PART 11: TOWER CRANES

11.1 General

Tower cranes (both new and second-hand) require design verification by an inspection body in accordance with the PECPR Regulations and Parts 2 and 6 of this code, prior to certification for use within New Zealand.

Parts 3, 4, 7, 8 and 9 of this code also apply.

A supplier, controller or manufacturer of such a tower crane shall provide this documentation, as in Part 8.1, to the inspection body carrying out the design verification.

(1) A statement to confirm that the seismic requirements and wind loadings for operating in New Zealand have been taken into account in the design calculations as per Appendices E and F is required. The statement shall specify the maximum in-service and out-of-service design wind speeds. The zone factor (ZF) of 1.2 shall apply to all cranes. Wind forces are to be calculated as per the version of AS/NZS 1170.2 Structural Design Actions - Wind Actions applicable at the time of submission for design verification in New Zealand, or equivalent standards.

(2) For minimum load safety device requirements required on the various crane types, refer to Appendix A.

Picture 3: Tower Crane

11.2 Additional Requirements

In addition to the requirements in Part 11.1 and Part 3: Operational Requirements for Controllers, the following are also required:

(a) Electrically powered cranes should have phase failure protection so that, in the event of a phase failure, ALL phases are shut down.

(b) All new rope luffing tower cranes shall have a secondary brake on the luffing drive. This is not retrospective.

(c) Prior to initial erection in New Zealand, and thereafter annually whilst erected and in service an inspection shall be carried out by an equipment inspector of, but not limited to, the items listed in Appendix H of this code.

(d) All tower cranes should be overload tested to 125% SWL after design approval certification and before the first use in New Zealand. (This test may be performed outside New Zealand if witnessed by a properly authorised and approved testing/inspection authority.) Thereafter, cranes are not to be overloaded except where agreed by the inspection body and the manufacturer. Setting of the load limits is to be performed, in accordance with the manufacturer's instructions, by a competent person, duly authorised by the controller, at each and every erection or configuration change, or every 12 months whilst the crane is erected or in regular service.

Testing of the load limits is to be performed each week by the crane operator or a competent person whilst the crane is erected or in regular service.

(e) A plan should be developed for dealing with any emergency.

11.3 Inspections

Inspection of new and existing tower cranes is to be in four distinct parts as follows:

Part 1: Tower Crane - Inspection at Erection and After Repairs (by an equipment inspector for certification)

Prior to erecting a tower crane the following certificates and documents must be provided:

(a) Statement from the controller with details of the crane configuration, which must be within design verified parameters, including number of tower sections, jib length, counterweight weights certificate, rating sheet, rope certificates, planned changes in height with details of tie-ins, number of tower sections between tie-ins, details of any clash zones and load testing programmes.

(b) Foundation certificate from a CPEng, covering both design and construction.

(c) Certificate from an NDT company accredited by IANZ to perform the particular type of inspection required covering crack testing of all base anchors to be used. Irrespective of the results of any NDT reports, re-use of base anchors is not to exceed the recommendations of the manufacturer. The date of testing of all anchors is to be recorded.

(d) All crane bolts operating in tension shall be tested for defects by visual and magnetic particle inspection techniques upon each dismantling of the joints/connections or every five years, whichever occurs first, or earlier if recommended by the manufacturer. This includes slewing, tower and tower head bolts, if applicable. Any bolts found with crack-like indications shall be removed from service and destroyed. Calibration Certificates for any bolt tensioning devices, such as torque wrenches, are required.

The following minimum checks shall be made by the equipment inspector:

(e) Maintenance and repair records including any new rope certificates

(f) General condition and proper identification of crane structure, fastenings, towers, boom sections, counter boom sections, counterweights (fixed or moving), A-frames, cab section, base section, climbing frame, rails

(g) General wear and tear, protective coating condition etc.

(h) Hydraulic systems, actuators and attachments

(i) Condition of pendant ropes and bridles.

The following must be addressed either prior to or immediately after erection, as practicable:

(j) Slew ring inspection and report are to manufacturer's specifications

(k) Sheaves and bearings

(l) Hoist, luffing and slew brakes and linings

(m) Safety guarding

(n) Hoist, luffing, trolley and counterweight ropes

(o) Hooks, hook blocks and swivel bearings.

The following must be addressed immediately after erection:

(p) Crane assembly and configuration

(q) Statement from qualified erection supervisor (refer Table 4.1) that the crane has been erected in accordance with the manufacturer's recommendations, including the vertical alignment tolerances of the tower.

(r) Test weight certificates.

Inspection prior to testing is to include:

(s) Crane access ladders and platforms

(t) Tensile bolt installation

(u) Rope anchors and dead ends

(v) Pins washers, split pins and locking plates

(w) Hydraulic installation

(x) Electrical equipment, earthing and electrical Certificates of Compliance

(y) Signage.

Testing is to include:

(z) Crane operation

(aa) Operator's cab and controls

(bb) Hoist, trolley and boom limit switches

(cc) Load-moment cutouts

(dd) Hoist speed limiters

(ee) Phase failure and rotation protection (where uncertified)

(ff) Calibration and testing of load-moment cutouts, SLIs and load indicators where fitted (refer Appendix A) in accordance with the manufacturer's instructions

(gg) Free slew.

Refer to Appendix H: Tower Crane Inspections.

Further detailed in-depth inspections may be required depending on results of visual inspection.

Additional items may be identified by the crane owner for inspection.

All signage hoardings and advertising billboards or banners that in any way affect the wind forces acting on the crane, other than as originally provided for by the manufacturer, must be specifically authorised by the manufacturer for the specific crane model and use during both in-service and out-of-service conditions, in accordance with the requirements of clause 11.2(4) as appropriate.

The mountings of any non-OEM signage hoardings, billboards and banners shall be approved by a CPEng. Flags (including hook-mounted flags) must be authorised by the manufacturer for the specific crane model and use and be attached to the crane only during in-service conditions.

Note: Tower cranes are not to be erected for the first time until the equipment inspector is in possession of a certificate of design verification and a foundation certificate.

Part 2: Tower Crane - Annual In-Service Inspection (by an equipment inspector for certification)

Inspections and testing will cover (but are not limited to) the following items:

(a) Inspection of all documents from last inspection, including log books

(b) Maintenance and repair records including any new rope certificates

(c) General wear and tear, protective coating condition etc.

(d) Hydraulic systems, actuators and attachments

(e) Condition of pendant ropes and bridles

(f) Slew ring inspection and report are to manufacturer's specifications

(g) Sheaves and bearings

(h) Hoist, luffing and slew brakes and linings

(i) Safety guarding

(j) Hoist, luffing, trolley and counterweight ropes

(k) Hooks, hook blocks and swivel bearings

Testing is to include:

(l) Crane operation

(m) Operator's cab and controls

(n) Hoist, trolley and boom limit switches

(o) Load-moment cutouts

(p) Hoist speed limiters

(q) Phase failure and rotation protection (where uncertified)

(r) Calibration and testing of load-moment cutouts, SLIs and load indicators where fitted (refer Appendix A) in accordance with the manufacturer's instructions.

Part 3: Tower Crane - In-Service Inspection and Testing at Alteration of Height and/or Jib Length (by an equipment inspector)

Inspections will cover (but are not limited to):

(a) General inspection of crane condition

(b) Inspection and identification of added tower sections and/or other components

(c) Confirmation of the configuration of the tower system

(d) Checking results of magnetic particle inspection report of tower bolts where applicable

(e) Inspection of tie-in collars and supports and documentation of manufacture

(f) Either a load test or statement of a satisfactory load test acceptable to the inspection body

Note: After any repairs have been carried out, the crane is to be load tested to the figure provided by the manufacturer in the repair specification.

(g) Confirmation that rope length is suitable for the application.

Part 4: The inspection by an equipment inspector of climbing system components

(a) Either annually or prior to use, all tower crane climbing components shall be subject to an inspection by an equipment inspector, and a record of the inspection shall be kept on file and reported.

(b) Following the installation of the climbing system onto the tower crane and before being placed in service, all components must undergo a pre-operational inspection and systems check by a competent person. A record of this inspection shall be kept on file.