Cranes, hoists and winches—Safe use Part 1: …...This Standard specifies general requirements for the safe use of cranes, hoists and winches. NOTES: 1 Requirements applicable to

AS 2550.1—2011

Australian Standard®

Cranes, hoists and winches—Safe use

Part 1: General requirements

AS

2

55

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—2

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This Australian Standard® was prepared by Committee ME-005, Cranes. It was approved on behalf of the Council of Standards Australia on 19 January 2011. This Standard was published on 18 March 2011.

The following are represented on Committee ME-005:

• Australian Chamber of Commerce and Industry • Australian Industry Group • Australian Institute for Non-Destructive Testing • Bureau of Steel Manufacturers of Australia • Construction and Mining Equipment Industry Group • Consult Australia • Crane Association of New Zealand • Crane Industry Council of Australia • Department of Commerce, WorkSafe Division (WA) • Department of Justice and Attorney General, Qld • Department of Labour New Zealand • Department of the Premier and Cabinet (South Australia) • Electricity Engineers Association (New Zealand) • Elevating Work Platform Association of Australia • Engineers Australia • Horticulture New Zealand • Industry and Investment NSW • Institution of Professional Engineers New Zealand • Vehicle Loading Crane Interests • WorkCover New South Wales • WorkSafe Victoria

This Standard was issued in draft form for comment as DR AS 2550.1. Standards Australia wishes to acknowledge the participation of the expert individuals that contributed to the development of this Standard through their representation on the Committee and through the public comment period.

Keeping Standards up-to-date Australian Standards® are living documents that reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments that may have been published since the Standard was published. Detailed information about Australian Standards, drafts, amendments and new projects can be found by visiting www.standards.org.au Standards Australia welcomes suggestions for improvements, and encourages readers to notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at [email protected], or write to Standards Australia, GPO Box 476, Sydney, NSW 2001.

AS 2550.1—2011

Australian Standard®



Originated as part of AS 2550—1982.

Revised and redesignated in part as AS 2550.1—1993.

Second edition 2002.

Third edition 2011.

COPYRIGHT

© Standards Australia Limited

All rights are reserved. No part of this work may be reproduced or copied in any form or by

any means, electronic or mechanical, including photocopying, without the written

permission of the publisher, unless otherwise permitted under the Copyright Act 1968.

Published by SAI Global Limited under licence from Standards Australia Limited, GPO Box

476, Sydney, NSW 2001, Australia

ISBN 978 0 7337 9786 6

AS 2550.1—2011 2

PREFACE

This Standard was prepared by the Australian members of the Joint Standards

Australia/Standards New Zealand Committee ME-005, Cranes, to supersede

AS 2550.1—2002, Cranes, hoists and winches—Safe use, Part 1: General.

After consultation with stakeholders in both countries, Standards Australia and Standards

New Zealand decided to retain this Standard as an Australian Standard rather than develop

it as an Australian/New Zealand Standard.

The objective of this Standard is to specify general requirements for the safe use of cranes,

hoists and winches.

The objective of the AS 2550 series of Standards is to provide uniform requirements and

guidance for the safe use of cranes, hoists and winches.

Major changes in this Edition include extensive revision of the inspection and maintenance

requirements in Section 7, and the addition of a new Section 9 that specifies methods to

monitor design duty and introduce the concept of design working period. Section 9 of this

Standard is based on the concepts outlined in ISO 12482-1, Cranes condition monitoring,

Part 1: General.

Published Standards in the series are the following:

AS

2550 Cranes, hoists and winches—Safe use

2550.1 Part 1: General requirements (this Standard)

2550.3 Part 3: Bridge, gantry, portal (including container cranes) jib and monorail

cranes

2550.4 Part 4: Tower cranes

2550.5 Part 5: Mobile cranes

2550.6 Part 6: Guided storing and retrieving appliances

2550.7 Part 7: Builders’ hoists and associated equipment

2550.9 Part 9: Vehicle hoists

2550.10 Part 10: Elevating work platforms

2550.11 Part 11 Vehicle loading cranes

2550.13 Part 13: Building maintenance units

2550.15 Part 15: Concrete placing equipment

2550.16 Part 16: Mast climbing work platforms

2550.19 Part 19: Telescopic handlers

2550.20 Part 20: Self-erecting tower cranes

Statements expressed in mandatory terms in notes to tables are deemed to be requirements

of this Standard.

The terms ‘normative’ and ‘informative’ have been used in this Standard to define the

application of the appendix to which they apply. A ‘normative’ appendix is an integral part

of a Standard, whereas an ‘informative’ appendix is only for information and guidance.

3 AS 2550.1—2011

CONTENTS

Page

SECTION 1 SCOPE AND GENERAL

1.1 SCOPE ........................................................................................................................ 5

1.2 APPLICATION ........................................................................................................... 5

1.3 REFERENCED DOCUMENTS .................................................................................. 5

1.4 DEFINITIONS ............................................................................................................ 6

1.5 INSTRUCTIONS ........................................................................................................ 7

1.6 LEGISLATED RESPONSIBILITY............................................................................. 7

1.7 COMPETENCY OF PERSONNEL............................................................................. 7

1.8 RISK ASSESSMENT.................................................................................................. 8

SECTION 2 PLANNING

2.1 GENERAL .................................................................................................................. 9

2.2 PLANNING................................................................................................................. 9

2.3 MATTERS TO BE CONSIDERED........................................................................... 10

SECTION 3 SELECTION...................................................................................................... 11

SECTION 4 SITING

4.1 GENERAL ................................................................................................................ 12

4.2 CRANE STANDING................................................................................................. 12

4.3 PROXIMITY HAZARDS AND VISIBILITY ........................................................... 13

4.4 ENVIRONMENTAL RESTRICTIONS..................................................................... 13

4.5 CLEARANCES ......................................................................................................... 13

SECTION 5 ERECTION, COMMISSIONING AND DISMANTLING

5.1 IDENTIFICATION OF CRANE COMPONENTS .................................................... 14

5.2 ERECTION, COMMISSIONING AND DISMANTLING INSTRUCTIONS ........... 14

5.3 ELECTRICAL SUPPLY ........................................................................................... 14

5.4 COMMISSIONING................................................................................................... 14

5.5 SAFEGUARDING THE CRANE.............................................................................. 14

SECTION 6 OPERATION

6.1 OPERATIONAL INSTRUCTIONS .......................................................................... 15

6.2 CRANE-OPERATION MANAGEMENT ................................................................. 16

6.3 COMPLIANCE WITH INSTRUCTIONS ................................................................. 17

6.4 COMMUNICATION OF IRREGULARITIES .......................................................... 17

6.5 LEAVING THE CRANE UNATTENDED ............................................................... 17

6.6 OUT OF SERVICE ................................................................................................... 17

6.7 HOUSEKEEPING ..................................................................................................... 17

6.8 CRANE ACCESS AND EGRESS............................................................................. 18

6.9 PERSONS APPROACHING THE PROXIMITY OF A CRANE .............................. 18

6.10 CRANE OPERATION .............................................................................................. 18

6.11 LOAD SECURITY.................................................................................................... 20

6.12 CONTROL OF LOAD............................................................................................... 20

6.13 TAG LINES............................................................................................................... 20

6.14 COMMUNICATION................................................................................................. 20

6.15 HANDLING LOADS OVER PUBLIC ACCESS AREAS AND ADJACENT

BUILDINGS.............................................................................................................. 22

6.16 NON-POSITIVE LIFTING ATTACHMENTS.......................................................... 23

AS 2550.1—2011 4

6.17 INDICATING AND LIMITING DEVICES .............................................................. 23

6.18 RIDING ON THE CRANE STRUCTURE ................................................................ 23

6.19 SUSPENSION OF PERSONS BY CRANE............................................................... 23

6.20 OPERATION NEAR AERIAL CONDUCTORS (OVERHEAD POWERLINES) .... 25

6.21 UNDERGROUND CONDUCTOR CONTACT ........................................................ 29

6.22 SPECIAL DUTIES .................................................................................................... 30

6.23 WEATHER CONDITIONS....................................................................................... 31

6.24 INCIDENT OR DAMAGE........................................................................................ 31

6.25 MODIFICATIONS TO CRANES ............................................................................. 32

6.26 FIRE EXTINGUISHER............................................................................................. 32

6.27 DESIGNED LIFTS.................................................................................................... 32

6.28 MULTIPLE HOIST OR CRANE OPERATION ....................................................... 33

6.29 MANUALS ............................................................................................................... 35

6.30 VESSEL-MOUNTED CRANES ............................................................................... 36

SECTION 7 MAINTENANCE, INSPECTION AND REPAIR

7.1 GENERAL ................................................................................................................ 39

7.2 MAINTENANCE ...................................................................................................... 40

7.3 INSPECTION............................................................................................................ 40

7.4 REPAIRS................................................................................................................... 43

7.5 RECORDS................................................................................................................. 45

SECTION 8 INSPECTION OF ROPES, HOOKS AND LIFTING GEAR

8.1 ROPES ...................................................................................................................... 46

8.2 HOOKS AND HOOK BLOCKS ............................................................................... 47

8.3 LIFTING GEAR........................................................................................................ 48

SECTION 9 MAJOR ASSESSMENT FOR CONTINUED USE OR CHANGED

OPERATION

9.1 GENERAL ................................................................................................................ 49

9.2 RECORDING OF CRANE OPERATION................................................................. 49

9.3 ASSESSMENT OF DESIGN WORKING PERIOD.................................................. 50

9.4 MAJOR ASSESSMENT............................................................................................ 51

9.5 GENERAL OVERHAUL .......................................................................................... 52

9.6 DWP CALCULATION FOR CRANES..................................................................... 52

9.7 DWP CALCULATION FOR HOISTING MECHANISMS....................................... 55

APPENDICES

A STANDARDS FOR COMPONENTS USED IN LIFTING GEAR............................ 58

B EXAMPLE OF INSPECTION AND TESTING CERTIFICATE .............................. 60

C LICENCES TO PERFORM HIGH RISK WORK ..................................................... 65

D GUIDANCE FOR DESIGNED LIFTS ...................................................................... 66

E SAFE WORK PROCEDURES FOR THE MAINTENANCE AND THE

INSPECTION OF CRANES...................................................................................... 68

F RECOMMENDED MINIMUM MAINTENANCE AND INSPECTION

REQUIREMENTS FOR CRANES............................................................................ 70

G CHECKLIST TO DETERMINE SUITABILITY OF MANUFACTURER’S

INSTRUCTIONS ...................................................................................................... 71

H CRANE SERVICE RECORD (LOGBOOK) FORMAT............................................ 74

I USE OF EARTHMOVING EQUIMENT AS A CRANE .......................................... 76

5 AS 2550.1—2011

www.standards.org.au © Standards Australia

STANDARDS AUSTRALIA

Australian Standard



S E C T I O N 1 S C O P E A N D G E N E R A L

1.1 SCOPE

This Standard specifies general requirements for the safe use of cranes, hoists and winches.

NOTES:

1 Requirements applicable to particular types of cranes are specified in the specific parts of

AS 2550.

2 Requirements that are common to two or more types of cranes are contained in this Standard;

therefore, some requirements contained herein do not apply to all types of cranes.

1.2 APPLICATION

The requirements given in other parts of AS 2550 shall take precedence over the

corresponding requirements of this Standard.

Where earthmoving equipment is to be used as a crane, the requirements in Appendix I

shall apply.

Where this Standard uses the word ‘crane’ it shall be taken to mean ‘hoist’, ‘winch’ or

components as defined in AS 2549.

1.3 REFERENCED DOCUMENTS

The following documents are referred to in this Standard:

NOTE: A list of Australian Standards relevant to lifting gear is given in Appendix A.

AS

1318 Use of colour for the marking of physical hazards and the identification of

certain equipment in industry

1418 Cranes, hoists and winches (all Parts)

2076 Wire-rope grips for non-lifting applications

2549 Cranes (including hoists and winches)—Glossary of terms

2550 Cranes, hoists and winches—Safe use (all Parts)

2759 Steel wire rope—Use, operation and maintenance

4991 Lifting devices

AS/NZS

1554 Structural steel welding

1554.4 Part 4: Welding of high strength quenched and tempered steels

1891 Industrial fall-arrest systems and devices

1891.1 Part 1: Harnesses and ancillary equipment

3000 Electrical installations (known as the Australian/New Zealand Wiring Rules)

AS 2550.1—2011

© Standards Australia www.standards.org.au

6

AS/NZS

ISO 31000 Risk management—Principles and guidelines

The National Standard for Licensing Persons Performing High Risk Work (2006)

Website: www.safeworkaustralia.gov.au

1.4 DEFINITIONS

For the purpose of this Standard, the definitions given in AS 2549 and those below apply.

1.4.1 Competent person

A person who has acquired through training, qualification, experience or a combination of

these, the knowledge and skill enabling that person to correctly perform the required task.

1.4.2 Crane standing

The ground surface, temporary support structure, grillage, track, parking, or similar support,

on or from which the crane is supported during operation.

1.4.3 Demolition

The complete or partial dismantling of a building or structure by pre-planned and controlled

methods or procedures.

1.4.4 Designed lifts

An extraordinary and temporary lifting operation requiring an assessment of the design of

the crane, which may require a temporary re-classification or re-rating or a change in the

intended use of the crane.

NOTE: The following are examples of designed lifts:

(a) Some multiple crane lifts.

(b) Lifts where the centre of gravity changes or is difficult to determine.

(c) Lifts for hazardous materials.

(d) Lifts where the load lifted exceeds the published rated capacity of the crane.

1.4.5 Electrical apparatus

Any electrical equipment, including overhead powerlines and cables, the conductors of

which are live or can be made live.

1.4.6 Management

Reference to ‘management’ implies an activity not a line position.

1.4.7 Multiple crane lifts

A lifting operation employing more than one crane.

1.4.8 Multiple hoist lift

A lifting operation performed by two or more hoists, supported on a common structure.

1.4.9 Professional engineer

1 A person registered in a relevant area of practice on the National Professional

Engineers Register.

or

2 Where applicable, a Member of a Scheme established under Professional Standards

Legislation in the relevant jurisdiction.

or

7 AS 2550.1—2011


3 A Chartered Professional Engineer (CPEng).

or

4 Other person providing satisfactory evidence to a responsible authority that they have

the qualifications and experience to be competent to independently perform the

required tasks.

1.4.10 Shall

Indicates that a statement is mandatory for compliance with the objectives and intent of this

Standard.

1.4.11 Should

Indicates a recommendation.

NOTE: Neither following nor ignoring the recommendation results in non-compliance with the

Standard.

1.4.12 Spotter (safety observer)

A person specifically assigned the duty of observing and warning against unsafe approach

of the crane, its lifting attachments or its load, to electrical apparatus.

1.4.13 Synchronized motions

Two or more crane motions under the control of a single command output with

bi-directional communication so that the behaviour of one motion causes identical

behaviour of the others.

1.4.14 Tandem operation

An operating mode where the control of multiple cranes or crane components is from a

common control station.

NOTE: Under tandem operation, crane motions may be synchronized or not synchronized.

1.4.15 Third-party inspection

An inspection carried out by an independent competent person, who is not involved in the

maintenance of the crane.

NOTE: For the purpose of this definition, ‘independent’ means not employed by the same

organization unless that organization uses a quality process that confirms independence.

1.5 INSTRUCTIONS

Instructions shall be prepared, maintained and made readily available to the appropriate

personnel, to ensure the safe use of the crane. Such instructions shall include the

manufacturer’s instructions, recommendations and specifications where available or where

any of these instructions, recommendations and specifications are not available from the

manufacturer or are deemed inappropriate, they shall be drawn up by a competent person.

All instructions shall be not less than those specified in this Standard.

1.6 LEGISLATED RESPONSIBILITY

The reader is referred to the applicable occupational health and safety legislation or work

health and safety legislation for instruction on who is responsible for ensuring that items of

plant are operated in a safe manner.

1.7 COMPETENCY OF PERSONNEL

All activities required to be carried out under this Standard shall be carried out by a

competent person(s).

AS 2550.1—2011


8

1.8 RISK ASSESSMENT

A risk assessment shall be undertaken by a competent person before carrying out the

operation required to be undertaken by the crane. The risk assessment shall address the

proposed operation rather than each individual lift. The assessment shall be in writing and

shall take into account the following:

(a) The task to be carried out.

(b) The range of methods by which the task can be done.

(c) The type of crane that will be required or that can be used.

(d) The hazards involved and the associated risks.

(e) The actual method and the other requisite plant and material.

(f) Emergency and rescue procedures.

As a result of the risk assessment, the competent person shall formulate a safe work method

procedure, which shall be monitored for ongoing effectiveness and modified whenever it is

found to be deficient, when the task changes or when the associated risks change.

NOTE: Guidelines on hazard identification and risk assessment procedures are given in

AS/NZS ISO 31000.

9 AS 2550.1—2011


S E C T I O N 2 P L A N N I N G

2.1 GENERAL

The planning and application of crane requirements should commence as early as possible

in the development of each project. Planning should include consultation with relevant

stakeholders (e.g., the crane manufacturer, proprietor, supplier, operator, designer, importer

and agent).

The suitability of the crane for the operation it is involved in should be assessed by a

competent person when it is planned to change owner or alter the use of a crane.

NOTE: For cranes to be used on construction sites, the planning should include consultation with

the principal contractor and building contractor.

2.2 PLANNING

The following planning activities shall be carried out by a competent person(s) in

consultation with relevant stakeholders:

(a) The selection and safe use of the crane.

(b) The installation of the crane.

(c) Ensuring that the supporting structure is capable of supporting the crane.

(d) Appraising an existing crane for suitability for use.

(e) Adequate competent personnel availability for all tasks.

(f) Suitable equipment availability for the installation, maintenance, operation and

dismantling of the crane.

(g) Condition monitoring of the crane and associated equipment.

(h) The maintenance, inspection and safe operation of the crane and associated

equipment.

(i) The preparation, availability and maintenance of instructions for the assembly,

operation, maintenance and inspection of the crane.

(j) Emergency procedures for the evacuation of personnel from the crane, if applicable.

(k) Procedures to deal with reasonably foreseeable situations.

(l) Procedures to deal with reasonably foreseeable emergencies.

(m) Where cranes are required to operate in or near buildings or structures, consideration

to be given to crane loadings and access at the project design stage.

(n) Where cranes are required to operate in tandem, the following shall be considered:

(i) Operator controls.

(ii) Synchronization of crane controls.

(iii) Load handling attachment.

NOTE: The results and, where appropriate, the reasoning behind the decisions should be

documented.

AS 2550.1—2011


10

2.3 MATTERS TO BE CONSIDERED

At appropriate stages during planning, the following matters shall be considered, where

applicable:

(a) Establishment of a management plan.

(b) Selection of cranes.

(c) Lightning protection.

(d) Appropriate earthing for the conditions; for example, static electricity build-up due to

electromagnetic radiation (EMR), wind.

(e) Site access and crane siting.

(f) Safety of personnel.

(g) Protection and safety of public.

(h) Proximity of above- and below-ground services (e.g., power, gas, water).

(i) Procedures for the setting up of the crane.

(j) Procedures for lifting operations.

(k) Procedures for the dismantling of the crane.

(l) Selection of the personnel.

(m) Communication system(s).

(n) Weather conditions (e.g., anticipated wind speeds, rainfall and temperature range).

(o) Ground conditions.

(p) Proximity of excavations.

(q) Selection of lifting gear considering the size, type and condition of slings appropriate

for the load.

NOTE: Appendix A lists Standards for components that are used in lifting system.

(r) Personal protective equipment.

(s) Emergency procedures.

(t) The documentation of work procedures where the lifting operation is not of a routine

type (e.g., multiple crane lifting).

(u) Consultation and coordination with other groups working in the area.

(v) Night operations.

(w) Parking/storage facilities.

(x) Marking on crane and ancillary equipment (e.g., rated capacity, safety signs).

(y) Access for servicing.

(z) Interface with structures, plant and vehicles.

(aa) Obtaining any approvals or licences from statutory authorities or other relevant

parties.

11 AS 2550.1—2011


S E C T I O N 3 S E L E C T I O N

Before selecting a crane for a particular application, all relevant information shall be

obtained and all relevant operational criteria shall be determined, which shall include, as a

minimum, the following:

(a) The result of an appraisal of an existing crane, if applicable.

(b) The maximum permitted forces on the supporting structure.

(c) Power supply.

(d) Rated capacity of the crane.

(e) Classification of the crane taking into account the application, including—

(i) type of loads to be lifted;

(ii) mass of loads to be lifted;

(iii) speed of lifts; and

(iv) frequency of lifts.

(f) The maximum load that will be imposed on the crane.

(g) The maximum load moment that will be imposed on the crane.

(h) The nature of the rigging or slinging to be used.

(i) The position from which the load is to be lifted.

(j) The position in which the load is to be placed.

(k) The movement limitations of the crane and the load.

(l) Other limitations of the crane.

(m) Multiple crane lifting.

(n) Working environment that includes hazardous gases, corrosive atmospheres and high

ambient temperatures including full speed operation against in-service wind load.

(o) Projected upgrades or applications of plant that are likely to impact on the crane.

(p) The provision of a crane with a larger capacity to cater, where necessary, for changes

in the site environment (for example, increases in lifted load mass due to

manufacturing tolerances and rapid changes in weather conditions).

(q) The access to conduct regular maintenance or repair on equipment.

AS 2550.1—2011


12

S E C T I O N 4 S I T I N G

4.1 GENERAL

Consideration shall be given to the following factors:

(a) Crane standing (see Clause 4.2).

(b) Proximity hazards and visibility (see Clause 4.3).

(c) Environmental factors, e.g., noise and noxious fumes (see Clause 4.4).

(d) Clearances (see Clause 4.5).

4.2 CRANE STANDING

4.2.1 General

A competent person shall ensure that the loads imposed by the crane can be sustained by the

ground or any other means of support.

The loads imposed by the crane whilst in service, out of service and during erection and

dismantling shall be obtained from the crane manufacturer or a competent person. The

loadings shall include the combined effects of the following:

(a) Deadweight of the crane (including any counterweight, ballasting or foundation

where appropriate).

(b) Deadweight of the load(s) and any lifting attachment(s).

(c) Dynamic forces caused by movements of the crane.

(d) Wind loadings resulting from wind speeds up to the maximum permitted, taking into

account the degree of the exposure of the site.

A competent person shall ensure that the ground or means of support is such that the crane

can operate within the levels and other parameters specified by the manufacturer.

Loads shall not be imposed on any new concrete supporting structure until the structure has

reached sufficient strength.

4.2.2 Wind load

All aspects of wind loading, both in and out of service, on the crane standing due to

location, shall be taken into account, including the increased wind loads caused by

funnelling effects between adjacent buildings or structures.

NOTE: Wind loads may be affected by a change in the physical features of a crane’s location,

such as the erection or demolition of a building.

4.2.3 Underground services

The site shall be checked for the presence of underground services, ducts and similar

services. Where the check reveals the existence of underground services, precautions shall

be taken to ensure the stability of the crane, crane standing and integrity of the services.

4.2.4 Stability of crane standing

Where a crane is required to work in the vicinity of an excavation or an embankment, the

possibility of slip or collapse of the supporting surface shall be evaluated by a competent

person. Where necessary, the excavation or embankment shall be reinforced.

13 AS 2550.1—2011


4.3 PROXIMITY HAZARDS AND VISIBILITY

4.3.1 Proximity hazards

Consideration shall be given to the presence of proximity hazards including, but not limited

to, the following:

(a) Overhead powerlines (see Clause 6.20).

(b) Nearby structures or other cranes.

(c) Excavations.

(d) Fixed hazards.

(e) Personnel movement within the crane working area.

(f) Mobile equipment and vehicular movement within the crane working area.

(g) Public access areas including roadways, railways, rivers and aircraft flight paths.

(h) The effects of electromagnetic radiation (EMR) (e.g., busbars, strobe lights, induction

furnaces, welding) on radio, infra-red or electronic controls.

(i) Temporary installations or those installed after the crane (e.g., tilt-up bracing).

(j) The vicinity of airfields (applicable to operating high cranes).

4.3.2 Visibility

The crane should be sited in such a way that the crane operator has optimum visibility.

4.4 ENVIRONMENTAL RESTRICTIONS

Precautions should be taken against the effects of noise, exhaust gases, hydraulic fluids,

lubricants, fuel, dust and other environmental pollutants emitted by the crane.

4.5 CLEARANCES

Where two or more cranes are to work within a site, or share the same airspace, procedures

shall be established to prevent unplanned contact between parts of the cranes. Agreement

shall be reached on adjoining sites.

Clearances as set out in the applicable Part of AS 1418 or AS 2550 shall be maintained.

AS 2550.1—2011


14

S E C T I O N 5 E R E C T I O N , C O M M I S S I O N I N G

A N D D I S M A N T L I N G

5.1 IDENTIFICATION OF CRANE COMPONENTS

Where there may be confusion as to their location or orientation, components of cranes

subject to frequent erection and dismantling shall be clearly marked to prevent incorrect site

assembly. Any component with a mass greater than 250 kg should be marked with its mass.

The materials of construction of the major components and special fasteners involved in site

assembly should be recorded. This information should be marked on the components.

5.2 ERECTION, COMMISSIONING AND DISMANTLING INSTRUCTIONS

Instructions regarding erection, commissioning and dismantling shall be made available to

all relevant personnel on site in a written procedure. The following shall apply:

(a) Erection, commissioning and dismantling operations shall be supervised by a

competent person.

(b) Transport and stowing shall be in accordance with manufacturer’s instructions.

(c) The prescribed procedures for the assembly of components shall be followed in the

correct sequence, using the correct equipment and tools.

(d) Only parts and components meeting the manufacturer’s performance and strength

requirements shall be used.

(e) Jointing pins shall be assembled so that they can be removed by a person standing on

the outside of the assembly.

5.3 ELECTRICAL SUPPLY

Installation of the electrical supply shall be in accordance with AS/NZS 3000 and the

applicable parts of AS 1418.

5.4 COMMISSIONING

5.4.1 General

Commissioning shall be carried out in accordance with the written procedure required by

Clause 5.2.

5.4.2 Correct function of safety devices

Load moment systems, overload cut-outs or motion limit switches bypassed or disconnected

during erection shall be reinstated and tested in accordance with the written procedure

before the crane is put into operation.

5.5 SAFEGUARDING THE CRANE

Where there is a risk of adverse impact by mobile plant or vehicles, means shall be

provided to protect the crane.

Where required, aircraft warning lights shall be fitted to the highest part of the crane, and

the jib and boom sections shall be painted in high visibility colours in accordance with

AS 1318.

15 AS 2550.1—2011


S E C T I O N 6 O P E R A T I O N

6.1 OPERATIONAL INSTRUCTIONS

6.1.1 General

Operating instructions shall be established in relation to the operation of the crane. Such

instructions shall detail practices that shall be followed to help overcome hazards and

potential risks identified in a risk assessment and shall be issued to all crane operators.

The instructions shall give directions on all applicable operating procedures, as detailed in

this Standard, and any other identified directions.

6.1.2 Hazard identification

A hazard identification shall be performed.

NOTE: Guidance on risk management is given in AS/NZS ISO 31000.

6.1.3 Operating instructions

As a minimum, the operating instructions shall be the following:

(a) Pre-operational inspections shall be carried out by the designated person at the

beginning of each working shift in accordance with the pre-operational checklist.

(b) Where pre-operational inspections reveal a safety malfunction or potential risk, the

crane shall not be put in service until the risk has been assessed by a competent

person and the appropriate action recorded and carried out.

(c) All malfunctions and identified potential risks shall be reported and properly recorded

for assessment by a competent person and acted upon as appropriate.

(d) Cranes that are not in a safe condition shall be removed immediately from service and

shall remain out of service until repaired.

(e) The operational area shall be checked for hazards prior to and during each work shift.

(f) For remotely operated cranes, the load shall be constantly in view of either the

operator or a competent person who shall be able to relay the position of the load to

the operator at all times.

(g) Unnecessary operation of the crane motion limits shall be avoided.

(h) Cranes shall be left in a safe condition. Before the operator leaves a cabin-operated

crane, the crane shall be positioned at the designated parking place and all the crane

motions disabled against unauthorized operation.

(i) In the event of the operator becoming incapacitated through injury or illness and

unable to continue crane-operating duties, the crane shall be stopped, the operator

removed from the operational area and the fact reported to a responsible person.

An assessment shall be conducted by a competent person or persons to determine

whether the injury or illness was caused by the crane; the crane shall not be returned

to service until it has either been assessed as fit for service or made fit for service. All

crane motions shall be disabled until the crane has been assessed as suitable for

service and a replacement operator is available.

NOTE: It may be necessary to move the crane to an access point to allow the operator to

leave the crane, or to execute the emergency evacuation procedures.

AS 2550.1—2011


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6.2 CRANE OPERATION MANAGEMENT

The following requirements apply to the operation of the crane:

(a) The crane shall be operated within the rated capacity and design classification.

(b) Only authorized competent personnel that have the necessary physical, health and

other attributes to undertake the tasks assigned to them shall be involved in the

operation, inspection and maintenance of the crane.

(c) The crane shall be transported to site and erected in accordance with applicable

instructions that have been drawn up in accordance with this Standard.

(d) The crane shall not be put into operational service until it has been commissioned in

accordance with the requirements of the applicable Part of AS 1418. The initial

operation shall only take place after the sighting of an inspection and testing record

signed by a competent person.

NOTES:

1 A manufacturer may specify additional commissioning requirements.

2 Appendix B provides notes and general guidance on this subject, together with a typical

inspection and testing certificate format.

(e) Lifting equipment including the hook block, lifting beams and attachments shall be

appropriately marked in accordance with the applicable Australian Standard.

(f) The power supply shall be compatible with the requirements of the crane.

(g) Operators shall be fully trained and shall be certificated as required by the applicable

regulatory authority, to ensure that they have achieved the required competencies in

all aspects of the crane’s operation and sufficient understanding of the operating

instructions and emergency procedures.

NOTE: For a list of National Certificates of Competency, see Appendix C.

(h) Instructions applicable to the operation of the crane shall be provided to operators;

this may include manuals where applicable.

(i) All guarding shall be in place.

(j) Notices applicable to the various specified operating configurations of the crane shall

be readily accessible to the operator at all times.

(k) Access onto and egress from the crane shall only be at designated positions unless the

crane is in a breakdown situation. A procedure shall be developed to allow safe

access to the crane where the crane is at a location other than its designated service

position.

(l) A clear and defined pathway for the operators of cranes controlled by pendant or

wireless control shall be provided and maintained.

(m) Sufficient competent persons shall be available to assist the crane operator as

required.

(n) Procedures shall be established to deal with reasonably foreseeable emergency

situations and all operators shall be fully trained in their application.

(o) Inspections, maintenance and repairs shall be carried out in conformance with the

requirements of Section 7 of this Standard.

(p) Records shall be maintained and retained in accordance with Clause 7.5.

(q) Appropriate personal protective equipment shall be provided and personnel shall be

instructed in the use of such equipment.

(r) Personnel shall not be under the effect of drugs, including alcohol, that adversely

affect their performance.

17 AS 2550.1—2011


(s) Manufacturer’s safety bulletins shall be implemented.

(t) When out of service, external cranes shall be secured in accordance with Clause 6.6.

6.3 COMPLIANCE WITH INSTRUCTIONS

The crane shall be used in compliance with the instructions written in accordance with this

Standard.

6.4 COMMUNICATION OF IRREGULARITIES

Details of any irregularities in the operation of the crane, including any abnormal noise or

movement, and any incidents shall be communicated to the responsible person and recorded

in the crane service record (logbook).

6.5 LEAVING THE CRANE UNATTENDED

A manually controlled or semi-automatically operated crane shall not be left unattended

unless the following actions, where applicable, have been taken:

(a) All payloads shall be removed from the hook or lifting device.

(b) The hook shall be raised to a position where it is clear of obstructions or trafficable

areas, or hooked back or otherwise appropriately secured.

(c) All powered motions shall be disabled.

Means shall be provided and used to prevent unauthorized operation of the crane during the

crane operator’s absence.

NOTE: For details of methods to safeguard particular types of cranes, reference should be made

to the operating instructions.

6.6 OUT OF SERVICE

When putting a crane into the out-of-service condition, it shall be isolated in accordance

with Clause 6.5 and as follows:

(a) Cranes shall be positioned at their assigned parking stations and stowed in their

specific out-of-service configuration.

(b) Power supply shall be locked off.

(c) Where fitted, storm anchors shall be engaged.

(d) The engine shall be stopped and fuel supplies shall be turned off, where applicable.

(e) All doors and windows giving access to machinery or control cabins shall be locked

to prevent unauthorized access.

(f) Remote control equipment shall be isolated with locking key removed, where

applicable.

(g) Isolation and ignition keys shall be removed to prevent unauthorized operation.

6.7 HOUSEKEEPING

Housekeeping requirements are as follows:

(a) Each crane shall be kept clean.

(b) Loose objects shall not be left on any area of the crane from which they could fall

(e.g., moving parts, access, areas subject to vibrations or mechanical shocks).

AS 2550.1—2011


18

(c) Grease and oil spills, debris and other materials that could cause a hazard shall be

removed from the crane and associated walkways, stairways, platforms, ladders,

working areas and access areas.

(d) Hazardous substances (e.g., fuel) shall be stored safely.

NOTE: Regulations apply to the safe storage of hazardous substances.

(e) Tools or other loose objects shall be stowed in receptacles specially provided for the

purpose, or they shall be securely stowed.

6.8 CRANE ACCESS AND EGRESS

6.8.1 General

Access to and egress from a crane shall be by the means provided, such as the crane

operator access, the inspection access and the maintenance access as defined in the

applicable Part of AS 1418. The means of access/egress shall be properly designated.

Access to and egress from a crane shall be made only when the crane is stationary.

Where the crane is under the control of a crane operator, the crane operator shall be notified

before any person gains access to or egress from the crane.

6.8.2 Emergency egress

A procedure for the emergency egress of personnel from a crane shall be established.

NOTE: Consideration should be given to the installation of a communications system for use

during emergency egress.

6.8.3 Maintenance, commissioning, erection or dismantling

Access and egress shall be provided during maintenance, commissioning, erection or

dismantling at heights.

6.9 PERSONS APPROACHING THE PROXIMITY OF A CRANE

Personnel should not approach a crane when it is operating or travelling as there is a danger

that they may be struck by the crane or load, or trapped between fixed and moving parts of

the crane (for example, between the slewing superstructure and the non-rotating structure of

the crane).

Where personnel are required to enter a crane’s operating area during normal operations,

the operator shall be made aware of their presence (for example, establishing voice or

visual contact).

Barricades or guarding shall be provided where necessary.

6.10 CRANE OPERATION

6.10.1 General

Crane operation shall be subject to the following conditions:

(a) The rated capacity of the crane shall not be exceeded except for the express purpose

of a test of the crane under the supervision of a competent person, or for a designed

lift.

(b) The crane operator shall be familiar with the location and operation of the main

isolating switch.

(c) The crane operator shall be familiar with the emergency procedures.

(d) The crane operator shall be familiar with the location and operation of the firefighting

equipment.

19 AS 2550.1—2011


(e) Sudden stops, jerks or other movements that could cause the load to swing unduly

shall be avoided.

(f) The hook or load shall not be moved when the hook or load is out of sight of the

operator except when directed to do so by the competent person assisting the

operator.

(g) The hook or load shall be sufficiently raised to avoid collision with any object during

horizontal movement.

(h) Out of vertical hoisting shall not be undertaken.

(i) Moving the load, lifting attachment or other object horizontally, other than when the

load is freely suspended from the crane, shall be avoided.

(j) Unnecessary engaging of the crane, or part of the crane, with end stops shall be

avoided.

(k) The signals or directions given by the authorized person shall be followed, unless a

dangerous situation would be created by so doing in which case no movement shall be

undertaken.

(l) When loads have to be handled in the vicinity of persons—

(i) the crane operator shall be alert to the possibility of persons being trapped and

injured by the movement of the crane or load and exercise due caution; and

(ii) where the person controlling the load, or others persons, could be trapped, the

crane or load shall not be moved unless their safety is assured.

(m) Slack rope shall be avoided when landing a load.

(n) When out of service, the crane shall be positioned in its normal parking position.

When a crane is controlled by pendent or wireless control, the operator should have good

visibility of the load, to ensure that safe handling takes place. Where this is not possible, a

competent person shall be engaged to relay the position of the load to the operator at all

times during the lift, and shall communicate with the operator to ensure safe operation.

Provision shall be made for the security of the remote control transmitter against

unauthorized use.

6.10.2 Hoisting of loads

The crane shall not handle any load greater than the rated capacity applicable to the

configuration of crane and manner of loading or any load that may create an unsafe

situation.

The load shall be raised a short distance to test the winching system before continuing to

raise the load in the following situations:

(a) For the first load of each working shift.

(b) For the first load of each working shift that is greater than 50% of the rated capacity.

6.10.3 Use of motion limits

Unnecessary operation of motion limits shall be avoided unless such usage is to a functional

limit where a final limit is fitted.

6.10.4 Interruption of electric power supply

If the crane is handling a load when the power supply is interrupted and the load is in a

position likely to cause a hazard, where manual lowering capability is provided, the load

should be lowered manually to a safe position (e.g., floor level).

AS 2550.1—2011


20

6.11 LOAD SECURITY

Any load shall be adequately protected so that it cannot inadvertently fall when being lifted.

To ensure loading security, the following shall apply:

(a) The slings shall be suitable for the application.

(b) All slings shall be used in accordance with manufacturers’ instructions.

(c) The slings shall be correctly attached to the load and to the crane hook.

(d) Basket hitches shall not to be used wherever persons may be located near a lifted

load, unless the sling is positively restrained from sliding and the load is secured in

the sling.

(e) Where required, suitable protection shall be provided to prevent damage to the sling

or load.

NOTE: A list of Australian Standards relevant to lifting gear is given in Appendix A.

6.12 CONTROL OF LOAD

Where a load is hoisted under the direction of a competent person other than the crane

operator, that person shall direct the crane operator from the time the load is hoisted until it

is placed in position. The competent person shall ensure that the load clears all obstructions

and, where necessary, shall guide the load by an appropriate means, e.g., tag line

(see Clause 6.13).

Where a load is being controlled by more than one competent person, only one person shall

issue instructions to the crane operator and to the other competent person(s).

Before signalling the crane operator to raise a load, the competent person assisting the

operator shall ensure that—

(a) the slings are correctly applied to the load and to the crane hook (see Clause 6.11);

(b) the slings shall be rigged to prevent sliding;

(c) no part of the load is loose;

(d) the load is free and ready for hoisting;

(e) when hoisted, the load will not foul any object;

(f) when hoisted, the load will not constitute a hazard to any personnel; and

(g) the load placement area is ready to receive the load.

6.13 TAG LINES

When used, hand or tag lines shall be at least 16 mm in diameter and be made of

non-conductive material. Tag lines shall be maintained clean and dry and shall be assessed

before use. Lifting gear should not be used as tag lines. Taglines shall not be attached to the

lifting gear.

6.14 COMMUNICATION

6.14.1 General

Where communication is required between the operator and other personnel, a reliable and

efficient method of communication shall be established.

6.14.2 Hand signals

Hand signals should be as shown in Figure 6.14.

21 AS 2550.1—2011


6.14.3 Bell, buzzer and whistle signals

Bell, buzzer and whistle signals used should be as shown in Figure 6.14.

The bell or buzzer shall be located in a position where it can be readily heard by the crane

operator while at the control position.

If two or more cranes are operating in close proximity, the tones of each bell, buzzer or

whistle employed for the cranes shall be clearly distinguishable.

6.14.4 Radio communication

Where radio communication is used, the transmitting frequencies of the radio equipment

shall be selected to prevent interference to or from other radio equipment being used in the

vicinity of the crane.

Communicated instructions shall specify the motion first followed by the action.

AS 2550.1—2011


22

MOTION HAND SIGNAL

WHISTLE, BELL OR BUZZER SIGNAL

MOTION HAND SIGNAL

WHISTLE, BELL OR BUZZER SIGNAL

Hoisting raise

2 short • •

Hoisting lower

1 long —

Luffing boom up

3 short • • •

Luffing boom down

4 short • • • •

Slewing right

1 long, 2 short — • •

Slewing left

1 long, 1 short

— •

Jib-trolley out:

telescoping boom extend

1 long, 3 short — • • •

Jib-trolley in:

telescopingboom retract

1 long, 4 short

— • • • •

Travel and

traverse

Not applicable

STOP

1 short •

CREEP SPEED: APPROPRIATE HAND SIGNAL FOR MOTION WITH HAND OPENING AND CLOSING

FIGURE 6.14 SIGNALS

6.15 HANDLING LOADS OVER PUBLIC ACCESS AREAS AND ADJACENT

BUILDINGS

The handling of loads over highways, railways, rivers, adjacent buildings or other places to

which the public have access should be avoided. Where this is not possible, barricades shall

be positioned and maintained a sufficient distance around the operating area beneath the

crane to prevent people encroaching on that area. Alternatively, suitable overhead

protection shall be provided during the operation.

23 AS 2550.1—2011


6.16 NON-POSITIVE LIFTING ATTACHMENTS

Where loads are suspended by non-positive lifting attachments (e.g., magnetic, vacuum or

friction lifting attachments), personnel should be excluded from all areas that could be

affected by a falling load.

Where it is not possible to isolate personnel from the operation area of cranes fitted with

non-positive lifting devices, operational procedures shall be developed to prohibit personnel

working in the hazardous area; that is the area where personnel may be injured as a result of

failure of the lifting attachment.

The non-positive lifting device shall be sized to provide an adequate design factor on its

nominal rated capacity, taking into account the size, shape and mass of the lifted load.

6.17 INDICATING AND LIMITING DEVICES

Where indicating and limiting devices are provided, they shall not be switched off or made

dysfunctional during crane operation, except for—

(a) designed lifts in accordance with Clause 6.27; or

(b) testing and commissioning; or

(c) where the crane manufacturer has specified instructions for avoiding indicating and

limiting devices for specific operations.

6.18 RIDING ON THE CRANE STRUCTURE

Except for inspection, maintenance, commissioning, erection or dismantling purposes, only

those personnel correctly accommodated in the cabin or on the work platform shall be

permitted on the crane when it is operating. Personnel shall only ride on the crane structure

as necessary for inspection, maintenance, commissioning, erection or dismantling purposes.

A written procedure for riding on the crane structure shall be provided.

6.19 SUSPENSION OF PERSONS BY CRANE

6.19.1 General

A person shall only be suspended from a crane hook when accommodated in a workbox

designed for the purpose in accordance with AS 1418.17.

The use of the workbox shall be limited to those situations where it is necessary to elevate

personnel to carry out work where it is not reasonably practicable to use scaffolding or

equipment designed specifically to lift personnel.

6.19.2 Requirements for the crane used with a workbox

A crane used with a workbox shall—

(a) be fitted with a safety hook or moused accessory;

(b) be equipped with controls that return to the neutral position when released and this

action causes the motion to stop;

(c) be equipped with power lowering;

(d) be equipped with a positive free fall lockout control so that inadvertent

disengagement of the lockout is not possible;

(e) be fitted with an upper limit motion limiting device;

(f) be fitted with a down-limit motion limiting device, if the workbox is to be lowered

below the crane supporting surface;

(g) be such that at the maximum radius of the task to be performed, the crane has a

minimum rated capacity of 1000 kg; and

AS 2550.1—2011


24

(h) be such that, when the jib or boom of the crane is at its maximum radius for the task

to be performed, the rated capacity for the crane in this condition, when divided by 2,

is equal to or greater than the total load of the workbox and its contents.

6.19.3 Operation of the crane with suspended personnel

When personnel are suspended from a crane, the following requirements apply:

(a) The rated capacity of the workbox shall not be exceeded.

(b) The workbox and lifting attachments and records shall be inspected by a competent

person, prior to use.

(c) Personnel and materials shall be securely confined within the workbox.

(d) The workbox shall only be used to lift personnel and materials necessary to carry out

the work.

(e) The crane shall not be used to simultaneously raise, lower or suspend any other load.

(f) An appropriate work procedure shall be developed and implemented to transfer any

work materials from the workbox.

(g) The crane operator shall remain at the controls of the crane.

(h) All movements of the crane shall be carried out under power and free fall lockout

shall have been applied.

(i) Effective means of communication between any person in the workbox and the

operator shall be established.

(j) Mobile cranes shall not travel while people are in the workbox.

(k) Movements of the workbox shall be at slow speeds with minimum acceleration and

deceleration.

(l) The workbox shall not be secured to any structure except at designated landing(s).

NOTE: Workboxes should not be used in winds in excess of 7 m/s (25 km/h), electrical

storms, snow, ice, sleet or other adverse weather conditions that could affect the safety of

personnel.

(m) Flammable liquids, oxygen and acetylene cylinders, and similar flammable liquids,

shall be correctly secured and housed in a separate compartment from the personnel.

No more than the minimum quantities, sufficient to carry out the work, shall be

carried. Where flammable liquids are carried, a suitable fire extinguisher shall also be

carried.

(n) Personnel suspended from a crane shall wear a fall-arrest harness complying with

AS/NZS 1891.1, with the lanyard attached to a fall-arrest anchorage point.

(o) Personnel shall not enter or leave the workbox when elevated (except in an

emergency), unless each of the following conditions are met:

(i) A risk assessment has been completed that identifies that access and egress

from the workbox in this manner is safe, and that this means of access is safer

than all other alternative means.

(ii) The structural adequacy of the landing area has been established and the

landing area is clear.

(iii) Where the landing is at the edge of a structure, the maximum gap between the

workbox and landing does not exceed 100 mm, the workbox is secured to a

suitable point on the landing and access and egress does not take place unless a

fall-arrest harness is properly worn and attached to a suitable anchorage on the

structure.

25 AS 2550.1—2011


6.20 OPERATION NEAR AERIAL CONDUCTORS (OVERHEAD POWERLINES)

6.20.1 General

This Clause refers to hazards and risks presented by the set-up and operation of cranes in

the vicinity of overhead electrical conductors.

NOTES:

1 Various regulatory bodies in a number of States have issued codes of practice or industry

guidelines for the safe operation of cranes near overhead powerlines.

2 A conservative approach has been adopted. Separation distances have not been chosen based

purely on electrical voltages of conductors, nor whether the conductor is bare or insulated.

The distances were chosen based on experience and practical considerations, since cranes

cannot be operated as accurately as arcing distances can be calculated.

Before operating a crane from the stowed condition, a check for the presence of overhead

conductors and powerlines shall be undertaken.

Throughout this Clause, the following definitions apply:

(a) Aerial conductor—an overhead conductor that is either insulated or bare.

(b) Crane—includes crane, crane attachments (e.g., ropes and lifting beams) and the

crane load.

(c) Operation—where any crane components are moved or about to be moved from their

stowed position and in the instance of cranes having stabilizers, where stabilizers are

moved or about to be moved from their stowed position.

(d) Overhead powerline—aerial conductors and other parts that make up an aerial line for

the distribution and transmission of electrical energy.

(e) Electricity distributor—the power supply authority, transmission line operator,

generator, traction company or distribution company.

All aerial conductors shall be treated as ‘alive’ unless the crane operator has received from

the electricity distributor, or transmission line operator, documentary evidence that the

conductors have been positively de-energized, isolated and earthed.

Where such documentary evidence has been made available, it shall state the date and time

frame of isolation and any special conditions and precautions. The crane shall not be

operated in contravention of this documentary information.

6.20.2 Precautions when operating near live aerial conductors

The crane shall only be operated within close proximity of live aerial conductors if the

separation distances appropriate to the ‘no go zone’ or ‘spotter required zone’ and risk

controls given in Clause 6.20.3 are maintained.

A documented site-specific risk assessment shall be completed before the commencement

of the job by a trained and competent person. This assessment shall be verified immediately

before work commences, and its relevance monitored during the job. If initial associated

circumstances change, work shall cease until an appropriate risk assessment is undertaken.

Where a spotter is required to inform the operator in the event of the crane approaching the

zone boundaries shown, the following applies:

(a) The spotting operation shall be carried out by a competent person.

NOTE: Required competency levels may be defined by the Office of the Chief Electrical

Inspector or similar body in the applicable State.

(b) The spotter shall be positioned so as to minimize the risk of exposure to hazards.

(c) The spotter shall be able to clearly observe the separation distances.

(d) The spotter shall not undertake any other work whilst performing spotting duties.

AS 2550.1—2011


26

(e) The spotter shall be specifically instructed in the workplace hazards applicable to the

site.

(f) The spotter shall be able to communicate with the crane operator at all times during

erection, operation and dismantling.

6.20.3 Separation distances and risk controls

Where possible, the zone separation distances shall be not less than those shown in

Figure 6.20.3.

NOTE: The separation distances shown in Figure 6.20.3 include allowance for sag and sway of

line(s) due to the effects of wind and temperature.

Where the separation distances cannot be achieved, the electricity distributor shall be

notified in writing. The crane shall not be operated within the ‘no go zone’ until the

applicable requirements below are satisfied.

The separation distance between the crane and aerial conductor and risk controls when

operating in the vicinity of aerial conductors shall comply with the following:

(a) Overhead powerlines (up to and including 132 kV) The following applies:

(i) No go zone The crane shall not be operated in the ‘no go zone’ as indicated in

Figure 6.20.3 for overhead powerlines up to and including 132 kV, unless—

(A) written permission from the electricity distributor has been obtained;

(B) all conditions specified by the electricity distributor are complied with;

(C) the electricity distributor is notified before commencing work;

(D) a spotter performs spotting duties; and

(E) a pre-start site/job meeting has been convened and a risk assessment

completed.

(ii) Spotter required zone The crane shall not be operated in the ‘spotter required

zone’ as indicated in Figure 6.20.3 for overhead powerlines up to and including

132 kV, unless—


(B) a spotter performs spotting duties; and

(C) a pre-start site/job meeting has been convened and a risk assessment

completed.

(b) Overhead powerlines (greater than 132 kV) The following applies:

(i) No go zone The crane shall not be operated in the ‘no go zone’ as indicated in

Figure 6.20.3 for overhead powerlines greater than 132 kV, unless—

(A) an easement entry permit has been provided by the electricity distributor;

(B) written permission from the electricity distributor has been obtained;

(C) all conditions specified by the electricity distributor are complied with;

(D) the electricity distributor is notified before commencing work;

(E) a spotter performs spotting duties; and

(F) a pre-start site/job meeting has been convened and a risk assessment

completed.

27 AS 2550.1—2011


(ii) Spotter required zone The crane shall not be operated in the ‘spotter required

zone’ as indicated in Figure 6.20.3 for overhead powerlines greater than

132 kV, unless—


(B) an easement entry permit has been provided by the electricity distributor;

(C) a spotter performs spotting duties; and

(D) a pre-start site/job meeting has been convened and a risk assessment

completed.

(c) Public transport authorities Where aerial conductors are dedicated to the use of

public transport authorities (e.g., tramways and railways), the separation distance

shall be the same as that for aerial conductors up to and including 132 kV [see

Item (a)].

(d) Downshop conductors Before mobile machinery is set up for operation in the

vicinity of downshop conductors, the power supply to the conductors shall be isolated

prior to operation unless appropriate control measures have been developed and

implemented.

NOTES:

1 Downshop conductors (e.g., collector rails), should be clearly identified.

2 Clearances from downshop conductors should be in accordance with AS/NZS 3000.

(e) Barriers at ground level Where people not involved in the lifting operation could

otherwise come into the area of possible voltage step potential, barriers shall be

provided at ground level to prevent this from occurring. Appropriate warning signs

shall be displayed on the barriers. Pedestrians should be barricaded from the area of

possible voltage step potential (see Figure 6.20.4) in the vicinity of the crane and

associated equipment.

(f) Person to crane contact Only the crane operator shall be in contact with any part of

the crane during operation. If the load needs to be steadied during lifting, a

non-conducting tag line shall be used. All persons involved in the crane operation in

contact with the ground shall be provided with appropriate means of insulation from

the ground.

NOTE: In many instances, more than one dogger may be required to handle tag lines located

to apply counter-reacting forces, to prevent the load swinging in the direction of tension of

one of the tag lines.

(g) Earthing systems An appropriate earthing system shall be fitted to the crane and

shall be in use. Operators and those working in proximity to the crane shall be

advised of the limits of the effectiveness of the earthing equipment.

NOTE: The purpose of the earthing system is to provide an alternate path to earth to minimize

risks to personnel and plant, and it may not be likely to trip circuit breakers that form part of

the electricity transmission system. For specific advice and guidance about the earthing of a

crane consult with the electricity distributor/provider.

(h) High visibility bunting Where high visibility bunting is applied to the conductors, it

shall not be regarded as insulation.

AS 2550.1—2011


28

DIMENSIONS IN METRES

FIGURE 6.20.3 CLEARANCES FROM LIVE AERIAL CONDUCTORS

29 AS 2550.1—2011


6.20.4 Aerial conductor contact

If the crane or load contacts aerial conductors, the relevant electricity distributor shall be

immediately notified of the situation and, until assistance is received, a competent person

shall remain in a prominent position to warn of the danger of electrocution.

In such an event, the following precautions should be observed by the crane operator:

(a) Remain inside the cabin or on the crane.

(b) Warn all other personnel to keep away from the crane and not to touch any part of the

crane, rope or load.

(c) Without anyone approaching the crane, operate the crane in such a manner to break

contact, where possible.

(d) When unable to move or disentangle the crane from the aerial conductors, remain

inside the cabin or on the crane and take no further action until it is confirmed that

conditions are safe.

(e) Only when it is essential to leave the cabin or crane because of fire or some other

reason, to avoid being electrocuted, jump clear as far away from the crane as possible

and not touch the crane and the ground at the same time. When moving away from the

crane, shuffle or hop slowly across the affected area to avoid a simultaneous contact

across areas of high potential difference (see Figure 6.20.4).

Where the crane operator is immobilized, the power shall be isolated before assistance is

given.

When a crane has been in contact with a live aerial conductor, it shall be checked by a

competent person for any damage to the crane components. Any actions recommended by

the competent person shall be completed before the crane is returned to service.

6.21 UNDERGROUND CONDUCTOR CONTACT

When underground conductor contact occurs, the same precautions as given in

Clause 6.20.4 should be observed, as appropriate.

AS 2550.1—2011


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FIGURE 6.20.4 TYPICAL AFFECTED AREA SURROUNDING A CRANE

WHEN IN CONTACT WITH A LIVE AERIAL CONDUCTOR

6.22 SPECIAL DUTIES

6.22.1 General

The crane manufacturer should be consulted for the use of the crane for all special duties,

such as grabbing, pile driving, magnet lifting and demolition.

Where the crane manufacturer’s recommendations are not available, then the advice of a

professional engineer shall be obtained.

6.22.2 Grabbing and magnet crane service

When cranes are used for grabbing or magnet crane service, allowance shall be made for the

following, where applicable:

(a) Mass of the grab.

(b) Mass of the magnet.

31 AS 2550.1—2011


(c) Mass of other attachments.

(d) Mass of the load.

(e) Loads resulting from fast slewing.

(f) Grab or suction effects.

(g) Impact loads.

For these operations, consideration shall be given to the tear-off/break-out forces.

6.22.3 Lifting products of demolition

Lifting products of demolition may be hazardous because the loads may be greater than

assessed or may impose excessive dynamic loads on the crane. Cranes used for this purpose

shall have a rated capacity not less than 1.5 times the assessed load.

6.22.4 Inspection

After a crane has been used for special duties, it shall be subjected to an inspection, as

specified in Clause 7.4.3., before being returned to its usual lifting duties.

6.22.5 Recreational use

Crane structures shall not be used for recreational purposes.

6.23 WEATHER CONDITIONS

6.23.1 Wind conditions

Where it is necessary to lift loads with large wind-catching surfaces, the lift shall be

assessed taking full consideration of the wind loads likely to be experienced during the

operation and their effect on the load intended to be lifted. Such an assessment shall include

the likely effect a gusting or strong wind can have on the crane’s stability even when the

load being lifted is within its rated capacity.

An anemometer should be available at the working site, and located to provide an accurate

wind load reading on the crane or load.

Where wind speeds exceed the manufacturer’s operating recommendations, cranes shall be

placed out of service and, where applicable, storm brakes applied.

6.23.2 Visibility conditions

Where adverse weather conditions such as snow, fog and wind causing dust have an adverse

effect on visibility or the communication system, the crane shall be placed out-of-service

until conditions improve to such an extent that a dangerous situation no longer exists.

6.23.3 Wet conditions

Brake or clutch units and electrical equipment on all cranes shall be protected against the

ingress of water or other adverse weather conditions that may affect their efficiency.

Following shutdown periods and before the start of hoisting operations, all friction brakes

and clutches shall be carefully tested.

6.23.4 Lightning

Outdoor cranes should not be operated during a storm when lightning strikes could

reasonably be expected.

6.24 INCIDENT OR DAMAGE

When the crane is involved in any incident or the crane or equipment sustains failure or

damage that may affect its safe operation, it should be withdrawn from service.

AS 2550.1—2011


32

The crane operator shall report such occurrences.

NOTE: Statutory authorities may require such incidents to be reported.

The crane or equipment shall then be inspected and repaired as required by Section 7, and

declared satisfactory by a competent person before it is returned to service.

6.25 MODIFICATIONS TO CRANES

Modifications to any part of a crane, including the addition of signs, shall not be undertaken

without undergoing an engineering assessment by a competent person, for compliance with

AS 1418.1.

6.26 FIRE EXTINGUISHER

A fire extinguisher appropriate to the hazards involved shall be provided and correctly

fitted for every cabin-controlled crane.

6.27 DESIGNED LIFTS

Designed lifts shall comply with the requirements of this Standard and the applicable Part

of AS 1418. Designed lifts shall be preceded by a thorough, documented risk assessment

that will identify any hazards and the appropriate control methodologies.

Where multiple cranes are employed and their motions are not synchronized, the

requirements of Clause 6.28 shall apply.

NOTE: Guidance on designed lifts is given in Appendix D.

The rated capacity of a crane may be temporarily changed for the duration of a designed

lift. The crane marking need not be changed. The re-rating conditions shall be indicated in

writing to the operator.

The person developing the designed lift shall be a competent person, and shall define and

record the rationale for any deliberation associated with the review, as defined in this

Clause. A third party shall review the design characteristics of the crane. Consideration

shall be given to the effect this operation may have on the life of the crane.

A written work procedure shall be developed by the competent person, and shall include the

various control measures to be applied. The written work procedure shall be job specific

and shall specify the documents required for all items deemed necessary by the competent

person. The following items, as applicable, shall be included in the documentation:

(a) Crane identification.

(b) Crane configuration.

(c) Location of the site.

(d) Position of the crane(s) relative to the load and its final position.

(e) Climate and atmospheric conditions.

(f) Speed of crane movements (e.g., hoisting, slewing luffing, traversing).

(g) Load sharing in multiple crane lifts.

(h) Hoist speed matching in multiple hoist lifts.

(i) Synchronization of crane motions, or where this is not possible, methods taken to

reduce the effect of forces arising from the lack of synchronization.

NOTE: Lack of synchronization in crane movements (in particular travelling or slewing

motions) results in lateral forces being applied to the cranes, which may result in loss of

stability or structural damage. Procedures should be developed to monitor and control the

effect of lateral forces arising during such motions.

33 AS 2550.1—2011


(j) Crane support structure.

(k) Special lift operating procedure.

(l) Design checks, brake calculations, wheel loads, rope calculations, motor rating, load

and/or motion limits, hoist/block capacity.

(m) An inspection of all parts of the crane to be carried out in accordance with the

competent person’s instructions prior to and immediately after the completion of a

designed lift to verify the condition of the crane.

(n) Crane support considerations.

(o) Determination of centre of gravity.

A record of all designed lifts shall be maintained with the crane service record (logbook).

6.28 MULTIPLE HOIST OR CRANE OPERATION

6.28.1 General

Multiple crane lifting shall be used only when the physical dimensions, characteristics,

mass or required movement of the load prevent the operation from being carried out by a

single crane. Lifting operations using two or more cranes shall be preceded by a thorough,

documented risk assessment that will identify any hazards and the appropriate control

methodologies irrespective of whether the lift is a designed lift or is in accordance with the

requirements of this clause.

NOTE: During multiple crane operations, only motions in the same direction should be

undertaken simultaneously by the cranes, otherwise, the operation should be carried out in a

stepped sequence, undertaking only one motion at a time.

6.28.2 Crane type

Other than for designed lifts, lifting operations using two or more cranes shall use cranes of

the same type.

NOTE: For example, telescopic mobile crane/tower crane would require a designed lift

assessment.

6.28.3 Capacity requirements

Where the motions of multiple crane operations are not synchronized during the lifting

cycle, the following minimum capacity requirements for each crane shall apply:

(a) For two cranes ................................ 20% greater than the calculated share of the load.

(b) For three cranes .............................. 33% greater than the calculated share of the load.

(c) For four or more cranes .................. 50% greater than the calculated share of the load.

NOTE: These capacity requirements are not necessarily sufficient to address the hazards that may

arise during travel or slewing operations (see Clause 6.28.5.4).

6.28.4 Multiple hoist operation

Where a multiple crab crane is lifting a load other than that for which it was originally

designed, care shall be taken to ensure that the proportion of the load each crab supports is

accurately known.

Where a crane is fitted with two crabs and facility allowing tandem operation, the load shall

be handled in such a way that the rated load of each hoist is not exceeded and the load

being handled does not exceed the rated capacity of the crane.

AS 2550.1—2011


34

Where a crane is not fitted with facility for tandem operation or the load is suspended from

more than two hoist lines, load limiters shall be fitted to each hoist and the load shall be

handled in such a way that—

(a) the rated load for each line is not exceeded; and

(b) the load being handled does not exceed the rated capacity of the crane as specified in

Clause 6.28.3.

6.28.5 Planning for multiple crane hoisting

6.28.5.1 General

Multiple crane hoisting shall be planned with extreme care. Where multiple crane lifting is

involved, the following shall be considered and any resulting procedures shall be prepared:

(a) An accurate assessment of the proportion of the load to be carried by each crane.

(b) How the load proportioning is to be maintained.

(c) Whether each crane has appropriate additional capacity over the portion of the load to

be lifted.

(d) The operating characteristics of the cranes (e.g., speed of hoisting).

(e) Planning for keeping the hoist ropes within the range specified by the manufacturer.

6.28.5.2 Mass of load

If the load information is taken from a technical drawing, allowance should be made for

manufacturing tolerances. Loads should be checked for a build-up of deposits or contained

liquids that may increase the mass.

6.28.5.3 Mass of lifting gear

The mass of the lifting gear shall be part of the calculated load on the cranes and crabs and

its mass distribution shall be accurately known.

6.28.5.4 Load-handling attachments

Load-handling attachments shall be suitable for tandem operation. The use of non-positive

contact load-handling attachments, such as magnet and vacuum lifting appliances for

suspending a load between two or more cranes, shall be avoided. Loads shall not be

suspended at an angle.

6.28.5.5 Synchronization of the crane and crab motions

The crane motions should be synchronized; therefore, cranes of equal capacity and similar

operating characteristics should be used.

To allow for the probability of the motions of the cranes or crabs not being accurately

synchronized, particularly if the cranes or crabs have dissimilar operating characteristics,

the operation shall be performed at slow speeds with extreme care being exercised to

maintain the hoist ropes as close to vertical as possible. Procedures shall be developed to

monitor and control the effect of lateral forces arising during such motions.

NOTES:

1 The rated capacity of a crane is calculated on the assumption that the load will be raised and

lowered in a vertical plane. The crane structure will have been designed to withstand any

lateral loads imposed by accelerations in the various crane and crab motions; however, it is

unsafe to rely on this lateral strength to withstand horizontal components of non-vertical lifts.

2 In practice, there will always be some variation due to differences in response to the

activation of the motion controller and the setting and efficiency of the braking system.

35 AS 2550.1—2011


3 Synchronous operation of more than one crane and/or hoist may be carried out by a

combination of the following:

(a) Operator controls Two or more cranes may be operated by a common control station

such as a radio control system consisting of a master transmitter used to operate

separate receivers on each crane. The other transmitters are slaves that can only be

used when in single mode operation.

(i) Single mode is when each crane is operated by its own control station.

(ii) Tandem mode is when the crane combination is operated by a common control

station.

(b) Crane controls The control systems of the cranes being operated in tandem,

communicate with each other, such as by a bi-directional radio data link, to ensure the

following:

(i) All drives involved in the lifting motion are reliably switched off when an

overload or over-temperature limit of one of the hoist units is detected in the

system; however, the lowering motion is still possible for safety reasons.

(ii) All hoists involved in the lifting/lowering operation are switched off when a

lifting/lowering limit is actuated.

(iii) All travelling hoists involved in the operation are switched off when an

end-of-travel motion limit is actuated.

(iv) All cranes involved in the operation are switched off when an end-of-travel

motion limit is actuated.

(v) All associated axis drives are limited to the same rate in the event that a speed

reducing limit is actuated.

(vi) Any anti-collision systems between travelling hoist and/or cranes involved in a

tandem operation are bypassed.

6.28.5.6 Pick and carry

In pick and carry operations, the axis of both or all cranes or crabs shall be kept aligned in

the same direction. The possibility is that once out of alignment, the movement of one crane

or crab may push or pull either the other crane(s) or crab(s) and cause loss of stability.

NOTE: Instruments are available to monitor constantly the angle of the load, and the verticality

and force in each hoist rope throughout the lifting operation. Their use is recommended.

6.28.5.7 Wind

As multiple crane or crab hoisting operation is sensitive to weather conditions, particularly

wind speed. An adequate assessment of the prevailing conditions shall be made before

commencement of and during a multiple hoisting operation.

6.28.6 Supervision of a multiple crane hoisting operation

One competent person, who shall not be one of the crane operators, shall be in attendance

and in overall control of the multiple crane or crab hoisting operation. Only this person

shall give instructions to the crane operators, except in an emergency, when a stop signal

may be given by any person observing a situation leading to danger. If all necessary

locations cannot be observed from one position, additional competent personnel shall be

located at suitable positions to observe and report to the person in charge of the operation.

6.29 MANUALS

The manuals for operation, servicing, maintenance and recording of major and minor

occurrences to the crane or hoist and the operational environment shall be retained in a

location readily available to those who have a need to use them.

Where the crane service records (logbooks) or other records are retained on computer or

other electronic storage facility, the operators, maintenance and inspection personnel shall

be trained in the procedures to retrieve the required information.

NOTE: Requirements for the content of manuals are given in the applicable Part of AS 1418.

AS 2550.1—2011


36

6.30 VESSEL-MOUNTED CRANES

6.30.1 General

This Clause states the additional requirements for vessel-operated cranes for use in smooth

water except for Clause 6.30.10, which references requirements applicable outside smooth

water limits. The crane may be operated on a barge, pontoon or vessel. The combined mass

shall be considered as a vessel-mounted crane.

6.30.2 Mounting or operating position

The position of the crane on the barge, pontoon or vessel, both in the loaded and unloaded

conditions, shall take into consideration—

(a) the effect on freeboard;

(b) the strength of the vessel to support the crane structure;

(c) the installation of stops to prevent the crane approaching the vessels side; and

(d) the method of securing the crane when working outside smooth water limits.

6.30.3 Vessel characteristics

The list and freeboard allowable with the rated capacity and test load conditions shall be

determined by a competent person experienced in crane design and stability of waterborne

vessels.

NOTES:

1 As a general guide, the maximum list of the vessel under rated capacity conditions should not

exceed ±5 degrees with one half of the freeboard remaining. Confirmation should be obtained

from the crane manufacturer on the de-rating of the crane from land-based ratings when on

the barge, pontoon or vessel.

2 The manufacturer’s rated capacities for cranes mounted on vessels are frequently not greater

than 70% of the land-based rated capacity.

6.30.4 Items to be verified

A design check shall include the verification of the following details:

(a) Allowable freeboard of the vessel.

(b) Crane manufacturer’s rated capacity when operating on a barge, pontoon or vessel

combination giving consideration to Clause 6.30.3.

(c) Loads in the structure when the barge or pontoon is at maximum heel or list.

(d) Amount and position of ballast.

(e) Depth of water below the vessel, to ensure the vessel does not ground.

(f) Limiting weather conditions for the crane vessel combination.

(g) Ties, anchorages and supports are adequate at minimum and maximum heel or list.

6.30.5 Grabbing cranes

Prior to performing grabbing operations, a hazard identification and risk assessment shall

be completed by a competent person.

Where grabbing cranes are operated on a barge or pontoon, the mass of the grab and

contents should not exceed 75% of the rated capacity and a further 25% reduction of the

rated capacity of vessel-mounted cranes should be made where suction effects are present.

6.30.6 Pile removal operations

Prior to performing pile removal operations, a hazard identification and risk assessment

shall be completed by a competent person.

37 AS 2550.1—2011


Where a vessel-mounted crane is engaged in removal of piles and buried posts,

consideration shall be given to the buried depth and the angle of repose of the binding

material.

6.30.7 Testing

6.30.7.1 General

The crane and vessel combination shall be inspected after erection and before application of

any loads to ensure all ties, anchorages and ballast are in place and correctly secured and

the crane configuration is in accordance with the crane manufacturer’s or a competent

person’s advice and free from any defects that would preclude the vessel-mounted crane

from safely handling the test load.

A pre-operation test with no load applied shall be carried out to ensure the correct operation

of all controls, cut-outs, contactors, brakes, limiters and other devices as fitted.

The rated capacity indicator and all limits shall be checked to ensure the reduced rated

capacity and any increase in radius due to list of the vessel combination is considered and

appropriate action taken.

6.30.7.2 Stability test

If it is not possible to anchor the vessel to the shore, the vessel should be anchored to a craft

alongside. The anchorage should be of sufficient length to allow the vessel to take up a

natural list in the water.

The crane should be checked without load through 360 degrees of slew with the boom in the

least stable position to establish the position of maximum loss of freeboard of the vessel.

The position of minimum freeboard of the vessel shall be placed adjacent to the anchorage.

The crane shall be slewed through 360 degrees to ensure there is adequate freeboard and the

vessel will not be swamped under adverse conditions.

The crane shall be placed at the position of least stability and the test load applied

incrementally, checking the freeboard at each increment.

6.30.7.3 Function test

After the stability test, the crane shall be function tested. The function test should be

conducted with all motions operated at the lowest speeds.

The boom shall be set at maximum radius and the rated capacity applied. The crane shall

then be operated through all motions and the load hoisted to ensure that the load is applied

in the full range of each motion.

6.30.7.4 Brake test

The load shall be increased to 110% of the crane line pull and shall be hoisted 3 m above

the ground then lowered and arrested just clear of the ground. Where applicable, the hoist

and luffing brakes shall be tested and proved capable of sustaining the 110% test load for

10 min. This test may be carried out following the performance tests at operating

temperatures. Unless indicated by the manufacturer, the test shall be carried out on the top

layer of the drum.

6.30.8 Post-test assessment

After stability and function tests have been completed, a competent person shall complete a

thorough assessment to ensure the vessel and crane combination has withstood the test

loadings without structural damage and the mechanisms function free of any defect that will

affect the safety of the crane.

All cut-outs and limits shall be reset to normal operation requirements.

AS 2550.1—2011


38

6.30.9 Rated capacity charts

The rated capacity charts of the crane shall be securely fastened and clearly endorsed with

de-rating requirements applicable to the installation of the crane on the vessel.

6.30.10 Offshore and ship-mounted cranes

The requirements for shipping and operation outside smooth water are in various

classification societies’ rules.

39 AS 2550.1—2011


S E C T I O N 7 M A I N T E N A N C E , I N S P E C T I O N

A N D R E P A I R

7.1 GENERAL

Where manufacturer’s specifications for maintenance and inspection are available, they

shall be assessed by a competent person against the requirements of this Section and

Appendix G. Where they are determined to be adequate and appropriate, they shall be

applied to the crane.

Where the manufacturer’s specifications are not available, or deemed inappropriate or

inadequate by a competent person, a new or revised set of documented specifications

complying with this Section shall be prepared to replace the missing or inadequate

specifications (see Figure 7.1).

NOTE: The manufacturer’s specifications may be inappropriate or inadequate for a number of

reasons, including occupational health and safety requirements, the frequency of the use, the

severity of use and the operating environment.

Yes

Yes Yes

No

No

Use manufacturer’s

instructions

Use manufacturer’sinstructions with supplementaryinstructions in accordance

with Section 7

Assess againstAppendix G

Use Section 7to prepareinstruction

No

Are manufacturer’sinstructions avai lable?

Fullyapplicable?

Partlyapplicable?

FIGURE 7.1 APPLICABILITY OF MAINTENANCE AND INSPECTION FLOW CHART

Maintenance, inspection and repair shall be carried out in conformance with this Section,

the applicable Part of AS 1418, the applicable part of AS 2550 and instructions written in

accordance with this Standard. The maintenance, inspection and repair instructions shall be

readily available.

AS 2550.1—2011


40

The instructions shall be written in plain English and shall give specifications for suitable

tools and consumable items such as ropes, lubrication and hydraulic fluids.

All inspections, maintenance and repairs shall be carried out by a competent person.

NOTE: Guidance on safe work procedures is given in Appendix E.

7.2 MAINTENANCE

A preventative maintenance program shall be established giving consideration to the

manufacturer’s recommendations. It shall be based on the working environment and the

frequency and severity of use of the crane.

NOTE: Recommended servicing frequencies for different crane classifications are given in

Appendix F.

When parts and components are replaced, replacements shall be identical or equivalent to

the original equipment parts and components.

Where past experience has shown particular problems with a crane, a specific rectification

program shall be instigated.

All safety-related malfunctions and problems shall be corrected before the crane is returned

to service.

7.3 INSPECTION

7.3.1 General

Inspections shall be carried out at sufficient frequency to ensure the crane is kept in a safe

and satisfactory condition. Inspections shall be carried out in conformance with this

Standard, the appropriate part of AS 2550 and instructions written in accordance with this

Standard. All such work shall be noted in the records. Inspection shall be as follows:

(a) Pre-operational inspection.

(b) Routine inspection.

(c) Periodic third-party inspections.

(d) Major inspection.

For lifting devices, the inspection requirements of AS 4991 shall apply.

7.3.2 Pre-operation inspection

Before the commencement of each work shift, the crane shall be given a visual inspection

and functional test. The visual and functional tests may be carried out by the operator with

the intention of identifying obvious damage. The inspection and test should include the

following:

(a) Operating and emergency controls.

(b) Brakes.

(c) Safety switches and interlocks.

(d) Structure.

(e) Wire ropes to ensure they are on the drum and correctly reeved on the sheave.

Any personal protective equipment should also be inspected for correct function.

Identified safety-related problems shall be rectified and recorded prior to using a crane.

41 AS 2550.1—2011


7.3.3 Routine inspection

Routine inspection shall be carried out in accordance with the manufacturer’s

recommendations.

NOTE: The inspection should include all items specified in instructions written in accordance

with this Standard for routine inspections, including the following:

(a) All functions and their controls for speed, smoothness of operation and limits of motion.

(b) All emergency and safety switches and interlocks.

(c) Lubrication of all moving parts, inspection of filter element/s and fluid levels.

(d) Visual inspection and measurements, as necessary, of structural members and other critical

components such as brakes, gears, fasteners, pins, shafts, wire ropes, sheaves, locking

devices, electrical contactors, wear on wheels and rails.

(e) Signage, including warning signs and control markings.

(f) Checking electrical, mechanical and structural components for safe condition and function.

(g) Additional items nominated in the instructions written in accordance with this Standard.

Particular attention should be paid to any component with a recent or existing history of

repeated failures.

Opening of cover plates and removal of guards shall be as considered necessary by the

inspector due to the existing condition.

When parts and components are replaced, the replacements shall be identical or equivalent

to the original parts or components.

A written report shall be furnished on completion of the inspection.

NOTES:

1 A competent person may recommend that routine inspections be carried out more frequently.

2 Where manufacturer’s recommendations are not available, the routine inspections should take

place at intervals not exceeding those shown in Table F1 of Appendix F, unless the crane is

not in service.

7.3.4 Periodic third-party inspections

Each crane shall undergo a periodic third-party inspection to provide independent advice on

whether the level of maintenance and repairs are in accordance with this Standard.

The frequency of periodic third-party inspection shall be based on the working environment

and the frequency and severity of use of the crane.

NOTE: The periods specified in Table F1 of Appendix F should not be exceeded.

The inspection shall include all items specified in instructions written in accordance with

this Standard and include all items specified by the manufacturer for annual inspection

together with all routine inspection and maintenance items (see Clause 7.3.3).

As part of this inspection, the maintenance records of the crane shall be reviewed prior to

the inspection. After the inspection, a report on the current condition of the crane shall be

compiled.

NOTE: The usage of the crane should be verified for consistency with the design classification.

Particular attention should be given to the following:

(a) Past state of loading and utilization as compared to the crane classifications.

(b) Future intended state of loading and utilization as required by the user of the crane.

The inspection shall include checking electrical, mechanical and structural components for

safe condition and function. Opening of cover plates and removal of guards shall be as

considered necessary by the inspector due to the existing condition. Particular attention

shall be paid to any component with a recent or existing history of repeated failures.

AS 2550.1—2011


42

The inspection shall ensure that the requirements of Clauses 7.3.2, 7.3.3 and 7.3.5 have

been completed.

NOTES:

1 As the result of a periodic third-party inspection, a competent person may recommend a major

inspection.

2 For details of inspections for particular types of cranes, refer to relevant Part of the AS 2550

series.

3 Table F1 of Appendix F provides guidance on the inspection frequency for periodic third-

party inspections for typical crane classifications where a program of third-party inspections

is instituted.

7.3.5 Major inspection

Cranes shall be subjected to a major inspection to assess their suitability for continued safe

operation as follows:

(a) Unless assessed in accordance with Section 9 to determine when a major inspection is

due, after two-thirds of the design life specified by the manufacturer or the original

design Standard or, where this is unknown after 7 years of use.

(b) When an old crane is to be recommissioned and previous operating records do not

exist or the Standard to which it was designed and built is unknown.

The major inspection shall involve examination of those critical components identified by

the manufacturer, competent person or the assessment conducted in accordance with

Section 9. Where necessary, the crane shall be stripped down and paint, grease and

corrosion removed from critical components to allow a complete and thorough inspection.

Particular attention shall be given to the following:

(i) Structural, mechanical, electrical, instrumentation, control and operational anomalies.

(ii) Non-destructive testing of all nominated critical areas for evidence of cracking due to

fatigue or excessive stress.

(iii) Components whose maintenance records indicate repeated failures.

(iv) Braking systems.

(v) Adequacy of safety instructions and manuals for operation and maintenance.

(vi) Manufacturer’s safety upgrades.

A written report shall be furnished on completion of the inspection. A competent person

shall assess the results with regard to risks and hazards associated with the crane’s current

operation.

The following apply:

(A) The competent person shall specify the maintenance necessary to ensure its continued

safe operation.

(B) The competent person shall identify components that require particular attention in

subsequent periodic inspections.

43 AS 2550.1—2011


(C) The competent person shall determine the reasonable practicability of applying the

current requirements of the AS 1418 series, in particular the following:

(1) Rated capacity limiter and/or indicator.

(2) The indicating and motion limiting devices.

(3) Emergency retrieval system.

(4) Platform, handrails and gate.

(5) Controls and emergency stop (e.g., ability to unintentionally engage free fall).

Cranes assessed to be unsafe shall not be returned to service until rectified and reassessed

as safe to return to service.

NOTE: Persons carrying out such inspections should be supervised by a professional engineer.

7.4 REPAIRS

7.4.1 General

Any part of a crane that becomes so worn or damaged as to constitute a hazard or impairs

the operation of the crane, or may constitute a hazard before the next routine inspection,

shall be repaired or replaced.

NOTE: The repaired or new parts should comply with the manufacturer’s recommendations and

specifications, or the recommendations of a competent person, taking due cognizance of the

Standard to which it was designed.

All repairs shall be carried out by competent persons under competent direction and

supervision. The repairs shall be appropriately tested.

All repairs shall be adequately documented and recorded in accordance with Clause 7.5.

7.4.2 Assessment for repair procedure

A competent person shall make an assessment of the defects and damage requiring repair.

NOTE: The assessment should be recorded and form a report. The report should contain the

following:

(a) Details of how the incident happened or circumstances leading to the discovery of the

defective parts.

(b) Nature and extent of the damage and defects.

(c) Proposed action based on the manufacturer’s recommendations.

7.4.3 Alternative recommendations

7.4.3.1 Competent person’s report

Where it is not possible to obtain the manufacturer’s recommendations, or it is decided not

to follow the manufacturer’s recommendations, a competent person shall consider and

report on the following, as appropriate:

(a) Details of the proposed repair.

(b) Repair procedures.

(c) Design analysis.

(d) Selection of replacement material.

(e) Welding procedure specifications.

(f) Details of any heating or straightening process.

(g) Selection of the most appropriate method of non-destructive examination, including

the extent and level of testing.

(h) Post-weld heat treatment procedure.

AS 2550.1—2011


44

(i) Compliance with working and detailed drawings.

(j) Final acceptance and testing procedure.

7.4.3.2 Management of repairs

Following the review of the competent person’s report, the equipment shall be repaired or

scrapped. Where any component is scrapped, arrangements should be made to dispose of

the damaged component in a manner that ensures it remains unusable as a load-carrying

component.

Where it is decided to implement the manufacturer’s recommendations, instructions

incorporating such recommendations shall be prepared. Such instructions shall be followed.

Where it is decided not to implement the manufacturer’s recommendations, then the

competent person’s recommendations shall be followed.

A records management system, which ensures all activities affecting the repair are fully

documented, shall be maintained. These records shall be transferred with the ownership of

the crane and retained for the life of the crane.

As a minimum, the following records shall be retained:

(a) Detailed drawings and calculations.

(b) Material test certificates.

(c) Non-destructive examination reports.

(d) Inspection and testing procedure and details.

(e) Welding procedure records.

(f) Welder qualification records.

(g) Heat treatment charts.

(h) Dimensional checks.

(i) Inspection reports.

(j) Final acceptance testing.

(k) Certificate of compliance.

(l) Competent person’s report.

(m) The competent person’s qualifications.

(n) Repairer’s report.

Following repairs, the crane shall undergo the load and operational tests specified in the

applicable Part of AS 1418 to an extent commensurate with the type of alteration or repair.

7.4.4 Repair work

The repairer selected to carry out the work shall be acceptable to the competent person.

Repair work shall be carried out according to the following:

(a) Personnel with the necessary qualifications and experience shall be engaged on the

work.

(b) Work instructions shall be provided.

(c) All work shall be conducted in accordance with relevant Australian Standards or

other applicable national or international Standards.

(d) All final non-destructive testing shall be conducted by a competent person.

A records management system shall be established for the documentation produced by

repairers and received from other bodies for transfer to the owner.

45 AS 2550.1—2011


7.4.5 Welding repair examination

The examination of welding repairs shall be carried out in accordance with the

manufacturer’s repair procedure, or the appropriate weld inspection Standard. Where these

are not available for structural members, the extent of non-destructive examination shall be

not less than the extent of non-destructive examination given in Table 7.4.5.

TABLE 7.4.5

EXTENT OF NON-DESTRUCTIVE EXAMINATION

Extent of NDE, %

Weld category

(see

AS/NZS 1554.4)

Visual examination

(see Notes 1 and 4)

Magnetic particle or liquid

penetrant or other similar

technique (see Notes 2, 3 and 4)

Radiography or

ultrasonics

(see Notes 4 and 5)

GP 100 Nil Nil

SP 100 100 50 to 100

FP 100 100 50 to 100

NOTES: 1 Visual examination—to examine 100% of welds to determine none have been omitted and the

required weld size has been achieved.

2 Upon satisfactory completion of the visual examination of the structures, it is normal practice to

employ magnetic particle NDE for SP and FP category welds.

3 Liquid penetrant examination may be used in GP category welds as an alternative to magnetic

particle examination, but magnetic particle examination is preferred.

4 The acceptance criteria shall be as shown in AS/NZS 1554.4.

5 NDE percentage to be determined upon accessibility.

7.5 RECORDS

A crane service record (e.g., logbook) of the significant events concerning the safety and operation

of the crane shall be kept and be readily available. The records shall be easily understood, and

written in plain English. Records may be in any suitable format. These records shall be transferred

with ownership of the crane.

NOTE: A suggested format for a crane service record (logbook) is shown in Appendix H.

Documentation stating that the crane has been inspected by a competent person and is in a

safe and satisfactory condition shall be readily available.

The checks, adjustments, replacement of parts, repairs and inspections performed and all

irregularities or damage concerning the unit’s safe use shall be recorded.

In addition, all complete routine inspection reports, all complete periodic third party

inspection reports and all complete major inspection reports shall be maintained and made

available for examination as required.

NOTE: Any system that records these events and is readily available to the operator should be

accepted as meeting the intent of this Clause.

AS 2550.1—2011


46

S E C T I O N 8 I N S P E C T I O N O F R O P E S , H O O K S

A N D L I F T I N G G E A R

8.1 ROPES

8.1.1 Replacement of ropes

The examination and discard criteria for wire ropes and their replacement shall be in

conformance with the crane manufacturer’s guidelines or, where not available, AS 2759 and

AS 1418.1. For multiple rope hoists, the ropes shall be matching ropes of the same

construction and tensile strength.

8.1.2 Rope reeving

Where it is possible to vary the number of falls of the hoist rope or parts of rope in the

luffing system, these shall be in accordance with instructions written in accordance with

this Standard for boom and jib lengths and loads to be lifted.

NOTES:

1 If a load moment system is fitted, the system generally operates accurately only when its

setting corresponds to the length of boom or jib fitted and the type of rope reeving adopted.

2 Where a crane is fitted with a load-sensing device, the device may require adjustment after a

change of reeving before the crane is placed in service.

8.1.3 Rope guards or keepers

Where rope guards or keepers are fitted to sheaves, hook blocks or drums, they shall remain

in their correct positions and shall be removed only for the purposes of maintenance,

inspection or adjustment.

NOTE: This is of particular importance if, under certain circumstances, the rope system develops

a slack rope condition. Failure to observe this could allow a rope to run off a sheave or drum and

become trapped or damaged.

8.1.4 Guide rollers and guide sheaves

Where guide rollers or guide sheaves are fitted, they shall be checked frequently to ensure

that they are free to rotate. Where boom or jib protective strips are fitted, they shall be

frequently checked for security and serviceability.

NOTE: A seized roller or sheave may cause serious damage to a rope, leading to its premature

failure.

8.1.5 Rope drums and sheaves

Rope drums and sheaves shall be examined for wear, at regular intervals.

Sheaves shall revolve true and freely on their supporting shafts and particular attention

shall be given to lubrication.

8.1.6 Rope terminal fittings

Wire rope terminations shall be carried out in accordance with manufacturer’s

specifications. In the absence of manufacturer specifications, terminal fittings as specified

in AS 2759 shall be used to attach a rope to a drum, anchorage, hook block or structure of

the crane. Improvised fittings shall not be used.

Attention shall be given to the assembly of wedge and socket fittings, and such fittings shall

be provided with a rope tail clip as specified in AS 2076.

47 AS 2550.1—2011


8.1.7 Rope lengths

Ropes of the correct length shall be fitted. Before hoisting operations commence following

installation of a new rope or a change of configuration, the rope drums shall be checked in

the extreme spooling conditions to ensure that the rope lengths are correct. The settings of

the limit devices shall be checked.

NOTE: With variable boom or jib lengths it may be necessary to fit a specific length of rope for a

particular boom or jib length and rope reeving combination. Too short a rope may result in the

rope completely paying out with the entire load being taken by the anchorage. Too long a rope

may exceed the drum spooling capacity and result in the rope riding over the flanges and

becoming trapped in the machinery causing severe damage and possibly premature rope failure.

8.1.8 Rope stretch

Rope stretch may create problems with the setting of hoisting limiting devices and the

overfilling of the drum. Frequent inspections, particularly during the early life of the

installed rope, shall be carried out to determine whether the limiting devices require

adjustment or the rope needs to be cut back to the appropriate length.

8.1.9 Examination of ropes

A visual examination shall be performed during the pre-operational inspection for kinking,

bird-caging, damage and correct reeving.

A thorough examination shall be carried out by a competent person during the routine

inspection phase. The acceptance and discard criteria shall be in accordance with AS 2759.

NOTE: Rope wear is affected by climatic and environmental conditions, e.g., saline, corrosive or

abrasive atmosphere.

Particular attention should be paid to those sections of rope close to rigid terminal fittings.

NOTE: Ropes that are composed or more than one layer of strands, such as non-rotating ropes,

may deteriorate internally at the interface between the layers.

If multi-layer drums are used, the examinations hall include not only that part of the rope

that is in constant use, but also that part of the rope that remains spooled and inoperative on

the drum for long periods.

Boom and fly-jib suspension ropes are often placed at positions remote from the basic crane

structure. Such ropes shall be carefully examined, particularly those sections lying round

sheaves.

8.2 HOOKS AND HOOK BLOCKS

The hook or hook block shall be capable of handling the nominated load. The hook shall not

be loaded beyond its working load limit.

To prevent displacement of the sling or load, the hook should be provided with a safety

catch or other effective device to minimize the risk of the sling or load becoming detached.

The hook shall not be overcrowded.

NOTE: Where multiple slings are used, they should be attached to a bow-shackle, which is then

placed on the hook. This prevents the danger of the hook being strained owing to the spread of

the slings and also the danger of a sling fouling the safety catch or slipping over the point of the

hook.

All end links, rings or shackles shall ride freely on the hook.

NOTE: When the crane is working with a single fall of rope and the load is set down, thus

relieving the tension in the hoist rope, the hook can spin. Personnel should always exercise care

when approaching the hook to disconnect the sling.

AS 2550.1—2011


48

8.3 LIFTING GEAR

8.3.1 Identification and marking

Each lifting attachment shall be clearly and permanently marked in accordance with

AS 4991.

8.3.2 Inspection

All lifting attachments shall be inspected immediately prior to use. Regular inspection,

consistent with the design and usage of the attachments, shall be carried out by a competent

person, and the extent of each inspection shall be consistent with the design and usage of

the attachment.

NOTE: See Clause 7.41 for more information.

49 AS 2550.1—2011


S E C T I O N 9 M A J O R A S S E S S M E N T F O R

C O N T I N U E D U S E O R C H A N G E D O P E R A T I O N

9.1 GENERAL

Cranes are designed for a finite lifetime duty, which is given in load cycles and loading

intensity and is not principally related to calendar working time. Classification of crane

duty provides the crane owner a means to specify the intended duty in order to achieve the

intended useful operational lifetime of the crane.

Typically, the operational lifetime for industrial cranes is 25 years; however, a specified

crane classification may be related to any calendar time depending on the application (e.g.,

5–10 years for a special limited use or 40 years for a long-term investment).

Approaching the design duty means an increased probability of hazards, which are unlikely

to be uncovered by periodic, physical inspections. For the safety of the crane operation, it is

crucial that the actual duty is monitored regularly and compared to the design duty.

This Section specifies a method to monitor, during a long-term operation, the actual duty

and how to compare this to the original design duty, which was specified through the

classification (i.e., C, M and S ratings).

The design working period (DWP) introduced in this Standard is directly related to a

theoretical design life and it shall not be considered as a guaranteed life in any respect. Due

to the probabilistic nature of metal fatigue and other influencing factors, premature failures

during the design life cannot be ruled out; however, the design working period represents a

proven estimate of a safe operational life of the crane, with due consideration to specified

design regulations and acceptable design factors.

The design working period is measured in hours or cycles. It is based on the crane being

maintained in correct working order.

9.2 RECORDING OF CRANE OPERATION

9.2.1 General

The crane user should keep records of the crane usage, adequate to identify the criteria

specified by the crane manufacturer and applicable to carry out the assessments described in

this Standard.

Records shall be kept of maintenance, inspections, repairs, modifications and relevant

exceptional occurrences (e.g., overloads, extreme climatic conditions and collisions).

NOTE: Failure to keep records of use will dictate the necessity for more frequent major

inspections (see Table 9.6.2).

9.2.2 Methods of duty recording

Estimation of the duty history may be divided into the following categories, based on

systematic and reliable data collection and documentation procedures:

(a) Crane operation data is recorded by a special, purpose-built system, which always

operates automatically when the crane is in use. The crane driver does not have a

possibility to switch off the recording system.

(b) The crane is provided with counters recording the crane operation data. The user

collects and documents the operation data manually from the counters.

(c) The crane duty history is estimated and recorded during the periodic third-party

inspection and is based on a regular process in which the crane is working. The crane

is an integral part of the process. Process data is documented.

AS 2550.1—2011


50

(d) The crane duty history is estimated and recorded, based on a general production data

of the site, where the crane is working.

(e) The crane duty history is unknown (e.g., in case of a second-hand crane). The duty

for DWP calculation is based on rational estimate or assumed to be according to

design classification and design life reduced, using the factor f1 from Table 9.6.2

(i.e., 1.5).

NOTE: Design life is generally 25 years for the structure and 10 years for mechanisms, unless

specified.

9.3 ASSESSMENT OF DESIGN WORKING PERIOD

9.3.1 General

Many components of a crane may fail because of metal fatigue, which is difficult to predict

or estimate by physical inspections. Safeguarding against fatigue failure by physical

inspections only is uneconomical due to the following:

(a) The safe time window for an inspection from detectable to critical crack size may be

short, leading to unnecessary frequent inspections.

(b) Detecting of a fatigue crack may be impractical, often requiring major disassembly of

a component.

(c) Planning and scheduling of future repairs of the crane is not possible.

A ‘non-acceptance’ by an inspection requires typically immediate actions and

possibly interruption of crane operation.

The purpose of the assessment of DWP is to estimate accumulated duty of the crane and

assess its remaining life.

It is assumed that all inspections scheduled for the crane have been carried out, that any

damages suffered during the operation are appropriately repaired and that maintenance

work and replacement of worn parts are carried out in accordance with the manufacturer’s

instructions or, where not available, the instructions of a competent person.

9.3.2 Schedule

Assessments of DWP should be carried out in conjunction with the periodic third-party

inspections.

A competent person shall conduct the assessment, unless the crane is equipped with an

automatic recording system [see Clause 9.2.2(a)].

9.3.3 DWP calculation method

The applied DWP calculation method should follow the specification and classification of

the original design Standard, as closely as possible. Clause 9.6 gives DWP calculation

methods for cranes classified and designed according to AS 1418.1.

The DWP calculation shall cover the crane as a whole including the structure and

mechanism.

The classification or design basis in the previous Standards may not be in accordance with

the current applicable Part of AS 1418. In order to have a solid theoretical basis for the

DWP calculation, the owner may ask the manufacturer or a competent person for a

re-classification according to the current Standard. The modified design classification shall

correspond to an equivalent or lower duty than the original one.

51 AS 2550.1—2011


9.4 MAJOR ASSESSMENT

9.4.1 General

The major assessment shall contain both—

(a) a theoretical part, where the remaining design life of each component of the crane is

analysed based on the duty estimation; and

(b) a practical part, where physical inspections of all critical components and systems of

the crane are inspected for integrity and functionality.

Upon checking the remaining life of the critical components, the competent person shall

identify components that have reached their design life that require overhaul for future safe

use.

NOTE: It should be recognized that the different parts of the crane approach the design limits at

different phases, depending on the type of the use and configuration of the crane. These

differences should be considered in the major assessment.

The theoretical analysis of the component remaining design life does not have to rely on the

methods of the original design Standard, but state of the art methods may be applied instead. This

should include consideration of the measured work cycles and their true effect on the crane

fatigue.

The major assessment shall be carried out under the supervision of a competent person. The

procedure should be based on the information provided by the crane manufacturer or, where

unavailable, the competent person shall determine the scope of the inspection.

9.4.2 Criteria for major assessment

A major assessment shall be made to survey the condition of the crane, when the

assessment of DWP indicates that the crane duty will reach one of the design limits prior to

the next periodic third-party inspection, or one of the following indicates it should be done

earlier:

(a) Any increase in the frequency of the reported defects.

(b) When an inspection reveals a significant deterioration in the condition of the crane.

In cases where the user takes into operation a second-hand crane, for which there is no

information concerning the earlier operation, the major assessment shall be made prior to

using the crane.

9.4.3 Manufacturer’s instructions

The manufacturer shall provide the user with the classification data necessary for the DWP

assessment. This information shall be given in the owner’s manual of the crane.

Additionally, the manufacturer shall specify the following:

(a) Limits for exceptional conditions and loadings to which the crane is designed.

(b) List of components and areas to be included in the major assessment.

(c) Methods and acceptance criteria for physical inspections.

(d) Recommendations for overhaul requirements in respect to findings in major

assessment.

(e) Criteria for findings preventing the further use of the crane.

NOTE: In the absence of manufacturer’s instruction, see Clause 7.1.

9.4.4 Report

A report of the major assessment shall be prepared. The report shall be kept with other

service documents of the crane.

AS 2550.1—2011


52

As a minimum, the report shall contain the following:

(a) Identification of the criteria used for the assessment.

(b) The results and significant findings.

(c) Requirements for any action to be completed before further use of the crane.

(d) Recommendations for actions to be carried out within a given operational time.

(e) New DWP prior to the next major assessment.

(f) Modified inspection periods before the next major assessment, if appropriate.

9.5 GENERAL OVERHAUL

9.5.1 General

General overhaul (GO) is a set of repair, replacement and maintenance actions, which are

necessary for the safety of the further use of the crane. Some issues may require immediate

actions; some may be postponed, in which the case these actions shall be scheduled

according to the future duty of the crane.

NOTE: Some manufacturers offer general overhaul kits to enable the complete refurbishment of a

hoist to an as-new condition. Once the hoist is overhauled by the manufacturer, the manufacturer

can then recertify the hoist for a complete new design life.

9.6 DWP CALCULATION FOR CRANES

9.6.1 General

Two basic duty factors and the crane classification as a combination of the two duty factors

are given in the applicable Part of AS 1418, as follows:

(a) Number of operating cycles (CT), grouped into classes U0 to U9.

NOTE: CT is similarly used in AS 1418.1 to represent the total number of operating cycles,

when the cycle count is a design assumption.

(b) Load spectrum factor (Kp), with spectrum Classes Q1 to Q4.

Group classification of the crane into Classes C1 to C9 is derived as a combination of the

two duty factors U and Q.

In cases where the basic duty factors or their classes are specifically given and known to the

user, the DWP calculation should be based on Clauses 9.6.3 and 9.6.4. In cases where the

crane classification only is known, the DWP calculation shall be carried out according to

Clause 9.6.5.

The two duty factors are of equal relevance. The DWP of the crane is reached when any

criterion reaches its design value. It is then an issue for the special assessment to find out

which of the crane components are critical in respect to each duty factor.

9.6.2 Factor for duty estimation

When calculating the DWP of a crane, the estimated duty from the history shall be

increased by a factor f1 according to Table 9.6.2, to cover the unreliability in the duty

recording and estimation.

53 AS 2550.1—2011


TABLE 9.6.2

FACTOR ƒ1 FOR DUTY ESTIMATION

Method of duty recording ƒ1

1 Automatic recording system 1.0

2 Counters and manual documentation

or

Estimation based on a special, documented process

1.1

3 Estimation based on documented production of the site 1.2

4 Estimation based on undocumented, estimated production of the site 1.3

5 Crane duty history is unknown 1.5

9.6.3 Number of operating cycles

In cases where the manufacturer has specified the class of utilization for the crane, the

design value for the number of operating cycles (CD) shall be taken from the Table 9.6.3.

TABLE 9.6.3

THE MAXIMUM NUMBER OF

OPERATING CYCLES

Class of utilization

CD

(cycles)

U0 16 000

U1 32 000

U2 63 000

U3 125 000

U4 250 000

U5 500 000

U6 1 000 000

U7 2 000 000

U8 4 000 000

U9 >4 000 000

The DWP of the crane is reached, that is the actual duty has reached the design value in

respect to total number of working cycles, when:

ƒ1 × Ca = CD

where

ƒ1 = the safety factor for duty estimation according to Clause 9.6.2

Ca = the total number of operating cycles determined for the crane operation at a

time point in question based on Clause 9.2.2

CD= the design value for the number of operating cycles of the crane according to

Table 9.6.3

9.6.4 Load spectrum

In cases where the manufacturer has specified the load spectrum class for the crane, the

design value for the load spectrum factor (Kp) shall be taken from Table 9.6.4.

AS 2550.1—2011


54

TABLE 9.6.4

DESIGN VALUE Kp FOR THE

LOAD SPECTRUM FACTOR

Spectrum class Kp

Q1 0.125

Q2 0.25

Q3 0.50

Q4 1.00

For calculation of the load spectrum class from the actual operation history, values of

payloads from each working cycle shall be recorded or estimated. The DWP of the crane is

reached, that is the actual duty has reached the design value in respect to load spectrum,

when:

∑=

=⎟⎟

⎠

⎞

⎜⎜

⎝

⎛a

1i

Dp

3

i

1

C

CK

P

P

f

where

f1 = the safety factor for duty estimation according to Clause 9.6.2

i = the index for an individual operating cycle

Ca = total number of operating cycles determined for the crane operation at a time

point in question based on Clause 9.2.2

Pi = the handled payload in a operating cycle i

P = the rated value of the payload for the crane

Kp = the design value for the load spectrum factor according to Table 9.6.4

CD = the design value for the number of operating cycles of the crane

9.6.5 Crane classification

This Clause is applicable to cases where the basic duty factors or their classes are not

specified and the crane classification only is known. In the DWP calculation, the actual load

spectrum and the number of operating cycles are combined and converted to correspond to

the state of loading where load spectrum Kp = 1 (see Table 9.6.5).

TABLE 9.6.5

CONVERTED DESIGN NUMBER OF OPERATING CYCLES BY CRANE CLASS

Crane class C1 C2 C3 C4 C5 C6 C7 C8 C9

Cclass

(cycles)

8 × 103

16 × 103

32 × 103

63 × 103

125 × 103

250 × 103

500 × 103

1.0 × 106

4.0 × 106

The DWP of the crane is reached, that is the actual duty has reached the design duty

corresponding to the given crane classification, when:

class

3

1i

i

1

a

C

P

P

f

C

=⎟

⎠

⎞⎜

⎝

⎛

∑=

where



55 AS 2550.1—2011


Ca = total number of operating cycles determined for the crane operation at a time

point in question based on Clause 9.2.2

Pi = the handled payload in an operating cycle i


CClass

= the converted design number of operating cycles according to Table 9.6.5

9.7 DWP CALCULATION FOR HOISTING MECHANISMS

9.7.1 General

This Clause is applicable both to hoist mechanisms as an integral part of a crane and to

serial hoist units to which a mechanism class is specified.

Two basic duty factors and the mechanism classification as a combination of the two duty

factors are given:

(a) Total operation time (T).

(b) State of loading of the mechanism specified by the load spectrum factor (Km).

(c) Classification of the mechanism as a combination of the two duty factors.

In cases where specific design values for the basic duty factors (T, Km) are known (e.g., for

a purpose-built crane) the DWP calculation should be based on those factors according to

Clause 9.7.2. In cases where the mechanism classification only is known, the DWP

calculation shall be carried out according to Clause 9.7.3.

9.7.2 Crane-specific design duty factors are known

In cases where the manufacturer has specified the state of loading through the L-class of the

load spectrum factor, the design value for this shall be taken from Table 9.7.2(A).

Otherwise a crane-specific value of Km shall be used.

TABLE 9.7.2(A)

DESIGN VALUE Km

FOR LOAD

SPECTRUM FACTOR

State of loading Km

L1 0.125

L2 0.25

L3 0.50

L4 1.00

In cases where the manufacturer has specified the total duration of use through the

classification, the design value for the total duration of use (TD) shall be taken from

Table 9.7.2(B). Otherwise, a crane-specific value of TD shall be used.

AS 2550.1—2011


56

TABLE 9.7.2(B)

DESIGN VALUE TD FOR THE

TOTAL DURATION OF USE

Class of utilization TD

, h (hours)

T0 200

T1 400

T2 800

T3 1 600

T4 3 200

T5 6 300

T6 12 500

T7 25 000

T8 50 000

T9 100 000

T10

>100 000

For calculation of the cumulative loading for a hoist mechanism, values of total hoisted

loads from each work cycle shall be recorded or estimated. The effective working part of

the load cycle and the return part of the work cycle shall be considered.

The DWP of the hoist mechanism is reached, that is the actual duty has reached the design

values, when:

Dm

1i

3

A

A

,

3

A

Ai

i1

a

t TK

PP

P

PP

PP

tf

C

iR=

⎥

⎥

⎦

⎤

⎢

⎢

⎣

⎡

⎟⎟

⎠

⎞

⎜⎜

⎝

⎛

+

+⎟⎟

⎠

⎞

⎜⎜

⎝

⎛

+

+

∑=

where



Ca = the actual, total number of hoisting cycles at a time point in question

ti = the hoist mechanism running time during a loaded part of the hoisting cycle i

tR,i = the hoist mechanism running time during a return part of the hoisting cycle i

Pi = the handled payload in the hoisting cycle i

PA = the sum weight of the fixed and non-fixed load-lifting attachment


TD = the design value for the total operation time

Km = the design value for the load spectrum factor of the mechanism

9.7.3 Mechanism classification is known

This Clause is applicable to cases where the mechanism classification only is known. In the

DWP calculation, the load spectrum and the total operation time are combined and

converted to correspond to the state of loading Km = 1.0.

57 AS 2550.1—2011


TABLE 9.7.3

CONVERTED DESIGN VALUE FOR TOTAL OPERATION

TIME BY MECHANISM CLASSIFICATION

Crane class M1 M2 M3 M4 M5 M6 M7 M8

Tclass

h

100

200

400

800

1600

3200

6300

12 500

The DWP of the hoist mechanism is reached, that is the actual duty has reached the design

classification, when:

class

1i

3

A

A

,

3

A

Ai

i1

a

T

PP

P

t

PP

PP

tf

C

iR=

⎥

⎥

⎦

⎤

⎢

⎢

⎣

⎡

⎟⎟

⎠

⎞

⎜⎜

⎝

⎛

+

+⎟⎟

⎠

⎞

⎜⎜

⎝

⎛

+

+

∑=

where



Ca = the actual, total number of hoisting cycles at a time point in question

ti = the hoist mechanism running time during a loaded part of the hoisting cycle i

tR,i = the hoist mechanism running time during a return part of the hoisting cycle i

Pi = the handled payload in the hoisting cycle i

PA = the sum weight of the fixed and non-fixed load lifting attachment


TD = the design value for the total operation time

Tclass = the converted design value for the total operation time according to

Table 9.7.3

AS 2550.1—2011


58

APPENDIX A

STANDARDS FOR COMPONENTS USED IN LIFTING GEAR

(Informative)

The following is a list of Standards for components that are used in lifting systems:

AS

1138 Thimbles for wire rope

1353 Flat synthetic-webbing slings

1353.1 Part 1: Product specification

1353.2 Part 2: Care and use

1380 Fibre-rope slings



1438 Wire-coil flat slings



1666 Wire-rope slings



2076 Wire-rope grips for non-lifting applications

2089 Sheave blocks for lifting purposes

2317 Collared eyebolts

2318 Swivels for lifting applications

2319 Rigging screws and turnbuckles

2321 Short-link chain for lifting purposes

2740 Wedge-type sockets

2741 Shackles

2759 Steel wire rope—Use, operation and maintenance

2841 Galvanized steel wire strand

3569 Steel wire ropes—Product specification

3585 End fittings for synthetic flat-webbing and round slings

3775 Chain slings—Grade T



3776 Lifting components for Grade T chain slings

3777 Shank hooks and large-eye hooks—Maximum 60 t

4142 Fibre ropes

4142.1 Part 1: Care and safe usage

4142.2 Part 2: Three-strand hawser-laid and eight-strand plaited

59 AS 2550.1—2011


AS

4497 Roundslings—Synthetic fibre



4991 Lifting devices

AS 2550.1—2011


60

APPENDIX B

EXAMPLE OF INSPECTION AND TESTING CERTIFICATE

(Informative)

This Appendix sets out guidelines for and includes an example of an inspection and testing

certificate.

The testing certificate includes a list of the items that would normally be included in a

thorough inspection schedule; however, items not included in this list are not precluded

from requiring inspection.

The list of items for inspection is not considered to be a complete list.

Persons and organizations conducting testing and inspections should develop their own

testing and inspection manual, which should set out complete details of all testing and

inspections to be carried out and the Standards to which the inspections conform.

For all inspection details, the manufacturer’s recommendations should be adhered to.

Additional details may be necessary to ensure that inspection and testing is complete in

relation to the previous and future use of the equipment, as well as the previous inspection

and testing history.

For all of the items in the list of items to be inspected, the appropriate status code has to be

circled to indicate the condition of the item with an explanatory comment included where

required.

Status Code:

A = Inspected—No action required

B = Adjustments/Repairs made

C = Additional repairs required

D = Urgent repairs required

E = WARNING: DO NOT USE

61 AS 2550.1—2011


Equipment No.: .................................... Sheet No.: ...............................

1 Title: Inspection and testing certificate for a crane.

2 Equipment data:

Registration No.: ....................................................................................

Identification No.: .....................................................................................

Model No.: .....................................................................................

Serial No.: .....................................................................................

Manufacturer’s name: .....................................................................................

Date of manufacture: .....................................................................................

Date and time of last

inspection:

Owner’s name: .....................................................................................

Address: .....................................................................................

Telephone No.: .......................... Facsimile No.: ...................................

Maximum rated capacity: .............................................................................. kg

Classification: ....................................................................................

NOTE: Each item marked ‘unsatisfactory’ should be referred to in the remarks section.

This notation should provide an explanation if the machine is to be passed for immediate use.

AS 2550.1—2011


62

The following is a list of items to be inspected. It is not considered a complete list.

Status Code

Description

Tick one

Comments/Action

3 Items inspected

Records (A B C D E) ..............................................

Operating manuals (A B C D E) ..............................................

Maintenance manual (A B C D E) ..............................................

Guarding (A B C D E) ..............................................

Safety gear (A B C D E) ..............................................

Lubrication (A B C D E) ..............................................

Trailing electric cables (A B C D E) ..............................................

Locking provisions at parking landing (A B C D E) ..............................................

Electrical earthing (A B C D E) ..............................................

Wiring diagram (A B C D E) ..............................................

Indicator lamps (A B C D E) ..............................................

Access (A B C D E) ..............................................

Clearances (A B C D E) ..............................................

Gates and latches (A B C D E) ..............................................

Protective meshing (A B C D E) ..............................................

Safety requirements for personnel access

and egress

(A B C D E) ..............................................

Limit switches (A B C D E) ..............................................

Driving mechanisms (A B C D E) ..............................................

Driving machine isolation (A B C D E) ..............................................

Marking (A B C D E) ..............................................

Ropes (A B C D E) ..............................................

Rope guides (A B C D E) ..............................................

Luffing mechanism (A B C D E) ..............................................

Slewing mechanism (A B C D E) ..............................................

Guidance system (A B C D E) ..............................................

Restraint system (A B C D E) ..............................................

Anchoring system (A B C D E) ..............................................

Drums and sheaves (A B C D E) ..............................................

Brakes (A B C D E) ..............................................

Counterweights (A B C D E) ..............................................

Controls (A B C D E) ..............................................

Isolation (A B C D E) ..............................................

63 AS 2550.1—2011


4 Repairs

Details of examination of repairs or alterations carried out:

..............................................................................................................................

..............................................................................................................................

..............................................................................................................................

..............................................................................................................................

Status Code

Description

Tick one

Comments/Action

5 Tests

Controls (A B C D E) ...................................................

Motions (A B C D E) ...................................................

Load test (A B C D E) ...................................................

Hoist brakes test (A B C D E) ...................................................

Emergency stop (A B C D E) ...................................................

Power supply (A B C D E) ...................................................

Working limits (list each) (A B C D E) ...................................................

Safety limits (list each) (A B C D E) ...................................................

Clearance (A B C D E) ...................................................

Controls (A B C D E) ...................................................

Indicators (A B C D E) ...................................................

Other test (list each) (A B C D E) ...................................................

6 Test site/station detail:

Name: ...............................................................................................................

Address: ...............................................................................................................

Telephone No.: ........................................... Facsimile No.:

Date of final test: ......................................................................................................

AS 2550.1—2011


64

7 Certification

(a) Equipment general condition description: ...........................................................

.........................................................................................................................

.........................................................................................................................

(b) Remarks:...........................................................................................................

.........................................................................................................................

(c) Recommendation:..............................................................................................

I recommend that:

(i) This equipment be re-examined and tested on or

before ........................................................................................................

(ii) The following components of the equipment be re-examined and tested, as

appropriate, on or before the date indicated for the item:

Item Date

(d) The examination was:

Routine: .........................................

Periodic third party: ........................

Major:.............................................

(e) I hereby certify that I have examined and tested, as appropriate, Equipment No.

..................................................................................................................

and I find that the equipment is not/is in a satisfactory condition for safe use.

NOTE: For commissioning of new equipment, it should be certified that the equipment

complies with the relevant Parts (including Sections) of AS 1418 series.

(f) Number of sheets attached: ................................

(g) Competent person’s details:

Name: ..............................................................................................

Address: ..............................................................................................

Telephone No.: ................................... Facsimile No.: ...................................

Qualifications: ..............................................................................................

Relevant experience: .......................................................................................

.............................................................................................................................. ..

(h) Signature: ......................................... Date: ......................................

65 AS 2550.1—2011


APPENDIX C

LICENCES TO PERFORM HIGH RISK WORK

(Informative)

The following is a list of the licenses for high risk work, as given in the National Standard

for Licensing Persons Performing High Risk Work (April 2006), that are relevant to the

crane industry:

(a) Dogging (DG).

(b) Basic rigging (RB).

(c) Intermediate rigging (RI).

(d) Advanced rigging (RA).

(e) Tower crane operation (CT).

(f) Self-erecting tower crane operation (CS).

(g) Portal boom crane operation (CP).

(h) Bridge and gantry crane operation (CB).

(i) Vehicle loading crane operation (CV).

(j) Non-slewing mobile crane operation (CN).

(k) Slewing mobile crane operation (up to 20 t)(C2).

(l) Slewing mobile crane operation (up to 60 t)(C6).

(m) Slewing mobile crane operation (up to 100 t) (C1).

(n) Slewing mobile crane operation (open/over 100 t) (CO).

(o) Boom-type elevating work platform operation (WP).

(p) Materials hoist (cantilever platform) operation (HM).

(q) Hoist (personnel and materials) operation (HP).

(r) Concrete placing boom operation (BP).

NOTES:

1 The above list was correct at time of publishing.

2 The National Standard for Licensing Persons Performing High Risk Work can be downloaded

from the Safe Work Australia website at: www.safeworkaustralia.gov.au

AS 2550.1—2011


66

APPENDIX D

GUIDANCE FOR DESIGNED LIFTS

(Informative)

D1 USE

Where any of the following conditions apply, consideration should be given to the use of a

designed lift:

(a) Multiple hoisting operations using two or more cranes or hoists where chosen to

perform the lift as a designed lift or where the requirements of Clause 6.27 are not

applicable to the intended lifting operation.

(b) The mass of the load is not evenly distributed.

(c) The load has an irregular shape.

(d) Load-sharing devices, such as equalizing beams, are to be used.

(e) There is a limited duty cycle.

D2 DESIGN

Determine the loading on each leg of each sling, which is a result of—

(a) the mass of the load;

(b) the location of the centre of gravity of the load;

(c) the rigidity of the load;

(d) the angle of the applied load to the vertical;

(e) the measured length of each leg of the sling while under load; and

(f) the geometry and operation of any load-sharing device.

Other factors to be taken into account include the following:

(i) In a four or greater leg sling arrangement, load distribution in the sling legs.

(ii) In specific cases, a lower design factor may be applicable.

(iii) In a hazardous location or in a detrimental environment, an additional design factor

may be necessary.

(iv) Considerations for any bending of slings and efficiencies of eyes of slings may

necessitate an additional design factor.

D3 PROCEDURE

A written work procedure should be developed incorporating the following:

(a) Crane’s make and model.

(b) Crane’s configuration and set-up.

(c) Location of site and site requirements.

(d) Pick up and landing locations.

(e) Climatic and atmospheric conditions.

(f) Speed of operation for hoisting, luffing, slewing and travelling.

(g) Simultaneous movements.

67 AS 2550.1—2011


(h) Supervision and observation of personnel.

(i) Use of load cells.

D4 OPERATION

A designed lift should be supervised by a competent person.

AS 2550.1—2011


68

APPENDIX E

SAFE WORK PROCEDURES FOR THE MAINTENANCE AND THE

INSPECTION OF CRANES

(Informative)

E1 SCOPE

This Appendix provides guidance on the safe working procedures for the maintenance and

inspection of cranes.

E2 RESTRICTION OF ACCESS

Personnel should not gain access to a crane or crane superstructure except where such

access is necessary for them to carry out their duties.

E3 AUTHORIZATION FOR ACCESS

Personnel should not gain access to a crane unless authorized.

E4 WARNING TO OTHER PERSONNEL

The person responsible for safety within the area where the crane is located should ensure

that all personnel within the area, and those who may enter the area, are warned of potential

hazard.

E5 WORK NEAR CRANES

Where maintenance or other work needs to be performed near a crane, electric power to the

crane-supply conductors or crane, where applicable, should be disconnected except where

the crane, or part of the crane, needs to be energized to effect maintenance work.

Precautions should be taken to ensure that personnel in the vicinity of the crane are not

subjected to an electrical hazard or a hazard due to movement of the crane.

E6 WORK ON CRANES

Electric power to the crane should be isolated and internal combustion engines should be

stopped except where the crane, or part of the crane, needs to be energized to effect the

maintenance or inspection.

Precautions should be taken to ensure that personnel involved in the maintenance or

inspection of the crane are not subjected to an electrical hazard or a hazard due to

movement of the crane. Where the electric power is not isolated or the internal combustion

engines are not stopped, not less than two persons should be present, one of whom should

be free to take any action necessary to protect personnel in an emergency.

When working on a crane, the following precautions should be observed:

(a) The crane should be taken out of service.

(b) The crane should be moved to a position remote from the operating position, where

applicable.

(c) The crane should be prevented from moving.

(d) Only tools suitable for the purpose should be used.

(e) All maintenance and inspection should be in accordance with instructions written in

accordance with this Standard (see Clause 1.5).

69 AS 2550.1—2011


E7 LOCK-OUT OF MAIN ISOLATOR OR CRANE ISOLATOR

Where the power supply to the crane is isolated, the main isolator should be locked in the

‘off’ position and the means of unlocking retained by the person responsible for the

maintenance or inspection as nominated in instructions written in accordance with this

Standard.

The person responsible for the maintenance or inspection should ensure that all tools,

equipment and other loose materials have been removed from the crane and its working

area, including crane runways as applicable, and that safe conditions prevail for the

resumption of normal operation of the crane before the power is restored to the crane.

E8 OVERHEAD MAINTENANCE OR INSPECTION

Where overhead maintenance or inspection could create a hazard from falling objects, the

area below should be isolated from surrounding areas and hazard warning signs displayed.

E9 MAINTENANCE AND INSPECTION IN ELEVATED POSITIONS

Where personnel are required to work in elevated positions and there is a danger of falling,

means should be provided to prevent falling. Where fall-arrest harnesses are used, they

should comply with AS/NZS 1891.1.

AS 2550.1—2011


70

APPENDIX F

RECOMMENDED MINIMUM MAINTENANCE AND INSPECTION

REQUIREMENTS FOR CRANES

(Informative)

F1 SCOPE

This Appendix lists the minimum recommended inspection and maintenance procedures

that should be performed at regular intervals according to the classification and class of

utilization of the crane.

F2 CONTROL POINTS

F2.1 General

Test drive and general visual inspection. Check for loose objects and extraneous materials.

Check mounting of components, surface treatments.

F2.2 Structural

Check for corrosion, damage, deformation and wear.

F2.3 Function

Check on the condition of bearings, seals couplings, bushes and sheaves.

F2.4 Adjustment

Adjustment of brakes and limit switches as necessary.

F2.5 Lubrication

Lubrication and oil changes according to the manufacturer’s instructions.

F3 CONTROL FREQUENCY

The recommended minimum periods for routine maintenance and inspection are shown in

Table F1.

TABLE F1

RECOMMENDED MINIMUM MAINTENANCE AND INSPECTION SERVICE

REQUIREMENTS

C1 C2 C3 C4 C5 C6 C7 C8

Crane classifications

M1 M2 M3 M4 M5 M6 M7 M8

Operating hours per day ≥0.5 0.5–1 >1–2 >2–4 >4–8 >8–16 >16 >20

Routine maintenance weeks 12 12 12 12 8 8 4 4

Periodic third-party inspection,

weeks

52 52 52 52 52 52 52 52

NOTE: Periods may be varied dependent on the operating environment, the frequency and intensity of use

(see Clause 7.3).

71 AS 2550.1—2011


APPENDIX G

CHECKLIST TO DETERMINE SUITABILITY OF MANUFACTURER’S

INSTRUCTIONS

(Normative)

G1 SCOPE

This Appendix sets out a checklist to be used to assess the adequacy of the instructions

available for the crane.

NOTE: The scope of the necessary instructions is described in Clause 1.5.

G2 APPLICATION

The checklist shall be applied to each model type. Where an item can be confirmed as

adequate, the reference section in the Table shall be completed noting the reference Clause

or Section(s) contained in the instructions. Where the item cannot be confirmed as

adequate, the matter shall be referred to the manufacturer or competent person for

assessment and preparation of supplementary instruction.

Where some items contained in the checklists cannot be adequately addressed, the crane

shall be subject to the appropriate series of inspections and maintenance specified in

Clause 7.4.

Crane Make:

Model Number:

Year of manufacture:

Item Description Y/N

(see Note 1)

Reference

(see Note 1)

0 Identification

0.1 The manufacturer’s instructions correspond with the

subject crane (i.e., the model number and serial number

declared in the manual correspond with that on the

crane).

0.2 The owner of the crane is registered with the

manufacturer.

(see Note 2)

1 Use

1.1 The instructions for inspection, maintenance and use

apply to the environment in which the crane is being

used (e.g., at temperatures within the range permitted

by the manufacturer).

1.2 The operating instructions apply to the manner in which

the crane is used.

1.3 Modifications

Instructions have been prepared and addressed any

additional procedures that arise as the result of

modifications to the crane.

1.4 History

There is no history of repeated repairs or defects that

are not addressed in the manufacturer’s instructions.

AS 2550.1—2011


72

Item Description Y/N

(see Note 1)

Reference

(see Note 1)

2 Manufacturer’s specifications

2.1 Operating hours (see Note 3)

The total allowable operating hours is specified by the

manufacturer

The classification in accordance with AS 1418.1 is

declared.

2.2 Elapse of designed operating hours (see Note 3)

Guidance is provided as to the necessary action

required once the designed operating hours have

elapsed.

2.3 Hydraulic and electric circuits provided.

2.4 Operating specifications provided (e.g., lift and drive

speeds, hydraulic pressure settings, etc).

2.5 Specifications are provided for the adjustment or

assembly of components, (e.g., bolt torques, pad

clearances and proximity switch gap settings).

3 Inspection procedures

3.1 Routine inspection procedures

Inspection schedules are specified and apply over the

entire life of the crane.

3.2 Preventative maintenance procedures

Preventative maintenance instructions are specified and

apply over the entire life of the crane.

3.3 Critical areas

Details are provided, which identify critical areas

requiring routine inspection and frequency of inspection

(e.g., stub axles, chassis welds and similar critical

areas).

3.4 Inspection procedures

Procedures are provided detailing the method of

inspection of critical areas (e.g., visual inspection,

magnetic particle inspection and similar inspection

method).

3.5 Acceptance criteria

Criteria are provided against which critical areas can be

assessed.

4 General

4.1 Safety warnings and residual risks declared in the

operating and maintenance manuals.

5 Replacement parts (if applicable)

5.1 Consumables

Specifications provided relating to the replacement of

consumable items (e.g., hydraulic oil, filters and similar

consumables).

5.2 Components

Details provided relating to parts replacement and

required frequency of replacements (e.g., wire ropes,

bushes and similar replacements).

6 Documentation

6.1 Checklists are provided, which clearly identify the areas

and procedures necessary at each inspection.

6.2 Test report formats are provided to facilitate the

recording of test or inspection measurements against

specified criteria.

73 AS 2550.1—2011


NOTES to Checklist:

1 Where the question is answered in the affirmative, the reference should be quoted. Where the

answer is ‘no’ refer to Paragraph G2.

2 Registration with the manufacturer should be confirmed.

3 ‘Operating hours’ are sometimes expressed as ‘cycles’.

AS 2550.1—2011


74

APPENDIX H

CRANE SERVICE RECORD (LOGBOOK) FORMAT

(Informative)

This Appendix sets out an example of a typical crane service record (logbook) format

suitable for the safe use and maintenance of cranes.

The crane service record (logbook) may be arranged in four sections for clarity of use and

convenience, as follows:

(a) Section 1: Pre-operational safety checks log.

(b) Section 2: Routine maintenance and safety checks log.

(c) Section 3: Faults, difficulties and problems log.

(d) Section 4: Maintenance inspection log.

In Section 1 of the log, the safety checks actually carried out should be recorded. The safety

checks should be carried out at the frequency specified in instructions written in accordance

with this Standard (e.g., daily, before use).

In Section 2 of the log, the routine maintenance and safety checks actually carried out

should be recorded. The routine maintenance and safety checks should be carried out at the

frequency specified in instructions written in accordance with this Standard (e.g., weekly,

monthly, annually).

In Section 3 of the log, all the faults, difficulties and problems actually experienced in the

examination, checking, maintenance and operational use of the crane should be recorded

(e.g., corrosion, cracking, missing bolt, leaking seal, electrical faults, air entrainment).

75 AS 2550.1—2011


TYPICAL CRANE SERVICE RECORD (LOGBOOK)

Section 1 Pre-operational safety checks log

Date Time Operator safety checks

(name of operator or competent person)

Name of company, location,

department Signature

am/pm

am/pm

am/pm

am/pm

am/pm

Section 2 Routine maintenance and safety checks log

Date HourmeterRoutine

maintenance and safety checks

Company Qualifications Signature

h

h

h

h

h

Section 3 Faults, difficulties and problems log

Repairs Date Time Fault, difficulty or

problem Name of company,

location, department Comment Signature

am/pm

am/pm

am/pm

am/pm

am/pm

Section 4 Maintenance inspection log

Date Time Type of inspection Name of competent person Signature

am/pm

am/pm

am/pm

am/pm

am/pm

AS 2550.1—2011


76

APPENDIX I

USE OF EARTHMOVING EQUIMENT AS A CRANE

(Normative)

Where earthmoving equipment is used as a crane, the following requirements apply:

(a) The earthmoving equipment shall be travelled only with arm and boom retracted to

minimum practicable radius.

(b) Where the earthmoving equipment requires the use of stabilizers in order to achieve

stability, the equipment shall be supported by such stabilizers.

(c) No person shall be permitted under the boom or suspended load.

(d) All persons operating the earth moving equipment, slinging or directing the load shall

have the appropriate license, certificate or training, in accordance with the National

Standard for Licensing Persons Performing High Risk Work (April 2006).

(e) No person shall be lifted by earth moving equipment being used as a crane.

(f) Where a quick hitch is used, loads shall only be suspended from a lift point on the

quick hitch that complies with AS 1418.8, with the bucket and other attachments

removed.

(g) Lift points shall be arranged such that accidental unhooking of the load cannot occur.

(h) Operational speed shall be reduced from high-speed mode.

(i) Where the sling or tackle is wrapped over the back of the bucket, due care shall be

taken to ensure that it does not come into contact with any sharp projection or sharp

edge.

(j) Loads shall not be suspended from bucket teeth or adaptors.

(k) The rated capacity at each lifting point shall be prominently marked at the lifting

point. This shall not be exceeded under any configuration, that is, the lifted load plus

any attachments (bucket, etc.) shall not exceed the rated capacity.

(l) Deductions from the rated capacity for larger than standard buckets or quick hitch

devices shall be considered to determine the maximum allowable mass of the item

that may be lifted.

(m) Reference shall be made to the manufacturer’s manual for correct operation.

(n) Quick hitches shall be used only to support items of equipment specifically designed

to fit, and specifically designed for the duty to be undertaken.

(o) Quick hitches shall be maintained in proper working order at all times.

(p) A crane service record (logbook) shall be used to record servicing, maintenance and

repair work, and details of any malfunction that may occur with the machine.

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Cranes, hoists and winches—Safe use Part 1: …...This Standard specifies general requirements for the safe use of cranes, hoists and winches. NOTES: 1 Requirements applicable to