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East Anglia Construction Safety Group
Health and Safety Day 22nd April 2010
Tower Crane Safety Update
Tim WatsonTim Watson Consulting
Topics
■
An overview of the latest advances in tower crane standards and design
■
Some recent accidents and the lessons learned
■
Planning for the safe and effective installation and use of tower cranes on site
■
The Tower Crane Register
Latest Advances in Tower Crane Standards and Design
Old and New Standards
■
National Standards ► DIN 15018► NF E 52-081► FEM 1.001
■
EN 14439:2006 + A1:2010► One standard across Europe► Adopted by manufacturers
from January 2010
What's New in EN14439
■
Improved Safety in Service ►
Compulsory anemometer►
Anti-collision and zoning devices►
Improved cab visibility■
Improved Operator Comfort►
Requirements for cab heating and control station layout■
Improved Safety for Erection and Maintenance Personnel►
Reduction of crushing hazards►
Improved access►
Specifications for climbing systems■
Increased Requirements for Out-of-service Wind
Out-of-service Wind
European Storm Wind Map CPA TIN 027
Example
Out-of-service Wind Accidents
Common Requirements for Access – EN 13586
Common Requirements for Access Ladders
Zoning Systems
Standardised Minimum Requirements
Requirements for Operator’s Cabs
Some Recent Tower Crane Accidents and the Lessons Learned
Tower Crane Accident Survey
■
May 2000 – July 2009
■
At least 51 Serious incidents ►
8 in the UK
►
6 in China
►
5 in the USA
►
4 in Russia
►
4 in Netherlands
►
3 in South Africa
►
2 in Germany
►
2 in Malta
►
2 in Switzerland
►
1 in Bahrain
►
1 in Canada
►
1 in Irish Republic
►
1 in Israel
►
1 in Malaysia
►
1 in Philippines
►
1 in Poland
►
1 in Qatar
►
1 in Saudi Arabia
►
1 in Spain
►
1 in Singapore
►
1 in South Korea
►
1 in Taiwan
►
1 in Tokyo
►
1 in Vietnam
Service Condition
Service Condition Quantity
In-service 22
Climbing 7
Dismantling 6
Erection 6
Out-of-service 6
Not known 3
Under test 1
Failure AreaFailure Area QuantityFoundation/Base 11Jib 7Tower /Base 5Slew section 4Tower 4Crane top and climbing frame 3Falling tower section 2Jib pendant & luffing ropes 2Suddenly moving jib section 1Tower tie 1Not known 11
Causes
19
9
7
5
3
8Erection/Dismatling/ExtendingExtreme Weather
Foundation Problems
Mechanical Issues
Misuse
Not Known
Total 51
Canary Wharf – May 2000
Canary Wharf – May 2000
■
Crane was being climbed by a six man crew
■
Collapse occurred as the last mast section was being added on the Sunday
■
Three men fatally injured as result of the 120m fall
■
Debris over wide area of Canada Square
■
Issues:►
Training►
Long hours of work►
Inadequate planning►
Faulty equipment►
Manufacturer’s instructions not being followed
Worthing – February 2005
■
Two men killed■
One seriously injured
Worthing – February 2005■
De-rigging prior to dismantling
■
The two erectors fatally injured working on the jib removing hoist and trolley ropes
■
Third Erector had de-torqued tower bolts on one side of the mast
■
Jib was slewed■
Slackened bolts failed and crane collapsed
■
Crane owner prosecuted and fined £389,000 for not managing the dismantling process effectively
■
Issues►
Training►
Planning
Battersea – September 2006
■
BPR 222 Crane ■
Crane had been in use for a number of weeks
■
Joint below slew ring failed■
Jib fell across site into an adjacent road
■
Crane Driver + Member of public killed
■
Slew ring bolts had been replaced shortly after erection
■
Investigation concentrating on method used to replace bolts.
Seattle – November 2006
Seattle – November 2006
■
Official enquiry blamed inadequate design of foundation
■
Fatigue failure■
Lack of maintenance and inspection
■
Issues:►
Planning►
Base design►
Maintenance►
Thorough examination
Liverpool - January 2007■
JASO Luffer►
3 years old►
CE marked ►
DOC to EN 14439■
Crane was in use►
Light load►
Close to minimum radius►
Wind near maximum in- service limit
■
Jib fell backwards across the site during a lifting operation
■
1 Construction worker killed
Liverpool – Investigation Findings
■
Jib at small angle to the vertical■
Wind from the front held the jib up and caused the luffing rope to go slack
■
Luffing rope jammed in the sheaves■
Operator tried to lower off and paid out rope from the luffing winch, which looped down the back of the crane
■
Luffing rope became free allowing the jib to drop until the slack rope arrested its fall
■
Large dynamic load caused the jib to fail and the slewing section and counter jib became detached from the top of the tower at the slew ring
■
One of the counterweights fell on a construction worker causing fatal injuries
■
Issues:►
Crane design standard
Liverpool Animation
Croydon – June 2007
Croydon – June 2007
■
Climbing team had not used the equipment before and had not had any specific training on its use
■
Crane owner fined £100,000 + £33,196 costs
■
Issues►
Training ►
Planning►
Not following manufacturer’s instructions
New York – March 2008
■
Favelle Favco Luffing Jib Tower Crane
■
3 Fatalities■
Being climbed
■
Fabric lifting sling failed, causing tie to fall
■
Top of crane demolished building two blocks away
■
Issues►
Planning►
Selection of equipment
Miami – March 2008
■
Libeherr luffing jib crane
■
Climbing operation■
Tower section fell
■
2 Fatalities ■
Issues:-►
Planning►
Selection of equipment
Miami – March 2008
New York – May 2008
■
Kodiak luffing tower crane■
In-service but not lifting
■
2 Fatalities■
Slew ring support failed
■
Said to be 24 years old■
Same owner as March incident
■
Issues:-►
Maintenance ►
Thorough examination
Rotterdam – July 2008■
The crane was lifting a heavy load within its rated capacity close to the mast.
■
It was required to slew the crane & manoeuvre the load along the jib such that the load was very close to the maximum permitted at the required radius
■
During final positioning of the load it “ran away” down the jib, overloading the crane and causing it to fail at the mast section
■
Failure due to incorrect setting of the PLC/Inverter trolley motor control system
Common Issues
■
Inadequate Planning■
Inadequate Training
■
Maintenance Issues■
Through Examination Issues
■
Not Following Manufacturer's Instructions■
Poor Selection of Equipment
■
Poor Base Design■
Design Standard Issues
Planning for the Safe and Effective Installation and Use of Tower Cranes
on Site
Planning for Installation
■
Choose your tower crane supplier with care■
Maintain same key personnel from Crane Provider and Principal Contractor/Hirer throughout the process from initial enquiry to dismantling
■
Initial meeting on site to establish►
Site restrictions and hazards►
Temporary works requirements►
Responsibilities for liaison■
Detailed risk assessments and method statements
■
Method statement sign off■
Pre activity site inspection and meeting
■
Checks on day of operation■
Permits to erect, climb or dismantle
■
Keep Talking!!
Guidance on the Management of Installation Process
Guidance on the Management of Installation Process
Guidance on the Management of Installation Process
Guidance on Design of Foundations
Guidance on the Management of use of Tower Cranes
Guidance on the Management of use of Tower Cranes
Guidance on the Management of use of Tower Cranes
Guidance on Maintenance, Inspection and Thorough Examination
All Construction Plant-hire Association (CPA) and Strategic Forum Plant Safety Group
Guidance Documents can be downloaded free at
http://www.cpa.uk.net/p/Tower-Crane-Interest-Group
The Tower Crane Register
The Tower Crane Register
■
Aims to improve tower crane safety and public confidence in their safety
■
Register required by the Notification of Conventional Tower Crane Regulations 2010
■
Came into effect 6th April 2010■
Only affects conventional top slew tower cranes on construction sites – Not SETCs or Truck Mounted
■
Responsibility for ensuring notification is made rests with the user (hirer) of the crane
The Tower Crane Register When Notification must be Made
■
Notification must be carried out with 14 days of the date of any through examination:-►
following the crane’s installation and before being put into use for the first time on a particular site;
►
when the crane is reconfigured on site, eg when the height of the mast is altered;
►
when the crane stays on-site long enough for the existing thorough examination to expire;
►
if exceptional circumstances liable to jeopardise the safety of the crane have occurred.
The Tower Crane Register Information to be Notified
■
The name and address of the company providing the crane for use on the site.
■
The address of the construction site at which the crane has been installed;
■
Information sufficient to identify the crane including, where known, its date of manufacture.
■
The date of the thorough examination;■
The name and address of the employer for whom the thorough examination was made;
■
Whether the thorough examination revealed any defects involving imminent risk of serious personal injury.
The Tower Crane Register Method of Notification and Cost
■
Two ways to notify HSE► Online at http://www.cranesregister.org.uk;► By post by completing a form which can either
be downloaded from the above website, or by contacting HSE’s Infoline for a form and returning it to:
•
HSE Cranes Register, Health and Safety Executive, Field Operations Division, London Divisional Administrative Office, Rose Court, 2 Southwark Bridge, London SE1 9HS
■
Cost► £20 per Notification
Further Information
■
The Crane Register Website► www.craneregister.org.uk
■
HSE Guidance Leaflet INDG 437
Thank You