Technical Quality & Risk Guide

For Internal Use only

Thorough Inspection of Tower Cranes

In-service Inspection & Verification - GM IVS 004
December 2011

Move Forward with Confidence

 INDUSTRY & FACILITIES

GM IVS 004 Thorough Inspection of Tower Cranes

Rev 00

Date of first edition: 20/10/2011

Date of last revision: NA

Classification:
Category: In-service Inspection & Verification/Equipment Inspection/ Lifting and handling equipment
Corporate Product Code: I 22 (or I 10 by default in case of Multi Technical Fields)

Editor(s): Ad Hoc Group: (i.e. Ananthakrishnan Mukundamony, Alain Chandèze, Arnaud Marquant, Alexandre
Crinière, and Alain Henckes)
Editor Manager: Arnaud Marquant
Approved by: Alain Henckes

Forward:
The objective of this guide is to define minimum requirements for in-service inspections and should be mandatory
used, unless a specific regulation in force is available in a country. In this latter case, the criteria enclosed could
be added for a professional management of a lifting equipment park.
This is the free synthesis of the following:
• Lifting Operation and Lifting Equipment Regulations 1998 (LOLER),
•
st
French Regulation which came in force on March 1 2004 for inspection of lifting equipment and their
hoisting accessories,
• BV experience feedback,
It gives a general indication of some of the main requirements focused on priority to safety criteria and it is
organised to be fulfilled during the inspection.
After satisfactory completion of examination a Certificate including an annex shall be issued, and a Defect
Report will be issued for equipment failing the acceptance criteria for thorough inspection.

Note: The paragraph numbering adopted in the following guides, for every equipment, is derived from a global
matrix valid for all lifting appliances and their accessories
As a result, the numbering for particular lifting equipment - e.g. Tower Crane - does not include all paragraphs of
this set.

For accessories and tackles please refer to the “GM IVS 002 Thorough Inspection of Accessories.”

GM IVS 004 – Thorough Inspection of Tower Cranes Page 1/83

Rev 00
 SUMMARY

0.0 DESCRIPTION 3 8.2 LOCK-OUT OF USE (TAGGING OUT) 41

1.1 ACCESS TO THE CABIN AND TO THE 8.3 OTHER EMERGENCY STOPS 42
COCKPIT 5 8.4 INDICATORS, SIGNALING AND WARNING
1.2 OTHER ACCESS FOR MAINTENANCE AND DEVICES 43
TESTING 6 8.5 IDENTIFICATION OF CONTROL DEVICES 44
2.1 BUMPERS, SHOCK ABSORBERS 8 8.6 AUTOMATIC RETURN TO NEUTRAL POINT 45
2.2 RAILS AND BEAM BEARINGS, FASTENERS 10 8.7 WARNING SIGNALS 46
2.4 FOUNDATION, STATE AND SOIL STRENGTH 8.9 PROTECTING DEVICES AGAINST
AND SUPPORT STRUCTURES 12 UNWILLING OR NON VOLUNTARY
2.5 HORIZONTAL BLOCKING 13 OPERATIONS 47
3.2 GUYS AND TIES 14 9.1 FASTENERS, CLIPS, STRAPS, CLAMPS 48
3.4 CONNECTIONS, BRACKETS, ASSEMBLIES, 9.2 FASTENING DEVICES 49
JOINTS 15 9.4 MAIN RUNNERS AND LINES, GUYS (WIRE
3.8 GUIDES - ROLLERS - BUMPER- CART - ROPES OR CHAINS) 50
SKATES - DAMPERS 16 10.3 LOCKING DEVICE WHEN OUT OF ORDER 53
3.10 MAST, LADDER 17 10.4 BRAKES OF HORIZONTAL MOVEMENTS 54
3.12 DRIFT PLATE 18 10.5 HOIST BRAKE 56
3.13 JIB, BOOM, BOOM EXTENSION, TURRET 19 10.6 POWER AND GEAR TRANSMISSION
3.20 TELESCOPING CAGE 21 SYSTEM 58
3.23 COUNTER-JIB BALLAST 22 10.9 PROTECTION OF THE MOBILE PARTS OF
4.1 ASSEMBLY AND FASTENERS 23 THE POWER TRANSMISSION 59
4.3 POSITION HOLDING OUTRIGGERS ROAD 10.11 PROTECTION AGAINST FALLING OF
EXTENSIONS 24 OBJECTS 60
4.7 STABILIZERS 25 10.19 IMMOBILIZER ( IN SERVICE AND OUT OF
4.8 SLEEPERS, RAILS, SUB-FRAME 27 ORDER ) 61
4.15 BALLAST, COUNTERWEIGHT 28 11.1 LIMIT STOPS RELATING TO LIFTING
5.1 POWER SUPPLY LIMITATION 29 MOTIONS 62
5.2 EQUIPMENT, WIRING SYSTEM, COILING 11.2 ANY OTHER LIMIT OR TRAVEL STOPS -
UNITS 30 LIMIT SWITCH ACTUATOR 63
5.4 VOLTAGE, POWER, PRESSURE 31 11.4 ROLLOVER PROTECTION DEVICE 65
7.1 HEATING AND AIR CONDITIONED SYSTEM 32 11.6 LOCKING DEVICE OF MOBILE UNITS
7.2 CONSTITUTION, FASTENING DEVICE, FOOT DURING DRIVING PROCESS ON
RACK 34 ROAD/TRACK 66
7.3 PROTECTION AGAINST FALLS FROM 11.17 ANEMOMETER 67
HEIGHT 35 11.21 WIND-RELEASE DEVICE 68
7.5 OPERATOR’S PROTECTION 36 11.22 LIMITING DEVICE ACCORDING TO THE
7.6 PROTECTIONS OF THE ACCESSIBLE MOBILE LIFTED LOAD 69
ELEMENTS. 37 11.42 ANTI-COLLISION SYSTEM 70
7.8 WORKING VISIBILITY (GLASS 14.1 STATIC PROOF LOAD TEST 72
TRANSPARENCY, WINDSHIELD WIPERS, 14.2 DYNAMIC PROOF LOAD TEST 74
REARVIEW MIRROR) 38 CERTIFICATE 76
7.12 SEAT 39 ANNEX TO CERTIFICATE 77
8.1 START / STOP 40 DEFECT REPORT 80

GM IVS 004 – Thorough Inspection of Tower Cranes Page 2/83

Rev 00
0.0 Description

Tower Crane – Element Mounting

Tower Crane – Element Mounting with luffing boom

GM IVS 004 – Thorough Inspection of Tower Cranes Page 3/83

Rev 00
 Masson’s scaffold crane

Automatic self-erecting crane

GM IVS 004 – Thorough Inspection of Tower Cranes Page 4/83

Rev 00
1.1 Access to the cabin and to the cockpit

RISKS CONTROL MEASURES METHODOLOGY

Risk of falling during access to the
driving position or during labor.
Risk of drop of the hatch when access
by the roof of the cabin.
To secure access to the driving position of foot steps,
ladders, or recovery handles shall be installed on access to
the cockpit or to the cabin.
These devices including walkways shall be equipped with
anti-slip surfaces.
Implement a locking device on the hatch.
Verify that the foot steps, ladders or recovery handles are firmly attached to the
chassis and are in good condition (no distortion, breaks,...).
In the case of a gateway, check the condition of the guards and baseboards.
Check the status of doors and hatches and their support devices locking in the open
position.

Verify the interval between the levels of rest.

Check by visual inspection the gap between the
bars and the alignment of the sections of ladders.

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Rev 00
1.2 Other access for maintenance and testing

RISK CONTROL MEASURES METHODOLOGY

Risk of falling or shear during the access
to the maintenance and testing areas
subject to frequent assembly.
Access to maintenance and testing areas shall be safe,
be composed of foot steps or ladders secured to the
frame, handling rods recovery properly arranged.
The surfaces of the paths (foot-steps, ladder rungs,
walkways) shall be anti-slip.
Ensure the consistency of the assembly with the manufacturer's instructions.
The lack of instructions can not determine the conditions of assembly and installation
of the device.
Check the condition of the foot-steps, ladders, handling rods, walkways, guards,
baseboards (no distortion, fracture, defective fixing...).

GM IVS 004 – Thorough Inspection of Tower Cranes Page 6/83

Rev 00
 Check the condition of the
fixings

For safety reasons, do not fast to the lifeline if you

haven’t the assurance of its good condition.

The lifeline is out of the scope of the inspection.

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Rev 00
2.1 Bumpers, shock absorbers

RISKS CONTROL MEASURES METHODOLOGY

Drop or rollover of the equipment at the
end of the railway.
Distortion of the structure under
unamortized impact.
Projection of the operator in case of
unamortized crash.
End of railway shall be equipped with bumpers and
shock absorbers.
Ensure the consistency of the mounting bumpers with the manufacturer's instructions.
The lack of instructions can not determine the conditions of assembly and installation of
the device.
Check by visual inspection the good condition of the structure, the bumpers, the shock
absorbers and their alignment.

Ensure that the bumpers are positioned at least 1 meter

before the end of the rails
Ensure the presence and the fixing of splice bars
placed at the ends of the path of translation.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 8/83

Rev 00
 Bumpers installed at the ends of railways must be securely attached.
Shock absorbers shall be installed either on the frame or on the carriage.
The bumpers shall be designed to stop the tower crane or the beam of the crane in case of failure of the limit switch.
If risk of slipping (bumpers clamped on the railway) the bumpers should be installed at least one meter before the end of the railway.
Check the condition of welded or bolted devices.
Check the condition of bumpers including hydraulic devices, rubber and spring devices.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 9/83

Rev 00
2.2 Rails and beam bearings, fasteners

RISKS CONTROL MEASURES METHODOLOGY

Sideways running.
Premature wear of rails and rollers.
Derailment of the equipment.
Drop of mechanical parts due to over
strength.
Drop of the equipment.
Rollers adapted to the rail.
Alignment of rails and beams.
Fixing of the rails and beams adapted to the constraints.
Alignment and gap between rails.
Prefer splayed or welded joints.
Ensure the consistency of the assembly of the runway with the manufacturer's
instructions.
The lack of instructions can not determine the conditions of assembly and installation
of the device.
Check if any anomaly during the translation test.
Check if any abnormal noise when moving the equipment.
Check by visual inspection the structure, the means of assembly and the fasteners.

Check that there are no obstructions on the

railway

Ensure the presence of the

equipotential bonding

GM IVS 004 – Thorough Inspection of Tower Cranes Page 10/83

Rev 00
 Check the level of rail wear (matting, burrs, cracks)
Check the adequacy of rail and wheel (Clearance not too important).
Check the fixing of rails (cracks in welds, adjusting clips, lag screws)
Check the fastening of the beams especially for those suspended (welding, bolting).
Check the distortion of the frame elements.
Pay attention to different noises when moving the equipment.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 11/83

Rev 00
2.4 Foundation, state and soil strength and support structures

RISKS CONTROL MEASURES METHODOLOGY

Rollover of the unit may result from
failure of supports resulting itself from:

Insufficient strength of the
structure,

Presence of a nearby
excavation,

A poor stabilized embankment,

Presence of water infiltration that
can change the soil bearing.
Cranes must be installed following the
manufacturer's specifications and according
its instructions.
Calculation notes must ensure that the
strength of materials depending on the soil
type and maximum loads have been applied
in the light of mounting characteristics of the
crane and constraints due to the wind which
is subject the structure.
Consult the documentation to justify the resistance of the supports. This frame resistance must
be based on the nature of the soil, the presence of nearby excavation, the maximum wind speed
to consider the environment of the site and drawing back of charges from the maximum
reactions of the crane.
Check relevance of records about the justification of resistance supports towards the
characteristics of the crane (mark, type, height).
If descriptive elements and evidence of the resistance are not available, tests cannot be
performed, because, lack of descriptive and evidence of resistance of the frame do not allow
knowing the conditions of erection and setting up of the unit.
Check by visual inspection the condition of the foundation, infrastructure, wheel base, and the
anchorage (basis ...)

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Rev 00
2.5 Horizontal blocking

RISKS CONTROL MEASURES METHODOLOGY

Rollover or derailing of the unit may Manufacturer’s instructions should set the The lack of instructions forbids determining the conditions of setting up of the unit.
result from a poor basis with a lack of maximum allowable tolerances inclinations
horizontality or flatness. of frame supports and running tracks. Ensure that the wheel base is substantially level or that the ruling gradient complies with the
manufacturer's instructions.
Failure of one element of the structure
resulting from a wrong distribution of
stresses.

Verify this by using the followings:

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Rev 00
3.2 Guys and ties

RISKS CONTROL MEASURES METHODOLOGY

Structural failure resulting from improper The Manufacturer’s instructions Ensure the proper mounting of guys or tie rods and their assembly in accordance with the
installation (negative ruling gradient determine the position and number of manufacturer's instructions (number, length, position)
when off load) or a deterioration of the guys to be used depending on the In the absence of instructions the tests can not be performed and the conditions of setting up
guys. length of the boom and the counter-jib. and installation of the unit can not be determined.

Check by visual inspection the good conditions of components and their fastenings (see 3.5).

Guys and ties

Check the attachment of

tie rods

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Rev 00
3.4 Connections, brackets, assemblies, joints

RISKS CONTROL MEASURES METHODOLOGY

Destruction or collapse of the equipment
or part of the equipment due to localized
distortion, ruptures of connecting
elements contributing to the strength of
the equipment
The connecting parts shall resist: Check by visual inspection of accessible parts that the assembled elements have no defect which
design, calculation, manufacturing and may reduce their robustness and stability.
construction methods and proper Verify the absence of relative movements of components when the equipment is moving.
maintenance

Pins, staples Bolting, stop axle

GM IVS 004 – Thorough Inspection of Tower Cranes Page 15/83

Rev 00
3.8 Guides - rollers - bumper- cart - skates - dampers

RISKS CONTROL MEASURES METHODOLOGY

Loss of control of horizontal movement. Install adequate rails and rollers (shape, size). Pay attention to abnormal noises and behavior during the movement of the
Fall of the moving parts of the equipment Provide axles of rollers with stop devices (spring retaining equipment.
Derailment of the equipment ring , plates, pins, slotted nut). Check by visual inspection of the wear of the rollers, their fixing and
positioning

Check the status of

bumper and rollers
No cracks or tears
No distortions

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Rev 00
3.10 Mast, ladder

RISKS CONTROL MEASURES METHODOLOGY

Rollover or destruction of the crane
resulting from an improper composition
of the setting up of the masts, failure of
one of its components or an improper
setting up with the constraints due to the
effects of wind
Degradation of components subject to
distortion due to stress and weather
conditions.
Erection of the crane in compliance with the
Manufacturer’s instructions about
installation and assembly.
Determining types of component elements
of the tower according to wind speed and
should this happen the particular conditions
on the site.
Constructive provisions to ensure damage
due to stress and weather conditions.
Check the documentation which determines the wind speed to take into account on site.
Check the compatibility of elements of the tower with the Manufacturer's instructions based on
the maximum wind speed.
In the absence of instructions to ensure correspondence with the Manufacturer’s requirements,
the tests can not be performed and the conditions of assembly and installation of the unit can not
be determined.
In the absence of evidence supporting the maximum speed to take on the installation site, the
conditions of assembly and installation of the unit can not be determined.
Check by visual inspection:
- The condition of the frame, welds (no cracks, tears, peeling, distortion or severe
corrosion)
- The condition of the tower
- The absence of excessive clearance
- The proper implementation of assembly devices.
For bolted parts no clearance should be raised. (risk of loosening the bolts)
In the presence of appreciable clearance in the structure report to the Manufacturer to determine
the possible action to take.

The Manufacturer's instructions should define the maximum heights of the

equipment according to the different possibilities of setting up (wheelbase chassis,
basis, geographical area mounting ...). For heights greater than those specified in
manufacturer’s instructions, additional means for stabilization are required (ties,
anchors, wiring ...).

GM IVS 004 – Thorough Inspection of Tower Cranes Page 17/83

Rev 00
3.12 Drift plate
RISKS
Rollover of the crane by putting across
the boom or cons of the wind direction.
Tumbling of the crane due to the
presence of vertical stabilizer.
GM IVS 004 – Thorough Inspection of Tower Cranes
Rev 00
CONTROL MEASURES
The manufacturer’s instructions state the
position of the drift plates as well as their
number depending on the length of the
boom.
Vertical drift plates
METHODOLOGY
Check in the manufacturer’s instructions the correlation between indications on the position and
number of drift plates needed and those installed on the crane.
In lack of instructions, the conditions of assembly and installation of the equipment can not be
determined.
Check the condition of the vertical stabilizers and their fastenings.
Check the presence of any other elements (e.g. fixed or mobile advertising plates) with a
windage area on the boom, the jib or the tower.
Page 18/83
3.13 Jib, boom, boom extension, turret
RISKS
Structural failure resulting from
improper installation or a
distortion of structural elements.
GM IVS 004 – Thorough Inspection of Tower Cranes
Rev 00
CONTROL MEASURES
The manufacturer’s instructions shall
determine the composition of the jib and boom
elements and the characteristics of their
assembly
METHODOLOGY
Ensure that the setting up of the equipment complies with the
manufacturer’s instructions.
In the lack of instructions the tests can not be performed and the
conditions of assembly and installation of the equipment can not
be determined
Check by visual inspection:
- The conservation status of the elements, distortion or
significant corrosion.
- The presence of fixing and connecting devices
Ensure that:
- A vertical distance of 2m under the hook or the gripping
device, is respected for the last floor upon which workers
can be found.
- A minimum horizontal distance of 0.60 m is respected
between the fixed elements and any part of the crane.
- A minimum distance between the equipment or loads and
live power lines: 3 m for voltage < 50 000V and 5m for
voltage ≥ 50 000V
The provisions concerning the measures to be implemented to
mitigate the risks caused by interferences or banned flyovers are
excluded from this guide.
Page 19/83
 Absence of distortion, cracking or tears

No noticeable clearance
between elements.

No appreciable wear on the runway

Deterioration of the welded plate used to stop the axle assembly boom,
may lead to its untimely withdrawal.

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Rev 00
3.20 Telescoping cage

RISKS CONTROL MEASURES METHODOLOGY

Rollover of the unit resulting from
increased of the windage area on the
structure.
The manufacturer’s instructions state for the
right position of the telescoping cage during
assembly or disassembly stage.
Check that the position of the telescopic cage complies with manufacturer’s instructions.
Check the approval of the manufacturer in case of a different position from that which is
advisable.
In lack of manufacturer’s instructions, the conditions of assembly of the equipment can not be
determined.

Telescopic cages

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Rev 00
3.23 Counter-jib ballast

RISKS CONTROL MEASURES METHODOLOGY

Rollover of the equipment resulting from:

Underweight ballasting the
counter-jib

Fall of ballast.
Structural or slewing mechanisms
failures resulting from an excessive
ballasting of the counter-jib.
The manufacturer’s instructions specify the
weight of the main or counter-jib ballasts
depending on the characteristics of
assembly and installation of the crane.
Check that the weight and position of the counter-jib ballast comply with the manufacturer’s
instructions.
Check their fastening and securing.
In lack of instructions to ensure the consistency of the counter-jib ballast with the
recommendations set provided by the manufacturer, the tests can not be performed.
In lack of manufacturer’s instructions, the conditions of assembly and installation of the
equipment can not be determined.
Check by visual inspection of the conservation status of ballasts and their fastening on the
counter-jib.

Check the position of the ballast as a counterweight to the counter-jib

Check the setting up and maintaining the blocks to avoid swinging.
When the boom length is modified, ensure
the possibility of a change of the counter-jib
ballasts.

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Rev 00
4.1 Assembly and fasteners

RISKS CONTROL MEASURES METHODOLOGY

Rollover of the crane due to a failure
or a deterioration of fasteners or
assembly of the chassis.
The manufacturer’s instructions specify
the method of fixing and assembly of
chassis components including every
device for the assembly or
maintenance of the chassis component.
Setting up of bolts, pins drift pins, with
their stopping devices.
Ensure the correspondence of fasteners and assemblies with the manufacturer's
instructions.
In lack of instructions the conditions of assembly and installation of the equipment can
not be determined and the tests can not be performed.
Verify the absence of loose bolts, rods or pins without their stopping device designed
for preventing to untimely withdrawal.
Check that the pins are not sheared or oxidized, and pay attention to their accidental
opening.
Verify the absence of excessive clearance of assemblies secured with pins or bolts
(out-of-round wear)

Verify the presence of axles and bolts used to assemble the components including their stopping devices.

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Rev 00
4.3 Position holding outriggers road extensions

RISKS CONTROL MEASURES METHODOLOGY

Inadvertent movement of the outriggers Automatic locking devices (mechanical or hydraulic) on Check the presence, good conditions and operation of mechanical and / or hydraulic
or stabilizers support beams during beams to avoid going out of clearance limits. locking devices.
transport. In the case of hydraulic cylinders, they shall be
equipped with locking devices closed at rest.

Checked by visual inspection the condition and operation of the

locks of outriggers

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Rev 00
4.7 Stabilizers
RISKS
Rollover or destruction of the equipment
following the failure or blocking of stabilizers.
Drop in load due to the imbalance of the
equipment and lack of stability.
GM IVS 004 – Thorough Inspection of Tower Cranes
Rev 00
CONTROL MEASURES
Distribution device of responses made by the
support of the equipment consistent with the
strength of the soil.
Blocking to meet the tolerances of inclination
allowed by the manufacturer.
Following types of materials and conditions of use:

Additional means (stabilizers, supports or
anchors) can be implemented to ensure the
stability of the equipment.

All cylinders of the stabilizers whose failure
could cause loss of stability must be fitted
with manual or automatic locks.

The automatic locking hydraulic cylinders
shall be provided by controlled check-valves.

The blocking provided by fixed mechanical
systems does not require locks: nut and bolt.
METHODOLOGY
Ensure that the support conditions are correct.
Verify that the additional means to ensure the stability of the equipment comply
with manufacturer's instructions.
Ensure, when the system includes cylinders, the presence of check-valves, their
good condition and operation.
Verify that the stabilizers are working properly and they can be operated in their
full travel.
Check the state of:

Ducts and fittings to the chassis,

Base plates and attachments to cylinders,

Beams,

Cylinders,

Locks in transport position,

Axles stopping pins
.
Visually Check mechanical locks.
During a load test check that stabilizer position can not change actionning
commands.
Checked by a test load stabilizer positions can not change notably during the relief
of a support and action on the levers of power stabilizers.
This operation shall be carried out of the complete absence of all movement and
of all electrical or mechanical supply
Suspension Lock:
Some cranes are fitted with devices for securing the front and / or backwards
suspension in order to ensure their stability during operations on stabilizers and
tires.
Blocking can be achieved by mechanical or hydraulic.
When carried out by hydraulic cylinders, check the presence and operation of
locking devices normally-closed and pilot operated.
This operation shall be carried out of the complete absence of all movement and
of all electrical or mechanical supply.
Page 25/83
GM IVS 004 – Thorough Inspection of Tower Cranes Page 26/83
Rev 00
4.8 Sleepers, rails, sub-frame

RISKS CONTROL MEASURES METHODOLOGY

Rollover or drop of the load due to break of the chassis
or weather conditions.
Adequate design and fitting of the frame according to
the manufacturer’s instructions
Ensure that the assembly complies with the
manufacturer’s instructions.
Perform a visual inspection, no breaks, failures or
distortions.
In case of difficulties to achieve this control (no repair
pit, cleanliness conditions...), further investigations
could be required (e.g. NDT).

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Rev 00
4.15 Ballast, counterweight
RISKS
Rollover of the equipment resulting
from:
- Inadequate ballasting the
chassis.
- Tilting of the ballast.
Check fastening of the ballast
GM IVS 004 – Thorough Inspection of Tower Cranes
Rev 00
CONTROL MEASURES
The manufacturer’s instructions specify
the weight of the ballast according to
the characteristics of assembly and
installation of the tower crane.
Fastening of the ballast.
METHODOLOGY
Check with the manufacturer’s instructions that the weight of the ballast is correct
based on the maximum wind speed estimated on the site.
The absence of evidence supporting the speed limit to consider the installation on-site
can not determine the conditions of assembly and installation of the unit.
In lack of instructions to ensure the consistency of the ballast used with the basic
recommendations set by the Manufacturer, the conditions of assembly and installation
of the equipment can not be determined and the tests cannot be performed.
Check by visual inspection of the conservation status of ballast fastenings and station
keeping on the chassis
In case of swiveling
counterweight ensure that the
motion area is properly
delimited
Page 28/83
5.1 Power supply limitation
RISKS
Accidental starting can cause
uncontrolled movements.
GM IVS 004 – Thorough Inspection of Tower Cranes
Rev 00
CONTROL MEASURES METHODOLOGY
An easily accessible device shall perform Check the proper functioning of the locking device to isolate the unit from its power supply.
the functions of switching off and
separation.
All poles shall be switched off, with the
possibility of mechanical lock in the opened
position.
The device shall be directly accessible
Page 29/83
5.2 Equipment, wiring system, coiling units
RISKS CONTROL MEASURES
Accidental supplying of the bus-bar. Distance or special provisions for live parts
Live parts accidentally made accessible to avoid the contact with the moving parts of
the equipment or the load.
Putting in place a protective device (screen,
guards, security bars...).
Check by visual inspection the earthing of the frame or chassis
and presence of equipotential bonding.
GM IVS 004 – Thorough Inspection of Tower Cranes
Rev 00
METHODOLOGY
Ensure that :
• Wires, bus-bar and live parts are not accessible, protected by guards.
• Guards and protections are in good condition.
If the electrical panel is accessible in operation, check that the door can be locked in the closed
position.
Check by visual inspection the
mechanical insulation of the cable.
Page 30/83
5.4 Voltage, power, pressure

RISKS CONTROL MEASURES METHODOLOGY

Power, voltage, current inappropriate for Supply according to the manufacturer’s Check that the voltage and power are delivered according to manufacturer’s instructions.
appliances. instructions
Overheating, fire, drif or appliances
damages.

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Rev 00
7.1 Heating and air conditioned system
RISKS
Fire in the cabin due to the accidental
ignition of flammable materials or due to
the heating or air conditioned system
with consequences on the operator
(burns, asphyxia and drowsiness) and
the operation.
GM IVS 004 – Thorough Inspection of Tower Cranes
Rev 00
CONTROL MEASURES
Equipment that has the following hazards
should not be used:
- Emissions resulting from improper
adjustment or poor condition,
- Contact or collision with the operator,
- Faulty fixing,
- Heater with incandescent parts.
Prohibit the storage in the cabin of any
combustible (gasoline, oil, grease,
degreaser, rags…).
These products must be stored in closed
metal containers and placed outside the
cabin.
METHODOLOGY
Check by visual inspection:
- The absence of flammable materials in the cabin
- The lack of incandescent parts
- The fixing of the device,
- The presence and status, if any, of the protection against the risk of direct contact,
- The absence of any combustible in the cabin
Check by testing the good operation condition and the ventilation of the cabin
Page 32/83
 The heater or air conditioned systems must be Note the presence of the
safe extinguisher in the cabin

GM IVS 004 – Thorough Inspection of Tower Cranes Page 33/83

Rev 00
7.2 Constitution, fastening device, foot rack

RISKS CONTROL MEASURES METHODOLOGY

Operator's injuries as a result of:
- Fire and rapid destruction of the
cabin,
- Shearing or crushing when moving
near fixed elements
- Clashes with the projections.
Poor visibility causing errors on
operation.
The cab shall be arranged so that the driver is able to see the operation at any Check by visual inspection the condition of the
time. cabin.
The cabins shall be equipped with screens to prevent contact between the
operator and moving parts.
The cabin floor is by design or by adding a coating to be non-slip type.

Check the good condition of:

• The structure and fastening devices and trim panels
of the cabin,
• The supporting the driving position,
• The operator’s visibility is not hindered by the
addition of elements such as panels, photos,
stickers,
• The protective devices against the risks of shear,
• The cabin (no strain or tear sheet protruding that
may injure the operator when accessing or during
work).

GM IVS 004 – Thorough Inspection of Tower Cranes Page 34/83

Rev 00
7.3 Protection against falls from height

RISKS CONTROL MEASURES METHODOLOGY

Protection against falls from height. Install adapted railings, guards and crinolines. Check by visual examination the status of the protective devices

Verify the presence of removable guardrail

GM IVS 004 – Thorough Inspection of Tower Cranes Page 35/83

Rev 00
7.5 Operator’s protection

RISKS CONTROL MEASURES METHODOLOGY

The operator of the crane, when he Safety roof designed and manufactured with Check the good condition and fastenings of the safety roof.
controls the equipment from the cockpit materials of sufficient strength characteristics.
located at the lower place of the crane,
must be protected by a safety roof
against falling.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 36/83

Rev 00
7.6 Protections of the accessible mobile elements.

RISKS CONTROL MEASURES METHODOLOGY

Crushing, shearing of staff by a
mobile element or any mechanical
element in motion.
The manufacturer shall determine the means of Check that initial protections of mobile elements installed by the
protection to be implemented to protect against manufacturer have not been removed and ensure the effectiveness of their
the risk of contact with mobile elements. fastenings.
Prevent, by posting the potential risks and
prevent access by unauthorized persons.
Install adequate safeguards on every pulleys,
drums and gears, potentially accessible.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 37/83

Rev 00
7.8 Working visibility (glass transparency, windshield wipers, rearview mirror)

RISKS CONTROL MEASURES METHODOLOGY

Cut and injury to people in case of
broken glazing.
Possibility for the operator to fall on the
ground due to the disappearance of the
bottom or side window of the cabin.
Touching people or object with the load
in case of poor visibility.
The glazing shall be made of safety glass or other transparent
material offering equivalent guarantees for staff safety.
In case of wall or floor made by glass, they must be protected by
adequate mechanical guards.
If the floor has glass parts, all measures should be taken so that the
driver can not bear on these parts.
Check that:

The glazing are in good condition

The presence and the apparent good condition of protective
guards of lower part (ground level and lateral)

The cabin is equipped with a windshield wiper, if necessary.

For equipment outside a windshield wiper must be installed.

Check presence and condition of the protection against falls in cabins

equipped a floor with windows.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 38/83

Rev 00
7.12 Seat

RISKS CONTROL MEASURES METHODOLOGY

Loss of control of the load due to failure The driver's seat, if it exists, shall be secured to the cabin Perform visual inspection of the state and the fixing
of seat and arranged to allow easy driving of the equipment.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 39/83

Rev 00
8.1 Start / stop

RISKS CONTROL MEASURES METHODOLOGY

Non voluntary movement of the Install a easily accessible secured device to start and stop Check the condition of the device.
equipment or of one of its parts as a from the driving position. Perform a test run.
result of an involuntary action of the Adequate design
operator.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 40/83

Rev 00
8.2 Lock-out of use (tagging out)

RISKS CONTROL MEASURES METHODOLOGY

Using the device by an unauthorized Lock out of the access to the cab and or lock out of Check the closing of the door of the cab and the operation of the locking device.
person. the main switch on the ground floor

GM IVS 004 – Thorough Inspection of Tower Cranes Page 41/83

Rev 00
8.3 Other emergency stops

RISKS CONTROL MEASURES METHODOLOGY

Crushing or accidental strike with site personnel resulting
from uncontrolled movements caused by a failure of the
control circuit.
Accidental starting when operating on the mechanisms or
device of the equipment.
Installation of emergency stop buttons, visible Check conservation status and test the operation of emergency stop.
and quickly accessible from any person in the
danger zone and operating either on the main
power supply, or on dedicated movements
concerning devices close to mechanism.

EMERGENCY STOP
Check:
They are in good condition
They are secure
They are working properly

GM IVS 004 – Thorough Inspection of Tower Cranes Page 42/83

Rev 00
8.4 Indicators, signaling and warning devices

RISKS CONTROL MEASURES METHODOLOGY

No warning of the operator about Install all the necessary indicators to the safe operation of Visual inspection of the status of each indicator.
configuration and devices status at any the equipment (speed, pressure, electromagnets, locking Test of indicators.
time containers, overheating, cable overlap).

Check the general condition indicators (fixing, covers ...)

Ask the operator to check the operation of the indicators.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 43/83

Rev 00
8.5 Identification of control devices

RISKS CONTROL MEASURES METHODOLOGY

Mishandling causing a dangerous Clearly identify the control devices. Check the identification of control devices and perform a correlation test
movement of the load.

Check that the movement is in the direction indicated by the symbols

GM IVS 004 – Thorough Inspection of Tower Cranes Page 44/83

Rev 00
8.6 Automatic return to neutral point

RISKS CONTROL MEASURES METHODOLOGY

Continued movement of either party or Automatic return to neutral point from any Check the automatic return to neutral point of the service devices
the whole equipment as soon as the out of control service device
operator stops to drive.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 45/83

Rev 00
8.7 Warning signals

RISKS CONTROL MEASURES METHODOLOGY

Crushing or accidental strike with site personnel
resulting from movement of the load or of the
equipment.
For equipment with a cabin, a warning signal shall be
installed and shall be operated at the working station.
For equipment that can be driven from the ground a
warning signal shall be installed and operated from the
remote control.
Check operation of warning from cabin and from remote
control.
Where necessary to verify operation of devices including
light signals of travel.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 46/83

Rev 00
 8.9 Protecting devices against unwilling or non voluntary operations

RISKS CONTROL MEASURES METHODOLOGY

Non voluntary movement of the control device Service devices designed to prevent the start of one Verify the effectiveness of protection against involuntary operation of service
causing a accidental movement of the load. movement of the crane if not intended by the operator. devices.

Mechanical locking device

Sensitive detection device

Check the correct operation of protection against accidental
commands

GM IVS 004 – Thorough Inspection of Tower Cranes Page 47/83

Rev 00
9.1 Fasteners, clips, straps, clamps

RISKS CONTROL MEASURES METHODOLOGY

Degradation or breakage of the Cable ties should comply with the Ensure that the cable ties are set in accordance with the manufacturer’s instructions.
fasteners, clips, straps, clamps causing manufacturer's instructions. Verify that the ties of the fixed points of the cables are correctly implemented.
sliding of the cable and drop of the load.

Ensure cable connections comply with the

manufacturer’s instructions

Pay attention to fasteners placed at each end

GM IVS 004 – Thorough Inspection of Tower Cranes Page 48/83

Rev 00
9.2 Fastening devices
RISKS
Involuntary unhooking of the lifting
accessories and drop of the load.
Risk for the operator to get caught by
the hand on manipulating the cable
pulley block.
GM IVS 004 – Thorough Inspection of Tower Cranes
Rev 00
CONTROL MEASURES
The hooks shall be a model opposing the
accidental dropping of load.
The blocks shall be equipped with device
for handling.
Check the good conditions of
the safety latch
METHODOLOGY
Check by visual inspection the condition of the hook (no distortion, no wear, no corrosion, no
crack...).
Check it rotates freely without excessive clearance around its axis and check carefully
setting of the device (including stop rotation of the nut) if it is visible without disassembly.
Check the presence and condition of the safety latch or any equivalent device.
Check the condition of the handling devices of the block.
Check by visual inspection: kinks, wears,
corrosion, crack, failures
Page 49/83
9.4 Main runners and lines, guys (wire ropes or chains)

RISQUES MOYENS A METTRE EN ŒUVRE METHODOLOGIE DE VERIFICATION

Drop of the load due to failure of the Install suspension lines fitted to the constraints and conditions of use. Check by visual inspection the mains runners and
lines. lines.
Many causes can generate a rapid wear and failure of the lifting component:

CABLES
- mismatch of cable or chain to use,
- mismatch of cable diameters versus grooves of the pulleys,
- wrong stranding or wrong mode of winding of the cable on the drum,
- wrong duty ratio (load/ Safe Working Load)
- poor implementation of fasteners.

Cables
Ensure the cables are not worn or defective
Check the proper condition of cables
Apply the cables removable criteria:
- broken or cut strands
- flat areas caused by wearing
- reduction of the diameter over than 10%
- excessive distortion, crashing…

Note: ISO 4309 provides details on:

- maintenance, installation, testing and removal of cables.
- failure of a strand or the core of a cable
- rupture of external and close wires of a cable (one or two rope lays).
broken strands - apparent and significant wears (that occur on the portion of the cable in contact with
pulleys or friction areas). Kink
- corrosion (with complete disposal as soon as a wire is attacked and starts to lose its
section)
- important distortion (cable bent, flattened, unstranded ...)
- reduction of section when the cable is winded on pulleys

GM IVS 004 – Thorough Inspection of Tower Cranes Page 50/83

Rev 00
 Broken Pay attention to:
strand
Parts of the cable subjected to simple bending (on drum)

Parts of the cable subjected to alternating bending (on pulleys)

Parts of the cable subjected to permanent bending (pressure pulley
balancing)

The ends of the cable clamps (drum, fixed point)

Any portion of the cable subjected to a deflection

Any portion of the cable subjected to any force other than pure tension.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 51/83

Rev 00
9.5 Drums, pulleys, rope blocks, drive pinions, windlasses

RISKS CONTROL MEASURES METHODOLOGY

Degradation, disruption of cable due to
poor surface of the drum or of the pulley,
to a winding ratio is too low or its escape
from the drum or from the pulley.
The manufacturer determines the special
design to overcome these risks.
They also concern the installation of anti
bleeding on the pulleys and guard cables on
the drums
Ensure that minimum 3 wraps of the wire rope remain on the winch drum when the hook is at
the lowest position.
Ensure that the number of eligible layers and diameter of the wire rope is as per manufacturer’s
specification.
Check by visual inspection the condition of the drum and pulleys (surface flanges) and check
the fit to the profile of the cable drum grooves.

Check the good condition:

no unwanted marking on drum grooves,

presence of a cable guide device,

presence of the anti-ungroove system,

presence of stop devices on the axis,

no excessive clearance on the pulleys.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 52/83

Rev 00
10.3 Locking device when out of order

RISKS CONTROL MEASURES METHODOLOGY

In strong wind condition, uncontrolled The system shall be designed in order to ensure the continuous stop position of the Check the good condition of all devices
movement of the equipment in order to equipment when it is likely to move unexpectedly, especially under the action of wind. designed to ensure the continuous stop
avoid: position of the equipment.
- Derailment, These devices:
- Rollover, - Must be effective even in case of disruption of energy.
- Deterioration, - Can be manual , and allow vertical movements in case of particular risk
- Crushing of people. This requirement is applicable to all cranes installed outdoors.

Check the good condition of the devices:

- Distortion
- Defective fixings
- Broken welds
- Seizing.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 53/83

Rev 00
10.4 Brakes of horizontal movements

RISKS CONTROL MEASURES METHODOLOGY

Rollover of the equipment, loss of Brakes or equivalent devices shall be provided on all Check by visual inspection the braking system if any.
control of movements and involuntary horizontal movements of equipment in order to stop Perform a proof load test.
movements of the load or equipment them in any position.

These devices shall:

- Be able to operate even in case of loss of power.
Be able to operate automatically or be operated
easily at the driver position
- Be able to operate in any circumstances including
over-speed of wind
- Be properly set and maintained.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 54/83

Rev 00
 Check the good condition of visible elements and more particularly:
- That the brake linings have no important wear or are partially cut.
- The surfaces of friction of discs, drums, pulleys, or backing plates have no significant mark,
scratches or metal pull out,
- That the control system has no distortion that may reduce the movement of the braking system,
- Good condition and fixing of the control command devices, including safety stop device.

If possible, the covers should be removed to ensure the good condition of the device.
EFFICIENCY:
Perform a test of brake efficiency at nominal load.
No stopping distance is defined statutorily.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 55/83

Rev 00
10.5 Hoist brake

RISKS CONTROL MEASURES METHODOLOGY

Loss of control of the movements due to
lack of efficiency or failure of the
stopping devices.
Hoisting mechanisms fitted with breaking system or Check the condition of the braking systems, including fittings and other components if
equivalent devices able to stop or to maintain on it does not require disassembly of covers or guards.
position the highest loads (including overloads for Check by testing the braking system.
testing).
Stop and lock of the stop functions are automatically
ensured when the operator is no more acting and
even in case of interruption of power supply.

Check the condition of visible elements of the brake or equivalent device to shut down and more specifically:

The brake linings have pronounced wear, or partial cutting,

The surfaces of the discs, drums, pulleys, or flanges, have no streak, scratch or metal cutting,

The control system can freely move,

The parts of the control system are in good condition and stop safety devices are in place.

The clearances between pulley and jaws are properly balanced

GM IVS 004 – Thorough Inspection of Tower Cranes Page 56/83

Rev 00
Note

Whenever possible, please remove the covers in order to check the status of the device.
Check by proof load test their functioning and effectiveness.
Check that there are no significant shifts.
Check that the brake response time does not allow a descent when stopping at the end of an upward movement.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 57/83

Rev 00
 10.6 Power and gear transmission system

RISKS CONTROL MEASURES METHODOLOGY

Drop of the load or loss of control of the movement
resulting from the failure of a mechanism equipped
with a gear transmission system
Loss of movement control due to an important
clearance or the separation of elements of bodies
contributing to the transmission of movements.
Condition and use of the equipment as per
manufacturer's instructions
Check by visual inspection that the state of mechanism is not likely to cause
malfunctions.
Check by visual inspection the good conditions of mechanisms without removing:
gears, couplings, clutches, chain or belt transmissions, shafts bolting.
Ensure by testing for correct operation of mechanisms (noise, clearance…).
Check the lack of leakage.

Ensure during the tests:

No abnormal noise during operation (e.g., "cracking" characterizing the deterioration of mechanical gears, or bearings)

No excessive clearances

No dangerous vibrations.

Shafts, elastic or semi-elastic coupling cardan (belts, chains), output of shafts, bearings, are in good condition and
without any defect in their fixings.

No broken gear

No defective fixing of winch mount or drive motors,

No oil leakage

Check by visual inspection the clearance of the slewing ring (the lifting of a load and its removal allows its appreciation).

GM IVS 004 – Thorough Inspection of Tower Cranes Page 58/83

Rev 00
10.9 Protection of the mobile parts of the power transmission

RISKS CONTROL MEASURES METHODOLOGY

Personal injury or damage of crane
component by getting in contact with
moving parts.
The manufacturer shall determine the means of Check the manufacturer’s instructions.
protection to be implemented to protect against the risk Check the status, the fixing and good operation of the protective devices.
of contact with moving parts. The manufacturer’s
instructions shall comply with.
This includes the setting devices to prevent access to
dangerous areas.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 59/83

Rev 00
10.11 Protection against falling of objects

RISKS CONTROL MEASURES METHODOLOGY

Injury of people due to fall of any
object: counterweight of the brake,
pulleys, disc brakes, screwed or
bolted devices, covers, boxes...
Ensure protection against falling objects.
For removable covers, the counterweight of
the brake, the protection may be ensured by
safety chain or cable.
Check by visual inspection the presence and good condition of protections
including:

Guard the moving parts which can be s dangerous for people.

Any system which can avoid the fall of object.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 60/83

Rev 00
10.19 Immobilizer ( in service and out of order )

RISKS CONTROL MEASURES METHODOLOGY

Rollover of the equipment in service
due to wind effects resulting from an
uncontrolled speed of translation or
movement and a sudden shock on
the bumpers at the end of track.
Rollover of the equipment out of
order due to unintended movement
resulting from failure of the securing
device
The manufacturer’s instructions give the means to
mitigate the risk of unintended movement of the
equipment installed on railways.
Regardless of the brakes, cranes must be
equipped with devices securing their immobilization
when they are out of work: wedges, clips, anchors,
to avoid unintended movement in particular during
excessive wind.
Ensure the consistency of existing arrangements in compliance with the
manufacturer's instructions.
Ensure that the height of the crane does not exceed the maximum height in
standalone configuration; otherwise it requires means of anchors under the
conditions defined by the manufacturer.
Make sure that in case of stationary cranes mounted on a section of track
immobilizers are in correct place and in good conditions.

In some cases, it is necessary to secure the

crane out of order.

This immobilization is usually done on a track

section called "security stub" which is
dedicated for this purpose.

The ballast of the chassis having a limited

weight, the fastening with the thrust block
incorporated into the soil provides an "over-
ballasting".

Check by visual inspection the good condition of rail clamps

GM IVS 004 – Thorough Inspection of Tower Cranes Page 61/83

Rev 00
11.1 Limit stops relating to lifting motions

RISKS CONTROL MEASURES METHODOLOGY

Distortion or failure of the components
or cable causing the drop of the load or
the rollover of the equipment due to
overrun the amplitude of the lift.
Safety systems are defined by the manufacturer. The Read carefully the manufacturer’s instruction (record safety devices).
instructions specify their functions and thresholds setting. Check the condition and operation of the limit switch during testing.
These systems can be composed of all lifting limiting Check if available the automatic slowdown movement before its stop.
devices operating in both directions of movement of the
hook.
The stop mechanism may require some pre-slowdown.

Check the adjustment of the limit switch is not

affected by other movement of the boom (lifting,
slewing and erection).

GM IVS 004 – Thorough Inspection of Tower Cranes Page 62/83

Rev 00
11.2 Any other limit or travel stops - Limit switch actuator

RISKS CONTROL MEASURES METHODOLOGY

Distortion of the mechanisms due to
excessive stresses during the
mechanical abutment, causing the stop
of movement.
Damage of the equipment or of the
piping.
Safety systems are defined by the manufacturer’s
instructions. The instructions specify their functions and
thresholds setting.
These systems including of translation, orientation and
distribution movements. They could consist of limit switches
electromechanical, electromagnetic induction, …
Read carefully the manufacturer’s instruction. Check by visual inspection
the presence of safety devices.
Check by visual inspection and testing fixing parts and operation condition
of limiters.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 63/83

Rev 00
11.3 Load limiters

RISKS CONTROL MEASURES METHODOLOGY

Overloading of the crane resulting
in deformation, fracture of elements,
deterioration mechanisms, toppling
of the crane and falling of the load,
injury and death of people.
Crane shall be designed and fabricated with sufficient and
adequate safety systems to avoid overloading of the crane.
Crane load chart shall be as per that of the crane.
Safe load indicator shall be fixed on the crane and
calibrated according to the load chart.
Periodic maintenance and calibration of safe load indicator
should be performed.
Review the manufacturer’s documentation.
Ensure that crane is fixed with appropriate safe load indicator and
load chart as per manufacturer instructions.
Review the calibration report and ensure the accuracy of the safe
load indicator.
Safe load indicator shall stop lifting up movement of the load when
reaching 110% of the capacity and shall allow the lifting down of
the load
Ensure that safe load indicator can not be deactivated during the
normal operation of the crane.

The most common load limiters are:

• Weighing Pulleys (measuring the force on the cable)
• Torque arm on the winch

Note:
Safe load indicator may contain two different warnings:
- First warning for approach to rated capacity.
- Second warning for overload.
In this case, ensure that safe load indicator activates the warning alarms.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 64/83

Rev 00
11.4 Rollover protection device
RISKS
Rollover of the crane resulting in deformation,
fracture of elements, deterioration
mechanisms, toppling of the crane and falling
of the load, injury and death of people.
GM IVS 004 – Thorough Inspection of Tower Cranes
Rev 00
CONTROL MEASURES
Crane shall be designed and fabricated with
sufficient and adequate safety systems to avoid
overloading of the crane.
Crane load chart shall be as per that of the crane.
Safe load indicator shall be fixed on the crane and
calibrated according to the load chart.
These systems may consist of any device to
prevent movement contributing to the increase in
overturning moment (lifting, forward direction,
lowering or leaving the jib) and allowing reverse
movement.
METHODOLOGY
Review the manufacturer documentation.
Ensure that the rollover protecting device is present and in
good condition.
Safe load indicator shall stop lifting up movement of the load
and boom down operation when reaching 110% of the
capacity.
Ensure that, lifting up movement of the load and boom down
operation are stopped when reaching 110% of the capacity
and safe load indicator is giving warning sounds.
Page 65/83
11.6 Locking device of mobile units during driving process on road/track

RISKS CONTROL MEASURES METHODOLOGY

Movement of the folded up elements of the Mechanical locking device blocks the elements Check that the locking devices in the road position of the moving parts are in place
crane hitting some third parties during during transport. and in good condition (block the turret, telescopic elements…)
transport.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 66/83

Rev 00
11.17 Anemometer

RISKS CONTROL MEASURE METHODOLOGY

Rollover of the crane result of extreme climatic events. Installation on the crane of a device for measuring wind speed. Check the positioning and condition of the anemometer.
This device should allow the operator to follow the evolution of Check the light and sound alarms by using the test button.
wind speed and prevent the entire staff of the site when the wind
reaches the alarm thresholds.

Check the light and sound alarms using the test button

GM IVS 004 – Thorough Inspection of Tower Cranes Page 67/83

Rev 00
11.21 Wind-release device

RISKS CONTROL MEASURES CONTROL MEASURES

Rollover of the crane subject to wind Crane fitted out with a manual or electrical control Check the status of wind-release system and perform operating tests.
effects. device allowing the release of the orientation brake.

The location of the command of the wind-release device should not present any risk of shearing or crushing the operator.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 68/83

Rev 00
11.22 limiting device according to the lifted load

RISKS CONTROL MEASURES METHODOLOGY

Runaway of the hoisting mechanism as
a consequence of an overload that
results in the fall of the load.
Rollover of the crane caused by
excessive dynamic stresses.
Design of the equipment shall include safety devices to limit
the dynamic stresses experienced by the structure and
mechanisms and to avoid that anomalies damaged devices as
a result of wrong operating conditions (ineligible conditions of
use of load or inappropriate application speed of movement).
Consult the manufacturer’s instructions, identify the security devices provided
by the manufacturer and check the operational thresholds setting.
Check by visual inspection the good condition of the speed limited devices and
its correct operation by performing tests.

The limiting devices should allow:

To limit the lifting speed according the weight of the load.

To reduce automatically the operating movement according the
load lifted and the span used.

To obtain a revised load-curve for handling, at lower speed, a
more important load.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 69/83

Rev 00
11.42 Anti-collision System
RISKS
Typical risk situations include :
1. Hoist rope of high crane, hit by jib
of low crane (the load is jolted and
the banks-man thrown off balance)
2. Hoist rope assesses dangerous
area of high voltage power line with
disastrous results.
3. Load hits jib of low crane and spills
part of the load that fails on workers
below.
4. Load or hook is hit or snapped by
carriage.
5. Badly slung load drops on public
use area.
6. Jib of traveling crane hits mast of
interfering crane, or other obstacle.
The resulting damages could be:
1. Injury or death of man on public
area or the on site
2. Site or crane immobilization
3. Material damage to fixed obstacle
4. Damage to equipment
GM IVS 004 – Thorough Inspection of Tower Cranes
Rev 00
CONTROL MEASURES
Set up WAL and AC technologies
addressing the problems of direct collisions
and dropped load caused by collision i.e.:
1. Zoning WAL (Work Area Limitation)
able a full control of the area over which
the transported load of a crane is
allowed to sail, preventing risks of direct
collision – power line contact and/or
partial load drops
2. Anti-collision (AC) able to prevent the
collisions between the hoist rope or the
jib of a crane and the jib / counter jib of
all other cranes that can interfere with it.
Major benefit:
1. Management of interference between
tower cranes
2. Automatic prevention of collision when
cranes over-fly each other
3. Automatic prevention of over-flying of
sensitive or prohibited areas.
METHODOLOGY
Verify that an anti-collision and zoning system designed to prevent
cranes from flying over forbidden zones or colliding with one another
when multiple cranes are present on the job site is in place and made
operational. This system should detect the angle and ground radius of
the crane.
If yes, check with, the manufacturer’s instructions, that the crane is fitted
with multiple sensors for each of the measured parameters which are
then displayed in the operator’s cabin to keep them informed.
During a slow down movement testing, check the warning system in the
cabin and check the movement is decreasing and eventually stopped to
avoid collision with another crane or flying over a forbidden zone.
Note: Apart from this anti-collision system, air beacon indicates the
presence of cranes in zones that associated with air traffic (specified by
norm of the I.C.A.O International Civil Association Organization).
Generally 3 beacons are positioned at the end of the jib, the counter-jib
and the top of the crane.
Page 70/83
Tower crane space limit monitoring system Wireless network system Zone protection diagram

Building sites Modem, in radio contact, attached to the structure Air-beacon

GM IVS 004 – Thorough Inspection of Tower Cranes Page 71/83

Rev 00
14.1 Static Proof Load Test

Preamble

• Records of any major repairs or replacements shall be verified before commencing the tests.

• If any wire rope has been replaced, test certificates for the wire rope shall be reviewed and attached to the crane test certificate.

• Complete thorough examination shall be performed from the first to the last point described on the previous page of this guide,

• All safety switches shall be checked for correct operation. Any safety switch overridden during the test shall be re-set and checked for correct functioning after the

load tests.

• A line pull test shall be limited to the maximum wire rope pull per line in any configuration.

• Test personnel shall be positioned so that they are unlikely to be injured should there be a mishap. The test area shall be cordoned off to prevent any unauthorized

entry to site.

• When a load is lifted on the main hook with the fly jib fitted, the load on the main hook shall be reduced to allow for the weight of the fly jib and fly hook.

• All crane certificates shall be endorsed with the information necessary to ensure there is no ambiguity as to crane rigging at the time of test. This applies to boom

length, rope reeving, hook blocks, counterweights, track width, short or long crawlers, with or without fly jib etc.

All test certificates for cranes shall have crane capacity charts enclosed for verification.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 72/83

Rev 00
 Proof load test of the crane shall be performed at three different positions of the boom:

• Minimum boom length

• Intermediate boom length
• Maximum boom length

Proof load test shall be performed under 125% of the Safe Working Load (SWL) of each position unless otherwise specified by the manufacturer.
Surveyor shall ensure the accuracy of the weight of the test load.
Surveyor shall ensure that the fly jib and fly hook shall be deducted to determine the test load.

Test load shall be lifted at the slowest speed at a maximum height of 20 cm and for a minimum duration of 15 minutes.
Operator shall take necessary precaution to avoid dynamic or shock loading.

At the end of the test, surveyor shall check that the descent of the load is within acceptable limits specified by the
manufacturer.
Surveyor shall ensure that integrity of crane structure, boom, hook, winch, wire rope and all load bearing
members are intact.

To ensure the integrity of the winch a maximum line pull test shall be performed at any of the configurations.
During the tests, stability must be ensured without the addition of external load or devices not covered in normal
operation.

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14.2 Dynamic Proof Load Test

Preamble

• Records of any major repairs or replacements shall be verified before commencing the tests.

• If any wire rope has been replaced, test certificates for the wire rope shall be reviewed and attached to the crane test certificate.

• Complete thorough examination shall be performed from the first to the last point described on the previous page of this guide,

• All safety switches shall be checked for correct operation. Any safety switch overridden during the test shall be re-set and checked for correct functioning after the

load tests.

• A line pull test shall be limited to the maximum wire rope pull per line in any configuration.

• Test personnel shall be positioned so that they are unlikely to be injured should there be a mishap. The test area shall be cordoned off to prevent any unauthorized

entry to site.

• When a load is lifted on the main hook with the fly jib fitted, the load on the main hook shall be reduced to allow for the weight of the fly jib and fly hook.

• All crane certificates shall be endorsed with the information necessary to ensure there is no ambiguity as to crane rigging at the time of test. This applies to boom

length, rope reeving, hook blocks, counterweights, track width, short or long crawlers, with or without fly jib etc.

• All test certificates for cranes shall have crane capacity charts enclosed for verification.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 74/83

Rev 00
With a load of 110% of the SWL crane is tested for all its functions.

Boom shall not be extended and lowered from the set position.
Main hoist brake shall hold the proof load.

At the end of the test, surveyor shall check that there is no descent of the load.
Surveyor shall ensure that integrity of crane structure, boom, hook, winch, wire rope and all load bearing
members are intact.

During the tests, stability must be ensured without the addition of external load or devices not covered in
normal operation.

GM IVS 004 – Thorough Inspection of Tower Cranes Page 75/83

Rev 00
 CERTIFICATE
Of Test and Thorough Examination of Tower Crane
Certificate No.: Date of Inspection: 14th November 2010
Certificate
Name and Address of the Owner Place of Inspection Technical referential
BV Work instruction

Manufacturer / Date of Manufacture

Registration No: Owner Id No: Model No: Manufacturer Serial No:

Description of Test
Test Load SWL

Tones Tones

31.25 50.0
XXX % Safe Working Load

Load test duration: xxx mn

Based on Thorough Visual Examination, Functional Test and Proof Load test the equipment described
above was found satisfactory at the time of Inspection.

Date of Last Examination Date of Next Examination Date of Last Proof Load Date of Next Proof Load
(if applicable) Test Test (if applicable)
02nd March 2009 14th May 2011 16th January 2007 14th November 2014

Authorized name: Surveyor’s name:

Signature Signature

THIS IS TO CERTIFY THAT the above signed competent surveyor thoroughly examined the lifting equipment in the above-
mentioned place as per technical referential mentioned above. The liabilities are as per Bureau Veritas General Conditions of
Services.
GM IVS 004 / CERTIFICATE Page 1/1

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Rev 00
 Annex to certificate Of Test and Thorough Inspection
Of Tower Crane
Annex to certificate N°: Date of inspection:

Annex to certificate
CONDITION / REMARKS / PERFORMANCE
DESCRIPITION
TESTS

0 GENERAL DESCRIPTION OF THE

EQUIPMENT

0.0 Description
1 FIXED ACCESS
1.1 Access to the cab, to the cockpit
1.2 Other access for maintenance and testing
2 LANE, SUPPORTS
2.1 Bumpers, shock absorbers
2.2 Rails and beams bearing, fasteners
2.4 Foundation, state and soil strength and
support structures
2.5 Horizontal blocking
3 FRAMING
3.2 Guys and ties
3.4 Fixations, connections, brackets, assemblies,
joints
3.8 Guides - rollers - bumper- cart - skates -
dampers
3.10 Mast, ladder
3.12 Drift plate
3.13 Jib, boom, boom extension, turret
3.20 Telescoping Cage
3.23 Counter-jib ballast

4 CHASSIS
4.1 Assembly and fasteners
4.3 Position holding outriggers road extensions
4.7 Stabilizers
4.8 Sleepers, rails, subframe
4.15 Ballast, counterweight
5 SOURCE OF ENERGY
5.1 Power supply limitation
5.2 Equipement, wiring system, coiling units
5.4 Voltage, power, pressure

GM IVS 004 / CERTIFICATE / ANNEX Page 2/3

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Rev 00
 Annex to certificate Of Test and Thorough Inspection
Of Tower Crane
Annex to certificate N°: Date of inspection:

DESCRIPITION CONDITION / REMARKS / PERFORMANCE TESTS

7 CAB - DRIVER'S CAB

7.1 Air heating

7.2 Condition, fastening devices, foot rack,

7.3 Protection against falls from height

7.5 Operator's protection

7.6 Protection of the accessible mobile

elements

7.8 Working visibility (glass transparency,

windshield wipers, rearview mirror)

7.12 Seat
8 OPERATING AND MATERIALS
HANDLING DEVICES
8.1 Start / Stop
8.2 Lock-out of use (tagging out)
8.3 Other emergency stops
8.4 Indicators, signalling and warning
devices
8.5 Identification of control devices
8.6 Automatic return to neutral point
8.7 Warning signals
8.9 Protecting devices against unwilling or
non voluntary operations
9 MAIN RUNNERS, GUYS, DRUMS,
PULLEYS, FASTENING DEVICES
9.1 Fasteners, clips, straps, clamps
9.2 Fastening devices
9.4 Main runners and lines, guys (Wire ropes
or chains)
9.5 Drums, pulleys, rope blocks, drive
pinions, windlasses

GM IVS 004 / CERTIFICATE / ANNEX Page 2/3

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Rev 00
 Annex to certificate Of Test and Thorough Inspection
Of Tower Crane
Annex to certificate N°: Date of inspection:

DESCRIPITION CONDITION / REMARKS / PERFORMANCE TESTS

10 MECANISMS
10.3 Locking device when out of order
10.4 Brakes on horizontal movements
10.5 Hoist brake
10.6 Power and gear transmission system
10.9 Protection of the mobile parts of the
power transmission

10.11 Protection against falling of objects

10.19 Immobilizer ( in service and out of order )

11 SAFETY DEVICES
11.1 Limit stops relating to lifting motions
11.2 Any other limit or travel stops - Limit
switch actuator
11.3 Load limiter
11.4 Rollover protection device
11.6 Locking device of mobile units during
driving process on track/road
11.17 Anemometer

11.21 Wind-release device

11.22 Speed limiting device according to the
lifted load
11.42 Anti-collision system
14 PROOF LOAD TESTS
14.1 Static proof load test
14.2 Dynamic proof load test

Comment :

Surveyor’s name: Signature :

GM IVS 004 / CERTIFICATE / ANNEX Page 3/3

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Rev 00
 DEFECT REPORT
of Tower Crane
Defect report No.: Date of Inspection: 14th November 2010
Defect Report
Name and Address of the Owner Place of Inspection Technical referential
BV Work instruction

Manufacturer / Date of Manufacture

Registration No: Owner Id No: Model No: Manufacturer Serial No:

Equipment Description

Type of equipment :
Main hoist maximum capacity (SWL) : xxx t.

Main Hoist Line Pull Capacity: 4.2 t

Auxiliary Hoist Line Pull Capacity: 2.2 t

Defects Noticed

Final Conclusion:

Equipment to be submitted for re-inspection in order to be certified

Date of Last Examination Date of Next Examination Date of Last Proof Load Date of Next Proof Load
Test Test (if applicable)
02nd March 2009 AFTER REPAIR 16th January 2007 AFTER REPAIR

Surveyor’s name:
signature

THIS IS TO CERTIFY THAT the above signed competent surveyor thoroughly examined the lifting equipment in the above-mentioned place as per technical referential
mentioned above. The liabilities are as per Bureau Veritas General Conditions of Services
GM IVS 004 / DEFECT REPORT Page 1/1

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Rev 00
 Notes

GM IVS 004 – Thorough Inspection of Tower Cranes Page 81/83

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 Notes

GM IVS 004 – Thorough Inspection of Tower Cranes Page 82/83

Rev 00
 List of methodological guide
and associated documents

At the date of publication of this guide, other available documents are:

GM IVS 001 Thorough inspection of Mobile Crane

GM IVS 001 Certificate
GM IVS 001 Certificate / Annex
GM IVS 001 Defect Report

GM IVS 002 Thorough inspection of Accessories

GM IVS 002 Certificate
GM IVS 002 Certificate / Annex
GM IVS 002 Non available
GM IVS 002 Defect Report

GM IVS 003 Thorough inspection of Electrical Overhead Travelling Crane

GM IVS 003 Certificate
GM IVS 003 Certificate / Annex
GM IVS 003 Defect Report

GM IVS 004 Thorough inspection of Tower Crane

GM IVS 004 Certificate
GM IVS 004 Certificate / Annex
GM IVS 004 Defect Report

GM IVS 005 Thorough inspection of Forklifts

GM IVS 005 Certificate
GM IVS 005 Certificate / Annex
GM IVS 005 Defect Report

GM IVS 004 – Thorough Inspection of Tower Cranes Page 83/83

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Move Forward with Confidence