SS 497_Code of Practice for Design, Safe Use and Maintenance of Gantry Cranes

Overview of SS 497 : 2011

Code of practice for design, safe use and

maintenance of gantry cranes, overhead maintenance of gantry cranes, overhead travelling cranes and monorails hoists

24 September 2012

Foong Kah Choong

Member

Working Group for SS 497

Name

Convenor: Er. Manivel Rudrapathi

Members: Mr. Foong Kah Choong

Mr. Goh Chin Keong

Mr. Goh Kim Teo

Code of practice for design, safe use and maintenance of gantry cranes, overhead travelling cranes and monorails hoists

/ WG Acknowledgement

The organisations in which the experts of the Working Group are involved are:

R@dians Consultancy Services

MHE-Demag (S) Pte Ltd

Ministry of Manpower

PSA Corporation Ltd

2

Mr. Goh Kim Teo

Mr. Han Kin Sew

Mr. Kiang Seng Jack

Assoc Prof Ong Lin Seng

Mr Mark Ong

Mr Bernard Soh

Er. Alvin Yeo Kheng Hock

PSA Corporation Ltd

Workplace Safety and Health Council

W Richards Pte Ltd

Nanyang Technological University

Jenmon International Pte Ltd

Singapore Institute of Safety Officers

AY Safety Consultancy and Inspection Services

� SS 497 : 2011 is a revision of SS 497 : 2002,

which was for overhead travelling cranes only.

� SS 497 : 2011 is expanded to include

overhead travelling, gantry, jib cranes as well as

hoists on monorails.

� SS 497 : 2011 is aligned with current

industrial practices and legal requirements on

/ RevisionCode of practice for design, safe use and maintenance of gantry cranes, overhead travelling cranes and monorails hoists

3

industrial practices and legal requirements on

the safe use, design, maintenance and testing of

such cranes.

� SS 497 : 2011 is based on AS 1418.1 :

2002 – “Cranes, hoists and winches Part 1 :

General Requirements”.

� No significant changes design-wise except

the updating of referencing standards.

Overhead Travelling Crane


Overhead Travelling Cranes


Gantry Cranes

Full Portal Crane Semi-portal Crane


Jib Cranes

Monorail systemCode of practice for design, safe use and maintenance of gantry cranes, overhead travelling cranes and monorails hoists

7

Contents of SS 497 : 2011Section 1 - General1. Scope

2. Normative references

3. Definitions

4. Legislation relevant to this standard

5. Responsibilities

Section 2 – Design Considerations6. Group classification of cranes

/ SS Table of ContentsCode of practice for design, safe use and maintenance of gantry cranes, overhead travelling cranes and monorails hoists

8

6. Group classification of cranes

7. Loads and load combinations

8. Design of crane structures

9. Crane mechanisms

10.Electrical equipment and controls

11.Hydraulic equipment and controls

12.Pneumatic equipment and controls

13.Documentation and marking

14.Manufacture and construction

Section 3 – Operation and Maintenance15.Safe use and operation of cranes

16.Inspection and testing

Responsibilities of stakeholders in line with the Workplace Safety and Health Act

• Crane Owner

• Employer

• Crane Manufacturer

• Crane Supplier or local representative of the Crane Manufacturer

• Crane Erector

Duties of Stakeholders


9

• Crane Erector

• Crane Designer

• Lifting Supervisor, Rigger, Signalman


• 3.8 Crane erector

– The contractor who erects or dismantles the crane and

who shall be authorised by a crane manufacturer to do so.

The crane erector shall erect or dismantle a crane in The crane erector shall erect or dismantle a crane in

accordance to the manufacturer’s instructions. The

sequence of the processes and the methods being used

shall be strictly adhered to …………………………………

……………………. It is also the erector’s responsibility

that supervisors and workers involved in the erection and

dismantling work should be trained and competent in

such work.


• 3.13 Employer

– The person who engages operators, riggers and/or

signalmen under a contract of service to perform lifting

operation.

The employer has the duty to ensure that, where

applicable, every crane operator, rigger and signalman

has been trained on their respective roles to ensure safe

lifting operation.

Limiters and Warning Devices

•Overload Limiter (regardless whether crane is likely to

handle unpredictable loads that can result in overloading

of the mechanisms and structures)

•Load Indicator

•Hoisting and Lowering Limiters

/ Limiters & Warning

Devices


12

•End Stops (mechanical end stops shall be provided at

the ends of tracks / rails and bridges, and shall be able to

take up 100% of the buffer force at maximum speed at

full load)

• Long-travel and Cross-travel Motion Limiters

• Crane-to-crane or Crab-to-crab Limiters

• Working Space Limiters (to prevent crane colliding into structures in prohibited space e.g.

rooms/office cabins placed within the coverage of the crane movement)

• Indicators and warning devices

Documentation and Markings

Crane Manufacturer or Crane Supplier shall

provide:

•Crane Operator’s Manual (which includes

instructions on duties of operators prior to,

during and after operation)

/ Documentation &

Markings


13

•Maintenance Manual (which includes details

of safety precautions to be observed during

maintenance and servicing of the crane)

• Logbook or Service Record (where details of maintenance, service and repairs carried out on

the crane are recorded and kept up to date)

• Crane Parts book (where all parts and elements are adequately illustrated and identified)

Documentation and Markings

The following shall be marked clearly and visibly on

the crane structure (e.g. on the bridge):

•Serial Number assigned by the Crane Manufacturer

•Ministry of Manpower’s Lifting Machine Registration

Number


Documentation &

Markings

14

Number

• Safe Working Load (SWL) of the crane (SWL shall reflect maximum permitted SWL of the

crane as well as individual SWL of lifting devices where two or more lifting devices are fitted on

the crane)

E.g. 1. If the crane structure is designed to maximum SWL of 5 ton, and it consists of two

lifting devices with SWL 2 ton and 5 ton, the marking shall reflect SWL 5 ton (5/2 ton)

E.g. 2. If the crane structure is designed to maximum SWL of 10 ton, and it consists of two

lifting devices with SWL 5 ton each, the marking shall reflect SWL 10 ton (5 + 5 ton)

Manufacture and Construction

•Permanent means of

access shall be

provided for service

personnel to reach

those parts of the

crane which need

/ Manufacture &

Construction


15

crane which need

servicing and shall be

provided with the crane

stationed at its

servicing position so

that there is no need to

move the crane during

servicing.

• In cases where the permanent platform is not feasible, mobile access equipment (e.g. scissor

lift or boom lift) or scaffold structures are to be provided.

Repair, Modification and Maintenance

•All repair, modification and maintenance shall be handled by competent persons in the

relevant areas.

Who are these competent persons?

SS 497 : 2002 SS 497 : 2011

Repair Modification &

Maintenance


16

A person, who by way of his

vocational background and

experience, has good knowledge in

overhead travelling cranes.

A person, who through formal training

and work experience, possesses the

practical and theoretical knowledge

of cranes to enable the detection of

defects or weaknesses and

assessment of their fitness for the

intended purpose and safety for

continual use.

Inspection and Maintenance

� Initial Inspection (by Authorised Examiner for new and altered cranes, prior to initial use)

� Regular Inspection

- Visual Inspection

� by Operator before operations (pre-ops checks)

� by operator at periodic intervals together with a designated person in accordance to the Manufacturer’s recommendations

Inspection &

Maintenance


17

- Statutory visual examination (by Authorised Examiner)

Who are these designated persons?

SS 497 : 2002

A person who is designated by the

owner of the crane to conduct a

general inspection on the crane

before the start of each shift or work

day. He shall keep a record of such

general inspections and report any

anomaly to the owner for follow-up

actions.

SS 497 : 2011

A competent person who is appointed

in writing by the crane owner or

employer to conduct a general

inspection on the crane. He shall keep

a record of such general inspections

and report any anomaly to the owner

for follow-up actions.

Inspection and Maintenance Checklist

•All inspection, maintenance and

servicing shall be conducted and

recorded in checklists. If such

checklists are not provided by the

crane manufacturer sample “Daily

Pre-Operation” and “Maintenance


/ Inspection &

Maintenance

18

Pre-Operation” and “Maintenance

/ Installation” checklists are

provided in the annexure.


Information to be considered when installing an overhead

travelling or gantry crane

20

Be proud to use the SS 497 : 2011 in your Crane Specification

Documents

SS 497_Code of Practice for Design, Safe Use and Maintenance of Gantry Cranes