Investigation of a Tower Crane Collapse in San Francisco, California- November 28, 1989

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1 nvestigation of a Towe Cane Collapse in San Fancisco, Califonia- Novembe 28, 1989 U.S. Depatment of Labo Occupational Safety and Health Administation May 1990

2 nvestigation of a Towe Ca:'e Collapse in San Fancisco, Califonia Novembe 28, 1989 U.S. Depatment of Labo Elizabeth Dole, Secetay Occupational Safety and Health Administation Gead F. Scannell, Assistant Secetay Office of Constuction and Engineeing Mohammad Ayut> Fagance Uu David Lashgai Geoge Poneos Chales Culve May 1990 /"'"

3 ABSTRACT This epot pesents the esults of an investigation to detemine the cause of the collapse of a towe cane in San Fancisco, Califonia on Novembe 28, The failue occued when the cane was being aised o "climbed" to incease its woking height. ~ The inve5tigation included a detailed inspeotion of the oollapsed stuctue, eview of eyewitness accounts of the collapse, laboatoy tests and compute analyses of the stuctue. The cause of the failue was oveloading of stuctual membes in the towe due to otation of the cane duing the climbing opeation. The otation was likely due to adjustments being made to the climbing section that involved poweed slewing of the cane. The compute analysis indicated the stuctue was sensitive to otation of the supestuctue duing the climbing opeation. The esults of the compute analysis wee consistent with the mode of failue of the stuctue. A peexisting cack in a connection plate and a stuctual membe and bittle behavio of the mateials associated with the welding details may have contibuted to the failue. Keywods: Accident: collapse: cane: constuction failue: steel stuctue. i iii

4 PREFACE n Januay 1990, the Division of Occupational Safety and Health, Depatment of ndustial Relations of the State of Califonia (CalOSHA) equested assistance fom the u.s. Depatment of Labo, Occupational Safety and Health Administation (OSHA) in thei inves~i9'a~ion of ~he ool.l.apse of a ~oweoane ~ha~ ocoued on Novembe 28, 1989, in San Fancisco, Califonia. The pupose of the assistance was to povide technical suppot in detemining the cause of the collapse. This epot pesents the esults of the analysis of the cause of the collapse conducted by the OSHA Office of Constuction and Engineeing. The OSHA analysis was conducted in coopeation with CalOSHA. Statements obtained fom the witness inteviews conducted by the Bueau of nvestigation, Depatment of ndustial Relations and CalOSHA staff wee povided to the OSHA investigation team. The OSHA team and CalOSHA staff woked togethe in collecting data on the collapsed stuctue and in planning the laboatoy tests. Roy Beg, Ralph Allen, Jey Lombado, CalOSHA staff and John Tennison, Regional Manage, CalOSHAmade impotant contibutions in the conduct of this investigation. iv

5 EXECUTVE SUMMARY On Novembe 28, 1989, shotly afte 8: 00 a.m., a towe cane collapsed in the cente of the financial distict in San Fancisco, Califonia. Fou constuction wokes engaged in the climbing opeation of the cane and one peson on the steet below the cane wee killed. Given the time of day and the looation in a busy uban setting, the catastophic potential of this accident was substantial. At the equest of the Division of Occupational Safety and Health, Depatment of ndustial Relations of the State of Califonia (CalOSHA), the Occupational Safety and Health Administation (OSHA), u. S. Depatment of Labo, paticipated in the investigation of the accident. The pupose of the OSHA paticipation was to detemine the cause of the accident. Evaluation of compliance with safety egulations and enfocement actions elating to the accident wee the sole esponsibility of CalOSHA. The OSHA investigation began in ealy Januay The investigation included a detailed inspection o the collapsed stuctue, a eview of eyewitness accounts of the collapse, laboatoy tests to detemine the mechanical popeties of the stuotue and oompute analy~o~ of tho cano ~tuctuo. Thi~ wok was caied out in coopeation with CalOSHA. At the time of the collapse, a climbing opeation was undeway which involved aising the supestuctue o opeating potion of the cane. The sensitivity of the stuctue to a vaiety of loading conditions that could have existed duing this climbing opeation was evaluated. The loading consideed elated to: (1) luffing of the boom, (2) loss of olle suppot of the climbing section and (3) otation of the supestuctue. The esults of this evaluation togethe with physical evidence of the behavio of the stuctue in the collapse and eyewitness obsevations of the wok undeway at the time of the collapse wee used to detemine the cause of the failue. Based on the esults of the investigation, OSHA concludes that: 1. The likely cause of the failue was oveloading of stuctual membes in the towe due to otation of the cane duing the climbing opeation. The otation was likely due to adjustments being made to the climbing section that involved poweed slewing of the cane. 2. A peexi::sting cack in a connection plate and a stuctual membe and bittle behavio of the mateials associated with welding details may have contibuted to the failue. v

6 3. The climbing section was not coectly positioned with espect to towe section 15, paticulaly, in the thid climbing step. 4. The foces on cetain olles of the climbing section ae vey sensitive to otations of the cane supestuctue. 5. Failue of the cane in tems of exceeding the load caying capacity duing the climbing opeation occus at a countec1ookwise otation of appoximately 45 degees. '~ vi

7 TABLE OF CONTENTS ABSTRACT. ' PREFACE... EXECUTVE SUMMARY... / v NTRODUCTON Backgound OSHA nvestigation Oganization of the Repot CONDUCT OF THE NVESTGATON Stuctual Obsevations Cane nfomation Laboatoy Tests Analytical Studies Page iii iv 3. DESCRPTON OF THE CRANE AND THE CLMBNG OPERATON Desciption of the Stuctue Slewing Bakes J Climbing opeation Climbing Section Rolles DESCRPTON OF THE FALURE Backgound Eyewitness Accounts of the Failue Obsevations of Collapsed Stuctue Oveall Collapse Towe stuctue Towe Section Cimbing Section Climbing section Rolles Towe Section Climbing Tavese Boom Tuntable loa- Fame Guide Sheave Fames Miscellaneous Summay. 47 vii

8 page 5. LABORATORY TESTS ntoduction Mateial Popeties Analysis of Factue Sufaces Slewing Bakes STRUCTURAL ANALYSS ntoduction Compute Model and Analysis Pocedue Results of the Analysis ANALYSS OF COLLAPSE ntoduction 7.2 Summay of Significant Data 7.3 Failue Scenaio )JLl1 8. CONCLUSONS 9. REFERENCES APPENDX A - APPENDX B - CLMBNG PROCEDURE CALCULATON OF STRUCTURAL MEMBER PROPERTES AND LMT STATE VALUES. 201 viii

9 1. NTRODUCTON 1.1 Backgound On Novembe 28, 1989, shotly afte 8: 00 a.m., a towe cane collapsed in the cente of the financial distict in San Fancisco, ~ calitonia. Fou constuction wokes engaged in the climbing opeation of the cane and one peson on the steet below the cane wee killed. Given the time of day and the location in a busy uban setting, the catastophic potential of this accident was significant. The towe cane was being aised o "climbed" at the time of the collapse. Climbing involves aising the supestuctue o opeating potion of the cane, i.e., the tuntable, opeato's cab, machiney and boom and installing additional suppoting elements o towe sections to aise the woking height of the cane to the desied elevation as the building constuction pogesses. special pocedues, as outlined by the manufactue of the cane, ae followed duing this climbing opeation to contol the behavio of the potion of the cane being aised and maintain the stuctual integity of the suppoting stuctue. A sketch of the towe cane is shown in figue The figue illustates the configuation of the cane at the time of the collapse. Figue illustates the vaious opeating elements. Figue is a photogaph taken duing the climbing opeation thee weeks pio to the collapse, the last time the cane was aised. The cane was designed and manufactued by Peine Maschinen und Schaubenweke fo the Ameican Pecco Copoation headquateed in Millwood, New Yok. The cane is a climbing, luffing boom, towe cane. The towe was tied to the building unde constuction at two locations fo lateal suppot as shown in figue Repesentatives fom the Division of Occupational Safety and Health, Depatment of ndustial Relations of the State of Califonia (CaOSHA) and fom the U.S. Depatment of Labo, Occupational Safety and Health Administation (OSHA), wee on the scene within appoximately one hou of the accident. The State of Califonia has its own occupational safety and health pogam. CalOSHA, theefoe, was esponsible fo investigating the accident. Evidence in the fom of photogaphs and a videotape of the accident scene collected by OSHA egional office staff, on Novembe 28, 1989, was tuned ove to CalOSHA immediately following cleanup of the accident site. n ealy Januay 1990, calosha equested OSHA povide assistance in thei investigation of the accident. The pupose of this assistance was to povide technical suppot in detemining the cause of the accident. 1

10 One of the functions of the OSHA Office of Constuction and Engineeing headquateed in Washington, D. C., is to povide technical assistance to state govenment agencies. Accodingly, on Januay 3, 1990, a team of enginees fom the Office of Constuction and Engineeing met with CalOSHA staff in Califonia to begin this wok. The assistance povided by OSHA was limited to detemining the cause of the accident. Evaluation of compliance with saety egulations and enocement actions elating to the accident wee the sole esponsibility of CalOSHA. 1.2 OSHA nvedigation The OSHA investigation included a detailed inspection of the ct)llapsed stuctue, a eview of eyewitness accounts of the collapse, laboatoy tests to detemine the mechanical popeties of the stuctue and compute analyses of the cane stuctue. The wok was caied out in coopeation with CalOSHA. Eyewitness inteviews obtained by CalOSHA immediately following the accident wee povided to the OSHA investigating team. nspection of the collapsed stuctue and collection of elevant data wee done jointly. Both goups planned the laboatoy testing pogam. The laboatoy tests wee conducted by a pivate fim unde contact to CalOSHA. Thoughout the couse of the investigation, both goups woked togethe shaing infomation and jointly developing pespectives on the vaious aspects of the accident and the cause. 1.3 Oganization of the Repot This epot is oganized in nine Chaptes and Appendices: Chapte 2 descibes the pocedues followed by OSHA in conducting the investigation. Chapte 3 descibes the towe cane stuctue, the bakes and the climbing opeation used to aise the cane. Chapte 4 poviaes backgound inomation on the cane pio to the collapse and activities undeway at the time of the collapse. Eyewitness accounts of the collapse ae eviewed. Detailed obsevations of the collapsed stuctue and pefomance of the components of the stuctue ae also pesented. Chapte 5 descibes the esults of the laboatoy tests conducted to detemine the mateial popeties and evaluate the behavio of the stuctual components t)f the towe including the slewing bakes. 2

11 Chapte 6 pesents the esults o analytical studies conducted to evaluate the esponse of the towe and climbing section to a vaiety of loading conditions. Foces and stesses in the stuctual membes and the foces on the olles of the climbing section wee detemined. Failue mechanisms and associated loading conditions wee also detemined. Chapte 7 pesents the esults of the investigation. The infomation obtained in the investigation is used to identify the cause of the failue. Chapte 8 pesents the conclusions eached in the OSHA investiqation. ~ Chapte 9 lists the efeences cited in the text. The Appendixes include a desciption of the climbing pocedue and the calculations of the limit states fo the stuctual components. 3

12 . TOWER SECTON NO o m N M 0\ N CLMBNG SECTON. o. z o z o 1-4 Eo4 U ~ en 1 ~ ;, ~ E04 -, ::\---1_ 4 TOWER CRANE CONFGURATON PROR TO COLLAPSE FGURE

13 ..-./" MULTtPA~T LUFFNG CABLE 'ixe::l \Ule'."~ CAaLES LOA[ neoc v,rtical COUNTER WEiGHT :::---.\ COMPONENTS OF CRANE SUPERSTRUCTURE FGURE V1.~ ~

14 Climbing opeation on Tuntable on top of climbing section, new section on platfom at left. Figue

15 2. CONDUCT OF THE NVESTGATON 2.1 Stuctual Obsevations The collapsed stuctue was emoved fom the constuction site in downtown S~n Fanoisoo following the accidqnt, to a ~toagq yad of the Sheedy Cane and Rigging Company, 1215 Michigan Steet, San Fancisco, Califonia. Photogaphs, videotapes and accounts of the location of the pats of the collapsed stuctue obtained by CalOSHA immediately following the accident wee povided to the OSHA investigation team. The OSHA team's initial visit to the Sheedy Cane and Rigging Company stoage yad to collect data on the collapsed stuctue was on Januay 3, The team made six visits to the stoage yad ove the next fou months to collect additional data as the investigation poceeded. Detailed measuements, photogaphs, and sketches wee made of the patten of defomation of the towe sections, climbing tavese and climbing section. Data on othe components of the cane including the bakes and the electical system wee also collected. The OSHA team also Visited the Pecco copoation stoage yad in oakland, califonia, whee some pats of the collapsed stuctue wee stoed, to examine thei stuctual integity. OSHA staff visited a constuction site in San Fancisco in Febuay 1990, to obseve the opeation of a towe cane of the same type as the one that collapsed. 2.2 Cane nfomation ~! Geneal backgound infomation was collected on the stuctual details and opeating pocedues of this model of cane. Most of this infomation was obtained fom the opeating manual of the cane povided by the Ameican Pecco Copoation [1]. nfomation was also obtained fom Ameican Pecco Copoation enginees duing a visit by OSHA and CalOSHA staff to the copoation headquates in Millwood, New Yok on Mach 21, This visit also povided an oppotunity to opeate a simila demonstation model towe cane and become familia with the contol panel cabin, opeato's cab, the mechanical and electical systems and the cane's opeating chaacteistics. nfomation was also sought on the pefomance histoy of the collapsed cane. This included: (1) the maintenance log which contained details of past usage and epais, (2) epots on the esults of the inspection of the cane by Ameican Pecco Copoation staff following the Octobe 17, 1989, Loma pieta, Califonia eathquake, and (3) opeating pactices by the company esponsible fo eection and opeation of the cane at the time of failue. 9

16 2.3 Laboatoy Tests Laboatoy tests wee conducted to detemine the chemical composition and mechanical popeties of the stuctual steel. Chemical analyses, standad tensile tests and enegy absoption tests wee used fo this pupose. Metallogaphic and factogaphy tests wee conducted to evaluate the chaacteistics o the factue sufaces in the components of the stuctue. Examinations ~ wee also conducted on the components of the cane bakes. ndentations and defomations of thq fou columns in towq sqction 15 wee examined, in detail, to evaluate thei chaacteistics.! 2.4 Analytical Studies stuctual analysis of the cane towe and the climbing section was conducted, using a thee dimensional compute pogam, to detemine the esponse of the stuctue to a vaiety of loading conditions. This included loading conditions duing nomal climbing opeations and those that occued pio to the collapse. The foces in the membes of the climbing section, the olles and the membes of the cane towe wee computed at seveal locations of the boom duing the climbing pocess and at vaious degees of otation of the boom and compaed with thei failue loads. The sensitivity of the stuctue to the loss of the olle suppots of the climbing section was also detemined. n elastic esponse of membes and P Delta effects wee included in the analysis. 10

17 3. DESCRPTON OF THE CRANE AND THE CLMBNG OPERATON 3.1 Desciption of the Stuctue Figue is a sketch of the stuctue. This was the configuation of the cane on the moning of Novembe 26, 1969 at the time of the collapse. This model SN 355 cane, a climbing, luffing boom towe cane had a maximum each of 192 feet-6 inches and a maximum lift capacity of 17,100 pounds with two wi~ op~s. The cane was epoted to have been manufactued in 1982 and had been in use at vaious constuction sites. Table indicates the locations and details of its pio use, as obtained fom Ameican Pecco Copoation. The eection chonology and eection cew membes involved in the climbing opeation ae given in figue Note the eection cew on the day of the collapse wee involved in climbing the cane on Novembe 9 and Novembe 27, The cane had been cetified and placed in opeation on August 22, The height of the cane consisting of nine identical sections, nos. 1 though 9, at this time was 185 feet above the footings and was fee standing. On Novembe 9, 1989, thee additional towe sections, nos. 10, 11 and 12, wee added. The height then becdme 247 feet. Lateal suppot was povided by the stuctual steel fame of the building unde constuction as shown in figue On Novembe 27, 1989, thee sections, nos. 13, 14 and 15, wee added. The height then became 298 feet. A second lateal suppot was povided by a tieing into the building unde constuction. On the moning of Novembe 28, 1989, the climbing pocess was undeway to add anothe towe section no. 16. The accident occued duing this pocess. The towe sections consist of olled stuctual shapes fo the columns and ound stuctual tubing fo thq diagonal bacing membes. The diagonals ae welded to the columns. One towe section consists of fou identical columns and twenty-fou identical diagonals. The hoizontal membes at the top and bottom of each towe consist of channel sections and angles. The noth face columns ae povided with welded lugs, thee in each column, to suppot the climbing tavese and the climbing section duing the climbing pocess. The dimensions fo a towe section ae given in figue The climbing section consists of olled stuctual shapes fo the columns, one size fo the two noth columns and one size fo the two south columns. The diagonals ae ound stuctual tubing pin connected to the columns. n addition, thee ae igid stiffening beams at the location of uppe level olles and lowe level olles. The dimensions fo the climbing section ae given in figue Thee ae sixteen guide olles attached to the climbing sqction, Qight locatqd at th~ upp~ set of stiff~ning beams and eight located at the lowe set of stiffening beams. 11

18 These olles guide the climbing section as it moves up the towe section and povide lateal suppot. The climbing tavese consists of a fame compised of stuctual shapes and a hydaulic am o "hoist cylinde". The climbing tavese is suppoted on the lugs of the noth face columns of the towe~. Applying hyd~du1ic pessue extends the am sliding the climbing section vetically ove the uppemost towe section. The guide olles on the climbing section oll on the flanges of the towe section to guide the climbing section as the climbing section and cane supestuctue ae aised. The coss sectional dimensions and section popeties of the stuctual membes of the towe section and climbing section ae given in table At the beginning of the investigation, attempts to obtain the dimensions and stuctual designations fo these membes fom the cane manufactue wee not successful. The coss sectional dimensions listed, theefoe, ae measued values fom the collapsed stuctue. The section popeties in the tables wee calculated fom the measued dimensions. These values wee used in the stuctual analysis in Chapte 6. Figues 3.1.4, 3.1.5, and show a typical bolted connection between towe sections, a towe section viewed fom the bottom, typical connection plates between towe sections and the tuntable suppot fame. 3.2 Slewing Bakes Two dive motos and eduction gea sets wee used to contol slewing of the boom on the cane. Each moto incopoated an eddy cuent bake and a double shoe fiction bake. The fiction bakes function by pessue of two shoes against a otating bake dum on the slewing moto gea set. The pessue is povide by a compession sping and elease is achieved by counteacting the foce of the compession sping by a speading magnet, an electomagnetic device. The speading magnet is enegized, ~l~asing th~ fiction bakes:, whonovo thq slewing moto is unning unde opeato contol via the joystick. The magnet is deenegized, applying the fiction bakes, when the bake pedal is fully depessed. The fiction slewing bakes ae also applied when the electic powe is off. The fiction bakes can also be eleased manually by a hand leve located outside the cab and attached to an eccentic cam on the speading magnet. The esisting toque applied to the supestuctue by the slewing bakes is detemined by the togue and otational speed of the bake moto. The slewing bake had a toque of 74 ft-lbs and a otational speed of 1,820 pm. The togue applied to the supestuctue by the two bakes, theefoe, equaled 269 ft- kip (74 x 1820 x ). 12

19 Unde some cicumstances of opeation, the function of the two slewing bakes is alteed. Fo example, duing sevice with a hook each of moe than 65 feet, both slewing motos and slewing bakes ae used. f the hook each is less than 65 feet, one of the slewing motos is automatically switched off, and its fiction bake is opened electically by the speading magnet. The slewing action is then contolleq ny one moto ana one slewing bake. Accoding to the maintenance instuctions, the slewing bakes ae adjusted fo a deceleation time of 10.1 seconds, fom full slewing speed (Section of the ownes manual). The fiction bakes ae not intended to cause a sudden deceleation because of the dange of ovetuning, howeve, they can seve to lock the tuntable when slewing is not desied. Duing climbing up o climbing down, fo example, slewing is not pemitted. t is inteesting to note, that duing climbing, the boom is nomally adjusted to a hook each of 70 feet in ode to attain a balance of the boom, hoist and counteweight ove the climbing fame. Mino adjustments of the balance ae pemitted by luffing of the boom. Howeve, fom the discussion above, it is appaent that if the boom is luffed back (upwad) to a hook each of less than 65 feet, one slewing fiction bake will automatically be eleaseq. Slewing duing the Climb is then pevented only by one slewing bake. 3.3 Climbing Opeation - The woking height of the cane is inceased by climbing the cane o using the climbing section to aise the supestuctue above the uppemost towe section and adding anothe towe section. The climbing pocedue is descibed in the cane opeations manual and is included in Appendix A. Refeing to Appendix A, the climbing opeation can be sepaated into thee phases. The fist phase (sections though 3.4.5) involves pepaing tho stuctue. Adju~ting the guide olles, placing the new towe section on the eection platfom and balancing the cane ae key steps in this phase. As noted, in Section 3.4.2, the cane should not slew o otate afte the initial pepaations have been made fo climbing. The following method was used by the eection cew to place towe section 16 on the platfom of the climbing section. The method diffeed fom that descibed in the opeating manual: The new section was hoisted on the load line of the cane and elevated to a height of few feet above the elevation of the platfom of the climbing section 13

20 The cane was slewed towad the building - pointing the new section close to the building at the 17th floo level. The eection cew eached out to the new section and secued the end of cable to the new section as shown in figues and The ai-activated wench - located on the 15th floo pulled the cable. The cable passed though a pulley secued to a peimete beam on the 15th floo, went though the noth and south faces of the climbing section and the uppemost installed towe section and was tied to the new section. The new section was pulled towad the platfom in an inclined fashion since the minimum hook distance is 23 feet. As the south legs of the new section appoach the inteio of the platfom, the load line was loweed to allow the south legs to sit on the platfom. simultaneously, cable was pulled in to tilt the new section fom its inclined position into a vetical position. The noth legs of the new section bea on the platfom. The cable was disengaged fom the new section and tied to the noth face of the climbing section with enough slack in the cable to allow unobstucted upwad movement by the climbing section. The second phase (Section 3.4.6) o the actual climbing involves aising the supestuctue. This is caied out in thee lifts o "steps" as illustated in figue n each lift the climbing section is aised appoximately 6 feet-6 inches. A final lift of foot-5-l/2 inches is equied pio to inseting the new towe section. Between lifts the climbing section is suppoted on lugs on the noth towe section columns as the hydaulic am is etacted and epositioned fo the next lift. The thid phase (Section 3.4.7) involves installation of the new towe section and secuing it in place. The climbing pocess is clealy a hazadous opeation. Duing this time, potions of the stuctue ae no longe positively connected togethe and pope load tansfe between these potions equies maintaining a specific alignment o elative oientation of the components. Tansfe of the supestuctue load though the climbing section into the towe of the cane in figue 1.1.1, fo example, depends on the alignment of the olles on the climbing section. This load tansfe will be discussed futhe in Chapte 6. Many fims pefom the climbing opeation fo towe canes on weekends f 14

21 o othe special times in ode to minimize the isk to wokes and othes on o nea the constuction site in the event of an accident. Some juisdictions equie notification pio to climbing towe canes and that the wok be done at special times. 3.4 ClinbiD!! Section Rolle~ Thee wee sixteen guide olles attached to the climbing section which contolled vetical and hoizontal alignment of the climbing section duing the climbing pocess. Eight olles wee located at the uppe level about 7 feet fom the bottom and eight olles wee at the lowe level, at the bottom of the climbing section. At each level, fou guide olles wee positioned to oll again&t the Qdge of the flanges of the towe legs and the othe fou olles against the face of the flange of the towe legs. Figues and indicate the location of the guide olles. The olles fo the flange edges wee bevelled with the exception of the lowe southeast edge olle. A typical edge and flange olle is shown on figue The olles contained a bass bushing inside the hole to povide a smooth suface fo olling ove the shaft. The bushing was held in place by pess fit only. The bushings wee of unifom thickness. ~, The olles wee held in place by means of a ound etaining steel plate, 1/4 inch thick, connected to the shaft by two 1/4 inch ~ theaded bolts 3/4 inch long. Thee was a common steel washe unde the two bolt heads. The diamete of the etaining plate, was slightly lage than the outside diamete of the bushing. Figue shows the typical diamete of the etaining plate. The intent of the design of the plate and the bolts appeaed to be to keep the olle in place in a nomal climbing pocedue. The size of the bolts wee such that each bolt had an ultimate capacity of 1.4 kips, assuming an ultimate tensile stess of 50 ksi. An axial toce ot 2.8 kips would be able to push the olle off the shaft egadless of the size of the etaining plate. Evidently the etaining plate and the two etaining bolts wee not designed fo &ituation!'; wh~~ axial foces along the axis of the shaft wee pesent. Such foces would be pesent when the olles ae applying foces to the flanges at angles othe than 90 degees to the beaing suface. 15

22 Table Histoy of Cane Usage Usage Dates Eection Dismantling Total Usage 8/19/89 11/28/89 (accident) 3 mos. 3/1/88 8/30/88 5 mos. 7/18/86 8/14/87 13 mos. NOTE: Same cane fo both contactos 9/1/85 5/28/86 8 mos. Vendo site Type of Climbe The Eection Co. 600 Cal. Steet San Fancisco Mellon Stuat Co. Olando, FL A & S Stuctues 1144 Zeega Ave., Bonx New Yok Chase Concete 1144 Zeega Ave. Bonx, NY Ameican Bidge Chicago, L Calisle Constuction Newpot, KY 600 Cal. San Fancisco Gateway Ct. Olando, FL 4 Columbus Cicle, N.Y.C. 4 Columbus Cicle N.Y.C. 190 S. LaSalle Chicago Cincinnati, Ohio Top Climbe Top Climbe Jackinginside buildinq Top Climbe! i i!! Note: Manufactued in

23 TABLE DMENSONS AND STRUCTURAL PROPERTES OF THE COLUMN MEMBERS Web Flange Aea Axis x-x Axis y-y Location Depth in. Thickness in. width in. Aveage Thickness in. 2 in 4 in Z 3 J.n 4 J.n Z 3 in Towe section Climbing section SE & SW Legs Climbing Section NE & NW Legs >-' '" --~l ~

24 TABLE (Continued) DMENSONS AND STRUCTURAL PROPERTES OF THE DAGONAL BRACNG MEMBERS Location nside Diamete (in) Outside Diamete (in) Aea (in 2 ) (in 4 ) Z (in 3 ) Towe Section Climbing section OD = 3.0" Climbing section OD = 3.5" Climbing section OD ~ 4.2"

25 ERECTON CREW * PAUL CLNE * LONNE BOGGESS * DAVE GRADEN * STEVE TLTON CLMBNG UNDERWAY TO ADD 8'-0" SECTON NO. 16 ON =: O"l co ERECTON CREW ljj Z l' AM o fl1 N _ H PAUL CLNE PAUL CLNE - 8 D U l LONNE BOGGESS LONNE BOGGESS J:il l DAVE GRADEN DAVE GRADEN ~ U) Z L() (il 0 STEVE TLTON STEVE TLTON PAUL HAMLTON RON BESSEL (il 0 ~ (il ::t: :x: TE NTO THE BLDG ERECTON CREW PAUL CLNE PAUL HAMLTON LONNE BOGGESS DAVE GRADEN STEVE TLTON * KLLED N CRANE ACCDENT TE NTO THE BLDG o LO CRANE ERECTED AND CERTFED AUGUST 22, 1989 l' l -1---l- ERECTON CHRONOLOGY FGURE

26 N_ O -0 u N 7' _0 5 / 8 U1!j ~ ~. ; (7\ -..] - 0 V... 1/!j t3 1 ~~ ~ 0> ~?, U1 0 U1 0!j t3 w!" U1 PLAN OF TOWER ELEVATON ELEVATON SOUTH AND WEST FACES NORTH AND EAST FACES TYPCAL TOWER SECTON TYPCAL TOWER SECTON ~ FGURE l t =3

27 -0- OJ Ī N = 9-'6" ~- - :E.., -$-- - '~-- PLAN OF CLMBNG SECTON. -..J 0 = /1 FLAP WHEN RESTNG ON TOWER LUG ~ ~ -..J - / 0 = -- C. L. / -... U1 ROLLER./ ELEVATON OF THE CLMBNG SECTON EAST FACE N -' FGURE ~

28 Typical bolted connection between two towe sections. Figue

29 ~! Typical towe section - viewed fom the bottom. Figue

30 Typical bottom end plate of towe section. Figue

31 Undeside of tuntable. Single pin-hole fo climbing section, double pin-hole fo towe section. Tuntable - viewed fom the top. Figue

32 AR ACTVATED WN H (LOCATED ON THE 15TH FLOOR) ; CABLE WRE ", ' " "'. PLATFORM TRAY A.l FGURE A NEW SECTON TOWER CLMBNG SECTON PLAN VEW THE N~W SECTON ON THE CLMBNG PLATFORM FGURE

33 W N 23 '-0" - \ LOAD LNE CLMBNG., SECTON WRE.1../ TOWER SECTON 15TH FLOOR ++ ~..) ELEVATON A-A POSTONNG OF NEW SECTON ON THE CLMBNG SECTON PLATFORM LOOKNG WEST FGURE &1' ~

34 -.~ w ~ :s ~ CJi t:j n :2l 0 '!z:!z: 0.. :"" U1 ~ ~ ~; m tj.~ 8' 0 ~!Z: 0.. /\. ~ oil"..: f7 \ CLMBNG STEP #1 i () ~ H LUGS ON :s: NW & NE tl:l H!Z: G') ~. ld-- G h e,! /' V\,, CLMBNG STEP #2 TOWER COLUMN H~ DRAULC RAM CLMBNG '1 RAVERSE SCHEMATC LLUSTRATON OF THE PROCESS ON FGURE ~ ~ ~ J V\, i - CLMBNG STEP #3. CLMBNG ----1

35 w..., w,:.. ~ N _-1H 0 \) -fd:,:.. ~ fd.' TYPCAL EDGE ROLLER CROSS SECTON TYPCAL FLANGE ROLLER CROSS SECTON FGURE ==t

36 -t''6' "/32" DA.~., ~. TYPCAL RETANNG PLATE AND BOLT FOR THE ROLLERS 25/ 2.0" o ~ 5/ w FGURE U1 L"/32" DA. HOLE 1 ~

37 f1l,, i 4. DESCRPTON OF THE FALURE 4.1 Backgound Eyewitness accounts of the sequence of events associated with the collapse and desciptions of the collapsed stuctue ae pesented in this chapte. This infomation was used in detemining the cause of the collapse as descibed in Chapte Eyewitness Accounts of Failue A total of 96 pesons wee inteviewed to obtain infomation about the failue. This included wokes on the site, individuals on the steet o in adjacent office buildings and othes not at the site who had knowledge of the towe cane and wok pactices followed in opeating the cane. Most of the inteviews wee conducted within one month of the accident. These inteviews wee conducted by the Bueau of nvestigation, Depatment of ndustial Relations, state of Califonia and some of the eyewitnesses wee late einteviewed by OSHA staff to obtain additional infomation and claify potions of thei oiginal statements. This section summaizes the witness obsevations. Some witnesses wee casually obseving the cane opeations pio to the failue, othes began to obseve it when it became clea that something out of the odinay was happening. Many of the witnesses, howeve, did not obseve the events immediately peceding the failue o the initial stages of the collapse. Also, they wee only able to povide geneal desciptions of the collapse and not details useful in detemining the cause of the failue. Eighteen individuals wee able to descibe the event in some detail. The locations of these individuals ae shown in figue Most of the eyewitnesses wee in office buildings adjacent to the site. A summay of thei statements is pesented in table The dates the inteviews wee conducted ae also given in the table. The ten eyewitt;esses in table in adj acent buildings had unobstucted v~ews of the uppe potion of the cane, the tuntable, climbing section and towe stuctue. using an assumed aveage stoy height of 12 feet fo the office buildings, the elevation of each witness elative to the top of the cane (top of the tuntable) which was 285 feet above steet level can be detemined. witness no. 2 in table 4.2.1, fo example, on the 30th floo, was appoximately 75 feet above the level of the tuntable looking down on the stuctue. witness no. 4, on the othe hand, was appoximately 55 feet below the tuntable looking up at the top of the stuctue. The estimated line of sight distance in table is the distance measued along a staight line fom the witness location to the tuntable o top of the stuctue. The emaining seven witnesses listed in table wee on the constuction site and had vaying views of the cane at the time of 37

38 the failue. witness no. 4 involved with the climbing pocedue was the closest peson to the cane at the time of the accident and was able to povide impotant infomation on the activities undeway and the behavio of the stuctue. The summay of the key eyewitness statements in table pesents the highlights of the inteviews. t includes infomation on the activities immediately peceding the collapse and the behavio of the stuctue duing failue. The highlights pesented wee taken diectly fom the witness statements. No attempt was made to intepet the witnesses emaks. An attempt was made, howeve, to detemine the sequence in which the witnesses obseved the events. n some cases, this was not clea fom the inteview and some wit.nesses wee eint.qviqwed. :n eviewing the statements in table 4.2.1, the time peiod efeed to by the witness is impotant. witness no 2, fo example, was obseving the opeat.ions ove a peiod of time peceding the collapse. The statement by witness no. 5, howeve, efes to the events at the time of failue. The witness statements povide infomat.ion on: (1) the activities undeway on the cane pio to the collapse, (2) the behavio of the stuctue duing the time leading up to the collapse, and (3) the mode of failue of the towe stuctue. Activities undeway on the cane wee descibed by witnesses nos. 2 and 25. Witness no. 2, noted the boom was initially paallel to the building unde constuction pointing south with counteweights on the noth side of the towe. The boom had been aised and thee was no load on the hook. A numbe of witnesses confimed this oientation of the boom. witness no. 2, then noted that someone climbed up to the tuntable and afte looking in the cab went to the contol panel cabin (elay oom). An individual came out of the contol panel cabin (pesumably the cane opeato), they talked biefly, the wokman climbed down to the climbing section and the opeato went back to the contol panel cabin and then to the cab. witness no. 2 places the opeato in the cab befoe the cane stated to otate. Tlu-ee witnesses, nos. 17, 19 and 25, place the opeato in the cab duing the otation. Witness no. 5 did not see anyone in the cab duing the otation. Witness no. 17 notes that he was moving his hands while in the cab. At some time pio to the collapse, he was obseved tying to push his way out of the cab. witness no. 25 also saw him seated in the cab, then stand up quickly afte looking down at something the wokmen on the climbing section wee obseving. One witness, no. 31, not listed in table placed the opeato in the cab pio to the failue. Two witnesses, nos. 8 and 45, indicated they did not see anyone in the cab. Unfotunately, they did not indicate at what point duing the otation of the cane they obseved this. witnesses nos. 6 and 45 place the opeato on the tuntable holding onto a ail as the cane was collapsing. These obsevations ae not necessaily contadictoy since the opeato could have left the cab at some time duing the cane's otation, pobably afte sensing some poblem. 38

39 witness no. 4 was on the 16th o the 17th floo of the building unde constuction and was in diect communication with the cane opeato though the two-way adio and with the climbing cew on the climbing section platfom. He was about 85 feet fom the opeato's cab and 55 feet fom the climbing section platfom. This witness epoted a hydaulic leak on one of the top fittings.:of the am befoe the climbing opeation stated. This leak also occued the day befoe duing climbing. He indicated that a metallic sound indicative of "Ubbing" of metal sufaces was coming fom the climbing section duing the climbing of the towe. This sound gadually inceased and became intense duing the last climbing step. He indicated that the cew aised the towe to the desied elevation and the lift was almost complete. He indicated that a few minutes befoe the completion of the thid climbing step, the opeato luffed the boom up to coect the "leaning of the towe towads the south". This witness, at the time of the collapse, did not talk to the cane opeato o the climbing cew on the platfom as he was engaged in convesation on the adio with a diffeent paty on the gound. Thee was geneal ageement among the witnesses on the behavio of the cane leading up to the collapse. Nine witnesses indicated they obseved the cane otating counteclockwise, one witness obseved it otating clockwise. witness no. 25 indicated he obseved no otation. t is possible that his obsevation of the cane was limited to the time just pio to the collapse when the boom had otated aound and stuck towe section 16 which was esting on the climbing section. six eyewitnesses indicated they obseved the counteweights stiking the new towe section. The otation of the cane was a steady, nomal, unifom movement. No one obseved any acceleation o deceleation of the tuntable. n addition, the tuntable appeaed to emain hoizontal duing otation. Given the witnesses wee all at least 80 feet fom the cane, the tuntable could have tilted and gone unnoticed. six witnesses povided details of the collapse. All six indicated the cane fell in a southely diection afte the counteweights s:tuck towe section 16 4=>sting an th~ c1; mb; ng section. Some statements wee made about the southwestely column failing fist and the cane tilting in a southely diection acting like it was hinged. Also, that thee was a tension failue of two noth face legs, e.g., witness no. 6. witness no. 22 noticed a "piece of ion" flying though the ai at the time of the failue and saw one of the eection cew falling with the debis at the same time. The piece of ion, which was late detemined to be a olle guide fom the climbing section, landed on the 17th floo. One witness, no. 32, not listed in table as an eyewitness, indicated that the slewing bakes wee adjusted by the pesonnel of the steel eection company a week befoe the collapse because they wee "oveheating, too tight and gabbing." He said that Pecco's epesentative came and checked the adjustment. 39

40 4.3 Obsevations of Collapsed Stuctue Obsevations of the collapsed stuctue povided infomation on the failue mechanisms of the stuctue. This infomation was coelated with the witness obsevations and was helpful in identifying the sequence of the failue. This infomation was also used in detemining the cause of the failue Oveall Collapse The failue of the towe cane occued at about 8: 10 a.m on Novembe 28, The entie cane supestuctue fell in the southeastely diection. A geneal view of the debis afte the collapse is shown in figue The location Of vaious pieces of the stuctue is shown in figue The locations in figue ae based on ealy photogaphs of the accident scene, befoe any cleaing of the debis. A potion of the cane towe, e.g., climbing section, towe section 15, some components of towe section 14, towe section 16 and the climbing tavese fell on Keany Steet. A maj oity of the cane supestuctue also landed on Keany Steet. Some pats of the cane supestuctue landed on Califonia steet and on the 18th level of 600 Califonia steet and the oof of 601 Califonia steet. Duing the collapse, a numbe of buildings wee damaged due to the impact of potions of the collapsing stuctue. The conice of the building at 601 Califonia steet was damaged by the luffing boom tip and load blocks: the building at 580 Califonia steet was damaged by the climbing section, the stuctual steel fame of the building unde constuction was damaged by vaious pats of the cane supestuctue. n addition, the paving of Keany steet and the oof of the undegound gaage on Keany Steet wee damaged. Five bodies wee eooveed fom the debis whioh inoluded the body of the dive of a bus hit by the falling heel section and lowe ganty suppot. Fou bodies wee fom the eection cew. The body of the cane opeato was ecoveed in the vicinity of the smashed opeato's cab. t could not be ascetained whethe the body was emoved fom inside the opeato's cab o outside the cab Towe Stuctue The locations of the failues in the towe stuctue, towe sections 15 and 14, ae shown in figue The emaining potion of the failed towe is shown in figues and section 14 is the uppemost section in these photogaphs. The Qouthwest leg of towe section 14 was factued about 3 feet-4 inches below the top while the southeast, nothwest and notheast legs factued though the fou inch thick plate welded to the top of the legs of section 14. These plates seve as connection plates between two towe sections. Figue shows the factue sufaces fo this southwest leg. The top lug of the nothwest leg 40

41 of towe section 14 showed signs o: beaing type defonuation. Simila distess was obseved in the nothwest dog of the climbing tavese and will be discussed late in this section. Figues 4.3.7, and show the factue sufaces fo the southeast, notheast and nothwest legs. The location of the failed diagonals of towe section 15 and 14 ae shown in figue The othe diagonals in towe section 15 and 14 emained intact. The towe sections below section 14 wee examined to detemine if any pemanent defomation occued due to the collapse. All the sections appeaed to have emained elastic. The two lateal ties to the building unde constuction and thei connections wee epotedly fee fom any signs of distess pio to disassembly and emoval to the stoage yad Towe Section 16 Towe section 16, located on the platfom of the climbing section pio to collapse, landed on Keany steet with its top facing in a nothely diection. The noth face of towe section 16 was in contact with the paving. Figue shows the defomed shape of towo section 16 ~ubsgqugnt to the collapse. Most witnesses indicated that the counteweights hit towe section 16 as the cane otated pio to the collapse. Thee was a deep indentation on the southeast cone of the south flange of the notheast leg of towe section 16 and thee was blue paint ove it. The cane supestuctue was painted blue. This indentation was located about nine feet above the base of the section. This could not have been made by the counteweights as the west face of towe section 16 would come in contact with the counteweights. This indentation is believed to have been made on the steet by the edge of the tuntable. The edge of the tuntable was lying vey close to the notheast leg of towe section 16. Towe section 16, as shown in figue , has been defomed with the diagonals buckling pedominately in the east and west faces. No significant mak with blue colo was obseved on the west face of the towe section 16 whee the witnesses epoted seeing the counteweights stike the section Climbing Section The climbing section landed on the east sidewalk of Keany Steet, leaning against 580 Califonia Steet in an upight position. The west face of the climbing section was paallel to the 580 Califonia Steet building and the noth face was towads Califonia steet, Le., the climbing section otated appoximately 41

42 180 degees. Duing the fall, the climbing section hit the acade of 580 Califonia steet but damage was limited to beakage of window glass, defomation of window faming and the building facade. The climbing tavese and the hydaulic am wee no longe attached to the climbing section. They wee lying nea the climbing section. None of the fou columns of the Climbing section wee factued. The nothwest and southwest columns wee bent substantially. The southwest column was tosionally defomed. The notheast and southeast oolumns also showed signs of twisting and bending. Figues , , , and show the defomed shape of the notheast, southeast, southwest, and nothwest columns of the climbing section. The fou guide pins at the top of the columns of the climbing section wee sheaed and bent towad the noth as shown in Figue All 1-1/2 inch ~ pins wee found in place except one which was sheaed off. F The hoizontal membe at the uppe level of olles on the south face of the climbing section was deflected downwad. The hoizontal membe at the lowe level of ol1q~ QmainQd essentially staight. On the east face, the hoizontal membe at the uppe level of olles had an outwad deflection away fom the cente of the climbing section of about one inch measued in a hoizontal plane. The membe at the bottom level of olles on the east face had defomations believed to have been caused by impact. On the west face, the hoizontal membe at the uppe level of olles emained essentially staight but the hoizontal membe at the lowe level of olles had an upwad deflection of about thee inches. This deflection could have been due to impact. On the noth face, the hoizontal membe at the uppe level of olles did not defom. The hoizontal membe at the lowe level of olles on the noth face, howeve, had defomed in a vetical plane. Figue shows the defomed climbing section afte the collapse Climbing Section Rolles out o the sixteen olles, ou wee not attached to the Climbing section afte the collapse. All fou olles wee the edge olles meant to oll on the edge of the flanges of the towe columns. One of the olles was found on the 17th floo by witness no. 22. The othe thee olles wee found among the debis on Keany steet. Figue povides a desciption of the maks and defomations of the uppe level olles. Figue descibes the lowe level olles. Figues , , , and show the maks and indentation on the olles detached,fom the climbing section. Figues , and indicate the maks and indentations of the olles found in place on the climbing section. Futhe discussion of the olles is contained in Section and in Chapte '

43 4.3.6 Towe Section 15 Towe section 15 was found lying on Keany Steet in close poximity to the climbing fame. The top of towe section 15 was undeneath the climbing fame, pointing towads the east and the bottom pat of towe section 15 was towads the building unde constuction. ThQ ~outh face was up and the we~t face was facing noth. Section 15 sepaated fom section 14 by factues though the plates welded to the top of the towe section 14 columns at the notheast, nothwest and southeast cones. The factue at the southwest cone in the leg of towe section 14 was about 3 feet-4 inches below the top of the section. Figues , and and show the factues in the towe legs. The notheast, southeast and southwest legs of the towe section factued at diffeent locations. The southeast and southwest legs factued at the location whee two diagonal membes ae welded to the flange. The notheast leg sustained a patial factue though the south flange and the web only. This factue also occued at a section whee the two diagonals ae welded to the south flange Of the nothwest leg. The nothwest leg did not factue. Figue indicatq~ the points of failue in the legs of towe section 15. Most of the diagonals in the east and west face of towe section 15 factued. A few factued on the noth and south face. Figue shows the location of the factued diagonals of towe section 15. The nothwest leg of towe section 15 defomed towad the south bending unifomly along the length about the majo axis. The deflected shape, based on the field measuement is shown in figue The notheast leg also defomed below the factue towad the south. The deflected shape, based on the field measuement is shown in figue The defomations of the southeast and southwest legs ae shown in figues and Figue shows the diagonal failues. Thee was extensive damage to the edges u the [lqnge~ of the leg5 of towe section 15. All fou legs sustained damage. Figues , , and show the defomations obseved on the edge and the face of the flanges of towe section 15. The west edge of the south flange of the southwest leg had an indentation beginning at 2 feet-6 inches fom the bottom and ending at about 9 feet-6 inches fom the bottom. This indentation is maked (A) on figue The depth of this smooth beaing type defomation inceased with the height along the section. The last six inches exhibited the geatest defomation_ The natue of the indentation was such that it indicated a unifom incease in beaing stess fom the bottom to the top. The smooth unifom indentation was an indication it occued while the climbing section was ascending. The suface was fee of any scaling o 43

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