East Anglia Construction Safety Group. Tower Crane Safety Update

Transcription

1 East Anglia Construction Safety Group Health and Safety Day 22 nd April 2010 Tower Crane Safety Update Tim Watson Tim Watson Consulting

2 Topics An overview of the latest advances in tower crane standards and design Some recent accidents and the lessons learned Planning for the safe and effective installation and use of tower cranes on site The Tower Crane Register

3 Latest Advances in Tower Crane Standards and Design

4 Old and New Standards National Standards DIN NF E FEM EN 14439: A1:2010 One standard across Europe Adopted by manufacturers from January 2010

5 What's New in EN14439 Improved Safety in Service Compulsory anemometer Anti-collision and zoning devices Improved cab visibility Improved Operator Comfort Requirements for cab heating and control station layout Improved Safety for Erection and Maintenance Personnel Reduction of crushing hazards Improved access Specifications for climbing systems Increased Requirements for Out-of-service Wind

6 Out-of-service Wind European Storm Wind Map CPA TIN 027

7 Example

8 Out-of-service Wind Accidents

9 Common Requirements for Access EN 13586

10 Common Requirements for Access Ladders

11 Zoning Systems

12 Standardised Minimum Requirements

13 Requirements for Operator s Cabs

14 Some Recent Tower Crane Accidents and the Lessons Learned

15 Tower Crane Accident Survey May 2000 July 2009 At least 51 Serious incidents 8 in the UK 1 in Israel 6 in China 1 in Malaysia 5 in the USA 1 in Philippines 4 in Russia 1 in Poland 4 in Netherlands 1 in Qatar 3 in South Africa 1 in Saudi Arabia 2 in Germany 1 in Spain 2 in Malta 1 in Singapore 2 in Switzerland 1 in South Korea 1 in Bahrain 1 in Taiwan 1 in Canada 1 in Tokyo 1 in Irish Republic 1 in Vietnam

16 Service Condition Service Condition Quantity In-service 22 Climbing 7 Dismantling 6 Erection 6 Out-of-service 6 Not known 3 Under test 1

17 Failure Area Failure Area Quantity Foundation/Base 11 Jib 7 Tower /Base 5 Slew section 4 Tower 4 Crane top and climbing frame 3 Falling tower section 2 Jib pendant & luffing ropes 2 Suddenly moving jib section 1 Tower tie 1 Not known 11

18 Causes Erection/Dismatling/Exten ding Extreme Weather Foundation Problems 5 Mechanical Issues Misuse 7 Not Known 9 Total 51

19 Canary Wharf May 2000

20 Canary Wharf May 2000 Crane was being climbed by a six man crew Collapse occurred as the last mast section was being added on the Sunday Three men fatally injured as result of the 120m fall Debris over wide area of Canada Square Issues: Training Long hours of work Inadequate planning Faulty equipment Manufacturer s instructions not being followed

21 Worthing February 2005 Two men killed One seriously injured

22 Worthing February 2005 De-rigging prior to dismantling The two erectors fatally injured working on the jib removing hoist and trolley ropes Third Erector had de-torqued tower bolts on one side of the mast Jib was slewed Slackened bolts failed and crane collapsed Crane owner prosecuted and fined 389,000 for not managing the dismantling process effectively Issues Training Planning

23 Battersea September 2006 BPR 222 Crane Crane had been in use for a number of weeks Joint below slew ring failed Jib fell across site into an adjacent road Crane Driver + Member of public killed Slew ring bolts had been replaced shortly after erection Investigation concentrating on method used to replace bolts.

24 Seattle November 2006

25 Seattle November 2006 Official enquiry blamed inadequate design of foundation Fatigue failure Lack of maintenance and inspection Issues: Planning Base design Maintenance Thorough examination

26 Liverpool - January 2007 JASO Luffer 3 years old CE marked DOC to EN Crane was in use Light load Close to minimum radius Wind near maximum inservice limit Jib fell backwards across the site during a lifting operation 1 Construction worker killed

27 Liverpool Investigation Findings Jib at small angle to the vertical Wind from the front held the jib up and caused the luffing rope to go slack Luffing rope jammed in the sheaves Operator tried to lower off and paid out rope from the luffing winch, which looped down the back of the crane Luffing rope became free allowing the jib to drop until the slack rope arrested its fall Large dynamic load caused the jib to fail and the slewing section and counter jib became detached from the top of the tower at the slew ring One of the counterweights fell on a construction worker causing fatal injuries Issues: Crane design standard

28 Liverpool Animation

29 Croydon June 2007

30 Croydon June 2007 Climbing team had not used the equipment before and had not had any specific training on its use Crane owner fined 100, ,196 costs Issues Training Planning Not following manufacturer s instructions

31 New York March 2008 Favelle Favco Luffing Jib Tower Crane 3 Fatalities Being climbed Fabric lifting sling failed, causing tie to fall Top of crane demolished building two blocks away Issues Planning Selection of equipment

32 Miami March 2008 Libeherr luffing jib crane Climbing operation Tower section fell 2 Fatalities Issues:- Planning Selection of equipment

33 Miami March 2008

34 New York May 2008 Kodiak luffing tower crane In-service but not lifting 2 Fatalities Slew ring support failed Said to be 24 years old Same owner as March incident Issues:- Maintenance Thorough examination

35 Rotterdam July 2008 The crane was lifting a heavy load within its rated capacity close to the mast. It was required to slew the crane & manoeuvre the load along the jib such that the load was very close to the maximum permitted at the required radius During final positioning of the load it ran away down the jib, overloading the crane and causing it to fail at the mast section Failure due to incorrect setting of the PLC/Inverter trolley motor control system

36 Common Issues Inadequate Planning Inadequate Training Maintenance Issues Through Examination Issues Not Following Manufacturer's Instructions Poor Selection of Equipment Poor Base Design Design Standard Issues

37 Planning for the Safe and Effective Installation and Use of Tower Cranes on Site

38 Planning for Installation Choose your tower crane supplier with care Maintain same key personnel from Crane Provider and Principal Contractor/Hirer throughout the process from initial enquiry to dismantling Initial meeting on site to establish Site restrictions and hazards Temporary works requirements Responsibilities for liaison Detailed risk assessments and method statements Method statement sign off Pre activity site inspection and meeting Checks on day of operation Permits to erect, climb or dismantle Keep Talking!!

39 Guidance on the Management of Installation Process

40 Guidance on the Management of Installation Process

41 Guidance on the Management of Installation Process

42 Guidance on Design of Foundations

43 Guidance on the Management of use of Tower Cranes

44 Guidance on the Management of use of Tower Cranes

45 Guidance on the Management of use of Tower Cranes

46 Guidance on Maintenance, Inspection and Thorough Examination

47 All Construction Plant-hire Association (CPA) and Strategic Forum Plant Safety Group Guidance Documents can be downloaded free at

48 The Tower Crane Register

49 The Tower Crane Register Aims to improve tower crane safety and public confidence in their safety Register required by the Notification of Conventional Tower Crane Regulations 2010 Came into effect 6 th April 2010 Only affects conventional top slew tower cranes on construction sites Not SETCs or Truck Mounted Responsibility for ensuring notification is made rests with the user (hirer) of the crane

50 The Tower Crane Register When Notification must be Made Notification must be carried out with 14 days of the date of any through examination:- following the crane s installation and before being put into use for the first time on a particular site; when the crane is reconfigured on site, eg when the height of the mast is altered; when the crane stays on-site long enough for the existing thorough examination to expire; if exceptional circumstances liable to jeopardise the safety of the crane have occurred.

51 The Tower Crane Register Information to be Notified The name and address of the company providing the crane for use on the site. The address of the construction site at which the crane has been installed; Information sufficient to identify the crane including, where known, its date of manufacture. The date of the thorough examination; The name and address of the employer for whom the thorough examination was made; Whether the thorough examination revealed any defects involving imminent risk of serious personal injury.

52 The Tower Crane Register Method of Notification and Cost Two ways to notify HSE Online at By post by completing a form which can either be downloaded from the above website, or by contacting HSE s Infoline for a form and returning it to: Cost HSE Cranes Register, Health and Safety Executive, Field Operations Division, London Divisional Administrative Office, Rose Court, 2 Southwark Bridge, London SE1 9HS 20 per Notification

53 Further Information The Crane Register Website HSE Guidance Leaflet INDG 437

54 Thank You