Technical information for tower crane owners and operators that includes two safety alerts with links to the relevant codes of practice, guides and Australian standards.
Alert about the potential risks from fires on tower cranes.
The purpose of this alert is to advise officers and workers of businesses (or other PCBUs) of the potential risks from fires on tower cranes, following the catastrophic incident in Sydney in 2012.
A number of potential contributing factors have been identified, and given the serious consequences, this safety alert is being released to provide advice on inspections and possible modifications to control the risks.
Although the incident involved a diesel/hydraulic tower crane it is possible for a fire on electric tower cranes, so the following information should also be considered by those with electric tower cranes.
During a fire on the machine deck of a diesel/hydraulic powered luffing tower crane, the luff rope failed, allowing the jib to collapse onto the worksite below. Fortunately there were no injuries as the worksite had been evacuated and the jib fell into the evacuated worksite, rather than into a populated area.
The incident appears to have resulted from the fire heating the luff rope and weakening it to the point where it could no longer support the jib and consequently failed. The fire could have been fuelled by the diesel fuel or the hydraulic fluid used to power the crane motions, however at this stage the ignition source has not been identified.
There are a number of potential contributing factors on the machine deck to the fire starting and then continuing for sufficient time to damage the rope.
PCBUs that use plant must ensure risks to the health and safety of workers and others due to the plant is minimised as far as reasonably practicable.
As well as the general obligations to provide and maintain plant, it is expected that PCBUs with tower cranes undertake the following applicable actions, if they have not already done so since the incident:
This incident also acts as a reminder to principal contractors of the importance of a site evacuation plan and communication systems to effect the evacuation. Principal contractors are advised to review, and if necessary update, their site evacuation plans and communication systems in light of this example of a structural collapse. They are reminded that the WHS Regulation requires the emergency procedures to be tested.
Originally issued by the Industry Plant Consultative Committee in December 2012.
Industry plant consultative committee comprising SafeWork NSW, the Master Builders Association of NSW and the Construction, Forestry, Mining and Energy Union.
Guidance on how to minimise the risk of falls when using tower cranes.
This alert provides guidance to designers, manufacturers, suppliers, installers, operators, and persons with control of sites on how to minimise the risk of falls when using tower cranes.
Persons who access areas of a tower crane may be exposed to the risk of a fall resulting in serious injury or death. Crane personnel have fallen from the machine deck, and also from the access system within the tower.
Falls can occur over unguarded edges, through open penetrations and from ladders. The likelihood of falls occurring is substantially influenced by the design of the access system.
Recent inspections of tower cranes indicate that fall protection, particularly the design of access systems, can be improved. These improvements may apply to both older and newer model cranes, from various manufacturers and suppliers.
Tower cranes must have sufficient access to all work areas of the crane, including control stations and all parts requiring regular inspection or maintenance.
Risk management is usually most effective at the design stage. Designers and manufacturers of new tower cranes or components must ensure access is designed to minimise risk of falls, including by:
Where risk of falls cannot be sufficiently minimised by design, information on the remaining risk and alternate controls must be passed down the supply chain, for example fall arrest equipment used during crane erection.
Persons who supply tower cranes to site must ensure access sufficiently minimises risk of falls, so far as reasonably practicable. This includes:
Issues identified on out of service cranes are likely to be present on similar models currently in service. Whilst it may be reasonably practicable to wait until a crane is dismantled before making the modifications, interim measures to minimise falls may need to be developed for the duration of any current installation.
Persons who install, erect and commission tower cranes also have a responsibility for minimising risk of falls from tower cranes, including by:
Persons who service, maintain, operate or have control of site with tower cranes can also minimise risk of falls from tower cranes by:
Persons should not, however, make alterations to tower cranes without permission from a suitably qualified person, such as the designer or manufacturer.
The Work Health and Safety (WHS) Act requires persons conducting a business or undertaking to ensure, so far as is reasonably practicable, that workers and other persons at a workplace are not exposed to risks arising from the business or undertaking, including the risk of falls. Refer sections 19 to 24 of the WHS Act.
Part 4.4 of the WHS Regulation place specific obligations on duty holders to identify reasonably foreseeable risk of falls, and then manage accordingly.
Also, refer to:
The Master Builders Association of NSW and the Construction Forestry Mining Energy Union NSW have more information.
Industry plant consultative committee comprising WorkCover, the Master Builders Association of NSW and the Construction, Forestry, Mining and Energy Union.
Catalogue No.WC01450 © Copyright WorkCover NSW 0315
The following are the SafeWork NSW expectations in relation to the matters raised by the Coroners in relation to the tower crane fire and collapse at Broadway in 2012 and the death of a crane operator at North Sydney in 2014.
Under the Work Health and Safety (WHS) legislation various entities have obligations in relation to tower cranes, including the crane owners, others with management or control of the crane, those maintaining the crane and those with onsite management of the crane (usually the Principal Contractor).
As there are a wide range of tower crane designs and power sources there is no one size fits all solution. Whilst it is possible to minimise the risk of a fire on a tower crane it is not considered reasonably practicable to eliminate the possibility of a fire occurring, therefore the focus here is on minimising the risk by preventing a fire from reaching an intensity that could endanger the operator or result in catastrophic failure of the crane.
There is potential for combustible fluids to leak on to an existing fire causing a longer, more intense fire which could cause mechanical or structural damage to the crane.
These cranes should be fitted with a pre-plumbed, extinguisher system aimed at locations where the combustible fluids could pool and burn. Unless automatically activated, the control should be readily accessible to the crane operator.
The fitting of a fire warning system, eg a fire detection system or camera within the power pack with operator cabin display, should be considered. Where a fire warning system is not fitted, you will need to record that consideration and determination in the crane documentation, eg how the existing engine monitoring systems etc already provide adequate early warning.
Many electric cranes are considered to have insufficient quantities of combustible fluids to cause a fire of sufficient intensity and duration to warrant the above measures.
Even tower cranes without an operator cabin have inspection or maintenance workers working at height and should have fire extinguishers fitted to allow evacuation in the event of a fire.
The provision of programmed maintenance is a task relying on coordination between the site and maintenance provider to enable the maintenance to be conducted on schedule and in a safe manner. Unfortunately, like many outdoor activities, maintenance may be disrupted by the weather and may need to be rescheduled at short notice.
The WHS legislation requires that where more than one entity has a duty in relation to the same matter they must, so far as is reasonably practicable, consult, co-operate and coordinate activities with the other duty holders. However, each entity retains responsibility for their duty even if they delegate the actual actions needed to discharge the duty to others.
The site controller, usually the principal contractor, needs to consult, co-operate and coordinate activities with the maintenance provider to minimise, so far as reasonably practicable, the risks to health and safety of the maintenance personnel caused by the site controller’s actions or inactions. Issues to consider include:
All IROFSD suction and feed hoses running from the hydraulic oil tank should be replaced with fire resistant, or better grade, hydraulic hoses. The selection of replacement hoses should be made in consultation with a specialist hydraulic hose supplier or the crane manufacturer.
Where a crane is already erected on site, IROFSD hoses should be protected by a fire resistant cover, and the hose replaced as above before the crane is next erected.
The maintenance manual should be updated to list the new hose specifications, rather than the old IROFSD hoses, as the specification for future replacement hoses.
New cranes are to be supplied with fire resistant suction and feed hoses.
When crane operators or maintenance personnel are ascending/descending or working on the crane they are often alone and from the time they begin to climb the crane are engaged in remote or isolated work. Therefore an effective communication system is required to manage the risk of them being unable to get help in an emergency.
For crane operators, this could be as simple as having a 2-way radio in the cabin and advising a specified person that they are about to ascend/descend and for that person to wait for advice of completion of the climb before attending to other duties. If no such advice is received in a reasonable climbing time the specified person is to investigate and if necessary raise the alarm.
For maintenance workers, what is an effective communication system will depend on the circumstances, eg how many people are working on the crane, their locations, the tasks and weather. It may be carrying a 2-way radio or some other system.
Any changes made to the crane, fire warning systems or systems of work regarding the crane should be updated in the relevant crane documentation.
A list of faults which, if identified by the operator during an inspection.
This document is intended to assist crane crews and those persons with management or control of operating tower cranes.
It contains a list of faults which, if identified by the operator during an inspection or crane operation, are considered to warrant the immediate make safe and shut down of the crane until clearance to resume operation is given by a competent person.
Depending on the fault this clearance may be based on a diagnosis from a competent person with the crane company that operation can continue as is, or may require a site inspection, or repair / part replacement.
Note, the list does not include:
Industry plant consultative committee comprising WorkCover, the Master Builders Association of NSW and the Construction, Forestry, Mining and Energy Union.
Catalogue No.WC01715 © Copyright WorkCover NSW 0315
A summary of high level information for consideration throughout the life cycle stages of a tower crane.
This document provides a summary of high level information for consideration throughout the life cycle stages of a tower crane.
Industry plant consultative committee comprising SafeWork NSW, the Master Builders Association of NSW and the Construction, Forestry, Mining and Energy Union.
Key messages following the November 2012 crane fire at Broadway in Sydney.
The following key messages to industry were identified by the investigation and subsequent verification project following the November 2012 crane fire at Broadway in Sydney. They are most relevant to tower crane manufacturers and suppliers, however may also help crane crews or persons with management or control of tower cranes to work with crane companies to address site issues.
Service intervals, as defined by the manufacturer should be followed.
The system used should include:
Principal contractors (hirers) and crane companies (suppliers) have a joint legislated obligation to consult, cooperate and communicate in matters where they have joint responsibility, which would include ensuring this servicing occurs.
Documentation and record keeping should be improved to better meet the needs of the various parties, eg:
Operator’s Logbook systems are a part of ensuring safe crane use.
The logbook should:
Operator induction and assessment of competence should be conducted by a person(s) competent in use of the crane and site procedures, and may include:
Where there is no-one on site familiar with the specific crane it would be expected that the crane company be involved in inducting the first operator.
The crane company should be advised when a new crane operator commences.
A person from the hiring entity (usually the principal contractor) should be nominated as the crane supervisor.
This person should:
Principal contractors have legal obligations as principal contractors and also as a PCBU with joint responsibility for the crane.
To comply with those obligations they should:
Emergency planning for the site must include a response to issues with tower cranes. The plan should include:
There have been many advances in technology over the years that now provide reasonably practicable means to control risks better than when many of the tower cranes were manufactured. Improvements in technology should be considered for retrofitting in older cranes. Some are now considered mandatory in new cranes.
These advances include the features specified in Australian Standard AS1418.4 and the following:
Crane companies should have systems in place to review similar and reoccurring faults. Crane companies should identify why parts are failing and if maintenance needs to extend beyond fixing the immediate failed part. This analysis would include:
This analysis should include consideration of industry trends, known incidents, service bulletins and alerts issued by manufacturers and other information sources to identify factors that influence the service life of components.
The designer / manufacturer should also be informed, to provide them information that may assist them in identifying trends and therefore, if appropriate, addressing the issue more globally.
When a design change occurs, that may affect health and safety of a tower crane, the legislated design alteration process must be followed:
Alterations include:
WorkCover’s position is that this process must be followed for any design alteration that has already occurred or future design alterations that have the potential to affect health and safety.
The message is particularly important given the age of some tower cranes.
Fire extinguishers appropriate for the potential fire risk, during both operation and maintenance, should be provided in appropriate locations for the crane operator and maintenance personnel and consider the working location of the people and possible fire sources.
The risk of a fall must be managed in accordance with the hierarchy of control which requires using engineering, isolation and substitution controls in favour of administrative controls such as fall arrest systems.
Information on the risk of falls and control measures to be used must be passed down the supply chain.
Where the risk is managed by the use of a fall arrest system, emergency procedures, including rescue procedures, must be established and tested so that they are effective.
Industry plant consultative committee comprising WorkCover, the Master Builders Association of NSW and the Construction, Forestry, Mining and Energy Union.
Tower crane maintenance has come under increased scrutiny following the UTS fire. Three issues consistently raised are:
To address these, the Industry Plant Consultative Committee advises the following:
Following these will not only make your site safer, but also prevent costly delays waiting for parts or maintenance workers to become available after a failure has stopped the crane operating.