Part 12: Overhead travelling and portal cranes

Note: Overhead travelling and portal cranes are referred to as gantry cranes in this part. This includes straddle carriers.

12.1 General

Gantry cranes 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, designer or controller of such a gantry crane shall provide this documentation, as in part 5.2, to the inspection body carrying out the design verification and equipment inspection.

12.2 Additional requirements

In addition to the requirements in part 12.1 and part 3: Operational requirements for controllers, the following are also required:

1. Welding is to be carried out in accordance with the requirements of the construction standard or AS/NZS: 1554 Structural steel welding.
2. Cranes shall be designed and constructed to one entire standard (both mechanical and structural) when the mechanical and structural components are designed as a homogenous whole, i.e. mixing of standards is not acceptable. Exception is made in the case of purpose-built approved hoist units, utilising either chain or wire rope for lifting, when running on the crane beam as a separate unit. Any changes to the dimensions of the standard hoist runner shall be design verified.
3. A record of inspection of the crane during manufacture.
4. Suitable warning notices of any live conductors on gantries and access points.
5. Clearly marked electrical power isolation switches. Pendant controls and radio controls are to have an emergency stop/reset button fitted.
6. Safe and adequate means of access for inspection and maintenance purposes are mandatory. Where this physically cannot be provided, an alternative method must be agreed between the manufacturer, the supplier and the owner of the crane. The means of access must be included in the design verification and certification of the crane by the inspection body.
7. the crane supporting structure shall have a structural certificate covering the design and construction from a chartered professional engineer stating any load limitations or conditions. Where multiple lifting units are fitted to the cross travel of the crane beam, the safe working load of each lifting unit and any limitations of loading shall be prominently displayed on the crane beam. Where foundations are required for a free-standing gantry crane, investigations are needed to confirm that the ground on which the crane will stand is not subject to any form of subsidence.
8. In the event of failure of wheels or axles, provision is to be made on the long and cross travel to prevent a crane or any working part of a crane from falling off the rails.
9. Electrical installation shall comply with the Electricity Regulations 1997.
10. A visual inspection by an equipment inspector of the crane installation prior to testing.
11. A performance test for the full length of travel, where practical, including (if fitted):
    1. end limit switches
    2. proximity limits. If not specified in the standard the crane was designed to, for crane speeds less than 40 m/min, buffers are acceptable. However, for speeds greater than 40 m/min then proximity switches are necessary
    3. in all cases where two or more cranes are on the same runway then proximity limits must be fitted to all cranes
    4. load cells
    5. upper and lower hoist limits
    6. radio-control operation.

Note: Radio controls are to comply with BS 466 section 31.7 or equivalent.

12. Load testing to manufacturing standard or 125% of the maximum SWL if the manufacturing standard is not available.
13. Deflection test to be carried out in accordance with the standard to which the crane was manufactured, or 1/750th of the span under maximum safe working load if the standard does not specify deflection.

Note: This DOES NOT apply to wharf container cranes.

14. Test the operation of the hoist brake with the power supply turned off and maximum SWL applied.
15. Lowering of maximum safe working load by hand control with power off (where applicable).
16. Long travel braking (where applicable).
17. Any structural change to the crane or its components requires design verification.
18. Relocation of an existing crane to be re-inspected by an equipment inspector for the renewal of certificate and an overload test as if it was a new crane. The crane supporting structure shall have a structural certificate covering design and construction from a chartered professional engineer together with any load limitations.
19. Uprating of the crane is to be approved by a crane designer and design verifier. Increased loading on the supporting structure is to be approved by a chartered professional engineer. Testing to be carried out as for a new crane.
20. Replacement parts must be to the manufacturer’s specifications.
21. Annual visual and operational inspections by an equipment inspector are required to assess the general condition for continued safe operation and certification. This should cover (but is not limited to):
    1. maintenance and repair records
    2. operation of the crane to be demonstrated
    3. condition of hoist ropes and/or chains
    4. brakes and linings
    5. operation of all limit switches, alarms and proximity sensors
    6. operation of radio control in all modes (if fitted)
    7. rope anchors and dead ends. Approved Code of Practice for Load-Lifting Rigging, parts 4 and 5.1 apply.
    8. sheaves and bearings
    9. crane nameplate and details
    10. general condition of electrical equipment including pendant controls and phase failure protection
    11. foundations and supports for any apparent signs of distress. Where this is considered necessary, a chartered professional engineer’s report should be prepared on the condition of the foundations and supports.
    12. rails and securing attachments where access is practical.

Note: The full length of the long travel rails and securing attachments shall be inspected when the crane is installed, at the first annual inspection and thereafter every four years, unless the crane service or environment and so on requires more frequent inspection. Suitable temporary access to the full length of the rails must be provided, where practical, to permit close visual inspection.

13. driver controls (where fitted)
14. cab windows (where used as protection in steelworks etc.) and that the cab is securely attached to the crane structure
15. cross-travel trolley/crab
16. rope drums and wrap
17. couplings
18. handrails, ladders and guards
19. derailment catchers
20. end stops and buffers
21. wheels, including bearings and axles
22. crane structure and fastenings including welds, rivets and bolts, and cab to crane structure
23. coatings condition (paint, etc.)
24. lubrication
25. hooks
26. lifting spreaders when used as a hook.

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

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