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 , travelling cranes and monorails hoists 24 September 2012

Foong Kah Choong Member Working Group for SS 497

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

/ WG Acknowledgement Acknowledgement

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

Name Convenor:

Er. Manivel Rudrapathi

R@dians Consultancy Services

Members:

Mr. Foong Kah Choong

MHE-Demag (S) Pte Ltd

Mr.. Goh Chin Keong Mr

Ministry of Manpower

Mr. Goh Kim Teo

PSA Corporation Ltd

Mr. Han Kin Sew

Workplace Safety and Health Council

Mr. Kiang Seng Jack

W Richards Pte Ltd

Assoc Prof Ong Lin Seng

Nanyang Technological University

Mr Mark Ong

Jenmon International Pte Ltd

Mr Bernard Soh

Singapore Institute of Safety Officers

Er.. Alvin Er Alvin Yeo Kheng Khe ng Hock Ho ck

AY Safety Consultancy and Inspection Services 2


/ Revision

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 n ustr a pract ces an ega requ rements 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

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Overhead Travelling Cranes


Full Portal Crane

Gantry Cranes

Semi-portal Crane


Jib Cranes


Monorail system

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/ SS Table of Contents

Contents of SS 497 : 2011 Section 1 - General 1. Scope 2. Normative references 3. Definitions 4. Legislation relevant to this standard 5. Responsibilities

Section 2 – Design Considerations . roup c ass ca on o 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 Maintenance 15.Safe use and operation of cranes 16.Inspection and testing 8


Duties of Stakeholders

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 Designer • Lifting Supervisor, Rigger, Signalman

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• 3.8

Crane erector

– The contractor who erects or dismantles the crane and who shall be authorised by a crane manufacturer to do so.

e crane erector s a erect or smant e a crane n 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 & Warning Devices

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 •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 12


/ Documentation & Markings

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) •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)

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Documentation & Markings

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

• 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)

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/ Manufacture & Construction

Manufacture and Construction •Permanent means of access shall be provided for service personnel to reach those parts of the crane w c nee 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.

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Repair Modification & Maintenance

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

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.

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Inspection & Maintenance

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 - 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. 17


/ Inspection & Maintenance

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 ” “ / Installation” checklists are provided in the annexure.

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Information to be considered when installing an overhead travelling or gantry crane

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

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

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