Tower cranes critical faults

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:

design issues or issues such as structural rust which occur over long periods of time and should be identified and considered at servicing and higher level inspections.
issues such as flat battery on communication equipment or topping up of fluid from normal use that can be addressed on site
other issues that would by their very nature stop the crane, ie engine or power failure.

List of critical faults

Tower and other structural members including boom

Loose holding down bolts
Missing connection bolt(s) or pins
Impact, eg from another crane or mobile plant or crane hitting a structure, that has caused visible damage.
Damaged crane ties, eg following an impact or storm damage.

Slew

Malfunctioning slew drive or slew brake
Slew limits, if fitted, not functioning.

Hoist

Malfunction of hoist or brake(s)
Rope damage, condemnable
Sheave damage, condemnable
Any hoist limit malfunction, eg anti two block
Hook or swivel damage, condemnable.

Luff, where fitted

Malfunction of luff hoist or brake(s)
Rope damage, condemnable
Sheave damage, condemnable
Any luff limit malfunction, eg buffer limit.

Trolley travel, where fitted (ie non luffing cranes)

Travel limits malfunctioning, including deceleration limits, where fitted.
Rope damage, condemnable
Sheave damage, condemnable
Trolley wheels/ bearings malfunctioning.

Hydraulic system, where fitted

Hydraulic fluid leaks, other than minor weeping between connectors or around seals on hydraulic cylinders.
Bulge or cracking of a hose.
Fluid below minimum level, where unexplainable, as indicates a possible serious leak.

Controls, limiters and indicators (where fitted)

E stop malfunction
Load indicator malfunction (ie outside manufacturer’s calibration tolerance)
Radius indicator malfunction
Overload protection system malfunctioning (ie outside manufacturer’s calibration tolerance)
Engine indicators or warning devices malfunctioning.

Fire extinguisher or extinguishing system

Extinguisher or system missing, discharged or otherwise non-functional, except where a redundant (eg duplicate) extinguisher or system remains operational.

_{Acknowledgements}

_{Industry plant consultative committee comprising WorkCover, the Master Builders Association of NSW and the Construction, Forestry, Mining and Energy Union.}