewing unit are
three parts:

17
PARTS OF THE CRANE
The long horizontal jib
(or working arm), which
is the portion of the
crane that carries the
load.
A trolley runs along the
jib to move the load in
and out from the crane's
center:
18
PARTS OF THE CRANE
The shorter horizontal
machinery arm, which
contains the crane's motors
and electronics as well as
the large concrete counter
weights:

19
PARTS OF THE CRANE
OPERATORS CAB

20
The use of the anemometer is required for
the self-erecting tower crane with a hook
height of over 30 meters and top-slewing
cranes.

The crane jiib must be equipped with a

basket
The crane remote control must be
equipped with external lights to
indicate the condition of the
machine. The green light should
be placed so as to be visible from
the people who are close to the
crane.

In case of using remote control.

This shall be equipped with the
emergency stop
The skirting must avoid
falling objects. The image
provides an example of
conformity: the toe boards
is high enough to prevent it
(at least 50 mm, as a
general rule 100 mm).
In the tower there are no landings. very dangerous
The tower crane must have
landings at least every 10
meters

Balconies in the tower avoiding

falling objects and operators
The lack of a wiper for the cabin implies poor visibility

Example not in accordance

Example in accordance
The openings in the walkways can create a danger of falling.

The walkways must always

have openings smaller than 20
mm. The distance shown in
the picture may be a hazard to
the operator.
The label must indicate the
name of the crane.
Flow diagram: the label should
always indicate the loads that
the crane can lift.

Plate in a incomprehensible
language if not equipped with
original translations.

This plate is also impossible to

identify the necessary
information that should always
be included in the warnings and
labels
 General safety rules
The maximum load that a crane can lift is
determined by the design rating but the
crane cannot lift as much weight if the
load is positioned at the end of the jib.
The closer the load is positioned to the
mast, the more weight the crane can lift
safely.
31
 In a 300 tonne-metre rated crane for
example, if the operator positions the load
30 metres from the mast, the crane can
lift a maximum of 10 tonnes but if the load
trolley moves in to 15 metres then it can
lift 20 tonnes. Load switches in the cab
control this to prevent overloading.
The second element of stability is the
counterweight; the whole structure is like
a large seesaw. These weights, seen at
the opposite end from the jib, weigh many
tons.
 SAFETY Measures - Site
Away from high voltage power lines.
Away from excavation sites.
Prevailing Wind-speeds.
Away from water accumulation water
leaking under the foundation of the crane.
Overlapping levels with other cranes. To
avoid collision some one (competent
person) should plan the sequence of crane
33

movements.
34
DEEP ESCAVATION

35
FOUNDATION OF THE CRANE

36
37
INTERFERENCE BETWEEN CRANE

38
 Safety Measures - PPE
Safety Harness
Helmets
Safety Shoes
Fire Extinguishers
Easily Accessible
Trained
39
 Crane Safety Equipment
Automatic Safe Load Indicator
Load Radius Indicator
Motion Limiting Devices
Overload Cut-out devices
Level Indicator
Anemometer
Machinery Guarding
Zoning Devices (two or more cranes limit the
slew, the trolley motion, or the travel motion
40
 Crane Safety
Lighting Protection (Earthing)
Rail mounted tower cranes should be
fitted with an audible travel alarm.
Ladders Landing (Platform)
Access to and along jibs and counter
jibs for inspection and servicing should
be made safe. (catwalks should be
provided with handrails)
Clear vision from cab 41
43
 Tower Cranes
Visual Examination
Overload Test
(SWL raised to sufficient height to ensure that each tooth
of the train of gears is subjected to the load then lowered
to 100 mm to 200 mm above the ground.
SWL should then be increased by 25 % and this load
hoisted sufficiently to ensure that each tooth of the train
of gears is subjected to the overload then lowered to 100
mm to 200 mm just clear of the ground.
For horizontal jib cranes with trolleys the trolley should
be set at the maximum radius for SWL.
SWL (100 mm to 200 mm) 25 % of SWL (100 mm to
200 mm) 44
 Continued
Indicator test:
The crane should never loaded beyond
100 % of its SWL.
The radius at which the test load
corresponds to 110 % of the SWL
should be marked and the test load
should never be taken beyond this
point.
45
46
 Crane owners file
Each tower crane should have its own machine history
file, in either paper or electronic format, in which all
records of maintenance activities are kept by the tower
crane owner. These should include the following (as
applicable):
EC Declaration of Conformity;
pre-delivery inspections;
special maintenance procedures;
service reports and worksheets;
breakdown reports and worksheets;
daily and weekly inspection reports;
records of component replacement;
records of major overhaul;
erection, reconfiguration and dismantling records;
test reports;
BS EN 7121 PART 5

7.9.2 Crane owners file

wire rope and hook test certificates;
thorough examination reports;
records of defect rectification;
data logger records;
records of supplementary tests;
records of modifications and upgrades;
safety alerts from manufacturers;
records of extraordinary events (e.g.
replacement or repair of significant load
bearing components, severe overloading or
wind loading);
records of unusual applications.
BS EN 7121 PART 5
7.9.2.2 Crane users file to be kept on site
Under LOLER1998 [3] Regulation 5, where a crane is on site for an extended
period the user is required to be able to demonstrate that the crane has been
adequately maintained. A machine history file should also be kept on site by the
user to record all maintenance activities carried out on the crane while it is
erected on that site. This file should include the following (as applicable):
service reports and worksheets;
breakdown reports and worksheets, including records of defect
rectification, component replacement and work completed following
extraordinary events;
daily and weekly inspection reports;
erection and reconfiguration records, including records of modifications
and upgrades;
thorough examination reports and records of supplementary tests.
The records in the site machine history file will be less comprehensive than
those in the owners file as they will only refer to the period during which the
crane was on that particular site. Copies of records from the site file should be
added to the tower crane owners machine history file to ensure that the
owners file contains a complete cradle to grave record for the particular crane.
BS EN 7121 PART 5
TYPE OF INSPECTION
Thorough examination of a crane is required by LOLER 1998 [2]
Regulation 9 in the following circumstances:
before being put into use for the first time, LOLER Regulation
9(1):
NOTE 1 The only exception to this is if the crane is new and the
owner has an EC Declaration of Conformity that was made not
more than 12 months prior to the crane being used for the first
time. In this case the Declaration of Conformity will cover the use
of the crane for the first 6 month or 12 month period.
where safety depends on the installation conditions:
after installation and before being put into service for the first
time, LOLER Regulation 9(2)(a);
after assembly and before being put into service at a new site or
in a new location, LOLER Regulation 9(2)(b);
NOTE 2 This does not apply to a crane which moves from one
location to another to perform a lifting operation, is not fixed in
position, and is operating within the scope of the current report of
thorough examination.
BS EN 7121 PART 5

TYPE OF INSPECTION
periodically whilst in service, at maximum intervals
of 6 months for cranes that lift people and 12 months
for cranes that lift goods only, LOLER Regulation
9(3)(a)(i) and (ii), or in accordance with an
examination scheme, LOLER Regulation 9(3)(a)(iii);
after exceptional circumstances have occurred,
LOLER Regulation 9(3)(a)(iv).
BS EN 7121 PART 5

Scope of thorough examination

before the crane is put into use for the first time

The competent person who undertakes the thorough

examination should decide the scope of the examination. The
extent of the thorough examination should reflect the
likelihood of failure and the actual risk which could arise from
any such failure. It should also take into account when the
crane was made and the likely deterioration since
manufacture, which could increase risks in use. Records of
tests and inspections carried out by the manufacturer should
also be taken into account.
BS EN 7121 PART 5
Scope of thorough examination
following installation
The competent person who undertakes the thorough
examination should decide the scope of the examination.
LOLER 1998 [2] Regulation 9(2)(a) and (b) requires that
this establishes that the crane has been installed correctly
and is safe to use.
As a minimum, the examination should ensure the crane
has been installed, checked and tested in accordance with
the manufacturers instructions.
The scope of the thorough examination should be
proportional to the complexity of the installation and take
into account the reports of previous thorough
examinations, where applicable.
BS EN 7121 PART 5
Scope of periodic
thorough examination
The defined scope of thorough examination should be drawn up in
advance of the examination and should identify those parts of the
crane that should be thoroughly examined, together with required
supplementary supporting reports and tests and the extent to which
they should be witnessed. The defined scope of thorough
examination should specify the intervals at which the crane (or
individual parts thereof) should be thoroughly examined (within the
statutory maximum periods specified by LOLER 1998 [2] and MCA
LOLER 2006 [6] of 6 months and 12 months) and, where
appropriate, intervals for specific supplementary supporting reports
and tests. These intervals should reflect the anticipated rate of
deterioration and the likelihood and potential consequences of
failure.
BS EN 7121 PART 5

Thorough examination after

exceptional circumstances
LOLER 1998 [2] and MCA LOLER 2006 [6] require that if the crane is
subjected to exceptional circumstances it has to be removed from
service and subjected to a thorough examination to determine whether
it is safe to be returned to service.
Exceptional circumstances include an overload, jib clash, collision, use
for particularly arduous duties, failure of a structural component or
being subjected to weather in excess of design parameters.
The scope of the thorough examination should be proportional to the
nature of the exceptional circumstances and the extent of any repairs,
and should take into account the reports of previous thorough
examinations, where applicable.
BS EN 7121 PART 5
8.7.2 Components to be included
The following components should be included in the defined scope of thorough
examination for a tower crane (as applicable):
base structure, including fasteners, cast-in anchors, cruciform
base, chassis, internal climbing collar, grillage;
base information board;
tower sections and ties, including fasteners, ladders and rest
platforms and guard rails;
crane travelling base, drive system and rail track including
fasteners and end stops;
central (base) ballast, including fasteners and tie bars;
all bolts, pins and other fastenings;
slew section structure, including fasteners and slew ring;
slewing mechanism throughout its full range of movement;

NOTE 1 This list is not exhaustive.

NOTE 2 Luffing jib cranes should be at maximum radius.
BS EN 7121 PART 5
8.7.2 Components to be included
power supply cables and slip rings;
cab, including controls, indicators, seating,
windows, heating, security bars, wipers and
load charts;
counterjib and counterweights, including
pendants, fasteners, guard rails and
signage;
hoist and luffing winches and brakes,
including hydraulic systems;
hydraulic luffing systems;
control cabinets and wiring;
A frame, including sheaves, fasteners,
access ladders;
BS EN 7121 PART 5
8.7.2 Components to be included
limiting and indicating devices including:
rated capacity system (measurement of load, moment and
radius);
anemometer;
devices indicating:
over hoist limits;
luffing limits;
trolley limits;
slack rope limits;
rail travel limits;
jib structure, including pendants, fasteners, pivots, walkway,
sheaves, safety line, and wind sail boards;
trolley, including wheels and basket, and trolley winch;
hook block, including sheaves, hook and fall change system;
running wire ropes, including terminations.
BS EN 7121 PART 5
9.5 Overload testing
9.5.1 Preparation
When testing a rail mounted crane, at the start of testing the crane should be
positioned on a straight and level track with firm foundations and free from
obstructions.

9.5.2 Test procedure

The crane should be functionally tested without a load applied to determine
whether it is working properly.
With the trolley or jib at the maximum radius for the rated capacity, a load
equivalent to the rated capacity should be raised until every tooth in the train of
gears has been subjected to the load, then lowered to between 100 mm and 200
mm above the ground and the crane operated through all its permitted motions, to
determine whether the crane is safe to proceed with the test.

NOTE 1 During the raising of any load it might be necessary to luff-in the jib, or
trolley-in the load so that the radius is not exceeded owing to deflection of the
tower.
BS EN 7121 PART 5
9.5 Overload testing
The load should then be increased by the amount specified by the manufacturer
and this load hoisted until each tooth in the train of gears has been subjected to
the overload, then lowered to between 100 mm and 200 mm above the ground
and the crane operated through its permitted motions.

For horizontal jib cranes with trolleys, the trolley should be set at the maximum
radius for the maximum rated capacity. Suitable devices should be fitted to the
jib, for example clamps, at a position 50 mm beyond the maximum radius for
the maximum rated capacity to prevent the trolley from moving beyond this
point.

Any movement of the trolley beyond the set position and towards the clamps
indicates a problem with the trolley brake, which should be investigated and
rectified before further testing is carried out. For other cranes, the load lifting
attachments should be positioned at the maximum radius for the maximum
rated capacity.
BS EN 7121 PART 5
9.5 Overload testing
A load equivalent to the appropriate rated capacity should then be raised
until each tooth in the train of gears has been subjected to the load, then
lowered to between 100 mm and 200 mm above the ground and the crane
operated throughout all its permitted motions, subject to site limitations, to
determine whether the crane is safe to proceed with the test.

NOTE 2 For most tower cranes it is possible to operate the maximum rated
capacity at a number of radii, so for these cranes the motions include moving
the load back to the maximum radius position for that rated capacity, taking
care to stop before the clamp is reached.
BS EN 7121 PART 5
9.5 Overload testing
The load should then be increased to the test load specified by the manufacturer
and hoisted until each tooth in the train of hoist gears has been subjected to the
overload, then lowered to between 100 mm and 200 mm above the ground and
the crane operated throughout its permitted motions to ensure the overload is
applied to all parts.

If the tests are limited owing to site conditions it might be necessary to dismantle
and reassemble the test load at different positions throughout the arc of slew to
enable the crane to be thoroughly tested over its working area.
Otherwise duties should be restricted.

Where the loaded crane can travel on rail tracks, the overload should be travelled
the appropriate length of the track with the jib at right angles, at both sides and in
line with it, where such duties are permitted.
During the overload test, the crane should be operated at speeds appropriate to
the safe control of the load, for example the lowest possible speed of the crane.
During the overload test the crane should remain stable and the brakes on each
motion should function effectively.
 BS EN 14439/2007 + A2:2009
The design requirements for controls and control stations shall conform to
EN 13557 with the changes according to Table 2.

5.4.1.5 On tower cranes, windscreens wiper and washers shall be provided

on the front cabin window.

5.4.1.6 The minimum dimensions for effective hatch apertures shall be

0,55 m x 0,55 m.
On self erecting cranes the hatch:
can be under the driver seat, only if a other solution isn't possible;
can have its dimensions reduced to 0,50 m x 0,50 m when necessary due
to the size of the crane .

5.4.1.7 For self-erecting tower cranes , the dimensions of the standing area
shall be 0,2 m x 0,6 m minimum
BS EN 14439/2007 + A2:2009
5.4.2.4 Rated capacity limiters - Operating requirements

5.4.2.4.1 General

The rated capacity limiter shall operate at a load as close as possible to the
rated capacity to prevent the crane operator from handling load greater than the
rated capacity .

When the rated capacity limiter operates due to a load exceeding the rated
capacity or due to a load moment exceeding the rated capacity the limiter shall
operate at a load or a load moment greater or equal to 1, 1 times the rated
capacity under normal conditions of use.

NOTE The limitation of the load moment is ensured with at least 2 limiters ,
one operating on the rated capacity, the other on the radius .

The procedure to set up the load moment limiters of the crane shall be
described in the instruction handbook (Clause 7) .
BS EN 14439/2007 + A2:2009
5.4.2.4.2 Overriding

Provision far overriding the rated capacity limiter shall not be provided.

Use of the alternative setting of the standard rated capacity limiter foreseen by
the manufacturer is not considered as overriding if the crane is kept within its
designed and stated capacity as given in the instruction handbook .

5.4.2.5 Rated capacity indicators

5.4.2.5.1 The rated capacity indicator shall give a warning of the approach to the
rated capacity at a value between 90 % and 95 % of the rated capacity .

On tower cranes provided with remote controls , this rated capacity indicator
may be installed on the crane .
lt shall be a visual warning signal defined in 5.4 .6.2.
BS EN 14439/2007 + A2:2009

5.4.2.5.2 The tower cranes shall be provided with indicators as shown in the
Table 4. The choice is given between the solutions marked with a cross .
Other means providing equivalent information can also be used.

5.4.2.6.1 Motion limiters

The motion limiters shall be provided according to Table 5.
5.4.2.6.2 Overriding

When it is necessary to override motion limiters in normai operation (e.g.

change of the falls number , storage of the trolley) provision may be at the
control station.

The overriding devices shall be hold-to-run types and the crane components
and the crane's stability shall not be endangered .

5.4.2.7 For trolley drives on horizontal jib using ropes the breakage of a
trolley travelling rope shall initiate the stop of the trolley
 Motion LIMITER
a) Hoisting limiter YES
b) Lowering limiter YES
c) Slack rope limiter NO
d) Slewing limiter No if power supply via slipping assembly
e) Travelling limiter YES
f) Derricking limiter YES
g) Telescoping limiter NO if erection work - YES if working condition
h) Control station position YES, if the control station is moved during service
limiter
i) Working space limiter a Not mandatory, at the request of the user according
to the risk analysis of the job site
j) Anti-collision device Not mandatory, at the request of the user
k) Trolleying limiter YES
I) A-frame position limiter YES

a Working space limiter and crane being interdependent, the power supply shall
be such that when the crane is "on", the working space limiter is automatically "on"
.
BS EN 14439/2007 + A2:2009
5.4.2.10 Anemometer

Tower cranes shall be provided with an anemometer except for self

erecting cranes with a height under hook of less than 30 m measured with
a horizontal jib .
When an anemometer is installed, the information about the wind level
shall be given to the driver and could be achieved by different means
(speed value, visual signal, audible signal) . In any case the driver shall
have a warning level and an alarm level. When visual signals are used far
indicator, see Annex C far the choice of the color.

5.4.3 Guarding
5.4.3.1 Guards for moving parts
During the access to the control station , moving parts shall be guarded by
safety distances as defined in EN ISO 13857 or by provision of removable
or fixed guards.
The guards which may be used as walkways or work platform shall
be designed far this use, see EN 13586.
BS EN 14439/2007 + A2:2009
5.4.3.2 Prevention of crane components from falling

Crane parts such as gears , pulleys , trolley wheels , covers and boxes
shall be designed , assembled and fixed in such a way to prevent them
from falling during normal operation.

Covers , guards and access closures shall be fitted with hinges or other
means to prevent them from falling.

The trolleys shall be designed so that the wheels do not slip out from the
railway in case of rupture of the axis; furthermore the falling of the trolley
shall not be possible.

The output gears of the slewing gears shall be provided with covers or any
other device avoiding their falling in case of rupture.
BS EN 14439/2007 + A2:2009
5.4.3.2 Prevention of crane components from falling

Crane parts such as gears, pulleys, trolley wheels, covers and boxes shall be
designed, assembled and fixed in such a way to prevent them from falling
during normal operation.

Covers , guards and access closures shall be fitted with hinges or other
means to prevent them from falling.

The trolleys shall be designed so that the wheels do not slip out from the
railway in case of rupture of the axis; furthermore the falling of the trolley
shall not be possible.

The output gears of the slewing gears shall be provided with covers or any
other device avoiding their falling in case of rupture.
BS EN 14439/2007 + A2:2009
5.4.4 Access

5.4.4.1 General

The design requirements far access shall confarm to EN 13586 with

the changes as shown in Table 6.
Means of access can include a passing through the structure of the
crane even if the dimension does not comply with EN 13586.

Table 6 - Design requirements tor access

Clause in EN 13586:2004 Topic Change In this
European
Standard
6.2 .8 Completed by 5.4.4.2
Crushing hazard between moving parts
6.4.1 5.4.4.3
Rung ladders Completed by

6 .6 Completed by 5.4.4.4
Manholes
BS EN 14439/2007 + A2:2009
5.4.4.2 Crushing hazard between moving parts

Where persons could be present between moving parts a safety distance of

at least 0,5 m shall be observed. Where such a distance cannot be obtained,
guards (when possible) and warning notices shall be fitted .

5.4.4.3 Far all types of tower cranes, the first flight of ladder may be of 1O m
maximum . Furthermore far self-erecting cranes:
Flights of type 1 ladders shall be positioned to prevent persons falling more
than 1O m maximum; Type 1 ladders shall have rest platforms at least every
1O m;
Evacuation of an elevating contrai station in the event of power failure or
suchlike shall be possible by alternative means of egress . When a ladder is
used for this purpose, the dimensions defined in EN 13586 are not applicable.
The dimension m (clear width, Table 4) may be reduced to 0,2 m and the
dimension d (distance between the center line of the rung and vertical
surface) may be reduced to O, 1 m allowing the use of the rung at least by
one foot.
BS EN 14439/2007 + A2:2009
5.4.4.4 Hatch apertures

lf the crane construction does not allow larger dimensions , far type 2
access according EN 13586 the minimum dimensions far effective hatch
apertures shall be 0,5 m by 0,4 m.

5.4.4.5 Access provided in a horizontal jib

5.4.4.5.1 Generai
lf it is not possible to lower the jib to the ground to carry out a visual inspection
of the jib , a basket fixed to the trolley shall be provided . In addition a walkway
with :

- side protection , or

- personal protective device against the falls shall be fixed along the jib to reach
the mechanism(s) .
When during erection/dismantling, repair or the maintenance the basket cannot
be used, the use of personal protective device against the falls shall be possible
all along the jib
BS EN 14439/2007 + A2:2009
5.4.4.5.2 Walkway

The width of the walkway shall

comply with EN 13586:2004, Table 6
type 2.

When the size of the jib is sufficient to

walk inside the jib (dimension
between the walkway and the upper
member equal or more than 1,8 m) ,
toe boards shall be provided on each
side of the walkway with a minimum
height of 0,03 m. When the dimension
between the walkway and the upper
member is less than 1,8 m, toe board
is provided only on one side (see
Figure 1).
BS EN 14439/2007 + A2:2009
5.4.4.5.3 Position of the walkway, handrail and steel wire rope

Manufacturers shall take into consideration the dimension of the jib when
determining the position of the walkway , hand rail and steel wire rope.

5.4.4.5.4 4 Basket
The minimum dimension of the length/width of the basket shall be 0,5 x 0,35
m.
Manufacturers shall take into consideration the weight and the number of
persons when determining the basket.
The side protection shall comply with EN 13586:2004 , Table 7, type 2,
walkway . instructions and markings shall be provided tor the use of the
basket:
how to reach the basket;
admissible load and number of persons ;
warnings concerning residual risks e .g. shearing , entanglement.
BS EN 14439/2007 + A2:2009
5.4.5 Lighting
A fixed non-dazzling service lighting shall be provided and so arranged that the
necessary illumination of the control is provided. The minimum illumination
shall be 50 lux.

When the general area lighting does not permit sufficient illumination in a
machinery cabinet, supplementary lighting shall be provided. For maintenance,
the minimum illumination shall be 200 lux which may be obtained by additional
movable lighting .
BS EN 14439/2007 + A2:2009
5.4.6 Outside indicators on the crane
5.4.6.1 When outside indicators on the crane are requested far
anemometer and anti collision devices , see Annex C.

5.4.6.2 When cable less control is engaged, to fulfil requirements

of EN 13557 (C.8) and of EN 12077-2 (5.5 .1.2) :

it shall be indicated by a continuous green light located so that it is

visible to the persons next to the crane;

a yellow light installed on the crane visible to the driver shall give a
warning of approach to the rated capacity at a value which gives the
crane driver time to react to the warning and prevent the crane from
being overloaded . This indicator is not necessary if this information is
available on the remote control.
BS EN 14439/2007 + A2:2009
Outside indicators on the crane

C.1 When outside indicators in order to inform the persons working on the
site about the crane condition are used, the type of the light signals shall
be as given in C.2 and C.3. The light signals shall be visible by all the
persons concerned .

C.2 When an anemometer is installed and when outside indicators

are requested by local authorities . The light used shall be:

a yellow flashing light for the warning leve! ; a red flashing light for the
alarm leve!.
C.3 When an anti-collision device is installed and when outside
indicators are requested by local authorities ,
the light indicating that the device is out of order or in fault , shall be a
white flashing light.

NOTE In some cases when local authorities request to have a warning

indicating that the crane is in free slewing mode, a flashing green light
should be used.
BS EN 14439/2007 + A2:2009
D.3.3 Load tests

D.3.3.1 General
Load tests shall be performed taking into account the positions and
configurations causing the maximum loads or the maximum tensions in the
most important crane components. The manufacturer shall specify the
positions of the loads. The special load curves mentioned in the table are load
curves calculated with reduced acceleration and speeds and/or permissible
wind speeds which are specified by the manufacturer .

The procedure to test tower crane with a rated capacity above 100 t shall be
determined by the manufacturer .

NOTE The declaration of conformity of the tower crane confirms that fitness
for purpose has been achieved , there is no need to produce a further test
report or test certificate giving the result of the fitness for purpose .
BS EN 14439/2007 + A2:2009
D.3.3.2 Static test

Column 1 2 3
Test load 125 % 125 %
(in % of the load (in % of the special load
curve) curve)
admissible movement successive
admissible speed reduced speed in
accordance withnot prescribed, static test in
manufacturer's accordance with column 2 is
specifications sufficient
admissible wind speed calm or in accordance with
manufacturer's
specifications, respectively

The test load shall have a distance of 100 mm to 200 mm from the
floor for a period of time of at least 10 min.
The static test shall be considered successful if no ruptures,
permanent deformations or damages affecting the function or safety
of the crane are visible and if no connections have loosened or
become damaged.
D.3.3.3 Dynamic test

Test load 110% 110%

(in % of the load (in % of the special
Curve load curve)
admissible combined
movements
admissible speed maximum speed which is admissible tor
the suspended load
admissible wind maximum operating wind speed as
speed specified by the manufacturer

The tests shall include the repeated starting and stopping of each
movement throughout the whole sequence of the movement.

The dynamic test shall be considered successful if the corresponding

components have performed their functions and if the subsequent
examination has not revealed any damage on the components of drive or
supporting structure and if no connection has loosened or sustained
damage .
 DAC REQUIREMENTS 06/2012
DEFINITIONS
Load
Means any material, persons, or any combination of these that are lifted,
lowered or suspended by the Lifting Equipment.
Working Load Limit (WLL)
Maximum load (mass), lifting equipment may lift safely in the most
efficient configuration. For wire rope, chain and fiber rope slings this is in
direct lift i.e. eye to eye in a straight vertical line.
Safe Working Limit (SWL)
Maximum load (mass), lifting equipment may lift safely in a particular
configuration,. e.g. a sling used in a chocked condition its safe working
load is approximately 0.8 of its WLL.
Proof Load Test
The application of a predetermined load excess of SWL to assess the
ability of the equipment to withstand operation requirements. This
applied proof load shall never exceed the elastic limit of the item being
tested
 DAC REQUIREMENTS 06/2012
Repair
Restoring the original state of equipment by rebuilding or exchanging parts or
units. If essential parts with safety functions are to be rebuilt or exchanged, this
is considered to be a Major Repair. This is the case particularly in respect of
the exchange of the following:
i. Brakes,
ii. Safety Gear or catching devices,
iii. Over-Speed Governors,
iv. Load carrying parts (e.g. anchorages, open or closed spelters sockets,
primary structures etc),
v. Driving mechanisms and controls.
Inspection
Any physical activity, related to ensuring that an item of Lifting Equipment, in
its entirety and at a given location or environment, meets the specified design
and operating Standards and is safe to operate for a specified period. The
period is defined by the fact that the equipment should remain always the same
In-service Inspection
In-service inspection of lifting equipment undertaken onshore after installation
of the Lifting Equipment and prior to being put into service
DAC REQUIREMENTS 06/2012
16. Thorough Inspection
Inspection for compliance with manufacturers specifications and safe operation, as a minimum:
Lifting Equipment
Oil, fuel level and lubrication.
Ropes, rope terminal fittings and anchorages, rope drums and sheaves for any damage
and wear, wire rope manufacture certificate
Water draining from air reservoirs.
Operation manual & loading chart (refer to point 4.2.1 c)

Crane for any loose, cracks or damaged structural component including supports and outriggers where fitted.
Security of the counterweight, checking the correspondence of the removable weights to those shown
on the counterweight chart.
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 falls or parts of rope.
Indicator appropriate to the boom, jib or fly-jib length is fitted.
The condition of the Crane cabin (tidy condition and free from grease and oil, rags, tools and materials other
than those for which storage provision is made,
Safe access (hand-hold, steps or both, walking surfaces shall be skid-resistant type, visibility forward & other
sides).
Pneumatic systems and hydraulic systems including their safety devices.
Operation of the crane through all motions with particular attention to brakes.
Operation of all limit switches or cut-outs and safety devices (the checks to be made in non-operation
status).
While using telephone or radio communications (checks for functioning of the call signal and clearly hearing
the messages).
Fire extinguishers are in place and satisfactory for use.
* while undertaking the inspection, in case of suspecting indications like noise, remove covers or open gearboxes
DAC REQUIREMENTS 06/2012
(c) Upon arriving at any inspection site, there shall also be an obligation
from the IB for the inspector to enquire the following information:
Information about previous inspections.
If the Inspector cannot obtain sufficient information the inspection
must be treated like a first inspection and therefore proceed with the
normal inspections.

1 Site: Place at which inspection is being undertaken.

Manufacturing Operations Manual, Operator or Maintenance Manuals

of the equipment, safe working load charts in English and/or Arabic language
and in case not available and not possible to provide, the IB shall ensure that
an independent competent person be engaged by the owner to provide advice
and documentation to support the continued use of the lifting
equipment/Scaffolding, foundations, building ties, engineering drawings,
Installation procedures, Inspection procedures, Bolt sizes, grades and torque,
Wire rope size, grade and instruction, Markings etc.
DAC REQUIREMENTS 06/2012
Periodic inspections

Periodic Examination carried out based on equipment condition especially

before put into service, the working environment, the frequency and severity
of use of the lifting equipment. The inspection shall also include the
manufactures items, and if the manufacturers recommendations are not
available a competent person must specify, in writing, all the
items/components to be inspected together with the acceptance/rejection
criteria to be applied by the inspector.

Note 1: The inspection period is based on a normal working day of up to 8

hrs and a 5/6-day working week (2400 hours). When usage of the
lifting equipment exceeds these figures a competent person must
specify exactly, in writing, what the period of these inspections is.
Factors such as the environment, frequency and type of usage, quality
of maintenance shall be taken into account prior to establishing the
period of the inspection
DAC REQUIREMENTS 06/2012

The inspector shall ensure that the Wire rope terminations formed by
means of metal filled socket, self-tightening wedge type sockets, hand spliced
eyes, and ferrule secured eyes or any other system with equivalent safety. Also,
U-bolt grips shall not be used except for elevators.
The inspector shall verify the crane manufacturer recommendation
who designed the cranes according to the following standards:
1. AS (American)
2. FEM (European)
3. BSI (British)
4. DIN (German)
5. EN (Europe)
6. JIS (Japanese)
DAC REQUIREMENTS 06/2012

There are many other standards in each country but will be mostly derived by
one of the above mentioned codes.

The recommendation shall clearly state the no need to conduct the proof load
test and stipulate the time frame of the proof load test and the inspection body
shall approve as per the recommendation and this shall be included in the
checklist of inspection

In case the recommendation not available, the cranes designed to the above
mentioned codes shall be inspected as per Examination scheme approach.
Where the no of lifts are electronically logged and checked against the
acceptable life cycle of the crane stipulated by the crane manufacturer

In case of unavailability of the manufacturer recommendation or examination by

competent person against electronic logging of the equipment, the inspection
bodies shall conduct the proof load test every four years and this shall be
reported

The inspector must then, before issuing any Inspection Certificate, address every
issue raised in the previous Inspection Report, if any.
DAC REQUIREMENTS 06/2012
Periodic inspections
Periodic Examination carried out based on equipment condition
especially before put into service, the working environment, the
frequency and severity of use of the lifting equipment. The inspection
shall also include the manufactures items, and if the manufacturers
recommendations are not available a competent person must specify,
in writing, all the items/components to be inspected together with the
acceptance/rejection criteria to be applied by the inspector.

Note 1: The inspection period is based on a normal working day of up to 8 hrs

and a 5/6-day working week (2400 hours). When usage of the lifting
equipment exceeds these figures a competent person must specify exactly, in
writing, what the period of these inspections is. Factors such as the
environment, frequency and type of usage, quality of maintenance shall be
taken into account prior to establishing the period of the inspection

Note 2: As the result of a periodic inspection, a competent person may

recommend a major inspection.
DAC REQUIREMENTS 06/2012
Major inspection
Inspection to assess the suitability of the Lifting Equipment for continued safe
operation. The following cranes shall be subjected to a major inspection:
(a) Cranes that have reached the end of their design life or, where this is
unknown, after 25 years for the structure and 10 years for the mechanical
components.
Notes:
1. A cranes design life may not be the same as its actual life and depends
on such factors as its classification, usage and its operating environment.
2. Devices are available to record the actual usage of a crane to enable
assessment of its remaining design life. Guidance on condition monitoring is
given in ISO 12482-1.
(b) Old cranes that are to be re-commissioned and that do not have previous
operating records or that were designed and built to unknown Standards.
(c) Cranes that are to be upgraded or modified.
The following items shall be considered for major inspection:
(i) Structural, mechanical, electrical, instrumentation, control and
operational anomalies.
(ii) Non-destructive examination to an appropriate Standard.
(iii) Controls and emergency stop.
(iv) Braking systems.
(v) Manufacturers safety upgrades.
(vi) Adequacy of safety instructions and manuals.
(vii) The capacity and viability of upgrading the crane to the requirements of
the latest Standard.
DAC REQUIREMENTS 06/2012
4.2.2 Inspectors Checklists:
The Inspection Body shall use Checklist forms containing all the
requirements of relevant BS/ EN inspection standards prepared
internally and approved by DAC. The checklist forms shall contain
sufficient space to indicate the results of evaluating the inspection
methods. The Inspector must sign in the checklist after recording all
necessary information.
The Chief or senior Inspector/ Engineer must co-sign the checklist
whenever he makes verification visits to the site.

4.2.3 Reporting Defects in equipment under inspection:

a) Inspectors are required to be capable of making
identification of all types of defects found in equipment under
inspection; if the equipment is found unsafe and
represents an imminent danger the IB must advise the owner
to cease use of the equipment and report this incident immediately to
the related authority in Dubai.
b) Lifting Equipment Identification: The IBs must ensure the
ability to identify lifting equipment by say Serial
Number and Model Number, or some form of
Registration Number. If the lifting equipment (and some of
their critical components) cannot be identified (even by location in the case
of fixed cranes) the IB shall consider this as a defect in
the crane which must be reported immediately to
related authority in Dubai.
DAC REQUIREMENTS 06/2012

4.3.2 Inspection Frequencies:

Lifting Equipment
The mandatory inspection frequency intervals pertaining to all Contractors
Lifting Equipment are summarized in Annex 2.
General Requirements:
a) For all lifting Equipment the first and all subsequent inspections shall
include all functional tests, overload and safety tests.

A Periodic Inspection, includes the following:

(i) Identification of all critical components and areas;
(ii) Detailed visual inspection of all structural and critical components;
(ii) Tolerance checking where any wear is observed;
(iv) Checking of tolerances for wear limit on critical components; and
(v) Checks for corrosion.

b) In the event of a major repair the lifting equipment shall be subjected to a

Periodic inspection and Proof Load Test or other inspections specified by
a competent person, prior to being returned to normal service.
DAC REQUIREMENTS 06/2012

4.5 Inspection Certificate/Report

4.5.1 After an Inspection Body has completed an inspection of Lifting
Equipment/Scaffold and found no significant issues the inspection body
must issue an Inspection Certificate for Lifting Equipment/Scaffold.
The Inspection Body shall produce an Inspection Certificate for lifting
Equipment on the inspection to fulfill the clients needs, the related
authority requirements and the applicable clauses of BS/ BS EN
standards. The certificate shall be signed by the authorized Inspector
who has performed the inspection, or by any other appropriate
authority assigned by the IB. Computer-generated (Electronic
Signature) or rubber stamped signatures are not allowed on the
certificates. In case of scaffolding the certificate shall be signed by
scaffold inspector and approved by Chief/ Senior supervisor or Civil
Structural Engineer (or however named). Certificates not conforming to
the above requirements shall be rejected.
DAC REQUIREMENTS 06/2012

4.5.2 The certificate shall include the following information as a minimum; (*)
mandatory for compliance with ISO/IEC 17020 are marked with an
asterisk:
1* Designation of the document, i.e. as an inspection report or an inspection
certificate, as appropriate,
2* Identification of the document, i.e. date of issue and unique identification,
3* Identification of the issuing inspection body Name and address of the IB
issuing / endorsing the certificate,
4* Identification of the client Lifting equipment Owners/ Contractors
name and address,
5* Description of the inspection work ordered, 6* Date(s) of
inspection and Type of Inspection,
7 Information on where the inspection was carried out, The address of the
premises at which the Inspection was made,
8 Manufacturer or Supplier of equipment name and address,
9* Identification of the object(s) inspected and, where applicable,
identification of the specific components that have been inspected and
identification of locations,
DAC REQUIREMENTS 06/2012

10 Unique Identification Numbers, brief description and SWL of the

equipment,
11 Any reservations or restrictions on the use or Maximum Capacity of the
equipment,
12* Information on what has been omitted from the original scope of work,
13* Identification or brief description of the inspection method(s) and
procedure(s) used, mentioning the deviations from, additions to or
exclusions from the agreed methods and procedures,
14 Identification of equipment used for measuring/testing,
15 Where applicable, and if not specified in the inspection method or
procedure, reference to or description of the sampling method and
information on where, when, how and by whom the samples were taken,
16* If any part of the inspection work has been subcontracted, the results of
this work shall be clearly identified,
17 The Due date of next Thorough Inspection,
18 The Due date of next Proof Load Test, if applicable,
DAC REQUIREMENTS 06/2012
19 Applicable Reference Standard / Code,
20 Details of any major Repairs / Alterations carried out on the
equipment, provided that the clients inform IBs inspector of any
modifications or structural repairs,
21 Details of latest Inspection / Tests previously performed including
any NDT if possible,
22 Measuring units (for Loads / Weights) shall be in either/both Metric
kilograms or pounds,
23 Information on environmental conditions during the inspection, if
relevant,
24* the results of the inspection including a declaration of conformity and
any defects or other non-compliances found (results can be
supported by tables, graphs, sketches and photographs),
25 A statement that the inspection results relate exclusively to the work
ordered or the object(s) or the lot inspected,
26 A statement that the inspection certificate/report shall not be
reproduced except in full without the approval of the inspection body
and the client,
27 The inspector's mark or seal, if any,
DAC REQUIREMENTS 06/2012
28* Names (or unique identification) of the staff members who have
performed the inspection and in cases when secure electronic
authentication is not undertaken, their signature, (see also clause 13.3
of ISO/IEC 17020),
29 Name, Signature, and Designation of signing Authority of IB, (if different
than the inspector who performed the test)
30 Clearly defined Liability Clause of the IB
30 *Measurement of Scaffolding Structure (H, W & L),
31 *Location of Scaffolding with gridlines indication,
32 *Scaffolding Classification
33 *Scaffolding Number of working platform (refer to Approved Code of
Practice)
34 *Hard weather Conditions (ex. heavy rain & Winds).
Certificates issued by third party IBs that fail to give any of the above details will
be liable to rejection by the relevant authority in Dubai.
Therefore the Inspection Body must only issue an Inspection Certificate
when it is satisfied that the lifting equipment is likely to be able to perform
all the normal lifts within its capacity in accordance with the relevant load
chart
DAC REQUIREMENTS 06/2012

FREQUENCY FOR
LIFTING EQUIPMENT TYPE
PROOF LOAD TEST INSPECTION
(SWL)
Lifting Equipments:
Pedestal cranes, mobile cranes, forklifts, tower On initial supply Every twelve (12)
cranes After reinstallation, substantial months
Overhead traveling cranes, wall / pillar cranes, alteration or major repair
derricks At discretion of survey
Winches, hoist (air and electric), crabs, Telfer
hoist, powered working platforms, vehicle lifts or
hoists etc.
Mobile or movable jacks and associated Lifting
Equipment

LIST OF STANDARDS

PRODUCT TASK NAME STANDARD

Tower Crane Code of practice for safe use of BS 7121 2: Inspection, Testing
cranes (Tower) and Examination Sections
5,6,7,9,12,15
Tower Crane Code of practice for safe use of BS 7121:Part 5 Section 14
cranes (Tower)