Approved Code of Practice for Cranes

APPENDIX G: COMMON HAZARDS ASSOCIATED WITH TOWER CRANE ERECTION, DISMANTLING AND CLIMBING WORK

Refer to site management for site-specific hazards. The following table deals with common generic hazards only. Site-specific hazards must also be addressed, in full consultation with site management and all involved work group parties.

Hazard	Eliminate	Isolate	Minimise
Fall from height	Where tasks can be carried out at ground level, do so, rather than at height.	Maintain existing guardrails and ladder hoops to work and access areas, erect guardrails or other isolation means to prevent falls e.g., open areas between crane tower unit members while accessing between crane tower and main jib or counter jib	Approved safety harnesses with energy absorbers to be used where practicable when working at any height where the possibility of a fall exists and where there is no other means of fall protection. (Refer Crane Association Policy Guideline).As part of the work plan, where possible, adopt fall-restraint (work positioning) procedures with safety harnesses, to prevent a free fall, thus limiting the maximum fall distance to 600 mm.
Fall-arrest - isolation/ injury after fall from height with harness (suspension trauma)			Use approved safety harnesses with shock absorbers. Users of fall-arrest equipment and on-site rescue personnel must be trained in its proper use and recovery methods in the event of a fall.Wear only approved footwear and protective helmets.Rescue and retrieval equipment and trained personnel to always be on site whenever there is the need to use fall-arrest equipment on tower cranes. The helicopter rescue phone number is to be available on site.
Hit by falling object(s)	Tools are to be attached to tool belts worn by the individual where practicable and safe to do so, without creating a "snagging" danger.	All personnel to be made aware of hazard and the need to remain clear of crane operations and personnel working above. Tape off underside of work area and erect warning signs.	Only essential items to be taken up the tower crane. Safety helmets to be worn at all times other than when no danger above, or inside vehicles or other shelter.(Chin straps must be worn on helmets when up a tower crane.)
Tripping and falling over		N/A	Work areas and accessways to be kept clear of unnecessary materials and equipment.
Electrocution (from crane power supply)		Ensure crane is properly earthed.Lockout devices should be used wherever practicable.	Only qualified and certified electricians to perform electrical work on tower cranes.Crane operator and supervisor to be informed of precisely when electrical workers are working with current-bearing cables.
Electrocution (from external supply)	Turn off power.	Limit crane operations.	Ensure crane is properly earthed. All personnel to be made aware of hazard.No part of crane or load to come within 4 metres of power lines unless authorised by power authority and where designed for.
Crane self movements/ loads striking worker		Lockout devices should be used wherever practicable.	All personnel to be made aware of hazard.Crane operator must be made aware of all work and personnel on the crane and only carry out functions as directed by a designated and authorised person who is aware of all work and personnel on the crane. Ensure that only authorised personnel are permitted on the crane and are working in accordance with an established work plan. Supervisors to be constantly aware of all work being performed on or around the crane at all times.
Injury from exposure to crane machinery		All protection guards are to be in place at all times except when being worked upon or when necessarily removed for erection procedures.Lockout devices should be used wherever practicable.	Ensure no loose clothing or long hair. Lanyards to be secured when not in use and not able to snag upon moving machinery etc.Check all moving machinery for snag points.Correct protective clothing and equipment to be used in accordance with the type of work being done. Only experienced or supervised staff to work on tower cranes.
Fire and burning	Smoking and other sources of ignition are not to be permitted when handling flammable materials, e.g. solvents, oils, diesel fuel.	Flammable materials to be correctly stored. Also refer to HSNO requirements.	Fire extinguishers to be mounted in all crane cabs and available on site.
Load striking/ pushing personnel		All personnel not involved with the lifting operation to be kept clear of the area. The area should be taped off and warning signs erected.	The work process should be planned by experienced personnel. All work group parties should be involved in the planning process.Only appropriately trained, experienced and authorised personnel to operate and dog cranes. Radios to be used when lifting out of sight of operator. Where practicable, tag lines are to be used to control loads.
Load drop due to rigging problem	Only appropriately authorised personnel are to rig loads or otherwise participate in the crane operations. The crane operator may stop all proceedings if, in their opinion, safety is jeopardised by the actions of other personnel. All operations must be carried out in accordance with the Crane Association Crane Safety Manual and the Approved Code of Practice for Rigging.	All personnel not involved with the lifting operation to be kept clear of the area. The area should be taped off and warning signs erected.No person to be under suspended loads.Crane operator to avoid lifting loads over personnel, accommodation or traffic.	The work process should be planned by experienced personnel. All work group parties should be involved in the planning process.
Load drop due to crane/ lifting gear problem	All lifting gear to be certified and inspected prior to use. Only lifting gear suitable for the task to be used.Only authorised and qualified personnel are to rig and/or dog loads or otherwise participate in crane operations.Cranes must have up-to-date inspection certificates and be in proper working order in accordance with the Approved Code of Practice for Cranes and Crane Association Crane Safety Manual.	All personnel not involved with the lifting operation to be kept clear of the area. The area should be taped off and warning signs erected. No person to be under suspended loads.Crane operator to avoid lifting loads over personnel, accommodation or traffic.	The work process should be planned by experienced personnel. All work group parties should be involved in the planning process.
Load drop due to crane/ lifting gear problem		All personnel not involved with the lifting operation to be kept clear of the area. The area should be taped off and warning signs erected.No person to be under suspended loads.Crane operator to avoid lifting loads over personnel, accommodation or traffic.	The work process should be planned by experienced personnel. All work group parties should be involved in the planning process.Mobile crane operators should be holders of the New Zealand National Certificate in Crane Operation (Mobile) or studying for this qualification, or under the supervision of such a qualified person.All tasks to be carefully planned by experienced personnel.
Crane overloaded due to operator being unaware that limits were upset, or released for service purposes.	Crane operator and supervisor to be informed of precisely when limits are set, released and adjusted.	Limits must only be altered or adjusted by appropriately qualified personnel.Lockout devices should be used wherever practicable and warning signs are to be posted in the cab.All personnel not involved with the lifting operation to be kept clear of the area. The area should be taped off and warning signs erected.	No person to be under suspended loads.Crane operator to avoid lifting loads over personnel, accommodation or traffic.
Crane tip over		All personnel not involved with the lifting operation to be kept clear of the area. The area should be taped off and warning signs erected.No person to be under suspended loads.Crane operator to avoid lifting loads over personnel, accommodation or traffic	The work process should be planned by experienced personnel. All work group parties should be involved in the planning process.Mobile crane operators should be holders of the National Certificate in Crane Operation (Mobile) or studying for this qualification, or under the direct supervision of such a qualified person.Detailed copies of the crane's capacity charts are to be available on site and in the operator's cab.All lifting tasks are to be carefully planned by experienced personnel.
Personnel struck by vehicles			A temporary traffic safety management plan should be in place and all personnel made aware of their duties within this plan.Approved high-viz clothing to be worn by personnel working in same areas as any vehicles.
Hearing damage from excessive noise			Hearing protection to be made available and used when performing noisy operations such as gunning bolts and/or hammering pins.Advise personnel about reality of hearing damage and how to use provided hearing protection.
Solar eye damage			Staff should be made aware of the problem and encouraged to wear appropriate eye protection.
Structural failure of crane due to incorrect erection sequence		The work process should be planned by experienced personnel. All work group parties should be involved in the planning process.All personnel not involved with the lifting operation to be kept clear of the area. The area should be taped off and warning signs erected.	Crane erection supervisors must be thoroughly trained and experienced with the type of crane being worked upon. A complete and specific crane manual, in English, must be available on site at all times. The work process should be planned by experienced personnel, and all work group parties should be involved in the planning process.No person to be under suspended loads.Crane operator to avoid lifting loads over personnel, accommodation or traffic.
Crane endangered by high winds whilst prone in erection mode.	A comprehensive weather report specific to the locality and time should be sought prior to commencing erection, dismantling or climbing sequences. Adverse reports will result in the work not commencing or being suspended.	All personnel not involved with the lifting operation to be kept clear of the area. The area should be taped off and warning signs erected.	An emergency jib 'tie-off plan' should be established in the event of wind exceeding the maximum allowed for by the crane manufacturer, during erection sequences.Developing weather conditions should be monitored throughout the full work process.Climbing equipment should be thoroughly inspected and tested for operation before commencing climbing sequences.
Communication breakdown - includes critical and non-critical operations			All personnel shall be in direct contact with each other via two-way radios incorporating a base set and hand sets over an isolated but dedicated channel frequency. This is to ensure constant contact with each other, rather than relying on non-radio instructions being relayed from person-to-person. An observer will be stationed in such a position that they can see the operation being carried out. The role of that observer is to have control of the operation in progress, and be able to rapidly respond (initially by radio) to prevent an accident, or in the case of any emergency.