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OSHC Cataloging-in-Publication Data

Code of practice for tower crane safety / Occupational Safety and Health
Center. Department of Labor and Employment.
p.cm.
includes bibliographical references.
ISBN 971-8806-04-0

2. Construction industry-occupational safety. 1. Title

08.10.1 2002
2002-002
CIP

Information contained in this material may be freely quoted, reprinted or

reproduced, provided credit is given and a copy of the publication containing
the reprinted material is sent to the Occupational Safety and Health Center.

First Printing, 2002

Latest Printing, 2016
 TABLE OF CONTENTS

Chapter 1 - General Provisions

1.1 Objective 1
1.2 Application 1
1.3 Definitions 1

Chapter 2 - Duties and Responsibilities

2.1 Duties of Competent Person 3
2.2 Duties of Employer 3
2.3 Duties of Tower Crane Operator 3

Chapter 3 - Tower Crane Selection and Equipment Requirements

3.1 Conditions for the Selection of Tower Crane 5
3.2 Characteristics of Tower Crane 5
3.3 Responsibility for Safe and Reliable Crane 6
3.4 Responsibility for Crane Selection 6
3.5 Equipment Requirements 6
3.6 Identification 6
3.7 Load Rating 6
3.8 Crane Cabin 7
3.9 Wind Vaning 8
3.10 Operating Controls 8
3.11 Electrical Equipment And Wirings 9
3.12 Gear Boxes 9
3.13 Drum Assemblies 9
3.14 Stopping Mechanism (Brakes) 10
3.15 Lifting Accessories 11
3.16 Safety Features 13
3.17 Equipment Manuals And Record 13

Chapter 4 - Operating Procedures and Precautions

4.1 Safety Requirements Prior To Operation 15
4.2 Safety Requirements During Operation 16
4.3 Handling The Load 17
4.4 Electrical Hazards 19
4.5 More Than One Crane Operating In The Same Area 21
4.6 Traveling With Load (Rail-Mounted Cranes) 21
4.7 Signaling 22
4.8 Unattended Machine 22
4.9 Emergency Shutdown Procedures 23
Chapter 5 - Erection/Installation, Climbing, Telescosping
Dismantling & Transport
5.1 Erection/Installation 25
5.2. Tower Assembly & Erection 28
5.3 Turntable & Mast Assembly 29
5.4 Turntable & Mast Erection 29
5.5 Jib Assembly 29
5.6 Counter Jib Erection 29
5.7 Main Jib Erection And Fitting Counterweights 30
5.8 Electrical Installation 30
5.9 Wire Rope And Reeving 30
5.10 Erection Checklist 30
5.11 Bolting Procedures 32
5.12 Special Considerations For Rail-Mounted Cranes 33
5.13 Climbing 35
5.14 Telescoping 36
5.15 Dismantling 36
5.16 Transporting The Crane 37

Chapter 6 - Inspection, Testing & Maintenance

6.1 Inspection 38
6.2 Monthly Inspections 41
6.3 Testing 42
6.4 Maintenance 44

Annex - Hand Signals 46
References
 CHAPTER 1
GENERAL PROVISIONS
1.1. OBJECTIVE

The objective of this Code is to provide practical guidance on the safe use
of tower crane on administrative, technical and training aspects to ensure:
1.1.1. Prevention of accidents arising from the improper operation,
erection, installation, dismantling, telescoping, transport and
maintenance of tower cranes;
1.1.2. Appropriate implementation and use of this Code.

1.2. APPLICATION

This Code applies to individuals involved in the erection/installation,

inspection, operation, maintenance, repair, dismantling, telescoping,
alteration, mobilization and transport of tower cranes consisting of
mechanical design, electrical and civil engineering works.

1.3. DEFINITIONS

For the purposes of this Code, the following words and phrases are defined as:
1.3.1. Code - Refers to the “Code of Practice for Tower Crane Safety”;
1.3.2. Center of Rotation - The vertical axis about which the crane slews
or rotates;
1.3.3. Climbing Crane - A tower crane installed and supported in the
building or structure within which it stands, and which can be
raised as the number of floor increases;
1.3.4. Competent Person - The person designated, trained and certified
by the Department of Labor and Employment to assess the safety
condition of the tower crane; to inspect and to recommend all
matters related to safe use of tower crane;
1.3.5. Counter-jib - A secondary jib which carries the counter-weight or
a counterbalancing device;
1.3.6. Counterweight - Weights added to the crane in such a position
to provide a counterbalancing effect;
1.3.7. Erection Crew – A group of persons trained and designated by
the employer to perform the erection/installation, dismantling
and transport of tower crane;
1.3.8. Fixed-luffing jib - Mounted on pivots at the jib foot but unlike
the luffing jibs, these are held by jib pendants at a fixed angle of
inclination;
1.3.9. Freestanding Height - The maximum height at which a tower crane
can operate without being held by ties;
1.3.10. Hoisting - The movement of the hoist block in the vertical
direction;

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1.3.11. Interference - A condition in which the jib can come into contact
with another structure, crane or the hoisting ropes of another
crane or any other obstacles;
1.3.12. Interference Zone - The area where interference can occur;
1.3.13. Jib - The main structure from where the load is suspended;
1.3.14. Licensed Engineer - A duly licensed engineer by the Professional
Regulation Commission;
1.3.15. Limit Switch - A device that stops a particular crane motion at its
predetermined extremities or limits of operation;
1.3.16. Load Capacity Chart - The chart that shows the crane’s lifting
capability for different load radii;
1.3.17. Load Moment Limit Switch - A limit switch that prevents the crane
from being loaded beyond its safe working load at a particular
radius;
1.3.18. Load Radius - The distance between the center of the load to the
center of the rotation;
1.3.19. Luffing Jib - Pivoted at the jib foot and supported by luffing cables
much like the main jib on a mobile crane. The hoist rope, which
supports the load usually passes over a sheave at the jib head,
and the hook radius is altered by changing the angle of inclination
of the jib;
1.3.20. Maintenance-in-charge – The person designated, trained and
authorized by the employer to conduct the preventive and
corrective maintenance of tower crane;
1.3.21. Public Area - The place where the public has unlimited access;
1.3.22. Radius Indicator - A device that shows the load radius;
1.3.23. Rigger - A person whose duty is to estimate, secure load and give
appropriate signals for the purpose of safe load lifting;
1.3.24. Safe Working Load - The maximum load which can be safely
handled by a crane under conditions as specified by the
manufacturer or the competent person;
1.3.25. Service Conditions - In-service, with the crane handling loads up to
the safe working load in allowable conditions; Out-of-service, with
the crane not required for use or out of use due to unallowable
conditions;
1.3.26. Slew - The rotary motion of a crane jib about the center of rotation;
1.3.27. Standards - The Occupational Safety & Health Standards (OSHS)
of the Department of Labor and Employment (DOLE) of the
Philippines;
1.3.28. Static Crane - A tower crane that is free standing or anchored to
a building;
1.3.29. Mast - The part of the tower crane which provides elevation and
support for the jib mounting;
1.3.30. Traveling - A movement of the crane along the rail track;
1.3.31. Trolleying - A movement of the trolley along the jib to vary the
distance between the hook to the center of rotation.

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 CHAPTER 2
DUTIES AND RESPONSIBILITIES
2.1. DUTIES OF COMPETENT PERSON

The competent person should:

2.1.1. Be responsible to asses the safety condition of the tower crane;
2.1.2. Ensure the practical application of this Code;
2.1.3. Carry out inspection of tower crane.

2.2. DUTIES OF AN EMPLOYER

The employer should:

2.2.1. Provide operations manual of the tower crane;
2.2.2. Ensure that all employees who are involved in the installation,
erection, operation and maintenance are well-trained in safety
procedures;
2.2.3. Establish safety inspection program;
2.2.4. Assign only certified and competent tower crane operator;
2.2.5. Ensure that operators and other workers involved in the operation
of tower crane are made aware of Standards, Code of Practices,
instructions and procedures relating to prevention of accidents
and injuries;
2.2.6. Provide supervision to ensure that workers perform their work
with due regard to their safety;
2.2.7. Take immediate actions to stop the operation of tower crane
when there are dangers to the safety of the operators and/or
other workers involved in its operation;
2.2.8. Provide appropriate first-aid and welfare facilities and personal
protective equipment (PPE) to tower crane operator and other
employees involved in its operation;
2.2.9. Ensure not only the safety of the operator and other workers but
also the safety of the public and properties within the vicinity.

2.3. DUTIES OF TOWER CRANE OPERATOR

The tower crane operator should:

2.3.1. Ensure that he is in good physical and mental condition and
not at risk to impair safe operation of tower crane, of particular
importance to consider are the following:
2.3.1.1. Physical dexterity;
2.3.1.2. Eyesight (with or without spectacles);
2.3.1.3. Hearing (with or without hearing aid);
2.3.1.4. Any medication which could impair attention,
concentration and judgment;
2.3.1.5. Any drugs (tranquilizer, sedative, narcotics, etc.),
alcohol and other substances usually abused.

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 2.3.2. Cooperate as closely as possible with their employer in the
application of the prescribed safety and health measures.
2.3.3. Protect their own safety and health and that of other persons
who may be affected by their acts or omission at work.
2.3.4. Ensure the proper use and maintenance of personal protective
equipment (PPE), protective clothing and facilities placed at their
disposal, and never misuse anything provided for their own and
the protection of others.
2.3.5. Report to their immediate supervisor and to the workers’ safety
representative any risk or situation which they cannot properly
handle by themselves.
2.3.6. Except in an emergency, not interfere with, remove, alter or
displace any safety device or other appliance furnished for their
own and the protection of others, or interfere with any tower
crane method or process adopted to avoid accident and injury,
unless duly authorized.
2.3.7. Be aware of the limitations of the equipment and any part thereof.

CHAPTER 3
TOWER CRANE SELECTION AND EQUIPMENT REQUIREMENTS
The tower crane’s basic characteristics shall fit the job’s requirements to eliminate
possible occurrence of unsafe conditions in the execution of the job.

3.1. CONDITIONS FOR THE SELECTION OF TOWER CRANE

3.1.1 In selection of tower crane over mobile crane, the following con-
ditions shall be considered:
3.1.1.1. Need for a crane in a given location is long-term;
3.1.1.2. Site is constricted or congested;
3.1.1.3. Lift heights are extremes & the reach may be deep;
3.1.1.4. Need for mobility is little but lift frequency is high;
3.1.1.5. Cost of rentals;
3.1.1.6. Load placement is easier by a crane working from with-
in rather than from outside.

3.2. CHARACTERISTICS OF TOWER CRANE

3.2.1. In selecting the most suitable type, size and number of tower
crane for a particular application, consideration shall be made
not only on factors such as weights, dimensions and lift radii of
the heaviest and largest load, but also other characteristics of
available cranes such as the following:
3.2.1.1. Type and size of the base for the crane;
3.2.1.2 Maximum free-standing height of the crane;
3.2.1.3. Maximum braced height;
3.2.1.4. Climbing arrangement;
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 3.2.1.5. Weight of the crane that will have to be supported by
the building;
3.2.1.6. Jib length available;
3.2.1.7. Possible necessity of auxiliary guys;
3.2.1.8. Available head room between the maximum height po-
sition of the hook and the uppermost work level;
3.2.1.9. Area that has to be covered;
3.2.1.10. Lifting and lowering speeds;
3.2.1.11. Length of rope the hoist drum carries;
3.2.1.12. Number and size of rope needed to do the hoisting;
3.2.1.13. Service availability and cost;
3.2.1.14. Cost of off-site transport, erection, dismantling and charges
for climbing the machine;
3.2.1.15. The capacity of crane must be determined and recom-
mended by the competent person.

3.3. RESPONSIBILITY FOR SAFE AND RELIABLE CRANE

3.3.1. Selection of a tower crane for any job should be made only after
a thorough examination of all factors involved. Those responsible
for selection should ensure that the unit is going to be safe
and reliable for as long as it will be used, under all anticipated
conditions to which it will be exposed and operated.

3.4. RESPONSIBILITY FOR CRANE SELECTION

3.4.1 The responsibility of crane selection involves not only to get

the job done as quickly and economical as possible, but also to
eliminate all possibility of hazards to on-site personnel, public
and property.

3.5. EQUIPMENT REQUIREMENTS

3.5.1. Any tower crane safety program should ensure that all necessary
equipment is on the machine and in order;
3.5.2. The supplier, owner and users of tower crane should be held
responsible to the availability of any equipment or instruction
relating to safety.

3.6. IDENTIFICATION

3.6.1. Every major structural, electrical and mechanical component (see

Annex) of a tower crane should have permanent durable plate
bearing the following:
3.6.1.1. Manufacturer’s name;
3.6.1.2. Machine model number;
3.6.1.3. Serial number;

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 3.6.1.4. Year manufactured;
3.6.1.5. Weight of the unit.
3.6.2. Identification numbers should be clearly marked on all basic
removable components and attachments of the tower crane to
show that they belong to a specific machine.

3.7. LOAD RATING

3.7.1. Every tower crane should be equipped with a substantial and

durable load chart, with clearly legible letters and figures and
having the following information:
3.7.1.1. Crane model number;
3.7.1.2. Serial number;
3.7.1.3. Date of manufacture;
3.7.1.4. A full and complete range of the manufacturer’s
approved crane load ratings of all stated operating radii
(or jib angles) for each recommended counterweight,
jib length, tower height or other installation conditions;
3.7.1.5. Lifting speed instructions;
3.7.1.6. Recommended parts of hoist reeving, size and type of
rope for various crane loads;
3.7.1.7. Essential precautionary or warning notes relative to
limitations on equipment & operating procedures;
3.7.1.8. Drum data, available line pull, permissible line pull,
line speed and rope spooling capacity;
3.7.1.9. Wind velocity operating limits.
3.7.2. Load chart should be securely attached to the cab in a location
easily visible to the operator while seated at his control station.
3.7.3. When crane is operational from the remote control console, the
load chart should be attached to a substantial plate secured to
the console.

3.8. CRANE CABIN

3.8.1. Every operating cabin intended for attachment to the structure of

the crane or placed at a remote location should meet the following
requirements:
3.8.1.1. Be constructed of fire-proof materials.
3.8.1.2. Be designed and constructed to protect the operator
and the control from different weather conditions.
3.8.1.3. Be of sufficient size to allow operation without
inconvenience, particularly with regard to roof height
and floor space.
3.8.1.4. Be provided with roof of adequate strength to protect the
operator from falling objects and weather conditions.
3.8.1.5. Be securely attached to whatever structure it is located
on.

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 3.8.1.6. Be designed and constructed to provide the operator
with a clear and unrestricted view of the load and jib
point in all normal working positions, visibility to either
side and as clear a view of the job site as possible.
3.8.1.7. Have windows constructed of safety glass or equivalent
and designed to provide ventilation as needed. The front
window should have a section which can be removed or
held open if desired.
3.8.1.8. Fitted with a lock to prevent unauthorized entry when
the unit is left unattended, unless the control unit can
be separately locked. The cab doors should be restrained
from opening and closing accidentally whenever the
crane is in use.
3.8.1.9. Have safe access route to and from the cab. The means
of access to the cabin should ensure that there is no
danger of the operator being trapped in the cabin.
3.8.1.10. Where access is through the floor, there should be
sufficient room in the cabin for the operator to stand
beside the trap and raise it without difficulty.
3.8.1.11. If the vertical position of the control cabin is adjustable, the
means of access and exit should be effective at all levels.
3.8.1.12. Have lighting in the cabin adequate to enable the ope-
rator to see clearly enough to perform his work.
3.8.1.13. Be provided with an operator’s seat that is fully adjustable.
3.8.1.14. Have all working surfaces to and from the cab be of the
anti-skid type.
3.8.1.15. Have guardrails on all outside and access platforms. If
they are too narrow for guardrails, handholds, steps, or
safety line should be provided at convenient points
above the platform.
3.8.1.16. Have the following accessories:
3.8.1.16.1. Windshield wiper
3.8.1.16.2. A CO2 or dry-chemical fire extinguisher
3.8.1.16.3. A warning device to be sounded while
slewing and traversing

3.9. WIND VANING

3.9.1. The main jib of the tower crane should be able to turn freely with
the wind and align itself to the direction of the wind.

3.10. OPERATING CONTROLS

3.10.1. All controls being used during the normal operating cycle should
be located within easy reach of the operator.
3.10.2. All controls should automatically return to neutral when released.
3.10.3. The controls should be arranged so that accidental displacement
is prevented.
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 3.10.4. The voltage used in the controls should be between 25 - 50 volts.
3.10.5. The main power switch should be lockable and located within
easy reach of the operator.
3.10.6. Each control should be clearly marked to indicate its function.
3.10.7. All controls should be installed to move in the direction of the
resultant load movement or machine movement.

3.11. ELECTRICAL EQUIPMENT AND WIRINGS

3.11.1. All components connected electrically to a crane’s structure

should be grounded.
3.11.2. All electrical equipment and wiring should be installed in
accordance with the provisions of the Philippine Electrical Code.
3.11.3. Strain-relief connectors should be used in power cable
connections.
3.11.4. All electrical equipment and connectors should be of weather-
proof type.
3.11.5. Power feeders for the crane, which run inside the crane tower
should be securely fastened at regular intervals and correctly
grounded.

3.12. GEAR BOXES

3.12.1. Gear boxes should be designed so that gears will be automatically

lubricated.
3.12.2. All gear boxes should be rigidly constructed and fitted with
inspection covers.
3.12.3. Gear boxes should be oil tight.
3.12.4. The gears should be readily movable.

3.13. DRUM ASSEMBLIES

3.13.1. Ensure all drum assemblies are provided with the following:

3.13.1.1. Adequate power and operational characteristics to

perform all hoisting, holding and lowering functions;
3.13.1.2. Suitable clutching or power-engaging devices to facilitate
immediate starting and stopping of the drum motion;
3.13.1.3. Fail-safe brakes that are capable of supporting all rated
loads and operate automatically should power fail;
3.13.1.4. Brakes and clutches with adjustments to compensate
for wear, and maintain adequate force in springs when
used;
3.13.1.5. All derricking mechanisms should be provided with
positive locking device;
3.13.1.6. Drums of sufficient rope capacity, with recommended
rope size and reeving to perform all raising and lowering

8
 functions under recommended and actual service
conditions;
3.13.1.7. Adequate means to ensure even spooling of the rope
on the drum;
3.13.1.8. At least three (3) full wraps of rope remaining in the
drum in all service conditions;
3.13.1.9. Drum end of the rope anchored by a clamp securely
attached to the drum;
3.13.1.10. Drums with runs and flange guards of sufficient size to
prevent the rope from jumping off the drum;
3.13.1.11. Grooved drums with correct groove pitch and depth for
the diameter of the rope;
3.13.1.12. Flanges on grooved drums projecting either twice the
rope diameter or 50 mm (2 inches) beyond the last
layer of the rope, whichever of the two (2) is greater;
3.13.1.13. Drum rotation indicators located to afford easy sensing
by the operator;

3.14. STOPPING MECHANISM (BRAKES)

3.14.1. Every brake on the tower crane should be fail-safe with the brake
being automatically applied whenever there is power failure.
3.14.2. The brakes applied should not release until the power has been
restored and only when deliberately released.
3.14.3. The restraining torque of the brake should be at least 25% greater
than the maximum torque applied to the drum under service
conditions, ignoring any effects caused by friction.
3.14.4. Where electro-mechanical brakes are used:
3.14.4.1. They should be designed to apply a braking torque as
soon as the current is cut off;
3.14.4.2. Arrangement should be made to prevent the brake
magnet from being energized by secondary current
when the main supply is interrupted;
3.14.4.3. The brakes should not be released until the driving unit
is energized and capable of transmitting torque to the
drum.
3.14.5. All load holding brakes and clutches should have sufficient size
and thermal capacity to control all rated loads with minimum
recommended reeving.
3.14.6. Foot brake pedal should be roughened or covered with high
friction materials so the operator’s foot will not easily slip off.
3.14.7. The springs that apply the brakes should be of the compression
type, and should be stressed in excess of 50% of the torsional
elastic limit of the material.
3.14.8. The wearing surface of all brake drums should be machined and
smooth and free from defects.
3.14.9. The counterweights must be fixed securely to their levers.

9
 3.14.10. The brake blocks and lining should be protected from rain, grease
and oil.
3.14.11. All brakes should be provided with simple and easily accessible
devices for easy detection of the wear of lining, except when
the adjustment is automatic and not required during the life of
the lining.
3.14.12. The brake on the slewing drive should be capable of preventing
the jib of the crane from drifting, under wind pressure up to the
maximum operating wind pressure specified by the manufacturer.
3.14.13. On rail-mounted cranes, each carriage drive should be equipped
with hydraulic or magnetic brake of sufficient size, to stop the
crane within a distance equivalent to 10% of the traveling speed of the
crane.

3.15. LIFTING ACCESSORIES

3.15.1. Jib Stops

3.15.1.1. Luffing jib tower cranes, like mobile crane should have
a jib stop which effectively prevents the jib from toppling
- or being pulled backwards over the tower.
3.15.1.2. Jib stop should combine the functions of disengaging
the derricking motor and physically stopping the jib as
it reaches a predetermined maximum angle.
3.15.2. Sheaves
3.15.2.1. The sheave groove should be smooth and slightly larger
than the rope to prevent the rope from being pinched
or jammed in the groove.
3.15.2.2. The sheave groove should be smoothly contoured,free
of surface defects and should possess rounded edges to
ensure long and efficient rope life.
3.15.2.3. The sheave should be perfectly aligned so that rope and
sheave flanges will not be subjected to severe wear and
avoid rapid deterioration.
3.15.2.4. The depth of the sheave groove should be at least 1½
times the rope diameter.
3.15.2.5. The tapered side walls of the sheave groove should
not make an angle of more than 26° with respect to the
center line.
3.15.2.6. The bearings should be either permanently lubricated or
equipped with means for lubrication.
3.15.2.7. If the sheaves are carrying ropes that can be momentarily
unloaded, as in the case of hoist line, the sheave should
be equipped either with cable keepers or with close-fitting
guards that prevent the ropes from becoming fouled. The
block is lying on the ground with the ropes loose.
3.15.2.8. Sheave flanges must be inspected at regular intervals
for any sign of cracks.

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 3.15.2.9. When replacements on sheave parts become necessary,
only equipment supplied or approved by the crane
manufacturer should be fitted.
3.15.2.10. The groove surfaces on both sheaves and grooved drums
and the complete surface on smooth drums should be
perfectly smooth.
3.15.2.11. If imprint of outer wires of previous ropes is evident due to
high contact pressure between the rope and drum surface,
then the drum should be re-surfaced and contact pressure be
reduced by:
- decreasing the load on the rope; or
- increasing the drum diameter; or
- replacing the drum with one made of harder metal

3.15.3. Limit Switches

3.15.3.1. A ll tower cranes of every configuration should be
equipped with built-in safety devices which operate
automatically to prevent damage to the machine should
the operator make an error.
3.15.3.2. Every tower crane should have the following:
- A hook height limit switch that causes the hoist
drum to stop whenever the load hook reaches a
predetermined maximum height position.
- Luffing jib limit switches that cause the derricking
drum to stop whenever the jib is raised to an angle
too high or lowered to an angle too low.
- Trolley limit switches that cause trolley motion to
stop whenever the trolley reaches a predetermined
maximum out or maximum in position.
- Overload limit switches that cause the hoist drum
to stop whenever the load being lifted exceeded
the maximum rated load for any radius or jib angle.
- Travel limit switches for rail-mounted cranes that
apply the carriage brakes whenever the crane nears
the end of the track.

3.15.4. Guards and Protective Structures

3.15.4.1. The owner of the tower crane should ensure that
all exposed moving parts such as gears, pulleys,
belts, chains, shafts, flywheels, etc. which might
constitute a hazard under normal
operating conditions are guarded or fenced.
3.15.4.2. Every machine guard should allow for routine inspection
and maintenance and be capable of supporting
without permanent distortion, a man’s weight, unless
the guard is located where it is impossible to step on it.
3.15.4.3. All electrical panels, components and wires should be

11
 insulated in areas where the operator or maintenance
personnel could accidentally come in contact with them.

3.16. SAFETY FEATURES

3.16.1. All tower cranes should be equipped with the following safety
features and devices:
3.16.1.1. A metal receptacle secured permanently to machine for
storing tools and lubricating equipment;
3.16.1.2. Adequate lighting for night operation;
3.16.1.3. Fire extinguishers with operating and maintenance per-
sonnel familiar with their use and care.
3.16.1.4. Jib angle indicators on all machines having jibs capable of
moving on the vertical plane, with clearly visible indi-
visible indicator and readable by the operator within 1°
at his control station.
3.16.1.5. An effective audible warning signal mounted on the carriage
of rail-mounted cranes, with control for the device with-
in easy reach of the operator.
3.16.1.6. Shock-absorbing jib stops and derricking safety shut-offs on
all luffing jib cranes.
3.16.1.7. In addition to providing safe means of access to the crane, it
is recommended that safety lines with runners for the
attachment of safety lanyards be fitted to tower crane
jibs, and that safety platforms be attached to the trolleys
of saddle jibs to facilitate inspection and maintenance
3.16.1.8. Trolley radius markers that will accurately inform the
operator of the radius of the load hook.
3.16.1.9. A device that will prevent automatic restarting of motors
at the resumption of power during power interruption.

3.17. EQUIPMENT MANUALS AND RECORD

3.17.1. Manufacturer’s manuals containing all pertinent data relating to

operation and maintenance for the specific model of crane in use
should be provided in each machine. The manual should include,
but not necessarily limited to the following information:
3.17.1.1. Equipment designation or type;
3.17.1.2. Name of equipment manufacturer;
3.17.1.3. Name of equipment designer, if other than the manufacturer;
3.17.1.4. Equipment model number and serial number;
3.17.1.5. Year of original sale of the manufacturer;
3.17.1.6. Weight of individual structural elements, mechanical
components and individual counterweight;
3.17.1.7. A copy of the load chart plus any and all rated combinations
and variations in capacity and geometry;
3.17.1.8. Inspection and maintenance procedure including:

12
 - Material specifications on jib and tower elements
- Welding specifications for all structural components
- Bolting and torquing specifications
3.17.1.9 Lifting tackle specifications;
3.17.1.10. Erection procedures;
3.17.1.11. Operating precautions;
3.17.1.12. Dismantling procedures.
3.17.2. If the equipment is not provided with a logbook, then one should
be started, maintained and kept on the worksite for the regular
or periodic recording of all internal and external inspections,
examinations, tests, repairs, maintenance and hours of service
related to the machine. All entries should be dated and signed
by the operator, repairman and supervisor.
3.17.3. Purchase, lease, or use of any piece of equipment which has been
modified, altered, or otherwise subjected to any deviation from
the original manufacturer’s specifications should be prohibited,
in any way unless there is documented proof that the change is
certified safe for operation by a competent authority.

CHAPTER 4
OPERATING PROCEDURES AND PRECAUTIONS
It must be recognized that written rules cannot cover all situations that may arise
during the operation of the machine; in cases where no written rule applies the
operator should be prepared to use his own judgment.

4.1. SAFETY REQUIREMENTS PRIOR TO OPERATION

4.1.1. Never use or allow the use of any tower crane not in perfect
mechanical condition.
4.1.2. Before starting operations, inspect, test or maintain the crane
in accordance with the recommendations in the manufacturer’s
manual and this Code.
4.1.3. Replace all parts and components showing excessive wear,
damage or other defects that might affect safe operation of the
crane.
4.1.4. The operator should:
4.1.4.1. Regularly check all parts subject to wear and report all
cases of excessive wear without delay.
4.1.4.2. Report any abnormal mechanical noises.
4.1.4.3. Check all brakes and limit switches everyday.
4.1.4.4. Inspect the main structure, wedges, support collars and
shoring daily to make sure there are no apparent faults/
hazards.
4.1.4.5. Lubricate the crane regularly but only when it is at rest.

13
 4.1.4.13. Keep fingers, feet and clothing away from belts, gears and
ropes, unless the machine is shut down and no one can
re-start it.
4.1.4.14. The operator should read the manufacturer’s manual
to have knowledge of preventive maintenance in order
to spot a malfunction in the machine before an accident
occurs.
4.1.5. Never use or allow the use of any tower crane when weather
conditions could cause hazards to personnel, property or the
public.
4.1.6. Never operate or allow anyone to operate any tower crane until
that person is thoroughly familiar with the machine and its safe
operation.
4.1.7. Before putting the crane into operation check that all guards,
controls, clutches, brakes, gears and the like are properly set.
4.1.8. If there is a warning sign on the crane or controls, do not turn on
the crane or attempt to operate it until the problem is solved and
the warning sign has been removed by the person who placed it.
4.1.9. Before operating the controls, blow the horn and make sure that
all personnel clear the area.
4.1.10. Never move a rail-mounted crane without first making certain
that no one will be endangered. When clear vision of the track
area is impossible, assign a signalman and sound the horn before
moving the crane.
4.1.11. The operator and the signalman should ensure that no one is
within the radius of rotation of any part of the crane or load,
unless he is authorized by the person-in-charge of the work to
be in the area.
4.1.12. Determine the weight of all loads before slinging them or
attempting to lift them. Make ample allowances and determine
the available capacity of the equipment being used.
4.1.13. All lifting accessories must be considered part of the load.
Calculate the entire load carefully and check it against the rated
lifting capacity of the crane.

4.2. SAFETY REQUIREMENTS DURING OPERATION

4.2.1. The operator should:

4.2.1.1. Remain alert to possible malfunctioning of the machine
while operating. If the crane malfunctions, shut it down
until the problem is corrected.
4.2.1.2. Remain alert to any unusual noises, loss of control or
bad response to control of the crane.
4.2.1.3. Make sure all controls work freely and easily with no
sticking and binding.
4.2.1.4. Watch for oil leaks, stop and correct them immediately.
4.2.1.5. During load lifting, test the brake before the load clears
one meter to assure the ability of the brake to hold the load.
14
 4.2.1.6. If the crane is being operated by more than one operator,
be sure to notify the next operator of any defects.
4.2.1.7. If the visibility of the signalmen is impaired by dust,dark-
ness, fog or rain, strict supervision of the crane operation
should be exercised.
4.2.1.8. Never allow anyone to climb the tower or get on the jib
when it is in motion.
4.2.1.9. Wear all necessary protective equipment such as hard
hats, safety glasses, safety shoes and gloves when
working on or around tower cranes.
4.2.1.10. Never attempt to adjust, repair or lubricate a moving
crane. Always lower the load to the ground, lock or support
the hoist block and shut off the master control.
4.2.1.11. The operator should never allow his attention to be diverted
from the operation of the crane.
4.2.1.12. Always position the load close to the tower to minimize
the slew.
4.2.1.13. The rigger should always use appropriate hand signals
(refer to Annex B).

4.3. HANDLING THE LOAD

4.3.1. The following should be ensured before making a lift:

4.3.1.1. The load has been correctly slung and well secured
to prevent the movement or dislodgment of any part.
All loose objects must be removed from the load and crane.
4.3.1.2. Taglines are used to control the load.
4.3.1.3. The load is free before lifting (not bolted, tied or fastened
to the ground or another object) and that all sling legs
are taking the load.
4.3.1.4. The jib head or trolley is directly over the load, the load
ropes are directly over the center of gravity of the load
and the hoist ropes are vertical.
4.3.1.5. The hoist ropes are not twisted around each other.
4.3.1.6. The hook should not be lowered to the ground allowing
the hoist rope to become slack.
4.3.1.7. If there has been a slack, check:
4.3.1.7.1 If the rope is properly seated on the
driver and in the sheaves.
4.3.1.7.2 The rope spooling on the drum for over
winding.
4.3.1.7.3 All non-operating personnel have been
warned or told to leave the immediate
area before working a lift.
4.3.1.8. Always know the weight of any load that is to be lifted.
4.3.1.9. There should be a competent individual assigned on a
full-time basis to be responsible for determining the

15
 weight of the load to be lifted.
4.3.1.10. Operator should not make a lift unless he has first
determined the weight of the load.
4.3.1.11. Never use the limit switches as stops. They should
never be put out of operation and should be kept well-
adjusted.
4.3.1.12. Know the radius of the load especially when utilizing the
full capacity of the crane.
4.3.1.13. Avoid impact loading caused by sudden jerking when
lifting or lowering. Raise the hoist rope gradually until
the slack is eliminated.
4.3.1.14. The controls should not be moved immediately to
maximum speed.Tension the hoist rope slowly before
actually using maximum speed to avoid possible
breakage of the rope
4.3.1.15. A llowances should be made for wind loading and
dynamic forces present in the normal operation of the
crane and load, and to ensure that the safe working load
is not exceeded during operation.
4.3.1.16. Ensure that the slingers keep their hands away from
pinch points when the slack is being lifted.
4.3.1.17. When lifting heavy loads, care should be taken to prevent
sudden loading or unloading of the hoist rope. Ease the
load, lift a few inches off the ground and hold, to check
the brakes.
4.3.1.18. For tower cranes with multi-speed hoist, slew and trolley
controls, never operate the control directly from low
speed to high speed. Operate it through each of the
speed ranges when starting and stopping the movement.
4.3.1.19. Make sure that all personnel stand clear while loads are
being lifted and lowered, and while the slings are being
drawn from beneath the load.
4.3.1.20. Never carry load over the heads of personnel.
4.3.1.21. If the load does not ride properly, lower it and have it
re-adjusted.
4.3.1.22. Never allow anyone to ride on a load that is being lifted.
4.3.1.23. Ensure that the load does not catch on obstructions
when lifting and slewing.
4.3.1.24. If a load hangs, for instance a big formwork element
hanging on to a concrete wall, do not try to lift the load
and never try to slew it free. The overload cut-outs will
not react to slewing, but the slewing may be powerful
enough to cause a structural failure.
4.3.1.25. Ensure that sudden starts and stops are not made when
slewing or rotating the crane:
- Rotational speeds must not swing out the load
beyond the radius at which it can not be controlled;

16
 - Rapid slewing of a suspended load causes the
load to drift away from the crane, thus increasing
the radius and could cause the crane to collapse.
4.3.1.26. The load should always be kept directly below the jib
point or trolley.
4.3.1.27. Before slewing a load above the uppermost floor deck,
be sure the slew path is clear.
4.3.1.28. Never allow anyone to work under a suspended load unless
the load has been adequately supported from the floor,
and all conditions have been approved by the supervisor
in-charge of the operation.
4.3.1.29. Never use the crane to drag a load sideways. Make verti-
cal lift only.
4.3.1.30. Neither the load nor the jib should ever be lowered to a
point wherein less than three (3) full wraps of rope re-
main on the drum.
4.3.1.31. Do not lift loads with excess slings hanging loose. Never
allow any excess cable or sling to be suspended beneath
the crane.
4.3.1.32. Watch for jib kickback on luffing crane. Never operate
with the jib at a higher angle than reflected on the capa-
city chart, for a sudden release of the load may throw
the jib back over the tower.
4.3.1.33. Do not let the load strike the building.
4.3.1.34. Allow maximum clearance between the hook block and
trolley sheaves.
4.3.1.35. The operator must never leave his position at the control
while the load is suspended.
4.3.1.36. When loading or unloading a truck, ensure that its driver
leaves the cab and always work at the rear of the truck.
4.3.1.37. When loading, the loads must be set on adequate block-
ing to prevent damage to the slings. They must be safely
landed and properly blocked before being unhooked and
unslung.

4.4. ELECTRICAL HAZARDS

4.4.1. To reduce the possibility of electrical accidents, the following

measures should be taken:
4.4.1.1. Never move any part of the crane or load rope into
the “absolute limit of approach” or the area surrounding
every live power line unless the power line has been
de-energized or properly insulated.
- Philippine Electrical Code provides the absolute
limit of approach as shown in the table below:

17
 Line Voltage Absolute Limit of Approach
151 to 600 1.00 m.
2400 1.00 m.
7200 1.10 m.
23000 1.15 m.
34500 1.20 m.
46000 1.35 m.
69000 1.50 m.
115000 1.85 m.
138000 2.05 m.
161000 2.25 m.
230000 2.85 m.
4.4.1.3. Barriers should be installed to remind crane operator/
driver of the limit approach.
4.4.1.3. Signaler or banks-man should warn the operator
whenever the jib, the load or the hoist rope gets near
to the limit of approach.
4.4.1.4. If practical, remove all power lines that are under the
slew areas of the crane.
4.4.1.5. If it is impossible to move power lines, then have the
local power company insulate or disable them.
4.4.1.6. The operator must pay attention to the signalman’s
hand signals and warnings when working near power
lines.
4.4.1.7. Slow down the operating cycle of the crane by reducing
hoist, trolley and slew speeds when near power lines.
4.4.1.8 If a load has to be moved near overhead power lines,
issue strict warnings to all ground personnel to stand
clear of the load at all times.
4.4.1.9. If a load has to be guided by hand, a special check should
be made with the signalman before the slinger touches
the load.
4.4.1.10. Use taglines whenever possible. The best tagline is dry
polypropylene rope. Manila and nylon ropes retain
moisture and can conduct electricity.
4.4.1.11. Do not stockpile, load or unload any material near a
power line.
4.4.1.12. Treat all overhead lines as live until you have reliable
information otherwise.
4.4.1.13. Use extreme caution when working in proximity to
radio transmission towers for the crane’s jib can act
like antenna and become electrically charged. In this
situation, hook a heavy copper earth strap to the crane
(both boom and tower) and run it directly to earth. Never
earth it to the building.
4.4.1.14. It is the responsibility of the owner/crane user controlling
the crane to:
- Provide a qualified signalman;
- Provide adequate and advance notification to the
electrical authority for the removal, insulation or

18
 isolation and earthing of power lines;
- Ensure that the electrical authorities are fully
informed as to when the operations are to begin,
when they are due to be completed and when
any location changes are planned;
- Report every incident involving contact with a
live line to the electrical authority and safety
inspector, so that inspections and repairs can
be made to prevent damaged live lines from
falling;
- Completely inspect the crane for possible damage
caused by electrical contact;
- Wire rope should be replaced if it touches a po-
wer line since the arc is usually of sufficient
power to either weld or badly pit the wires.
4.4.1.15. The electrical cables leading up the tower to the jib can
be twisted and damaged, if the crane is slewed more
than three (3) or four (4) revolutions in any one direction
without reversing to unwind the twist in the cables.

4.5. MORE THAN ONE CRANE OPERATING IN THE SAME AREA

4.5.1. Minimize the probability of collision on cranes or the hoisting

ropes or loads fouling each other by observing the following
precautions:
4.5.1.1. The crane should be located in such a way that the ope-
rators have a clear view of other cranes operating with-
in collision danger areas;
4.5.1.2. The operators should have direct communication with
each other so that one operator may alert the other of
impending danger;
4.5.1.3. Overall lifting program should be set out and controlled
by one man who is in contact with all operators and
slingers, and assigns priority of operation for the crane.

4.6. TRAVELING OF RAIL-MOUNTED CRANES

4.6.1. To reduce the possibility of accident due to traveling of rail

mounted crane, the operator must evaluate thoroughly the local
conditions, determine safe practices and exercise precautions
such as the following:
4.6.1.1. The traveling procedures must be in accordance with
the manufacturer’s instructions;
4.6.1.2. The slew brake should be set;
4.6.1.3. Never travel with load;
4.6.1.4. Travel limit switch should be installed and always in
good condition;
4.6.1.5. Travel speed must be as low as possible;

19
 4.6.1.6. Sudden starts and stops should be avoided;
4.6.1.7. Do not carry the jib at its highest angle;
4.6.1.8. Do not move the crane until the path of the travel is clear.

4.7. SIGNALING

4.7.1. A competent signalman must be always present if the operator

cannot clearly see the hook and load and the path of travel of a
rail-mounted crane at all times.
4.7.2. A signaler or signalman should be employed when the crane has
to work close to overhead power lines.
4.7.3. Two-way radios should be used for all tower crane signaling
operations.
4.7.4. If the operator losses contact with the signalman for any reason,
he must stop the movement of the crane until communication is
restored.
4.7.5. Two signalmen should be assigned where loads are picked up at
one point and lowered at another, such may occur when placing
concrete, one signalman to direct the lift and the other to direct
the descend.
4.7.6. If it is desired to give instructions to the operator other than those
provided for by the established signal system, the operator should
be instructed to stop all hoisting motion first.
4.7.7. The signalman must:
4.7.7.1. Position himself so as to obtain a full view of the load
at all times;
4.7.7.2. Be fully qualified by experience with the operation;
4.7.7.3. Be able to converse in the same language as the operator;
4.7.7.4. Be responsible for keeping the public and all unauthorized
personnel outside the crane’s operating radius;
4.7.7.5. Direct the load so that it never passes over anyone;
4.7.7.6. Be in constant communication with the operator at all
times by a two-way radio.

4.8. UNATTENDED MACHINE

4.8.1. The operator must never leave the controls of the crane while
any load is suspended.
4.8.2. Before leaving the crane unattended the operator must:
4.8.2.1. Lower all loads;
4.8.2.2. Position the trolley near the tower at minimum radius;
4.8.2.3. Raise the hook to its highest position;
4.8.2.4. For luffing jib cranes, the jib should be brought at 15°
position and the hook raised to its highest position;
4.8.2.5. All tower cranes must be allowed to swing freely in the
wind. The friction clutches on the slewing gears must be
fully opened;

20
 4.8.2.6. Where the in-service condition requires a tower height
greater than permissible for out-of-service conditions,
the crane must be guyed or anchored to the building.
Secure rail-mounted cranes to the tracks by installing
rail clamps;
4.8.2.7. Place all controls in the off position;
4.8.2.8. Place the main power switch in the off position and lock
the switch box;
4.8.2.9. Lock the control console;
4.8.2.10. Lock the control cab door.

4.9. EMERGENCY SHUTDOWN PROCEDURES

4.9.1. If crane is driven against electric overhead lines:

4.9.1.1. Do not leave the crane;
4.9.1.2. Move the crane out of the risk zone;
4.9.1.3. Do not allow any person to get nearer the crane;
4.9.1.4. If the electric line is not affected, cut the current of the
electric line;
4.9.1.5. Do not leave the crane unattended even after being sure
that the live wire is disconnected.
4.9.2. In the emergency repair of the crane:
4.9.2.1. Use lock-out/tag-out during emergency and normal re-
pair of the crane;
4.9.2.2. Lock the main control and remove the key;
4.9.2.3. Place a warning sign on the main switch.
4.9.3. In case of leaks on pneumatic installations:
4.9.3.1. Immediately repair damage pneumatic parts before it
can cause injuries and accidents;
4.9.3.2. Remove the pressure from the system sections and open
the pipes (hydraulic and compressed air) according to
manufacturer’s guidelines;
4.9.3.3. Place and fit correctly the hydraulic and compressed air
pipes;
4.9.3.4. Do not invert the connections;
4.9.3.5. Fitting length and quality must correspond to specifi-
cations;
4.9.3.6. Work on hydraulic installations are carried out by persons
having specific knowledge and experience with
hydraulics.
4.9.4. If there are forecasted strong wind/typhoon:
4.9.4.1. Suspend the operation of the crane when there is danger
due to forecasted strong wind;
4.9.4.2. Before commencing the work, inspect for possible ab-
normality or damage of every critical part of the crane
after a strong wind with velocity of more that 30m/sec.
4.9.4.3. In case of existing damage on the jib, fasten it securely

21
 to minimize further damage.
4.9.5. In case of structural failure:
4.9.5.1. Stop the operation of the crane;
4.9.5.2. Assess the damage on all structural components of the
crane;
4.9.5.3. Replace all damaged structural components. Damaged
sections or elements must be cut out and replaced in
conformity with machine specifications;
4.9.5.4. Inspect and check every critical part of the crane after
all damaged structural components have been replaced,
before commencing the work;
4.9.5.5. Structural repairs or alterations should be performed
by skilled persons with required special training and
experiences.
4.9.6. In case of earthquake:
4.9.6.1. Stop operation of the crane;
4.9.6.2. The operator should stay inside the cabin and disconnect
all energy sources;
4.9.6.3. Protect the head of operator with a helmet or similar device;

CHAPTER 5
ERECTION/INSTALLATION, CLIMBING, TELESCOPING, DISMANTLING
AND TRANSPORT
5.1. ERECTION/INSTALLATION

5.1.1. Erection/installation of a tower crane should be well planned and

carried out strictly in accordance with either the manufacturer’s
manual or the competent person’s instructions.
5.1.2. The project engineer, site superintendent, foreman, building
owner, architect, consultant or whoever is responsible for the use
of crane should be also responsible for its safe operation under
his control.
5.1.3. An engineering consultant should be retained to prepare and/or
approve all foundation, shoring and installation drawings, as well
as the planning of all phases of erection and use of the crane.
5.1.4. Every effort should be made to ensure complete safety of the
public, property and all personnel upon arrival of the crane at
the site until the time it leaves.
5.1.5. The following safety pointers should be given serious
consideration:
5.1.5.1 A site drawing should be prepared showing exactly
where the crane will be located and its operating and
maximum slew radii, shoring locations, ground elevation,
buried pipes, main power lines, other cranes, hoists,
structures, buildings and other pertinent site features;
5.1.5.2 The crane must be located so that there is at least 3 m
(10 ft.); clearance between the end of the jib and the
22
nearest obstacle;
 5.1.5.3 Rail-mounted, statically-mounted or mounted on tempo-
rary base cranes should never be located close to shoring
structures, excavations, slopes, trenches, backfilled or
uncompacted materials. Similarly, the base should not
be over or close to cellars, buried pipes and main power
lines;
5.1.5.4 The crane’s proposed location should be based on it’s
proximity to other cranes, particularly when their work-
king areas might overlap;
5.1.5.5 The crane should be located in such a way that it is not
required to work over areas to which the public has ac-
cess. If this is unavoidable, a signalman and warning
signs should be posted to draw attention to the operation
of the crane in the area and control access to the area
when necessary;
5.1.5.6 If there are any power or telephone lines within the ra-
dius of rotation of the crane, the crane must be located
so that there will be clearance from the extreme outer
point of the radius.
5.1.6. An erection area for the extensive use of the crew must be
provided to;
5.1.6.1. Permit the components to be stacked and handled, and
the crane to be erected without interfering with or
placing at risk the other site personnel;
5.1.6.2. Allow the movements of the mobile crane that will be used
to erect the tower crane;
5.1.6.3. Permit good access for the trucks delivering the crane
components.
5.1.7. Soil stability and bearing capacity must be taken into consideration
whenever the unit is rail-mounted, ground supported or mounted
on a temporary base.
5.1.8. Consideration must be given to the structural stability and bearing
capacity whenever the unit is supported on or by any structure:
5.1.8.1. If the structure supporting the crane is concrete, ensure
that the concrete has sufficient strength to support the
crane before it is installed or climbed to a new position.
5.1.8.2. The ground foundation or structure, intended to support
the crane, should be sufficiently strong and stable to
carry the load without any sinkage or deflection.
5.1.8.3. If the crane is to be set up in areas having high water
table or areas subject to flooding, the crane may be
required to have deep foundations or special ground
consolidation.
5.1.8.4. If it is necessary for the crane to be first erected on a
temporary base and then transferred to the building,
the guidelines must specify the following:
- The concrete cure strength before having the

23
 crane loads imposed upon them;
- The total height of the crane;
- The distance between supports in relation to
the tower height projecting above the top support;
- The clearance between the tower and the floor
openings accounting for climbing frames and any
protruding reinforcement;
- The correct tower orientation, climbing equipment
position and attachment;
- That the crane must be securely held by the climb-
ing frames before the bolts attaching it to the
base are released and that all wedges must be
securely locked to prevent them from working
loose and falling out during operation;
- The supporting beams should be securely anchored
to the floor to provide lateral restraint. The number
and size of the beams and bolts must be deter-
mined to suit each installation.
5.1.8.5. The steps of each climbing ladder must be at exactly the
same level for both panels to engage the ladder steps
during climbing.
5.1.8.6. The maximum floor loading at the edge of the hole for
the tower should be allowable without shoring.
5.1.8.7. The kind and extent of shoring required should support
the intended loads.
5.1.8.8. In securing the crane when it has reached its upper climb
position, it is good practice to wedge on alternate floors
and never at more than two levels. Usually, there are
eight (8) wedges per floor.
5.1.9. If the crane is free-standing, the installation instructions must
specify the following:
5.1.9.1. The maximum free-standing height, and if exceeded, the
designs must be provided for ties and tie frames, guys
or other suitable anchorages;
5.1.9.2. Procedures for balancing the crane before any ties are
attached;
5.1.9.3. The position of tie frames relative to tower joints and where
ties occur between tower joints;
5.1.9.4. Procedure for wedging the tower within the tie frame and
that the wedges be locked in position;
5.1.9.5. The erection drawings and instructions must specify
the following:
- The crane should be erected only during favorable
weather conditions and never when wind velocity
is more than the manufacturer’s specifications;
- The weights for ballast and counterweight should
be in accordance with the crane manufacturer’s

24
 instructions, and ensured or established by actual
weighing clearly marked on them;
- If concrete weights are used, they must be of the
correct mix;
- The correct torque for all structural bolts;
- The weights of all sub-assemblies that will be
lifted into place by the mobile crane;
- The correct method of testing the erected crane.
5.1.10. The person supervising the erection must ensure the following:
5.1.10.1. The foundation or base is in accordance with the approved
design drawings, is absolutely level and that the anchor
bolts are correctly located;
5.1.10.2. All components are clearly marked for correct identification
during assembly, and that only the correct structural
sections and components for the particular crane are used;
5.1.10.3. The main structural components of the crane are inspect-
ed and any damaged or defects found are repaired in
accordance with the manufacturer’s specifications and
instructions;
5.1.10.4. The electrical, mechanical and hydraulic components are
inspected in accordance with the manufacturer’s speci-
fications and instructions;
5.1.10.5. All tower nuts, bolts and pins are undamaged and checked
for correct size and grade;
5.1.10.6. All lifting tackle and auxiliary equipment are in good con-
ditions and capable of safe handling of all anticipated
loads;
5.1.10.7. Ensure that the trolley is correctly installed and that all
sheaves are in good working order and well lubricated;
5.1.10.8. All tower crane components should be properly slung
and handled to protect them from any damage;
5.1.10.9. The manufacturer’s manual for the crane being erected
should be available on-site for use by the personnel who
should be familiar with the erection procedures;
5.1.10.10. There is summary of assembly and dismantling
procedures in form of a checklist;
5.1.10.11. Any departure from the manufacturer’s standards on
substitution of parts or materials is allowed only if the
details have been discussed with and approved by the
manufacturer or competent person.

5.2. TOWER ASSEMBLY & ERECTION

5.2.1. The tower can be assembled by either installing each section

sequentially on the base and previous section or by laying
the sections flat, bolting them together and then erecting the
complete tower.

25
 5.2.1.1. If assembled flat, ensure that each section is
supported by timber blocking.
5.2.1.2. Regardless of the assembly method used, ensure
that each section is correctly oriented to the others
and that the ladders are continuous.
5.2.2. During erection, the tower should be supported or guyed
depending on its free-standing height.
5.2.3. In applying tension on the guys, ensure that the pull is even on
each and that the tower remains perfectly plumb.

5.3. TURNTABLE & MAST ASSEMBLY

5.3.1. Check the backlash between the pinion & ring gears and apply
suitable lubricant to the gears and slewing ring while on the
ground level.
5.3.2. On the ground level, both fore and aft pendants should be installed
and pinned in place.
5.3.3. Ensure that the turnbuckles are half extended.
5.3.4. In installing the mast, ensure that it is correctly oriented with
respect to the turntable.

5.4. TURNTABLE & MAST ERECTION

5.4.1. In installing turntable and mast, hoist the turntable and mast
assembly to the top of the tower then lower them gently into
position ensuring that the connection bolt holes line up.
5.4.2. The assembly should be oriented correctly with respect to the
tower and should be torqued into place.

5.5. JIB ASSEMBLY

5.5.1. Ensure that the sections are supported on timber blocking.

5.5.2. Short sections should be located as close to the tower as possible.
5.5.3. While the jibs are on the ground, torque the bolts to 100% of
their recommended values.
5.5.4. Ensure that the trolley is correctly installed and that all sheaves
are in good working conditions and well lubricated.

5.6. COUNTER JIB ERECTION

5.6.1. Counter jib should be erected/installed when the tower and

turntable are already in place.
5.6.2. Counter jib should be installed in the following manner:
5.6.2.1. It must be slung to ensure that it remains level when
installed;
5.6.2.2. Fit the jig into the turntable using the correct pins and
secure them with cotter pins;

26
 5.6.2.3. Lift up the back of the jib and install the pendants;
5.6.2.4. Lower the jib to hang by the pendants;
5.6.2.5. Adjust the turnbuckles so that the jib end is level breadth
wise and tilting up at the right inclination;
5.6.2.6. Check that the pendant pins are in good condition and
are retained by cotter pins.

5.7. MAIN JIB ERECTION AND FITTING COUNTERWEIGHTS

5.7.1. The main jib erection and counterweight fitting should be done
in the following manner and sequence:
5.7.1.1. Install the counterweight jib;
5.7.1.2. Install manufacturer’s recommended portion of
counter weight;
5.7.1.3. Install the main jib;
5.7.1.4. Install the remaining counterweight;
5.7.1.5. For cranes with counterweight trolley,
- Install the counterweight jib;
- Install all the counterweights at
manufacturer’s recommended radius;
- Install the jib;
- Roll the counterweight trolley out to the end.

5.8. ELECTRICAL INSTALLATION

5.8.1. Electrical installations should be under the strict supervision of

a competent electrician.
5.8.2. Before being put to use, the cranes electrical installation or
part-installation should be inspected to ensure the adequacy of
insulation and of earthing arrangements.
5.8.3. Appropriate isolating procedures should be strictly followed
whenever any part of the electrical system is live.
5.8.4. The main power supply, including disconnect switches,
transformers and other electrical equipment required to
supply power to the crane should be provided and installed
in accordance with Philippine Electric Code and local power
authority regulations.

5.9. WIRE ROPE AND REEVING

5.9.1. The hoist and trolley ropes should be installed in accordance with
the crane manufacturer’s instruction

5.10. ERECTION CHECKLIST

5.10.1. A detailed check of the crane should be made by the erection

supervisor or competent person after the erection is completed.

27
 5.10.2. Static and dynamic tests should be made to ensure the correct
operation of the crane.
5.10.3. The check points should include the following:
5.10.3.1. Electrical -
- Main power supply and circuit breakers are correct;
- Main power cables are well protected and strain relieved
every 6m (20 ft);
- Control cables are protected and strain relieved;
- Electrical cables are not damaged and clear of obstructions;
- Electrical panel cover screws are tightened;
- Control console is in acceptable condition and operating
satisfactorily;
- Line fuses are of correct sizes and supply voltage are within
limits;
- All motors are turning in correct direction;
- Crane is correctly earthed and all connections are secured.
5.10.3.2. Mechanical -
- Hydraulic power-pack is protected from damage and con-
nections are leak-proof;
- Climbing mechanism is complete and functional;
- Slewing ring bearing are adequately lubricated;
- Gear backlash is within tolerance;
- All drive assemblies are acceptable and oil levels correct;
- General lubrication of crane is satisfactory;
- Alignment and condition of trolley drive and limit switch
are satisfactory
- Trolley wheels, frame, sheaves and cable tension are accept-
able;
- Trolley track is smooth;
- Oil levels in hydraulic reservoir and gear reducer are correct;
- Ropes and pendants in good condition;
- Hoist drum is running freely;
- Hoist brakes are in good condition and operating;
- Operator’s manual is available on-site;
- There is sufficient rope on all drums (minimum of 3 full
turns left on the drum when the hook is at its lowest working
position);
- All machine guards are in place;
- All brakes operate automatically when power fails;
- Abnormal vibration noticed when crane operates;
- Load chart at the operator’s station;
- Jib stay ropes have correct tension;
- Counter jib is horizontal sideways;
- Counter weight consists of the correct number of concrete
sections and these are positioned and fastened as prescribed;
- All sheaves can rotate freely;
- Trolley rope has correct tension, so that the trolley can tra-

28
 verse with permitted loads without any slipping at the
driving pulley;
- All ropes run freely without touching any crane part
except the drums or sheaves grooves;
- Gear ring is fastened to the crane mast in the correct
manner-
- Circular form is not deformed;
- Teeth and roller track have the correct height in relation
to the pinion and support rollers;
- Support rollers are securely fastened;
- Amount of clearance between the support rollers and
the roller track of the gear ring is correct.
5.10.3.3. Structural -
- Crane is correctly wedged in building or guyed;
- Shoring around floor openings is acceptable;
- Tower is plumbed;
- All tower bolts are installed and correctly torqued;
- Tower sections are not damaged;
- Anchor bolts are installed and torqued;
- Turntable are damaged and free of cracks;
- All slewing ring bolts are correctly torqued;
- All mast bolts are torqued;
- Jib and counter jib connections at turntable are correct;
- Pendant turn buckles are locked;
- Jib and counter jib angles are correct;
- Jib and counter jib sections are correctly bolted and
torqued
- Counterweights are fastened and correct for the length
of jib;
- All pin connections are cotter pinned;
- All component mounting bolts are tight;
- All access ladders are continuous;
- All safety platforms and walkways are in position and
secured.
5.10.3.4. Electrical, mechanical and structural checks should be
made at least once a month.
5.10.3.5. Functional check should be made after erection under
no load conditions to ensure correct operation of all
motions, limit switches and brakes.
5.10.3.6. Proof testing should made at its rated capacity by ope-
rating through all its motion.
- All tower bolts are installed and correctly torqued;
- Tower sections are not damaged;
- Anchor bolts are installed and torqued;
- Turntable are damaged and free of cracks;

29
5.11. BOLTING PROCEDURES

5.11.1. Apply correct bolting and torquing procedures in tower crane

erection.
5.11.2. All nuts and bolts must be well-lubricated, of correct size and
grade and tightened sufficiently to develop a pre-tension greater
than the dynamic loads that will be applied to them.
5.11.3. If a good torque wrench is not available, use the “turn-of-the-nut”
method of achieving tightness.
5.11.4. Always follow the manufacturer’s recommendations when
replacing any structural nut and bolt.
5.11.5. The grades of both nut and bolt should be the same.
5.11.6. The nut should have sufficient size and mechanical properties to
withstand the ultimate tensile strength of the bolt.
5.11.7. Coarse threaded nuts and bolts should be used due to its greater
resistance to stripping than fine-threaded types.
5.11.8. Coarse threaded nuts require fewer revolution to tighten, have less
tendency to cross thread and do not require the careful handling
of fine-threaded fasteners.
5.11.9. Hardened steel bearing washers should be free of dirt, loose scale,
burrs, chips and be relatively smooth and flat.
5.11.10. In dealing with bolted fasteners, the following points should be
observed:
5.11.10.1. Never re-use nuts or bolts that have been heated with a
torch during removal;
5.11.10.2. Never mix different grades and sizes of nuts and bolts;
5.11.10.3. Store all nuts and bolts indoors;
5.11.10.4. Inspect all nuts and bolts for signs of corrosion, wear
and damage prior to installation;
5.11.10.5. Clean and lubricate all nuts and bolts;
5.11.10.6. Check for bolt protrusion (all threads on the nuts should
be engaged by the bolt);
5.11.10.7. Never re-torque a loose nut and bolt.

5.12. SPECIAL CONSIDERATIONS FOR RAIL-MOUNTED CRANES

5.12.1. The track should be level, stable and of adequate strength.

5.12.2. The design of the foundation of rail-mounted crane should be
based on actual soil conditions and the design should be approved
by a structural engineer:
5.12.2.1. If the capacity of the soil under the track cannot be
determined on the basis of general site soil
conditions, soil tests must be done to determine the
actual capacity;
5.12.2.2. The test should be conducted by either a qualified
person or a recognized soil testing agency.
5.12.3. The track bed and track must be laid in accordance with the

30
 manufacturer’s specification for grading, track bed, sleeper-spacing
and rail weight.
5.12.4. Never locate the rails any closer than 6m (20 ft) from an unshored
trench, excavation of back-filled area.
5.12.5. Consider installing the track on concrete pads and sleepers, if the
crane installation is going to be long term:
5.12.5.1. The concrete pads must be -
- Designed as a beam supported by flexible props and
supporting two (2) moving concentrated loads;
- Seated on a proper footing;
- Buried to provide lateral stability;
- Provided with cross ties;
- Equipped with a solid wooden girder along with a
concrete soleplate so as to give the track flexibility
and absorb vibration;
5.12.5.2. If wooden sleepers are to be placed on a ballasted base
or foundation then ensure that -
- The rails are placed on girders, which are in turn
attached to the sleepers;
- The ballast is either crushed stone or clean sand;
- If the supporting earth contains clay, and the ballast
is made up of compact sand which prevents the clay
from moving to the surface;
- The ballast extends at least 600 mm (24 in.) beyond
the outer edges of the sleepers;
- The sleepers are properly spaced, sound and at least
200 x 250 mm (8”x 10”);
- The sleepers are placed at an intervals of not more
than 500 mm (20 in.);
- The spacing of the sleepers decreases near the rail
ends and that the track terminals on two (2) sleepers
are placed side by side.
5.12.5.3. If wooden sleepers Regardless of the type of base or
sleeper used, it is necessary to use rods between the
rails.
5.12.5.4. All rail sections must be secured together with plates
with at least four (4) bolts.
5.12.5.5. The track which must have tie rods spaced at equal
intervals to maintain the correct gauge should be
installed over a sleeper.
5.12.5.6. The rail should be flat-buttoned, of cross section area
not less than the recommended dimension by the crane
manufacturer.
5.12.5.7. T he rails must be perfectly level and parallel and
their spacing must take into consideration the motion
between the rail and wheel flanges.
5.12.5.8. To prevent the crane from over-running the end of

31
 the track, travel limit switches and shock-absorbing
mechanical stop must be provided toward each end of
the track.
5.12.5.9. The stops should be at a distance not less than one half
(1/2) the track width, from the rail end.
5.12.5.10. The height of rail stops should be at least one half (1/2)
the diameter of the wheel.
5.12.5.11. In addition to rail stops, all rail-mounted cranes require
travel limit switches installed at least 2.5 m (8 ft) away
from the rail stops to cut off power from the travel
motors and apply the brakes.
5.12.5.12. All rail-mounted cranes should be equipped with wheel
guards installed at both ends of each track or bogey.
5.12.5.13. When left out-of-service, the crane should be anchored
to a concrete parking base in order to gain an extra
margin of stability in high winds.
5.12.5.14. The parking base should consist of four (4) concrete
blocks cast under the track:
- Weight and shape should be specified by the
manufacturer;
- Location should be such that four (4) corners of
the undercarriage are properly anchored to the
center of each block.
5.12.5.15. Both rails of the track should be electrically bonded at
each joint by means of a copper bar or heavy wire.
5.12.5.16. The tracks should be properly earthed to a terminal
provided for by the Philippine Electrical Code.
5.12.5.17. The earthing system should be of low impedance and
adequate current capacity to provide protection
when faults occur.
5.12.5.18.Before placing the crane on the rails, the erection
supervision should give the rail installation a
complete
and thorough examination.

5.13. CLIMBING

5.13.1. Climbing the crane, regardless of its type, should be a four (4) or
five (5) –man operation: one (1) man to run the climbing unit; two
(2) men to guide the panels into the climbing ladders; and one
(1) or two (2) men to place the supports, wedges and generally
observe the motion of the crane.
5.13.2. Before extending the height of the crane, checks should be made
to ensure that:
5.13.2.1 The wind velocity does exceed the maximum as
specified in the manufacturer’s instructions;
5.13.2.2 The correct amount of counter weight is in position on

32
 the crane;
5.13.2.3 The final height will not be greater than the maximum
free-standing height without the ties, or the maximum
height above the highest tie, will be as specified by
the manufacturer;
5.13.2.4 The jib is correctly oriented to the mast and direction
of wind velocity and is locked to prevent uncontrolled
slewing;
5.13.2.5 Climbing gear is correctly attached and functioning and
the crane is properly balanced;
5.13.2.6 All climbing frames, ladders, locking devices and machinery
is correctly installed, adjusted and in good working order;
5.13.2.7 Shoring is erected to the underside of the floors which
will support the weights of the crane;
5.13.2.8 The climbing pawls are free and can move easily;
5.13.2.9 The support frame for the climbing ladders is from
one floor above the level on which the crane is to be
supported after climbing.
5.13.3. Prior to the climbing operation, the wedges or clamps should be
released to allow for free upward movement of the tower.
5.13.4. The balancing load should be lifted by the crane and moved into
a suitable position along the jib which will assure the correct
balance of the crane for climbing.
5.13.5. After the crane has reached its final climb and is resting on its
floor support beams, ensure that it is wedged with hardwood
wedges between two (2) slabs in all four (4) directions.

5.14. TELESCOPING

5.14.1. In order to avoid risk of accident, the telescoping operations must

be carried out according to the manufacturer’s instructions.
5.14.2. During telescoping operations, never slew the jib, move the trolley
and operate the hoisting or lowering when the crane part is being
lifted.
5.14.3. Never let the telescoping assembly rest on the cylinder.
5.14.4. Carry out telescoping only with a wind velocity not exceeding 60
km/hr.
5.14.5. After each climbing operation, check the perpendicularity of the
crane.

5.15. DISMANTLING

5.15.1. The dismantling procedure of a tower crane is usually the reverse

of the assembly operation.
5.15.2. The dismantling operation is far more difficult and hazardous due
to the height involved and the interference of the structure for
which the crane was used.

33
 5.15.3. The dismantling operation should be carried out by a skilled crew
under competent supervision and strictly in accordance with the
manufacturer’s or agent’s instructions.
5.15.4. The requirements for dismantling and removing the crane must
be considered at the outset of the project when selecting the
type, size and location of the crane.
5.15.5. The crane is usually removed from the building by either a roof-
mounted derrick or by a mobile crane:
5.15.5.1. When using a derrick crane an engineering study should
be made to determine how to anchor the derrick and
what shoring requirements are needed to reinforce the
roof deck;
5.15.5.2. When a mobile crane is used, ensure that the ground or
foundation support of the crane is adequate.
5.15.6. Check the following whether using a derrick or mobile crane:
5.15.6.1 If crane sections are to be lowered to the roof deck for
dismantling check that the deck can take the extra load;
5.15.6.2 Know exactly the weight of all components to be lowered;
5.15.6.3 Never release any of the tower crane’s pins, bolts and
pendants until the sections or components are properly
slung and balanced, and the total weight is being carried
by another crane or the derrick;
5.15.6.4 Keep the area immediately below all lowering and un-
pinning operations completely clear of personnel, through
the use of the barricades.
5.15.7. Tower cranes are particularly severed on their slewing rings and
ringbolts and cracks have been found in many instances in the
welding of the gusset plates in the tower rings. It is strongly
recommended that:
5.15.7.1. The joint between the gear ring in the crane base and the
tower top-ring be broken whenever the crane is moved to a
new site;
5.15.7.2. The used bolts be destroyed;
5.15.7.3. The tower ring be examined for weld cracks and for flatness
of the bolting surfaces when dismantled and before each
erection.

5.16. TRANSPORTING THE CRANE

5.16.1. In transporting the crane, considerations should be made to avoid

damaging the machine. Damage to the crane usually does not
show up until later when the crane is making a lift.
5.16.2. When lifting structural sections onto floats, do not attach the
slings to the lattice members for they will bend.
5.16.3. The sections should be blocked and if sections are stacked on the
float, there should be blocking beneath them.
5.16.4. Do not chain the sections down unless the sections are padded

34
 where the chains are attached.
5.16.5. Never tighten the section with chain binders for they will over-
tighten the chain causing the main chord to deflect and bend.

CHAPTER 6
INSPECTION, TESTING & MAINTENANCE
6.1. INSPECTION

6.1.1. Regular inspection should be done to ensure the safety and

reliability of the tower crane.
6.1.2. All inspection activities should be performed by or under the
immediate supervision of competent person.
6.1.3. Inspection should be carried out only by persons who are
competent to detect and assess potential hazards that could limit
safe performance of the tower crane.
6.1.4. The inspector should have practical and theoretical knowledge
of the equipment to enable him to detect not only defects and
potential hazards, but also assess the impact of these defects/
hazards to the strength and function of the equipment.
6.1.5. The inspection must determine if any observed defect presents
possibility of failures, and if the crane will remain in safe condition
until the next scheduled inspection, considering the rate of
deterioration.
6.1.6. In order that safe inspection be carried out on tower cranes,
walkways, ladders and platforms should be provided on the tower,
jib and counter jib.
6.1.7. All persons working on the tower crane should be instructed to
use safety belts and lanyards to prevent serious injury from fall.
6.1.8. The main power switch must be turned off before inspecting any
of the electrical components.
6.1.9. All repairs to the electrical components should be done by or
under the supervision of a competent electrician.
6.1.10. An equipment logbook should be kept and maintained throughout
the machine’s working lift to record details of all modifications,
alterations, repairs, inspections, examinations and maintenance.
6.1.11. Frequency of inspection -
6.1.11.1. Prior to initial use of new and reinstalled tower cranes
after major alteration and repair, and every year thereafter;
6.1.11.2. For operational crane, visual inspection should be done
by the operator or qualified inspection with the use of
checklist recommended by the manufacturer;
6.1.11.3. In the absence of manufacturers manual, inspection
should be implemented on daily, weekly and monthly
intervals as recommended by the competent person;
6.1.11.4. Visual inspection by a qualified inspector at one to 12
month intervals, or specifically recommended by the
manufacturer;

35
 6.1.11.5. The following should be inspected at intervals defined
above or specifically indicated (including observation
during operation) for any defects that might appear
between regular inspection -
- All control mechanisms for maladjustments inter-
fering with proper operation-daily when in use,
- All control mechanisms for excessive wear of
components and contamination by lubricants and
other foreign matters,
- All crane function operating mechanisms for mal-
adjustments interfering with proper operation
and excessive wear of components,
- Load limit devices for proper operation and accu-
racy of setting,
- All hydraulic and pneumatic hoses particularly
those that flex in normal operation,
- Electrical apparatus for malfunctioning, signs of ex-
cessive deterioration, dirt and moisture accumulation,
- Crane hooks for deformation or crane hooks with
cracks or having more than 15% of normal throat
openings or more than 10°,
- Wedges and supports of climbing crane for loose-
ness or dislocation – daily, when in use,
- Braces or guys supporting crane masts (towers)
and anchor bolts base connection for looseness
or loss of pre-load a) braces and bolts after the first
day and the first week of operation and then
monthly or b) guys daily until pre-load stabilizes,
thenweeklyuntil pre-load stability indicates that
monthly checking will be adequate,
- Hydraulic system for proper fluid level – daily,
when in use.
6.1.12. Ensure that the tower crane is safe by having the following
inspections made on a 1-5 day basis:
6.1.12.1. Inspect all wire ropes (including standing ropes), sheaves,
drums, rigging equipment and attachments;
6.1.12.2. Check for freedom of rotation of all swivels;
6.1.12.3. Visually inspect the jib and tower for straightness and
for any evidence of physical damage, such as cracking,
bending or other deformation of the steel elements or
welds -
- Watch carefully for cracking or flaking of paint,
since this may indicate yielding of the metal which
may precede a failure,
- Be especially careful to look for bent lattice when
checking the structural section,

36
 - Every component must be absolutely straight and free
from bent.
6.1.12.4. Ensure that the crane is clean and free from tackle,
grease and oil on all walking surface;
6.1.12.5. Check that all exposed moving parts are guarded;
6.1.12.6. Check that all counterweights are secured;
6.1.12.7. Check the adequacy of all shoring and bracing;
6.1.12.8. Check that the tower support beams are secured in the
lateral direction and that they are not deformed;
6.1.12.9. Check that the bearing floors are not cracking;
6.1.12.10. Check the climbing unit and the ladders;
6.1.12.11. Check the torques of all tower, jib and base bolts and
when tightening the tower bolts, slew the jib so that
the counterweight is over the corner being tightened;
6.1.12.12. Check all the slewing ring bolts at least once a week-
- The rear half circle of bolts must be tightened
with no load on the hook when checking the
torque of the slewing ring bolts and when re-
tightening them;
- The crane should then be slewed and the
adjacent bolts should also be tightened;
- Do not re-torque the bolts more than once.
6.1.12.13. Check the slewing rings, slewing gears and gusset plates
in the tower ring for cracks;
6.1.12.14. Check that all the hardwood tower wedges are secured
daily when the crane is working;
6.1.12.15. Check all gearboxes for oil leakage and for tightness of the
bolts, a loose gear box will damage bearings and pinions;
6.1.12.16. Check all V-belts for proper tension, change all the belts
in the same group, if one belt need to be replaced;
6.1.12.17. Check that electrical cables are free of obstacles and do
not twist or bend over sharp edges;
6.1.12.18. Check for cuts and wear and for adequacy of terminals;
6.1.12.19. Check the tension of the screws on the contactors;
6.1.12.20. Check that the over-current relays are set correctly;
6.1.12.21. Check that the supply voltage is within the limits set by
the crane manufacturer;
6.1.12.22. Clean the slip rings and check that they are free from
burns;
6.1.12.23. Ensure that the power and control cables are tightly
connected and strain relieved;
6.1.12.24.Be sure the crane is sufficiently lubricated and the
lubricating oil reservoir are filled to their correct levels -
- Replace the filters whenever the oil is changed
and always refill with clean oil if the supply is
found to be low and dirty;
- Use oil that meets recommended specifications;
- Be sure to check the level plugs in gear boxes.
6.1.12.25.Visually inspect the machine deck for fluid leaks -

37
 - Hydraulic and oil system leaks must be corrected
before the crane is operated;
- All hydraulic hoses must be visually inspected
and replaced, if found faulty;
- Secure all caps and filler plugs for all systems.
6.1.12.26. Inspect and test all brakes and clutches for correct
adjustment and operation -
- Check load breaks by lifting a capacity or near-
capacity load a few inches from the ground and
hold onto the break;
- There should be no slippage.
6.1.12.27. Check that all brakes and friction linings are free from oil;
6.1.12.28. Check that the backlash between all gears is within
tolerance;
6.1.12.29. Check that the securing bolts of all motors are tight;
6.1.12.30. Inspect the main ring gear and pinion gear for damage
and lubrication;
6.1.12.31. Check that all rope sheaves run easily and smoothly;
6.1.12.32. Check that the trolley rope is well tensioned to prevent
undue wear on the sheaves;
6.1.12.33. Check that the hoist rope spools properly on the drum
and runs freely over the sheaves;6.1.12.34. Check the
lift, slew and trolley machinery;
6.1.12.35. Check that the machine is equipped with serviceable
and fully charged fire extinguisher;
6.1.12.36. Check the tracks and base of tail mounted cranes for -
- Loose connections and gaps between the rails;
- Incorrect electrical bonding and earthing;
- Inadequate drainage;
- Subsidence and uneven track;
- Bogey wear;
- Foreign material on the track such as building
materials;
- Inoperative travel limit switches and loose rail
stops;
- Adequacy of the rail clamps.
6.1.12.37. Check that all limit switches are properly set and
functioning;
6.1.12.38. Test weights should be lifted weekly to check the over-
load limits;
6.1.12.39. Automatic safe load indicators should be tested by
lifting a known load.

6.2. MONTHLY INSPECTIONS

6.2.1. In addition to the 1-5 day inspections, the following minimum

checks should be made monthly:

38
 6.2.1.1. Inspect the entire crane for structural damage and
check for distortion or cracks in the slewing ring area
and in the tower assembly;
6.2.1.2. Carefully inspect all welded connections for cracks -
main chords and lacings and other structural items for
paint flaking and cracking, darts, bends, abrasions and
corrosion;
6.2.1.3. Inspect for worn-cracked or distorted parts such as pins,
bearings, shafts, gears and rollers;
6.2.1.4. Inspect for cracked or worn sheaves and drums;
6.2.1.5. Inspect for excessive wear on brake and clutch system
parts and linings;
6.2.1.6. Check relays and all electrical equipment in the control
panel for corroded or burned contracts, loose screws,
broken parts and damaged cables;
6.2.1.7. Check condition of all electric motors, current draw
is within limits, air passages and fan blades are clear,
bearings are well packed, electrical insulation to earth
is within tolerance, brushes are not sticking or wearing,
rings are clean and that the motor couplings are all in
running condition;
6.2.1.8. Check all V-bolts for tension and alignment and also for
signs of chafing and cuts;
6.2.1.9. Check the operation of all friction couplings;
6.2.1.10.Tighten mounting bolts on all motors, pumps and gear
reducers;
6.2.1.11.Check all electrical connections for tightness;
6.2.1.12.Lubricate all running ropes;
6.2.1.13.Check all control mechanisms for excessive wear of
components and contamination by lubricants or other
foreign matter;
6.2.1.14.Inspect all hydraulic and pneumatic hoses, fittings
and tubing and require their replacement under the
following conditions-
- Any evidence of oil or air leaks on the surfaces
of flexible hoses or at the points at which the
hose in question joins the metal end couplings;
- Any abnormal deformation of the outer coverings
of hydraulic hose;
- Any leakage at connections which cannot be
eliminated by normal tightening;
- Any evidence of abrasive wear on the hoses.

6.3. TESTING

6.3.1. Testing is necessary to prove that only correct work has been
carried out on the machine and that machine is capable of safe
and reliable performance within its intended scope.
39
6.3.2. Immediately after the crane has been erected, it must run through
a series of tests in order to correctly set limit switches.
6.3.3. The adjustment of the “trolley in” and “trolley out” limit switches
should be done at no load and with the hook at its highest working
height. The limit switches must be set to stop the trolley before
it strikes the end stops on the main jib.
6.3.4. Hook height limit switch:
6.3.4.1. Prevent the hook assembly from fouling the trolley
or head block by adjusting the distance between the
lifting limit switch and trolley as follows -
- Use the minimum part reeve of the hoist in series;
- Raise the unloaded hook at maximum speed;
- Stop and check the appropriate amount of
over-run;
- Add to this measured over-run distance an extra
250 mm (1 ft);
- Adjust the distance between the stop frame and
the trolley to give this separation.
6.3.5. High jib and low jib limit switches must be adjusted by raising and
inverting the jib slowly (without load) and allowing it to come in
contact with the striker switches.
6.3.6. Travel limit switches should be installed on tail mounted cranes
and must be adjusted to stop the travel motor and apply the
brakes at least 2.5 m (8 ft) from the rail stop.
6.3.7. Overload limit switches should be checked by lifting a test weight
equal to the rated safe working load to about 2 meters off the
ground, and the switch adjusted to just permit the load to be
lifted.
6.3.8. The setting of all limit switches must be checked periodically and
their operation should be tested weekly.
6.3.9. In addition to testing after erection, 100% rated load tests should
be carried out on all cranes that have been extensively repaired,
altered of climbed to prove:
6.3.9.1. The structural integrity of the unit;
6.3.9.2. The adequacy of supporting structures and method of
holding the crane;
6.3.9.3. The adequacy of all functions under rated loads;
6.3.9.4. Confirm the adequacy of all repairs and alterations.
6.3.10. After each change on the anchoring or ballasting arrangements,
its security should be tested by the imposition on them of a load
25% greater than the maximum rated service load.
6.3.11. If for any reason the crane fails any portion of the functional test
or rated load test, then it must be removed from service until the
problem is corrected.
6.3.12. If the person carrying out testing considers that the maximum load
that may be safely lifted is less than the normal working load of
the unit, a loading diagram appropriate to the conditions should
be posted in place of the load chart.
40
 6.3.13. All cranes should be functionally tested at no load at the start of
every work shift to ensure that no one tampered with the crane
while it was unattended.
6.3.14. No units should be re-rated in excess of their original load
ratings, unless the rating changes are approved either by the
manufacturer of by an engineer capable of assessing the strength
of the structure.

6.4. MAINTENANCE

6.4.1. In order to keep the crane operating safety, reliably and efficiently,
it is essential to have preventive maintenance.
6.4.2. A preventive maintenance program should be developed based
on the equipment manufacturer’s recommendations.
6.4.3. Keep track and monitor all maintenance by using equipment log
book and recording of the details of hours worked, adjustments,
checks, repairs, replaced parts, inspections, examinations and
tests.
6.4.4. The maintenance personnel should adjust, extend or modify the
manufacturer’s recommendations to suit the specific needs of
the equipment.
6.4.5. All maintenance staff must be fully aware of the hazards involved
in working on tower cranes and must have a good working
knowledge of the machinery.
6.4.6. The following safety precautions should be taken as applicable:
6.4.6.1. Everyone working on the crane structure must wear
a safety belt and lanyard and tie himself to the
structure whenever there is possibility of falling;
6.4.6.2. Lock out and tag out the master power switch off
and place a sign on it indicating that it should not to
be switched on;
6.4.6.3. In no circumstance should the maintenance
personnel be on or under any part of the machine
when the power is on, or when the operator is at the
controls without full knowledge and consent of the
operator;
6.4.6.4. Be a good housekeeper, keep the hoist deck clean,
free of concrete, oil, grease, rags, cables and other
hazards.
6.4.6.5. Use only non-flammable solutions for cleaning, and
be sure your shoes are clean and dry before climbing
on the structure;
6.4.6.6. Keep hands, feet, and clothing away from gears,
ropes, drums and sheaves;
6.4.6.7. Never wear loose clothing, which may become
entangled with moving machinery;
6.4.6.8. Be sure that safety equipment such as fire
extinguishers are available and in good condition;
41
 6.4.6.9. Before returning a crane to operational service, subject all
components which have been affected by maintenance or
repair to a visual inspection, followed by an operational check
by the operator to ensure that the components are functional;
6.4.6.10. Always replace protective guards and panels before operating
the machine;
6.4.6.11. Never re-start operations until all personnel are clear of the
crane;
6.4.7. Before being put back into service, damaged equipment requiring
significant or extensive structural repairs should be completely re-tested
by a qualified personnel.
6.4.8. Each tower, jib or mast section which has been involved in a mishap
causing structural failure and suspected of having been overstressed
must be removed from service, until a competent person has issued a
certificate stating that any necessary repairs done are satisfactory and
that the structural integrity has not been impaired.
6.4.9. Any structural tubes or other thin-walled structural sections which have
been buckled, dented or deformed, are not to be repaired. They must be
cut out and replaced with a new component.
6.4.10. Defects such as the following must be corrected immediately to ensure
safe operation:
6.4.10.1. All critical parts of functional operating mechanisms which are
cracked, broken, corroded, bent or excessively worn;
6.4.10.2. Defective load hooks must be discarded and repairs
by welding or reshaping are not acceptable;
6.4.10.3. Any corroded structural members must be cleaned
to bare metal and then repainted;
6.4.10.4. Do not paint over rust or old paint.
6.4.11. All replacement parts and repairs must have at least the same safety factor
and reliability as the original part, and be in accordance with the original
specifications of the equipment’s manufacturers.
6.4.12. Stop the machinery while lubricating, except in cases where the lubrication
system is designed for step application while the machinery is in motion.
6.4.13. All repairs and adjustments should be made only by properly designated
and authorized personnel.

42
44
45
46
 REFERENCES

ANSI/ASME B 30.3 – 1984, Hammerhead Tower Cranes (Includes Revision)

Japanese Legislation for Cranes and Mobile Cranes 1996

by Japan Crane Association, Gotanda Fuji Bldg., 1-12 Higashi Gotanda, I Chome
Shinagawa-Ward, Tokyo, 141 Japan

Philippine Electrical Code part 1 and 2 – Copyright 1996

by Institute of Integrated Electrical Engineers of the Philippines Inc., 41 Monte de
Piedad Street, Cubao, Quezon City

ANSI/ASME B 30.10, Hooks (Includes Revision Service)

Occupational Safety & Health Standards, Copyright Reserved for P.D. 49, Bureau of
Working Conditions, Department of Labor & Employment, Intramuros, Manila

Department Order No. 13 series 1998, Guidelines Governing Occupational Safety

& Health in the Construction Industry

Philippine Society of Mechanical Engineers Code, 1984

Accident Prevention Manual, Engineering & Technology

11th Edition, National Safety Council, Illinois, U.S.A., 1997

47
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