WSH COUNCIL - Crane Safety Symposium 2012 24th September
Tower Crane Safety
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Welcome Terence Tan Director – Customer Support Manitowoc Crane Care
Manitowoc Cranes Products and Services • Grove mobile telescopic cranes • Manitowoc lattice-boom crawler cranes • National Crane boom trucks • Potain tower cranes • Manitowoc Crane Care • Manitowoc Finance
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Manitowoc Crane Division
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Manitowoc Crane Care Division Products and Services • Training, parts, documentation and end-user support services • Dedicated service for all regions • Support for the life of a product • International dealer network with multiple locations • Support, training and parts service center available worldwide 24/7
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Tower Crane Safety
Program Outlines: 1. Introduction 2. Types of Tower Crane 3. Safe Distances 4. Fixing angles/Foundation 5. Safety limit switches/Weathervaning 6. Operator’s Aids 7. Anti-Collision 8. Maintenance. 9. Counterfeit Parts and Consequences
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Types of Tower Crane
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Kinds of Jib
Self-erecting More compact and easier to transport, this is an ideal crane for quick jobs in the city.
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Kinds of Jib
Fixed-jib
Meant for even the most demanding job requirements, this type of tower crane is built for heavy lifting.
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Kinds of Jib
Luffing jib
For job sites where operating space is limited, a tower crane with a luffing jib is preferred.
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SELECTING A TOWER CRANE:
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QUALITY (BRAND) – Proven safe, meets the required productivity performance, reliability, and in accordance with international standards. TYPE APPROVED.
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PRICE – consider the resale value. You pay for what you get.
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AFTER-SALES SUPPORTS (PARTS & SERVICE) – 24/7 support available? Local representative?
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LEASE OPTION, RENT-TO-OWN, FINANCING CONSIDERATIONS.
Maximum carrying load required
MCi85A/B
5t
MC115B MC175B
6t
8t
MC205B
MC235B
10t
10t
MC310-K12 MC310-K12 75LVF30 70RCS30 MC310-K16 MC475-M25
12t
16t
MCR225 75LVF35
Replace gray14t 25t box with image
Lifting is the primary use of cranes. Therefore, it is of utmost importance that you choose the crane that can carry the load that your job requires.
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MCR225 100LVF35
Maximum free-standing height (m)
MCi85A/B
35.70
MC115B MC175B
44.90 44.90
MC205B
59.70
MC235B
59.70
MC310-K12 MC310-K12 75LVF30 70RCS30 MC310-K16 MC475-M25
57.50
56.90
74.91
MCR225 75LVF35
MCR225 100LVF35
56.4 (at the shortest jib length)
For the construction of skyscrapers and tall structures, tower cranes are used with anchors to achieve towering heights.
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Maximum jib length (m)
MCi85A/B
50
MC115B MC175B
55
60
MC205B
MC235B
60
65
MC310-K12 MC310-K12 75LVF30 70RCS30 MC310-K16 MC475-M25
70
70
80
MCR225 75LVF35
MCR225 100LVF35
30m
With the wide range of jib lengths available, it’s easy to cover the operation radius required by varying projects.
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Min. Ground/Base Reqd. (Chassis) (m)
MCi85A/B
3.8 x 2.8
MC115B MC175B
4.5 x 4.5
4.5 x 4.5
MC205B
MC235B
6.0 x 6.0
6.0 x 6.0
MC310-K12 MC310-K12 75LVF30 70RCS30 MC310-K16 MC475-M25
6.0 x 6.0
6.0 x 6.0 8.0 x 8.0
MCR225 75LVF35
MCR225 100LVF35
6.7 x 6.4 (static cranes)
Ground space is one of the most important factors to consider in choosing what crane to use. Potain’s wide model range provides you ample options that you can choose from.
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Other Criterion
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Min./Max. Trolley Speed (m/min)
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Min./Max. Hoist Speed (m/min) (depends on load)
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Min./Max. Slewing Speed (rev/min)
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Min./Max. Travel Speed (m/min)
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Min. Electric power requirement (kVA)
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Min, Genset power requirement (kVA)
Respect Distances
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Respect Distances
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Fixing Angles/Foundation
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Fixing Angles/Foundation
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Fixing Angles/Foundation
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Safety Devices
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Limit Switches
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Load Limiters
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Anemometer (Wind Meter)
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Weathervaning Putting the crane out of service
• The crane should be in free slewing/weather vaning mode (rotation in 360°) •
No load suspended on the crane
• Raise the hook before the limit switch operates • Move the trolley close to the crane tower • Tighten the rails clamps (for travelling cranes) • Cut off the current by means of the isolating switch and lock this latter by means of a padlock
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Weathervaning Storm Wind Speed – Out of Service
• Recommended parking angle varies depending on jib length, crane height and crane model.
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Weathervaning – Limit Switch
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Anti Collision – Top Tracing
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Anti Collision – Top Tracing
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Anti Collision – Top Tracing
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Anti Collision – Top Tracing
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CRANE MAINTENANCE
Maintenance Schedule
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Maintenance of Slewing Mechanism
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Trolley Winch Maintenance
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RCS Hoist Winch Mechanism
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LVF Hoist Winch Mechanism
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Maintenance of the Mast Panels
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Maintenance of the Rope Angle Corrector
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Cable Winder Maintenance
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Adjusting the Tension of the Cable The tension of the cable is ensured by a torque transmitted by a friction drive. To adjust the torque, proceed as follows:
-The adjustment must be carried out with hot motor
-Unscrew the plug (1), turn it around and introduce it into the filling hole in order to block the adjusting screw (2)
- Turn the cable winder by hand to the right (A) (operator on the side of the cable winder) so as to increase the torque of the friction drive and to the left (B) to decrease it.
- The torque is exact when the cable bears at standstill on the lower roller of the guide roller box
- The friction drive must never be blocked:
-- neither to the right risk of damage of the friction pulley -- nor to the left risk to decentrate the collector with respect to the brush-holders
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Fishplate Shaft Maintenance
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Genuine Parts
Importance of using original spare parts
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COUNTERFEIT COMPONENTS
46 Crane’s Today, July 2007
WHY ARE COUNTERFEIT COMPONENTS DANGEROUS FOR US?
Legal Issue – Manufacturer & Govt. Bodies specify only original parts can be used on crane Safety Issue – Sub-standard material can affect crane’s stability Liability Issue – Original manufacturer will void the warranty and no insurance will cover your lost.
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SAFETY ISSUE 1. Source of Steel What is the source? - A general steel mill certificate provided by the steel manufacturer or by the general supplier will tell us the type of steel received, and the details about its mechanical and chemical properties. What is the steel mill’s manufacturing process? – The manufacturing process employed by the steel mill has the most important role in assuring the steel’s quality. 48
SAFETY ISSUE 1. Source of Steel What is the source?
(con’t)
– Poor quality control during the steelmaking process may cause cracks in the product. – Counterfeiter will not buy good steel in order to keep their price low!!
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SAFETY ISSUE 2. Grade of Steel
(Strength & Ductility)
Strength: The ability of the steel to withstand certain amount of load without breaking – Some of the materials used on tower section counterfeits are weaker than required and do not meet the necessary minimum static strength requirements. – Consequently, there is a much higher risk of material breakages, resulting in a higher risk of the crane stability.
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SAFETY ISSUE 2. Grade of Steel
(Strength & Ductility)
Ductility: The mechanical property of the steel that enables it to sustain plastic deformation before breaking −“B” Grade steel has good ductility at room temperature but become brittle at zero degree. “D” Grade steel has the same ductility of “B” Grade steel at -20 degrees C. −Ductile steel gives a warning before it fails- it deforms before it breaks. Brittle steel will fail without warning. −For Tower Crane, Manitowoc uses the Potain ST1011 standard 51
SAFETY ISSUE 3. Standard of Manufacturing – A good quality management system in the factory is essential to produce good and consistent product to exact dimensions and tolerances. – Counterfeiters copy us but they don’t copy our manufacturing standard.
VS POTAIN 52
COUNTERFEITER
SAFETY ISSUE 3. Standard of Manufacturing – Manitowoc’s Quality management system is certified to ISO 9001 by German certification TÜV. – What is the quality system used by the counterfeiter? – Who certifies them? Are the certification body qualified?
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SAFETY ISSUE 4. Working (Fatigue) Cycle Fatigue cycle: The number of work cycle provided by a component before it fails due to fatigue stress –When you use steel from an unknown steel supplier with weaker strength and lower Grade compounded with sub-standard weld joints & inconsistent manufacturing process, what can you expect? –Do the counterfeiter test their part for fatigue? –Original Manitowoc components come with the assurance that these parts will fully withstand the stresses imposed on them for the lifetime of the equipment. 54
LIABILITY ISSUES No Insurance Coverage
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LIABILITY ISSUES No Insurance Coverage If a person combines crane parts from different manufacturers and puts it in circulation – then that person, in legal terms, becomes a manufacturer and is responsible for declaring that the entire crane conforms with certain recognized safety standards such as CE. In Europe, the industry’s liability insurance association argued that combinations of components from different manufacturers required these cranes to be certified by a third party expert through preliminary design and approval tests. Previous examinations of individual components are rendered invalid once these components are combined. A fresh examination must be carried out in full on the new crane configuration. 56
Responsibilities – Everyone plays a part
Tower Crane Safety = Zero Accident • • • •
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Manufacturer/Industry/Authority Crane Operator Crane Owner Others – Safety officer, Project Manager etc…
Potain Tower Cranes
RESPONSIBILITIES OF A CRANE OPERATOR Only certified & qualified operators should be permitted to operate cranes. Exercise caution necessary for the safe operation of their equipment. Adhere to instructions in crane manual. Report any unsafe conditions, (including defects in the machine) to supervisor immediately. Check that all hitches are secured and all loose material is removed before lifting. Act on any emergency stop signal. 58
RESPONSIBILITIES AS A CRANE OWNER Crane accidents can be avoided through: • Adherence to the Manufacturer’s Instructions – Crane’s loading capacity » Lifting radius, weight & height should be determined before a lift takes place. » No loads should be lifted out of the crane’s lifting capacity.
•Buy only genuine Parts from Manufacturer or Authorized Dealers!! 59
Any Questions…..
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Thank You For Listening……
