Self Erecting Tower Crane Operators Guide

A GUIDE FOR SELF-ERECTING

TOWER CRANE OPERATORS

WorkCover. Watching out for you.

TRAINERS EDITION 2005

Disclaimer

This publication contains information regarding occupational health, safety, injury management or workers compensation. It includes some of your

obligations under the various workers compensation and occupational health and safety legislation that WorkCover NSW administers. To ensure you

comply with your legal obligations you must refer to the appropriate legislation.

This publication may refer to WorkCover NSW administered legislation that has been amended or repealed. When reading this publication you

should always refer to the latest laws. Information on the latest laws can be checked at www.legislation.nsw.gov.au or contact 1300 656 986.

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A GUIDE FOR SELF-ERECTING TOWER CRANE OPERATORS TRAINERS EDITION

This guide outlines the information and requirements for a trainer to instruct a trainee on the facets

of self-erecting tower crane operation.

This guide follows the information supplied in the compiled learners edition.

How to use this manual

Each section related to the relevant sections in the accompanying learners guide. Both booklets are required to be utilised hand in hand. Related questions from the assessment instrument are included at the end of each section to

facilitate easy understanding for the trainee.

Some general questions are taken from the cranes National Certificate of Competency Written Assessment for Cranes August 2000.

CONTENTS SECTION 1 Competency for self-erecting tower crane operators 3

SECTION 2 Types of self-erecting tower cranes 3

SECTION 3 Features of self-erecting tower cranes 3

SECTION 4 Crane controls 4

SECTION 5 Set-up crane 4

SECTION 6 Assembly/disassembly 6

SECTION 7 Limit switches 8

SECTION 8 Load/radius indicators 8

SECTION 9 Brakes 9

SECTION 10 Site/job planning 9

SECTION 11 Maintenance procedures 13

SECTION 12 Pre-operational 13

SECTION 13 Crane operation 16

SECTION 14 Loads and self-erecting tower 19

SECTION 15 Special operations 26

SECTION 16 Shutdown crane 27

SECTION 17 Rule of thumb and working load limits 29

SECTION 18 Load factors 31

SECTION 19 Rules to follow when slinging and handling a load 34

SECTION 20 Stacking 36

SECTION 21 Personal protective equipment 36

SECTION 22 Communication 36

SECTION 23 Flexible steel wire rope 37

SECTION 24 Wedge rope sockets 39

SECTION 25 Sheaves and drums for flexible steel wire rope 40

SECTION 26 Lifting chain 42

SECTION 27 Flat webbing and round synthetic slings 44

SECTION 28 Fibre rope 45

SECTION 29 Accessories 46

SECTION 30 Calculation 49

APPENDIX (I) Tables of masses 52

SECTION 1

COMPETENCY FOR SELF-ERECTING TOWER CRANE OPERATORS Points for trainer

Explain to the trainee the process of obtaining an assessment for a self-erecting tower crane operators competencies.

SECTION 2

TYPES OF SELF-ERECTING TOWER CRANES Points for trainer

Relate this section to the particular self-erecting tower crane to be used for the training practical sessions.

Ensure the trainee understands crane terminology in relation to self-erecting tower cranes. Explain to the trainee the different types of self-erecting tower cranes. Describe to the trainee the main functions and motions of a self-erecting tower crane. Practical session

Show the trainee the various components on the specific self-erecting tower crane used for the practical training.

Media application

Using a scale model, explain to the trainee the terminology for the various components on a self-erecting tower crane.

Use overhead transparencies to explain terminology for a self-erecting tower crane. Trainers notes

SECTION 3

FEATURES OF SELF-ERECTING TOWER CRANES Points for trainer

Explain to the trainee that some of these features may or may not be included for the particular self-erecting tower crane used in the training session.

Explain to the trainee the specific features of the self-erecting tower crane used in the training session. Practical session

Show the trainee the particular use of various features on the specific self-erecting tower crane used for the training sessions. Features include cabin (where applicable), the outriggers, electrical apparatus, hook blocks and sheaves.

Trainers notes

SECTION 4

CRANE CONTROLS Points for trainer

Review this section to ensure the trainee understands the use of each crane control and their particular function.

Practical session

Demonstrate to the trainee the use of the crane controls and their application for the particular self-erecting tower crane used in the session.

Explain to the trainee the use of the emergency stop button for the particular self-erecting tower crane used in the training session.

Trainers notes

SECTION 5

SET-UP CRANE Points for trainer

Review this section to ensure the trainee understands the issues involved in setting up/assembly of a self-erecting tower crane.

Explain to the trainee the purpose and use of properly set-up outriggers. Explain to the trainee the hazards of unstable ground or footings and reason for adequate packing of

outriggers.

Explain to the trainee the importance of adequate bearing for support of the tower crane. Questions for trainee/s

Question 1

Explain the requirements for preventing personnel from entering the counterweight-slewing radius of the crane?

Answer The area must be thoroughly barricaded.

Reference: Oral/written assessment question 25

Question 2

Should a self-erecting tower crane be set-up/assembled next to open trenches or excavations? Explain your answer.

Answer No. The self-erecting tower crane should not be set-up/assembled close to an excavation as the weight of the crane creates additional pressure to the adjoining soil and can cause the excavation to collapse resulting in the crane overturning. An engineer may need to approve the cranes position.


Question 3

What principles would apply to setting up/assembling a self-erecting tower crane next to an open trench/excavation?

Answer The self-erecting tower crane base (ie pad) area should be certified by an engineer.


Question 4

What action would be required if an excavation was dug adjacent to the base of the self-erecting tower crane?

Answers -

Stop operation and have the excavation immediately backfilled and compacted. Have the ground assessed by a qualified person. Barricade the area thoroughly to prevent a reoccurrence.


Question 5

Where is the information found to determine the area of packing required under outriggers? Answer In the manufacturers manual or seek approval from an engineer.


Question 6

List three points that should be considered when setting up outriggers? Answers -

All outriggers must be used as per the manufacturers instructions. All beams must be fully extended or as per the manufacturers instructions. Correct selection of footplate or packing. Outrigger pads must be securely pinned or connected to the outrigger beams.


Question 7

Why must the self-erecting tower crane be set-up/assembled level? Answer To ensure the self-erecting tower crane is stable and the crane can be operated at it rated capacity.


Question 8

When setting up/assembling a self-erecting tower crane what items need to be considered in regards to crane clearances?

Answers -

Ensure the counterweight tail radius is clear to slew 360 degrees to satisfy safety requirements for the particular worksite.

Ensure all site hazards in the slewing radius of the self-erecting tower crane have been assessed. Ensure barricades or fencing of a minimum one metre in height are used to prevent personnel gaining

entry to the slewing counterweight area of the self-erecting tower crane.


Question 9

When setting up/assembling a self-erecting tower crane where the ground or soil value cannot be identified (eg on a bitumen or concrete road), what precautionary methods would need to be taken?

Answer Assess the situation and ensure the assembly is set-up as determined by an engineer.


Question 10

What risks occur when packing is placed halfway along the outrigger beam to support the crane? Answer This creates an inside tipping point and reduces stability, possibly causing the self-erecting tower crane to overturn.


Question 11

A self-erecting tower crane has been set-up/assembled on a new site, which requires unloading of trucks from a street over a busy pedestrian footpath. What hazard controls are required to progress with the operation ensuring public safety?

Answers -

A hoarding and gantry must be in place that conforms to the relevant standard. Barricades, detours or pedestrian control could be utilised. Traffic control may be required.


Practical session

Demonstrate to the trainee the procedure for location of hazard controls before setting up/assembling the crane.

Demonstrate to the trainee the procedure for set-up/assembly of the particular self-erecting tower crane used in the training session.

Explain to the trainee the preparations for set-up/assembly of the crane on a new site. The following points must be taken into consideration.

The position of the self-erecting tower crane is satisfactory in relation to the task to be undertaken. Outriggers or stabilisers are extended, packed and set-up as per manufacturers specifications. Base levelled and bearing on all outriggers or stablisers. Counterweight is erected and adequate as per the manufacturers specifications or according to load

chart requirements.

Reference: Performance assessment section F

Trainers notes

SECTION 6

ASSEMBLY/DISASSEMBLY Points for trainer

Review this section to ensure the trainee understands the issues involved in assembly and disassembly of a self-erecting tower crane.

Questions for trainee/s

Question 1

What qualification must be held by personnel to assemble a self-erecting tower crane? Answer An intermediate or advanced riggers certificate


Question 2

When can additional counterweight be added to the crane? Answer As per manufacturers recommendation that apply to the specific self-erecting tower crane.


Practical application

Ensure the trainee understands the following points in assembly of the tower crane. Self erecting tower crane transported to site Assess hazards and implement a risk assessment or work method statement Assess individual environmental conditions such as weather and wind conditions Check engineers compliance certificate Erect barricades and ensure public safety Surface prepared for crane set-up Adequate clearances to assemble and unfold the crane as per manufacturers specifications Outriggers positioned and packed Self erecting tower crane levelled by using jacks Earth crane to the ground Connect the power supply Base counterweights installed or as per manufacturers specifications Trolley and hook block must be in correct position for unfolding of jib or as per manufacturers

specifications

The crane mast and jib must be unfolded in correct sequence against the prevailing wind. (Note: Extreme caution is necessary during the unfolding procedure to ensure each section is assembled correctly.) Follow the manufacturers specifications.

Remainder of counterweights are installed or as per manufacturers specifications Complete unfolding remainder of jib sections as per the manufacturers specifications Check all limits and all governors for correct functioning Load testing self-erecting tower crane under the supervision of a competent person

Reference: Performance assessment section G

Ensure the trainee understands the following points in disassembly of the tower crane. Note: Particular attention must be considered for the correct sequence of counterweight removal.

Trainers must use manufacturers manuals for each complete crane disassembly.

Reference: Performance assessment section H

Media application

Use a scale model or use OHPS to display the system and procedure involved in assembly and disassembling of a self-erecting tower crane.

Use a video supplied by the manufacturer to display the assembly and disassembling procedure for a specific self-erecting tower crane.

Trainers notes

SECTION 7

LIMIT SWITCHES Points for trainer

Explain to the trainee the importance of checking limit switches for correct functioning on each operational workday of a self-erecting tower crane.


Question 1

Why is it important to check the hoist limit or cut out switch prior to using the crane? Answer To ensure that it is operating correctly so that double blocking does not occur.


Question 2

Why is it important that all motion limits are checked for correct functioning? Answer To ensure that all limits are working to avoid causing any damage or injury.


Question 3

If you suspect a load sensor or limit switch is not functioning correctly, what action would you take? Answer Cease operation, report relevant personnel and await advice regarding action.


Practical session

Demonstrate the role of limit switches and point out the common locations of these switches. Demonstrate how the limits work by slowly running each motion into the limit activation point. Trainers notes

SECTION 8

LOAD/RADIUS INDICATORS Points for trainer

Explain to the trainee the importance of the load movement indicators and load weight indicators being in correlation with radius indicators. These devices must be accurate and correct for self-erecting tower crane operation.

Ensure the trainee understands the term operating radius. Questions for trainee/s

Question 1

How often should the load mass (weight) indicator be calibrated? Answer Every six months or by picking up a known weight in accordance with the manufacturers specifications.


Practical session

Show the trainee the location of load radius indicator both electronic and mechanical where applicable. Show the trainee the connection between the load chart and the load radius indicators. Trainers notes

SECTION 9

BRAKES Points for trainer

Explain to the trainee the importance of checking braking systems before starting operation. Inform the trainee on the procedure where any slippage or malfunction of braking systems is detected.

Practical session

Show the trainee the location of braking systems for the crane used in the training. Trainers notes

SECTION 10

SITE/JOB PLANNING Points for trainer

Explain to the trainee the importance of rules and procedures for industry and how they relate to the trainees particular area of work.

Explain to the trainee the responsibilities for crane operators and crane crews. Explain to the trainee the importance of understanding this section as this information relates to the

occupational health and safety (OHS) requirements for industry.

Explain to the trainee the importance of implementing an operational plan before work commences. Practical session

Perform an onsite hazard assessment of the worksite with the trainee. With the trainee, draw up an operational plan for the particular crane operation.


Question 1

List four job and/or site procedures that should be considered before you set up a self-erecting tower crane?

Answers -

Job requirements Priorities Workplace rules Specific site procedures Identify hazards Hazard control measures Site specific induction Lifting plans including lifting radii requirements Emergency procedures


Question 2

List six hazards that would need to be taken into account in your crane set up plan? Answers -

Powerlines Trees Surrounding structures Overhead service lines (steam, gas, fuel lines) Underground services (phone, gas, power, drainage, sewage) Dangerous goods/hazardous substances Weather conditions Personnel working around the crane or near the counterweight slewing arc of the crane Obstructions (scaffolding, ladders, excavations, stored materials and other plant) Other equipment (cranes, piling rigs, forklifts, elevating work platforms) Facilities (office, amenities and lunch rooms) Soil conditions eg recently filled trenches Inadequate lighting for night operations.

Reference: Oral/written assessment question 13 Question 3

List five methods of reducing hazards on site. Answers -

Identify/detect all site hazards Use barriers Use warning signs Utilise PPE for crane personnel Use spotters Use traffic control Use risk assessment processes Utilise hoardings and overhead gantries Implement adequate lighting for night operations Use visual identification on powerlines (eg tiger tails) Ensure awareness of public safety requirements Obtain relevant information (material safety data sheets, expert advice from councils and statutory

authorities)

Correct siting of crane. Reference: Oral/written assessment question 14

Question 4

What precautions must be observed when working near powerlines? List four precautions. Answers

Never work closer than the minimum distance specified in AS2550.1 or State regulations Ensure the crane is correctly earthed Barricades are erected around the work area and crane base for public safety PPE to be utilised Traffic signs/cones and barricades should be placed around the work area Follow procedures in AS2550.1.


What is the minimum distance any part of a crane or load is allowed to approach live electrical parts? Answer Relevant distances must be obtained from State authority regulations.

Note: Assessors must ensure that the applicant is aware of State authority regulations


List five essential procedures, which must be followed if the crane was to come into contact with the powerlines?

Answers

Try to move the crane away from the conductors using the crane cabin/remote controls. Warn all other people nearby. Remain in the crane cabin until power is disconnected. If it becomes essential to leave the crane cabin (if applicable) or the immediate vicinity of the crane,

jump clear as far away from the crane as possible and avoid touching the crane and the ground at the same. When moving away from the crane, shuffle or hop.

Machine checked prior to future use. Reference: Oral/written assessment question 17

Question 7

A person dogging a load puts a hand on the hook and receives an electric shock. What would be your initial action and what would you do to ensure the hazard is investigated?

Answers

If possible, lift the hook clear of the person dogging the load to break contact with the earth. Follow relevant first aid procedure, as required. If required, get somebody to assist. Report the hazard to an authorised person. Report the hazard to the authorities.


Question 8

Why is it important to consult with relevant workplace personnel and OHS officers before commencing work on sites?

Answer To ensure that the operator is aware of any workplace site rules and procedures.


What is the importance of having workplace emergency procedures? Answer To lay out a sequence that should be followed in case of an emergency.


Question 10

What must be provided for the crane working at night or in a darkened area? Answer There should be sufficient lighting over the whole work area.


Question 11

In the case of an emergency, why is it important to communicate with the person dogging the load prior to leaving the crane?

Answers

To be made aware of any areas that be unsafe to pass. To be advised of the nature of the emergency. To ensure that someone is aware that the crane operator is making their way down to a predesignated

muster point.

To be advised if it is safer to stay in crane cabin until the emergency passes. Reference: Oral/written assessment question 31

Question 12

What is the importance of taking lighting of the workplace into account when planning your job? Answers

To make sure work can be undertaken safely. To ensure lighted access and exit locations for emergency situations. To make sure adequate natural lighting or artificial lighting is provided to work safely under all

conditions.


Practical session

Show the trainee the pre-set up/assembly inspection requirements for the tower crane on arrival to the worksite for the first time. Included in this list is other information that must be sourced before operation of the tower crane.

Check the site plan for working radii at given locations from the self-erecting tower crane. Check the self-erecting tower crane outrigger pad area for proper bearing and adequate packing in

accordance with the manufacturers recommendation.

Identify the maximum free-standing height of the self-erecting tower crane for the particular worksite.

Obtain the manufacturers manual and daily operational logbook. Familiarise yourself with the manufacturers manual before operating.

Check for engineers compliance certificate for the crane standing. Check for commissioning tests for the crane standing. Check for a dedicated safe operating area for the operator.

Reference: Performance assessment section A

Trainers notes

SECTION 11

MAINTENANCE PROCEDURES Points for trainer

Explain to the trainee the importance of proper maintenance procedures for the crane operation. Explain to the trainee the maintenance procedures for the particular crane used in the training. Explain to the trainee that all guards must be in place to restrict personnel from moving and rotating

parts.


Question 1

Why is it important to separate defective equipment? Answer To eliminate the possibility of further use of unsafe equipment.


Practical session

Show the trainee the lubrication points on the crane; explain how often these points need to be greased. Trainers notes

SECTION 12

PRE-OPERATIONAL Points for trainer

Put emphasis in regards to the trainees obligations in performing pre-operational checks and inspections to ensure the self-erecting tower crane is ready to operate in a safe condition.

Review this section to ensure these points are covered as this section relates also to the performance assessment.

Before starting the tower crane ensure all motion controls are disabled or in the neutral brake on position before turning on the main switch or power.

Perform a test of all motion controls, brakes and limit switches before operation. Questions for trainee/s

Question 1

Why should the maintenance service logbook be used? Answer To record an accurate account of all services, maintenance and repairs of the self-erecting tower crane.


Question 2

If you found a defect in one of the main controls that would place the crane and/or personnel at risk, what would you do?

Answers

Secure area and the machine and report to an authorised person. Ensure the machine is repaired before re-commencing work.


Question 3

On checking the tower/mast, you notice a loose bolt at one of the tower/mast connections. What action should you take?

Answer Immediately stop work and contact an authorised person for a complete inspection of all tower/mast bolts and pins.


Question 4

On a pre-inspection, you discover the gearbox is leaking oil. What action should you take? Answer tag the machine and report the defect to the supervisor or authorised person before commencing operation.


Question 5

What action would you take if the crane is discovered to be out of level during a pre-operational check? Answers

Check the screw jacks and footings Check ground conditions Check for structural damage to stabiliser/outrigger components


Question 6

On checking the control panel you notice water in and around the panel. What action would you take? Answer Tag the machine and report to the supervisor or authorised person.


Question 7

How do you ensure the self-erecting tower crane level? Answer By checking the inbuilt level gauge fitted to the self-erecting tower crane or by using a spirit level on the base section.


Question 8

You notice loose and flaking paint on the mast of the crane. What action would you take? Answer Cease operation, tag the machine and immediately report to the supervisor or authorised person to arrange for an inspection of job welds for damage and wear.


Question 9

You noticed that one of the job section connection pins was loose, what would you do? Answer immediately stop work, tag the machine and contact and authorised person for a complete inspection of all pins.


Question 10

When interference (tampering) is identified, what action must be taken? Answer Tag the machine and report to an authorised person or supervisor.

Reference: Oral/written assessment for cranes question 51

Practical session

Demonstrate the use of the service logbook for the particular type of self-erecting tower crane used for the training.

Reference: Performance assessment section B

Demonstrate the pre-operational checks for the particular type of self-erecting tower crane used for training. Checks include:

Visually check for any maintenance personnel or servicemen working on or near the self-erecting tower crane.

Ensure there are no safety tags on the main isolation switch.

Inspect the travel mechanism and bogies. Check for oil leaks on slewing platform or on the ground. Inspect the travel limits. Check that the counterweights are in place and secure. Inspect the slew mechanism. Check that the tower bolts are secure. Inspect for any structural damage to the mast or tower. Identify any structural damage to the crane jib or structure. Inspect access ladders and kick plates (cabin type). Access to the cabin (if applicable) is unobstructed. Disable weather vane mode. Inspect outrigger footings for adequate bearing. Connect pendant control (where applicable). Check that outrigger locking pins are in place. Check that limits and all governors are in place.

Reference: Performance assessment section C

Demonstrate the checks that should be made before the self-erecting tower crane is started. Checks include:

Ensure barricades are in position around the counterweight slewing arc. Perform a visual check of the electrical cabinet and electrical system. Perform a visual check of the power supply. Examine all wire ropes, anchorages, splices and hooks. Check all oil levels eg hydraulic. Inspect the rope drums. Examine all brake mechanisms. Ensure there is adequate lubrication on all moving and rotating parts. Check the communication systems is operational. Ensure the rated capacity and manufacturers data plate is on the crane. Check the load radius indicator is in place. Check the load chart is in place. Ensure the fire extinguisher is present. Visual check of all mechanical equipment.

Reference: Performance assessment section D

Demonstrate the checks that should be made after the self-erecting tower crane is energised or started. Checks include:

Start up the self-erecting tower crane as per the manufacturers instructions Emergency stop switch is operational Check wind gauge is operating correctly Communication system is operational The back up signalling system is operational Travel brakes (rail mounted) Horn/lights/drive indicator Clear vision from cabin All gauges are in correct operating ranges Radius indicator Load moment indicator Load indicator/weight gauge Slew brake/lock/pin

Hoist brake tested Trolley brake tested Maximum radius limit tested Minimum radius limit tested Hoist limit tested Warning systems/devices checked for correct operation

Reference: Performance assessment section E

Trainers notes

SECTION 13

CRANE OPERATION Points for the trainer

Review this section to ensure these points are covered as this section relates to the performance assessment.

Explain to the trainee the responsibilities of controlled load movement when operating the tower crane. Explain to the trainee that excessive wind speeds can restrict or abate crane operations. Wind speeds for

in service operations are specified by the manufacturer and can be measured by an on-board anemometer.

Ensure the trainee understands the limits of operation such as slewing, radii and load limits. Inform the trainee on worked near radio transmission towers as the crane can become charged thereby

heating up certain components such as lifting slings.

Explain to the trainee the aspects of cabin controlled and remote controlled operation. In cabin controlled operation the operator is an integral part of the crane with the operator being on board and sensing all movements whereas the remote control operation deprive the operator of any feel of the crane movements.

Inform the trainee on keeping a watchful eye in all crane movements where possible. If the operator has to talk to somebody all crane motions must stop until full attention is back on the crane movements.


Question 4

An outrigger pad sinks when lifting a load on the self-erecting tower crane. What immediate action should be taken?

Answer Lower the load, assess the situation and seek assistance.


Question 5

What is the maximum wind speed that self-erecting tower cranes can work in? Answer As per manufacturers recommendations


Question 6

When crane operations are effected by extreme winds what should you do? Answers

Lower the load to the ground Put counterweight to the wind Shut the self-erecting tower crane down as per the manufacturers instructions.


Question 7

If you heard abnormal noises coming from the crane what would you check? Answer Check all lifting gear, running gear, structural and mechanical components.


Question 8

If any signals are observed through warning lights, cut outs or alarms, what actions would you take to have the problem rectified?

Answer Identify the problem and take appropriate corrective action.


Question 9

The crane will hoist up but will not hoist down. What action should be taken? Answer Identify the problem and take appropriate corrective action. A competent person may be required to assist or the load may need to be manually lowered with assistance.


Question 10

What qualification must be held by a person directing a load out of view of the self-erecting tower crane operator?

Answer A doggers certificate.


Question 11

If you heard a loud noise or felt vibration coming from the jib section, what would do? Answer Lower the load, cease operation immediately and notify the person dogging the load. Have an inspection carried out to identify whether damage has occurred during the lift.


Question 12

What hazards exist when using steel ladders or crane towers in wet weather? Answer The tower access ladder will be slippery and it would be easy for the operator to slip and fall.


Question 13

During operation of the tower crane, electrical power failure/fault occurs. What would you do? Answer Communicate with the person dogging the load and advise of the problem for rectification.


Question 14

Why is it important to have the jib head positioned correctly over the hook and load? Answer To reduce the risk of overloading or collapsing the crane and to precent the load from swinging on the lift.


Question 15

Can you use the jib of a self-erecting tower crane as a ladder to access a worksite or as a work platform? Explain your answer.

Answer No. Under no circumstances must the jib of a self-erecting tower crane be used as a method of access or as a work platform because it is unsafe and is not designed as an access route.

Reference: Oral/written assessment for cranes question 73

Question 16

Are you permitted to allow a person to ride upon the lifting hook, sling attachment or suspended load? Explain your answer.

Answer No. A person can only be suspended by a self-erecting tower crane in a suitable work box specifically designed to incorporate the necessary features.


Question 17

What would you do if you heard a sudden loud noise and felt a vibration coming from an area lower down on the base section of the tower crane?

Answer Lower the load, immediately cease operation and communicate with the person dogging the load. Organise an inspection of the crane base and tower to identify whether some form of heavy plant has struck the crane. Check for damage and report to an authorised person.


Question 18

List four precautions that must be taken when long travelling a self-erecting tower crane? Answers

Prior to operating, ensure that there are no obstructions or personnel on the rails. Ensure that the working radius has been calculated prior to travelling. When travelling the self-erecting tower crane, siren and flashing lights must be operational. Ensure that the load is controlled by the person dogging the load with the use of taglines where

necessary.

Ensure that people pushers or wheel guards are in place. Travel at minimum speeds. Ensure that the travelling self-erecting tower crane is mechanically stopped prior to reaching end

stops.


Question 19

If you detected a defect in one of the main controls, who would you report this to for rectification and who would responsible for the rectification work?

Answer To an authorised person or supervisor, who would then contact a competent person for corrective action.


Question 20

If the hook has landed on the ground, causing a slack rope, what would the correct procedure when re-spooling the rope?

Answer The weight of the hook or overhauling weight or applied weight must be on the rope when re-spooling. This can be achieved by luffing the jib or telescoping the angled jib outwards.


Question 21

If the self-erecting tower crane is located near aircraft traffic zones, what action must be taken? Answers

A red warning light should be installed at the upper most point of the crane. Directions from airport authority may state operational hours for the crane operation. Information from the airport authority may state maximum jib elevations for any luffing type

operations.


Question 22

If a heavy load is to be lifted what precautions would you take to work within a given radius? Answer Ensure the jib or boom deflection is taken into consideration. Adjust boom angle or trolley radius to maintain vertical lifting application.

Reference: Oral/written assessment for cranes question ?

Media application

Use a whiteboard and make up a list of hazardous occurrences that could effect crane operation. Practical session

Using close supervision allow the trainee to control the motions of the crane. Note: This must be performed under strict close supervision.

Demonstrate to the trainee the process of catching the hook. (Use a scale model or other device.)

Demonstrate to the trainee the process of crane operation addressing the points below. Load secure Load correctly slung Conduct trial lift Lift conforms with load chart Jib positioned over load correctly Hoist load Move load Lower load Luff up (where applicable) Luff down (where applicable) Slew load Telescope boom Travel with load All movements smooth/adequate speed Tag line used Signals interpreted correctly Load placed correctly on dunnage Load unslung Raise hook and attachment to safe height.

Reference: Performance assessment section J

Trainers notes

SECTION 14

LOADS AND SELF-ERECTING TOWER CRANES Points for trainer

Explain to the trainee how the operating radius is displayed on the crane. Show the trainee the methods of determining the load mass of various materials and loads. Show the trainee how multiple fall hoist reeving is applied. Explain to the trainee the dangers associated with snigging and dragging loads. Sling and lift and load slightly off the ground and show the trainee the checks that must be performed

before lifting further.

Explain to the trainee the application of lifting a personnel lifting box with personnel aboard. Show the trainee how to read and interpret a load chart on the crane. Explain the deductions required to

calculate the net capacity. Deduct items such as the load mass, the weight of the hook block and attachments such as spreader beams and slings. Where specified the weight of the hoist rope may be deducted.


Question 1

Explain how the hook radius is indicated on the crane? Answer The hook radius is displayed on the control device and may also be displayed on flags or signs installed on the underside of the jib or as per specific crane design.


Question 2

How do you determine the rated capacity if the self-erecting tower crane? Answer By checking the load chart plate fitted to the crane or control unit.


Question 3

Who should be involved in the process of assessing the load before lifting? Answer A person dogging a load and the crane operator or rigger if applicable.


Question 4

Who would be responsible for checking all lifting gear for example chains and slings? Answer The crane operator in conjunction with the person dogging the load.


Question 5

How do you know when the multiple load falls are required? Answer As per the load cart specifications.


Question 6

Give three different ways in which the mass (weight) of a load can be determined? Answers

Delivery dockets Public weighbridge certification The manufacturers information Weight may appear on the load itself Calculate or estimate.


Question 7

State three reasons why you are not permitted to drag or snig a load. Answers

Load swing may occur The load may topple Damage to the sling may occur Structural damage to the crane by exceeding the rated capacity of the crane may occur.


Question 8

With the load suspended just off the lifting surface, what three observations and checks need to be made? Answers

The load is securely slung. All crane equipment is functioning correctly. Stabiliser/outrigger footing is secure.


Question 9

List six requirements that would permit you to lift personnel using the crane. Answers

The unit must be specifically designed as a workbox. Tare weight of the workbox must be displayed on the box. The maximum number of occupants allowed in the box must be displayed on the box. The maximum mass that can be carried in kilograms must be displayed on the box. The identification reference must be displayed on the workbox. The workbox must not contain more than three persons, one of who must be competent in crane

signals.

The workbox must be in a safe working condition. Slings shall be permanently attached to the workbox by locked shackles or other similar means. The workbox must have a provision for attachment of safety harnesses for personnel. The workbox must be painted in high visibility colours. Where an access door is fitted, it shall open inwards and be provided with means to secure the door. The workbox is only to be used to lift persons and their equipment. The crane lifting the workbox shall be fitted with a safety hook. The crane lifting the workbox shall be equipped with controls that return to the neutral position when

released the motion to stop.

The crane lifting the workbox shall be equipped with power lowering. The crane lifting the workbox shall be equipped with a lockout control to prevent free-fall of the

workbox and its contents.

The crane lifting the workbox shall be fitted with an up limit switch on the hoist motion. The crane lifting the workbox shall be fitted with a down limit switch if the workbox is to be lowered

below the cranes supporting surface.

The crane operator shall remain at the controls of the crane when the workbox is suspended with personnel.

The crane operator shall ensure that at the maximum radius of the task to be performed the crane has a minimum rated capacity of 1000kgs.

The crane operator shall ensure that when the jib is at the maximum radius for the task to be performed, the rated capacity for the crane in this condition, when divided by two, is equal or greater than the total load of the workbox and its contents.

The crane operator shall ensure that they have a means of communication with any person in the workbox.


Question 10

State three essential items of information you would expect to obtain from a load chart. Answers

The mass of the hook block The winch line pull measure in tonnes or kilograms The rated capacity for an applied crane configuration Multiple rope fall capacities (eg two fall and four fall hook block configurations). Note: Other answers may also be considered applicable.


Question 11

List three items that need to be deducted from the (ie stated rated) capacity of a crane to determine its payload ie the load the crane can lift.

Answers

The mass of the hook block. The mass of any lifting attachments such as spreader beams, ladies or kibbles. The mass of the lifting slings.


Question 12

When dealing with a crane load chart, what is meant by the term operating radius? Answer The operating radius is the measurement from the cranes centre of rotation to the vertical freely suspended hoist line.


Question 13

When the precise reading is between load chart capacities, do you increase or decrease the rated capacity?

Answer Use the lower rated capacity.


Question 14

If the jib is luffed up to a 10 degree angle does this alter the rated load capacities of the crane? Refer to load chart Q.

Answer Yes


Question 15

If the jib is in a folded configuration, where only the base section of the jib is available, does this alter the rated capacities of the crane compared to using a fully extended jib section? Refer to load chart Q.

Answer Yes


Question 16

Refer to load chart Q

A self-erecting tower crane with load chart Q is set up as follows: Main jib length 30.00 metres Working radius 21.00 metres Work area 360 degrees Fitted with a two-fall hook block Jib fully extended

i. What is the maximum load that can be raised on the hook block at the specified radius?

ii. If the hook block is re-reeved to a four-part configuration, what is the new capacity at the same radius as question i?

iii. What is the maximum capacity of the four-fall hook block configuration? (Do not take radius into consideration.)

Answer Refer to load chart Q: 30.00 metre jib at a 21.00 metre radius with the jib fully extended using a two-fall hook block configuration.

i. Rated capacity (SWL): 1530kgs

Hook mass deductions: 120kgs

Net load: 1410kgs

ii. Rated capacity (SWL): 1480kgs

Deductions: 205kgs

Net load: 1275kgs

iii. Rated capacity (SWL): 4000kgs

Deductions: 205kgs

Net load: 3795kgs


Question 17


A self-erecting tower crane with load chart Q is set up as follows: Main jib length 30.00 metres Working radius 29.00 metres Work area 360 degrees Fitted with a four-fall hook block Jib fully extended


ii. If the hook block is re-reeved to a two-part configuration, what is the new capacity at the same radius as in question i?

iii. What is the maximum capacity of the two-fall hook block configuration? (Do not take radius into consideration.)

Answer Refer to load chart Q: 30.00 metre jib at a 29.00 metre radius with the jib fully extended using a four-fall hook block configuration.



Net load: 795kgs


Deductions: 120kgs

Net load: 930kgs

iii. Rated capacity (SWL): 2000kgs

Deductions: 120kgs

Net load: 1880kgs


Question 18


A self-erecting tower crane with load chart Q is set up as follows: Main jib length 30.00 metres Working radius 13.00 metres Work area 360 degrees Fitted with a four-fall hook block Jib folded


ii. If the jib is unfolded and fully extended what is the new capacity at the same radius as question i?


Answer Refer to load chart Q: 30.00 metre jib at a 13.00 metre radius with the jib folded using a four-fall hook configuration.



Net load: 3092kgs


Deductions: 205kgs

Net load: 2175kgs

Rated capacity (SWL): 4000kgs

Deductions: 205kgs

Net load: 3795kgs


Question 19


A self-erecting tower crane with load chart Q is set up as follows: Main jib 24.00 metres Working radius 21.00 metres Work area 360 degrees Fitted with a two-fall hook block Jib fully extended


ii. If the hook block is re-reeved to a four-part configuration, what is the new capacity at the same radius as question i?

iii. What is the maximum capacity of the two-fall hook block configuration? (Do not take radius into consideration.)

Answer Refer to load chart Q: 24.00 metres jib at a 21.00 metre radius with the jib fully extended using a two-fall hook block configuration.



Net load: 1550kgs ii. Rated capacity (SWL): 1720kgs

Deductions: 205kgs

Net load: 1515kgs iii. Rated capacity (SWL): 2000kgs

Deductions: 120kgs

Net load: 1880kgs


Question 20 Refer to load chart Q

A self-erecting tower crane with load chart Q is set up as follows: Main jib length 24.00 metres Working radius 23.00 metres Work area 360 degrees Fitted with two-fall hook block Jib fully extended


ii. If the hook is re-reeved to a four-part configuration, what is the new capacity at the same radius as question i?

iii. What is the maximum capacity if the four-fall hook block configuration? (Do not take radius into consideration.)

Answer Refer to load chart Q: 24.00 metre jib at a 23.00 metre radius with the jib fully extended using a two-fall hook block configuration.



Net load: 1380kgs


Deductions: 205kgs


Deductions: 205kgs

Net load: 3795kgs

Reference: Oral/written assessment question ?

Question 21




ii. If the jib is unfolded and fully extended, what is the new capacity at the same radius as question i?


Answer Refer to load chart Q: 24.00 metre jib at a 13.00 metre radius with the jib folded using a four-fall hook block configuration.




Deductions: 205kgs

Net load: 2975kgs iii. Rated capacity (SW): 4000kgs

Deductions: 205kgs

Net load: 3795kgs Reference: Oral/written assessment question ?

Question 22 Refer to load chart Q



ii. If the jib is unfolded and fully extended, what is the new capacity at the same radius as question i?


Answer Refer to load chart Q: 24.00 metre jib at a 14.00 metre radius with the jib folded using a four-fall block configuration.




Deductions: 205kgs


Deductions: 205kgs

Net load: 3795kgs Reference: Oral/written assessment question 134

Media application

Use the load chart Q to explain the load chart applications required for written assessment. Use a variety of other load charts relating to different self-erecting tower cranes to assess the trainees

understanding of load chart interpretation.

Practical session

Show the trainee how to lift loads with the crane, working within the rated capacity specified by the crane manufacturer.

Explain to the trainee how the radius indicator is displayed. Show the trainee where the load radius is displayed.

Explain the load chart and its capabilities to the trainee using different jib angles/configurations. Reference: Performance assessment section L

Trainers notes

SECTION 15

SPECIAL OPERATIONS Points for trainer

Explain to the trainee the regulations regarding multiple crane lifts. Explain to the trainee the system of climbing the crane where applicable. Questions for trainee/s

Question 1

How do you lower the load in the event of a power failure? Answer As per manufacturers recommendations.

Note: This operation differs from crane to crane. Operators must know their particular crane and be able to describe to the assessor exactly how it is done. Operators have a responsibility to ensure that they can emergency lower on any self-erecting tower crane that they operate. It is essential for the applicant to know this. If not, then they should not be assessed as competent.


Question 2

Is it permitted to carry out a multiple crane lift with a self-erecting tower crane and another crane? Answer No.


Question 3

Where is the information found to show how to climb the self-erecting tower crane (if applicable) by inserting extra tower sections?

Answer In the manufacturers manual for the self-erecting tower crane.


Media application

Show a video or scale model to the trainee regarding climbing of the crane where applicable. Practical session

Show the trainee how to lower the hook manually using manual lowering techniques in case of an emergency situation.

Describe to the trainee how to climb (jack the crane vertically) by demonstrating the procedure appropriate to the self-erecting tower crane, where applicable.

Show the trainee how to unfold and fold the jib on a self-erecting tower crane by demonstrating the procedure appropriate to the tower crane, where applicable.

Reference: Performance assessment section N

Trainers notes

SECTION 16

SHUTDOWN CRANE Points for trainer

Explain to the trainee the shutdown procedures for overnight out of service requirements. Ensure the hook is positioned appropriately for out of service conditions. Face the crane jib downwind (wind at the back of the crane) on shutdown before engaging weathervane

mode.


Question 1

Can any load remain suspended from the hook following shut down or when the crane is unattended? Explain your answer.

Answer No, this is unsafe. If during the course of a lift the crane operator must leave the controls, the load should be placed on the ground with the crane shut down in the prescribed manner as per the manufacturers instructions.

Note: No operator, no load.


Question 2

How should a self-erecting tower crane be left unattended overnight? Answers

Load to be removed Jib folded to manufacturers specifications Crane is weathervaned to engineers recommendations or manufacturers specifications.


Question 3

What would you do with the platform access hatch (if applicable) on shut down? Answer Ensure that it is securely closed and locked with a key lock.


Question 4

What must be done to the base of a travelling tower self-erecting tower crane on shut down in regards to securing the crane.

Answers

Ensure that the blocks are placed at the base of wheels to prevent movement of self-erecting tower crane.

Make sure that the electric motor to the travelling wheel mechanism is isolated and locked. Reference: Oral/written assessment for cranes question ?

Question 5

On shutting down an electric powered self-erecting tower crane, what is an important consideration? Answer Ensure that all electric circuits are fully isolated and locked off.


Question 6

If the self-erecting tower crane is to be left in free slew, why is it important that you raise the jib and hook clear of obstructions for the full 360 degrees around the crane?

Answer When in free slew the self-erecting tower crane can paravane (spin rapidly) in a severe storm or cyclonic winds. The crane must clear surrounding buildings and other obstructions or the jib or crane may be folded down.


Question 7

You are operating a self-erecting tower crane that is on a travelling base. Why is it essential that travel locks be clipped to the rails as you leave the crane?

Answer These locks stop the self-erecting tower crane from being blown uncontrollably down the rails by strong winds.


Question 8

On a self-erecting tower crane why is the trolley and hook brought in close proximity to the tower for parking?

Answer So that the trolley-hook assembly creates less wind resistance thereby eliminating excessive forces on the outriggers and foundations.


Question 9

An operational self-erecting tower crane is situated very close to a neighbouring building. The building is under the jib-slewing radius of the self-erecting tower crane. What special precautions must be undertaken to shutdown?

Answers

The self-erecting tower crane must not be weathervaned as a collision with the building could occur. The crane jib may be luffed up to avoid collision with the building. The self-erecting tower crane may be locked off as per the manufacturers instructions. The self-erecting tower crane may be packed up as per manufacturers specifications. Guying of the crane jib may require an engineers approval.


Practical session

Explain to the trainee the process of shutting down the tower crane covering these points. Ensure barricades are in position. Ensure the hook block/trolley assembly is suitably positioned for stowing as per the manufacturers

specifications.

Lower/retract jib in accordance with the manufacturers specifications. Slings removed. Weathervane self-erecting tower crane in accordance with the manufacturers specifications. Raise hook to maximum height. Lock and secure remote control unit. Lock and secure self-erecting tower crane. Turn the isolator switch off and secure.

Reference: Performance assessment section M

Trainers notes

SECTION 17

RULE OF THUMB AND WORKING LOAD LIMITS Points for trainer

Explain to the trainee the rule of thumb formulae used to identify working load limits (WLL) for all sling types such as fibre, flexible steel wire rope (FSWR) and lifting chain.


Question 1

What is the formula or rule of thumb for determining the working load limit (WLL) for an unidentified synthetic rope?

Answer Diameter in millimetres squared = the WLL in kilograms

Note: If unknown, the formula for fibre rope should apply or be accepted.

Reference: Written assessment for cranes question 1

Question 2

Calculate the WLL for one of the following i. 12mm diameter unidentified synthetic rope

ii. 15mm diameter unidentified synthetic rope

iii. 20mm unidentified synthetic rope.

Answers

i. Diameter in mm2 = 12mm = 12 x 12 = 144kg WLL

ii. Diameter in mm2 = 15mm = 15 x 15 = 225kg WLL

iii. Diameter in mm2 = 20mm = 20 x 20 = 400kg WLL

Note: if unknown, formula for fibre rope should apply or be accepted.


Question 3

What is the rule of thumb formula used to calculate the WLL of a flexible steel wire rope (FSWR)? Answer Diameter in millimetres squared x 8 = the WLL in kilograms


Question 4

Calculate the WLL of one of the following: i. 15mm diameter FSWR

ii. 20mm diameter FSWR

iii. 25mm diameter FSWR

Answers

i. Diameter in mm2 x 8 = 15 x 15 x 8 = 1800kg WLL

ii. Diameter in mm2 x 8 = 20 x 20 x 8 = 3200kg WLL

iii. Diameter in mm2 x 8 = 25 x 25 x 8 = 5000kg WLL


Question 5

What is the rule of thumb for calculating the WLL for a grade 80 high tensile chain? Answers

Diameter in millimetres squared x grade x 0.4 = WLL in kilograms; or Diameter in millimetres squared x 32 = WLL in kilograms


Question 6

Calculate the WLL of grade 80 high tensile chain at one of the following diameters: i. 10mm

ii. 12mm

iii. 15mm

Answers

i. Diameter in mm2 x 32 = 10 x 10 x 32 = 3200kg WLL

ii. Diameter in mm2 x 32 = 12 x 12 x 32 = 4608kg WLL

iii. Diameter in mm2 x 32 = 15 x 15 x 32 = 7200kg WLL


Practical session

Demonstrate to the trainee the process of identifying WLLs for a specified sling type used on the tower crane.

Trainers notes

SECTION 18

LOAD FACTORS Points for trainer

Discuss with trainee the application of utilising load and reeve factors for determining actual sling ratings on lifting.


Question 1

A sling of 2.0 tonnes WLL is reeved around a circular load. What is the sling now capable of lifting? Answer 2.0 tonnes x 0.75 load factor = 1.5 tonnes


Question 2



Question 3



Question 4



Question 5

A sling of 5.0 tonnes WLL is reeved around a square load. What is the sling now capable of lifting? Answer 5.0 tonnes x 0.5 load factor = 2.5 tonnes


Question 6

A sling of 4.0 tonnes WLL is reeved around a square load. What is the sling now capable of lifting? Answer 4.0 tonnes x 0.5 load factor = 2 tonnes


Question 7

A sling of 3.0 tonnes WLL is reeved around a square load. What is the sling now capable of lifting? Answer 1.5 tonnes x 2.00 load factor x 0.5 reduction factor square load = 1.5 tonnes


Question 8

A sling of 1.5 tonnes WLL is used in a basket hitch around a square load. What is the sling capable of lifting now?

Answer 1.5 tonnes x 2.00 load factor x 0.5 reduction factor square load = 1.5 tonnes


Question 9

A sling of 1.5 tonne WLL is reeved around a square load. What is the sling now capable of lifting? Answer 1.5 tonnes x 0.5 load factor = 0.75 tonnes


Question 10

A lifting beam with a mass (weight) of 300kg is supported by a two legged sling shackled to the beam forming an included angle of 90 degrees at the crane hook (see diagram). Two slings are shackled to the underside of the lifting beam and vertically down to lifting eyes on a machine if mass 2500kg. What is the minimum WWl required of each of the four slings?

Answer

Slings between the machine and beam =

Total weight of 2500kg divided by the load factor of 2.00 = 2500 2.00 = 1250kgs for each sling.

The slings between the beam and hook =

A total weight of 2800kg divided by the load factor of 1.41 (for a 90 degree included sling angle) = 2800 1.41 = 1986kg for each of the upper slings.

Upper slings require a WWL of 1986kgs each.

Lower slings require a WWL of 1250kg each


Question 11

If two slings are spread at an included angle of 90 degrees, what is the load factor applied to the load being lifted?

Answer For a 90 degree included angle the load factor is 1.41.


Question 12




Question 13




Question 14




Question 15

From the drawings below select the included angle closest to 90 degrees.

Answer D is the correct diagram


Question 16

What reduction must be made to the WLL of a FSWR sling when it is reeved on a round load? Answer A 25 per cent reduction.


Question 17

What reduction must be made to the WLL of a FSWR sling when a basket hitch is used to cradle a square load?

Answer A 50 per cent reduction.


Question 18

What load factor must be applied to the WLL of a FSWR sling when a basket hitch is used to cradle a square load?

Answer Load factor of 1 is applied. The rated capacity (SWL) remains the same as the WLL.


Question 19

What safety factor must be applied to the WLL of a FSWR sling when a basket hitch is used to cradle a round load?

Answer Load factor 2 is applied. The rated capacity (SWL) is double the WLL.


Practical session

Demonstrate to the trainee how load factors effect operations in sling application and sling configurations. Trainers notes

SECTION 19

RULES TO FOLLOW WHEN SLINGING AND HANDLING A LOAD Points for trainer

Describe to the trainee approved methods of utilising lifting gear and equipment. Discuss with the trainee the benefits of using tag lines for load control. Discuss with the trainee the hazards involved with stuck loads such as formwork shutters, sheet pile or

concrete pre-cast panels.

Explain to the trainee the hazards involved with wind affected loads such as shutters, roofing iron and cladding.

Discuss with the trainee the application of using multiple sling arrangements and which slings are taking the load.


Question 1

What factors should be considered when using taglines? Give at least four examples. Answers

Weather conditions Electrical hazards Tagline change over may be required at designated point in the lift. Person holding the tagline should wear PPE. Ensure that the line is not fouled. Taglines should be held correctly. Tagline length requirement. Tagline size requirements.


Question 2

When lifting concrete formwork shutters in gusting wind conditions, what measures would you ensure are undertaken to control the load?

Answers

Load must be attached to taglines. Shutters may be laid down and lifted horizontally with taglines attached. Operations may have to cease until wind conditions reduce sufficiently.


Question 3

A long load of reinforcement steel bars is to be lifted off a truck close to the sheeted scaffolding perimeters of the site. How can the load be controlled to prevent contact and subsequent snagging with the scaffold?

Answer The person dogging the load should control the load with a hand held tagline.


Question 4

An internal lift formwork shutter to green concrete weighing two tonnes is to be lifted. The weight is taken and the shutter does not budge, what should you do?

Answers

Stop hoisting if the load on the crane is over two tonnes. The shutter may be jammed; this may require some levering by the formworkers. Ensure all personnel are clear of the shutter in case the shutter springs off the lift shaft wall.


Question 5

List three reasons why packing or dunnage is used when slinging or landing a load. Answers

To protect the load. To facilitate the connection/disconnection. To prevent damage to lifting gear.


Question 6

You have formwork shutters to lower from the top of a building when a strong wind blows up. What are the hazards?

Answer Shutters are large in area but light in weight, therefore they could flap/spin around in the wind so will need to be secured. The wind loading with such a large surface area could destabilise the self-erecting tower crane.


Question 7

Why must you pack/lag the edges/corners of sharp loads? Answer To protect load slings and lifting gear from damage.


Question 8

A four legged bridle sling arrangement is attached to a rigid load. How many sling legs would be assumed to support the load?

Answer two diagonally opposite sling legs must be capable of supporting the load.


Question 9

A three legged bridle sling arrangement is attached to a rigid load. How many sling legs would be assumed to support the load.

Answer Any two legs of the sling arrangement.


Question 10

A four legged bridle sling arrangement is attached to a flexible load. How many sling legs would be assumed to support the load?

Answer The entire four sling legs.


Practical session

Demonstrate to the trainee the application of various sling loads. The loads should be lifted using different sling arrangements to cover this section.

Trainers notes

SECTION 20

STACKING Points for trainer

Explain to the trainee the process of stacking loads allowing for proper clearance whilst ensuring stability of the load.

Trainers notes

SECTION 21

PERSONNEL PROTECTIVE EQUIPMENT Points for trainer

Ensure the trainee understands the requirements for personnel protective equipment (PPE) whilst operating a self-erecting tower crane.

Trainers notes

SECTION 22

COMMUNICATION Points for trainer

Converse with the trainee regarding the use of communication techniques where a dogger is used with provide signals.


Question 1

What communication equipment can the crane operator utilise other than two-way radio? Answers

Hand signals Whistles, hooters Light signals


Question 2

If given a stop signal by someone other than the person dogging the load, what would you do? Answer Stop operations immediately and await further directions.


Practical session

Ensure the trainee understands and knows the applicable crane whistle signals for operation. Reference: Performance assessment section I

Trainers notes

SECTION 23

FLEXIBLE STEEL WIRE ROPE Points for trainer

Discuss with the trainee the application of wire rope usage in hoist ropes, suspension ropes and sling configurations.


Question 1

What is the minimum allowable size FSWR for load handling purposes? Answer 5mm diameter

Reference: Written assessment question 14

Question 2

What is the maximum allowable temperature that FSWR can be exposed to before it is unsafe for lifting purposes?

Answer 950C


Question 3

What is the formula that indicates the maximum amount of broken wires permitted in FSWR? Answer Where 10 per cent of the total numbers of wires are broken in one rope lay or in eight diameters of rope.


Question 4

Using the formula for maximum amount of broken wires in FSWR, work out one of the following: i. The construction of the rope is 6/19 and 12mm diameter.

ii. The construction of the rope of is 6/24 and 20mm diameter.

iii. The construction of the rope is 6/36 and 54mm diameter.

Answers

i. 6/19 = 6 x 19 = 114 wires

10% x 114 = 11.4 wires

Therefore, in one rope lay 11 wires.

Rope length to inspect = 12mm x 8 = 96mm

ii. 6/24 = 6 x 24 = 144 wires

10% x 144 = 14.4 wires



iii. 6/36 = 6 x 36 = 216 wires

10% x 216 = 21.6 wires




Question 5

What is meant by the term core slippage? Answer Core slippage occurs when the outer wire strands slip over the inner core of the opposite lay.


Question 6

What will condemn a FSWR sling from safe use? List at least six defects. Answers

Kink or fractures from bending or reeving Crushed or jammed strands Damaged splice Exposure to high temperatures Core collapse Bird-caging - where the strands loosen from their proper tight lay Stretched or overloaded High stranding Corrosion loose and springy wires indicate serious corrosion Knotted sections Wear caused by badly maintained or aligned sheaves The number of broken wire exceeding allowable limit.


Question 7

Explain the use and advantages of a wire rope thimble? Answer Thimbles are designed to protect the load bearing area inside the crown of the eye from chafing and distortion and to form a hard eye in a rope.


Question 8

Explain the reason for using swaged aluminium alloy fitting or a thimble fitting. Answer to form an eye splice or thimble eye in a wire rope (FSWR).


Question 9

What are the most obvious indications of a defective swage fitting? Answers

The tail of the FSWR has slipped inside the swage fitting. The steel collar thimble is loose on the rope. The fitting is loose. There is a broken wire at either end of the swaged fitting.


Practical session

Using a number of defective slings, have the trainee determine the defects that cause condemnation of a FSWR sling.

Trainers notes

SECTION 24

WEDGE ROPE SOCKETS

Points for trainer

Converse with the trainee regarding the proper use of wedge sockets. Questions for trainee/s

Question 1

From the diagrams below, select the correct methods of reeving a hoist rope in a wedge rope socket.

Answer Correct answer is D or E.


Question 2

Are you permitted to use wire rope (bulldog) grips to connect two lengths of wire rope for lifting purposes? Explain your answer.

Answer No, the wire rope could crush or pull through the bulldog grip.


Question 3

Should the wedge protrude outside the narrow end of the socket fitting? (As shown in the diagram.)

Answer Under no circumstances should the wedge protrude at the narrow end of the socket.


Question 4

What is the minimum amount of tail projection for the dead end of a rope used with a wedge socket? Answer In most cases, the tail on the dead end of the rope should project at least 200mm.


Question 5

What should be secured to the tail of a rope when in use with a wedge socket fitting to indicate slippage? Answer A bulldog grip must be applied only to the tail of the rope below the socket.


Practical session

Demonstrate to the trainee the correct assembly of a wedge socket and a bulldog grip. Trainers notes

SECTION 25

SHEAVES AND DRUMS FOR FLEXIBLE STEEL WIRE ROPE Points for trainer

Converse with the trainee regarding the application of sheaves and wind drums for FSWR. Explain the defects that can affect a sheave. Explain the occurrence of two blocking. Explain to the trainee the process of inspecting sheaves, drums and running ropes on the crane before

starting the operation.

Show the trainee the process of changing the hook block from a two fall to a four fall reeving configuration.

Question for trainee/s

Question 1

What will condemn a sheave from safe use? List at least three defects. Answers

Excessive wear in the groove of the sheave. Cracks or any damage in the flange of the sheave. Twisted/deformed or out of shape. Worn sheave pins, hinge pin wear. Damaged cheek plates or cheek plate wall/partition is too close to too far from sheave.


Question 2

List two effects double blocking can have on the crane and equipment. Answers

Can cause the FSWR to break. Can cause the load to drop. Can damage the sheave. Can cause structural damage to the crane.


Question 3

When the rope construction is unknown, what is the rule of thumb method used to calculate a sheave size?

Answer the basic rule of thumb used to calculate sheave size is rope diameter x 20.


Question 4

How much of the FSWR should sit neatly in the base of the groove of a sheave? Answer one third or 120 degrees.


Question 5

How deep must the sheave groove be in relation to the rope diameter being used? Answer the sheave groove should not be less than 1.5 times the diameter of the FSWR being used.


Question 6

When the maximum number of turns is wound on a drum, how far must the flange of the drum extend about the outer layer of rope?

Answer The drum flange must extend above the outer layer of the wire rope by at least two rope diameters.


Question 7

What is the advantage of using a jockey sheave? Answer A jockey sheave ensure that the hoist rope remains at the correct fleet angle to the winch drum.


Question 8

What will occur if the sheave groove is too large for the diameter of the given rope? Answer This will cause rope flattening of the rope.


Question 9

What will occur if the sheave groove is too small for the diameter of the given rope? Answer This will cause rope pinching and sever abrasion.


Question 10

How is the diameter of a sheave measured? Answer A sheave is measured across the face of the sheave to the inside of the grooves on either side in millimetres.


Question 11

When the hook or the block is at the lowest possible point, what is the minimum amount of full turns of wire rope that must remain on the winch drum?

Answer A minimum of two full turns.


Question 12

What happens if the fleet angle of the hoist rope is incorrect? Answers

Spooling or uneven coiling of the hoist rope on the hoist drum. The hoist rope may be pulled off the sheave and subsequently jam.


Question 13

What problem would occur if the jockey sheave seized? Spooling or uneven coiling of the hoist rope on the hoist drum. The hoist rope may be pulled off the sheave and subsequently jam.


Question 14

What are the approved methods of fixing the hoist wire to the boom head? List two methods. Answers

By using a hambone wedge socket. By using hand splice or machine splice with thimble. By using wire adjusters.


Question 15

List two methods used to secure/fix the tail of the hoist rope to the winch drum. Answers

Socket and wedge Clamp and bolts.


Practical session

Have the trainee inspect each sheave on the crane where applicable. The trainee can state which defects can affect sheaves.

Trainers notes

SECTION 26

LIFTING CHAIN Points for trainer

Use a high tensile lifting chain set for the trainee to inspect for defects. Questions for trainee/s

Question 1

What is the smallest size diameter chain allowable for safe load handling for: i. Grade 30 chain?

ii. High tensile grade 80 chain?

Answers

i. Basic grade 30 = 8mm

ii. High tensile grade 80 = 5.5mm


Question 2

What is the maximum temperature that a sling can be subjected to before the rated capacity (SWL) is affected for:

i. Grade 30 chain sling?

ii. High tensile grade 80 chain sling?

Answers

i. Basic grade 30 2600C

ii. High tensile grade 800C 4000C

Note: If 2600C is exceeded, the WLL of the chain is reduced.


Question 3

What is the maximum amount of wear permitted in the link of a chain? Answer The maximum amount of wear permitted in a chain is ten per cent of the diametrical cross section.


Question 4

Where on a chain link is wear most likely to occur? List two points. Answers

Links will wear at the link ends from the metal wear down. Links will wear on the outer sides of the link from being dragged.


Question 5

What will condemn a chain fr

Documents

Self Erecting Tower Crane Operators Guide