Part 10: Tower cranes

10.1 General

Tower cranes (both new and second-hand) require design verification by an inspection body in accordance with the PECPR Regulations and parts 2 and 5 of this code, prior to certification for use within New Zealand.

Parts 3, 4, 6, 7 and 8 of this code also apply.

A supplier, manufacturer or controller of such a tower crane shall provide this documentation, as in part 5.2, to the inspection body carrying out the design verification.

1. A statement to confirm that the seismic requirements and wind loadings for operating in New Zealand have been taken into account in the design calculations as per appendices E and F is required. The statement shall specify the maximum in-service and out-of-service design wind speeds. The zone factor (ZF) of 1.2 shall apply to all cranes. Wind forces are to be calculated as per AS/NZS 1170.2:2002 Structural design actions – Wind actions.
2. For full details of the safe load indicators, radius indicators and so on that are required on the various crane types, refer to Appendix A.

10.2 Additional requirements

In addition to the requirements in part 10.1 and part 3: Operational requirements for controllers, the following are also required:

1. Electrically powered cranes should have phase failure protection so that, in the event of a phase failure, ALL phases are shut down.
2. All new rope luffing tower cranes shall have a secondary brake on the luffing drive. This is not retrospective.
3. Initial inspection of used cranes and annual visual and operational inspections are required to assess the general condition for continued safe operation and certification.
4. All tower cranes should be overload tested to 125% SWL after design approval certification and before the first use in New Zealand. (This test may be performed outside New Zealand if witnessed by a properly authorised and approved testing/inspection authority.) Thereafter, cranes are not to be overloaded except where agreed by the inspection body and the manufacturer. Setting of the load limits is to be performed, in accordance with the manufacturer’s instructions, by an adequately trained person, duly authorised by the controller, at each and every erection or configuration change, or every 12 months.
Testing of the load limits is to be performed each week by the crane operator or a competent person.
5. A plan should be developed for dealing with any emergency
6. Inspection of new and existing tower cranes is to be in four distinct parts as follows:

Part 1: An inspection by an equipment inspector prior to erection together with inspection of any repairs found necessary

Inspections will cover (but are not limited to):

1. an inspection of all components shall be carried out on every occasion prior to a tower crane being erected. This is commonly referred to as a ground inspection.
2. maintenance and repair records including any new rope certificates
3. general condition of crane structure, fastenings, towers, boom sections, counter boom section, counterweights (fixed or moving), A-frames, cab section, base section, climbing frame, rails
4. all parts to ensure they are marked for identification purposes
5. slew ring inspection and report to manufacturer’s recommendations
6. coatings condition (paint, etc.)
7. general wear and tear (including report on electrical equipment by an appropriately qualified person)
8. weld condition
9. counterweight section
10. sheaves and bearings
11. hoist, luffing, slew brakes and linings
12. safety guarding
13. winch drums
14. gearing
15. power pack
16. hydraulic system, rams and attachments
17. condition of hoist, luffing, trolley and pendant ropes and counterweight ropes
18. bridle
19. rope anchors and dead ends
20. hooks, hook blocks and swivel bearings
21. base anchors to be subject to magnetic particle inspection for cracks and the date of testing recorded
22. crane bolts operating in tension to be tested for defects by visual and magnetic particle inspection techniques upon each dismantling of the joints/connections or every five years, whichever occurs first, or earlier if recommended by the manufacturer. This includes slewing, tower and tower head bolts, if applicable.

Note: Any bolts found with crack-like indications shall be removed from service and destroyed. IANZ-endorsed NDT reports are required.

Further detailed in-depth inspections may be required depending on results of visual inspection.

Additional items may be identified by the crane owner for inspection.

All signage hoardings and advertising billboards or banners that in any way affect the wind forces acting on the crane, other than as originally provided for by the manufacturer, must be specifically authorised by the manufacturer for the specific crane model and use during both in-service and out-of-service conditions, in accordance with the requirements of clause 10.1(1) or 11.1(1) as appropriate.

The mountings of any non-manufacturer-original signage hoardings, billboards and banners shall be approved by a chartered professional engineer. Flags (including hook-mounted flags) must be authorised by the manufacturer for the specific crane model and use and attached to the crane only during in-service conditions.

Note: Tower cranes are not to be erected for the first time until the equipment inspector has been presented with the completed design verification.

Part 2: The inspection and testing of the tower crane after erection and annual inspection for recertification.

Inspections and testing will cover (but are not limited to) the following items.

The following documentation is to be provided by the controller to the equipment inspector prior to testing commencing:

1. Statement from the controller with details of crane configuration, which must be within design verified parameters, including number of towers, jib length, counterweight weights certificates, rating sheet, new rope certificates, planned changes in height with details of tie-ins and number of towers between tie-ins, details of any clash zones and load-testing programme.
2. Foundation certificate, covering design and construction, from a chartered professional engineer and crack testing results of base anchors. IANZ-endorsed NDT reports are required.
3. IANZ-endorsed NDT report of crack testing of tower bolts.
4. Statement from the erector, who needs to have obtained a nationally accepted qualification, that the crane has been erected in accordance with the manufacturer’s recommendations, including the vertical tolerances of the tower.
5. Test weight certificates.
6. Torque wrench accuracy certificate.

Inspection prior to testing to include:

1. crane access
2. base section installation
3. tower bolts
4. rope anchors and dead ends
5. ladders and platforms
6. pins, washers, split pins, locking plates
7. boom sections
8. counterweight sections
9. hydraulics
10. general electrical equipment.
11. bolt torques (where applicable) to be checked in accordance with the manufacturer’s recommendations.

Refer to Appendix I: Tower crane inspections – minimum requirements for a tower crane inspection checklist.

Testing to include:

1. crane operation
2. driver’s cab and controls
3. hoist, trolley and boom limit switches
4. load moment cutouts
5. hoist speed limiters
6. phase failure and rotation protection
7. calibration and testing of load moment cutouts, SLIs and load indicators, where fitted, in accordance with the manufacturer’s instructions.

Part 3: The inspection by an equipment inspector and testing of the tower crane at alteration of the height and/or jib length when installed on a site

Inspections will cover (but are not limited to):

1. general inspection of crane condition
2. inspection and identification of new tower sections
3. confirmation of the maximum number of towers between tie-ins
4. checking results of magnetic particle inspection report of tower bolts where applicable
5. inspection of tie-in collars and supports and documentation of manufacture
6. statement of a satisfactory load test by an independent inspection organisation

Note: After repairs have been carried out, the crane is to be tested to the figure provided by the manufacturer in the repair specification.

7. confirmation that rope length is able to reach the lowest point with three turns left on the drum.

Part 4: The inspection of climbing system components

1. Prior to use, all tower crane climbing components shall be subject to an inspection by an equipment inspector, and a record of the inspection shall be kept on file and reported.
2. Following the installation of the climbing system onto the tower crane and before being placed in service, all components must undergo a pre-operational inspection and systems check by the person in control of the climbing operation. A record of this inspection shall be kept on file.

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