Self Erecting Tower Crane Operators Guide

A GUIDE FOR SELF-ERECTING
TOWER CRANE OPERATORS
TRAINERS EDITION 2005
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A GUIDE FOR SELF-ERECTING TOWER CRANE OPERATORS

TRAINERS EDITION
This guide outlines the information and requirements for a trainer to instruct a trainee on the facets
of self-erecting tower crane operation.
This guide follows the information supplied in the compiled learners edition.
How to use this manual
Each section related to the relevant sections in the accompanying learners guide.
Both booklets are required to be utilised hand in hand.
Related questions from the assessment instrument are included at the end of each section to
facilitate easy understanding for the trainee.
Some general questions are taken from the cranes National Certificate of Competency Written
Assessment for Cranes August 2000.
Page 1
CONTENTS
SECTION 1 Competency for self-erecting tower crane operators
SECTION 2 Types of self-erecting tower cranes
SECTION 3 Features of self-erecting tower cranes
SECTION 4 Crane controls
SECTION 5 Set-up crane
SECTION 6 Assembly/disassembly
SECTION 7 Limit switches
SECTION 8 Load/radius indicators
SECTION 9 Brakes
SECTION 10 Site/job planning
SECTION 11 Maintenance procedures
13
SECTION 12 Pre-operational
13
SECTION 13 Crane operation
16
SECTION 14 Loads and self-erecting tower
19
SECTION 15 Special operations
26
SECTION 16 Shutdown crane
27
SECTION 17 Rule of thumb and working load limits
29
SECTION 18 Load factors
31
SECTION 19 Rules to follow when slinging and handling a load
34
SECTION 20 Stacking
36
SECTION 21 Personal protective equipment
36
SECTION 22 Communication
36
SECTION 23 Flexible steel wire rope
37
SECTION 24 Wedge rope sockets
39
SECTION 25 Sheaves and drums for flexible steel wire rope
40
SECTION 26 Lifting chain
42
SECTION 27 Flat webbing and round synthetic slings
44
SECTION 28 Fibre rope
45
SECTION 29 Accessories
46
SECTION 30 Calculation
49
APPENDIX (I) Tables of masses
52
Page 2
SECTION 1
COMPETENCY FOR SELF-ERECTING TOWER CRANE OPERATORS
Points for trainer
Explain to the trainee the process of obtaining an assessment for a self-erecting tower crane operators
competencies.
SECTION 2
TYPES OF SELF-ERECTING TOWER CRANES
Points for trainer
Relate this section to the particular self-erecting tower crane to be used for the training practical
sessions.
Ensure the trainee understands crane terminology in relation to self-erecting tower cranes.
Explain to the trainee the different types of self-erecting tower cranes.
Describe to the trainee the main functions and motions of a self-erecting tower crane.
Practical session
Show the trainee the various components on the specific self-erecting tower crane used for the practical
training.
Media application
Using a scale model, explain to the trainee the terminology for the various components on a self-erecting
tower crane.
Use overhead transparencies to explain terminology for a self-erecting tower crane.
Trainers notes
SECTION 3
FEATURES OF SELF-ERECTING TOWER CRANES
Points for trainer
Explain to the trainee that some of these features may or may not be included for the particular selferecting tower crane used in the training session.
Explain to the trainee the specific features of the self-erecting tower crane used in the training session.
Practical session
Show the trainee the particular use of various features on the specific self-erecting tower crane used for
the training sessions. Features include cabin (where applicable), the outriggers, electrical apparatus, hook
blocks and sheaves.
Trainers notes
Page 3
SECTION 4
CRANE CONTROLS
Points for trainer
Review this section to ensure the trainee understands the use of each crane control and their particular
function.
Practical session
Demonstrate to the trainee the use of the crane controls and their application for the particular selferecting tower crane used in the session.
Explain to the trainee the use of the emergency stop button for the particular self-erecting tower crane
used in the training session.
Trainers notes
SECTION 5
SET-UP CRANE
Points for trainer
Review this section to ensure the trainee understands the issues involved in setting up/assembly of a selferecting tower crane.
Explain to the trainee the purpose and use of properly set-up outriggers.
Explain to the trainee the hazards of unstable ground or footings and reason for adequate packing of
outriggers.
Explain to the trainee the importance of adequate bearing for support of the tower crane.
Questions for trainee/s

Question 1
Explain the requirements for preventing personnel from entering the counterweight-slewing radius of the
crane?
Answer The area must be thoroughly barricaded.
Reference: Oral/written assessment question 25
Question 2
Should a self-erecting tower crane be set-up/assembled next to open trenches or excavations? Explain
your answer.
Answer No. The self-erecting tower crane should not be set-up/assembled close to an excavation as the
weight of the crane creates additional pressure to the adjoining soil and can cause the excavation to
collapse resulting in the crane overturning. An engineer may need to approve the cranes position.
Page 4
Question 3
What principles would apply to setting up/assembling a self-erecting tower crane next to an open
trench/excavation?
Answer The self-erecting tower crane base (ie pad) area should be certified by an engineer.
Question 4
What action would be required if an excavation was dug adjacent to the base of the self-erecting tower
crane?
Answers Stop operation and have the excavation immediately backfilled and compacted.
Have the ground assessed by a qualified person.
Barricade the area thoroughly to prevent a reoccurrence.
Question 5
Where is the information found to determine the area of packing required under outriggers?
Answer In the manufacturers manual or seek approval from an engineer.
Question 6
List three points that should be considered when setting up outriggers?

Answers All outriggers must be used as per the manufacturers instructions.
All beams must be fully extended or as per the manufacturers instructions.
Correct selection of footplate or packing.
Outrigger pads must be securely pinned or connected to the outrigger beams.
Question 7
Why must the self-erecting tower crane be set-up/assembled level?

Answer To ensure the self-erecting tower crane is stable and the crane can be operated at it rated
capacity.
Question 8
When setting up/assembling a self-erecting tower crane what items need to be considered in regards to
crane clearances?
Answers Ensure the counterweight tail radius is clear to slew 360 degrees to satisfy safety requirements for
the particular worksite.
Ensure all site hazards in the slewing radius of the self-erecting tower crane have been assessed.
Ensure barricades or fencing of a minimum one metre in height are used to prevent personnel gaining
entry to the slewing counterweight area of the self-erecting tower crane.
Question 9
When setting up/assembling a self-erecting tower crane where the ground or soil value cannot be
identified (eg on a bitumen or concrete road), what precautionary methods would need to be taken?
Answer Assess the situation and ensure the assembly is set-up as determined by an engineer.
Question 10
What risks occur when packing is placed halfway along the outrigger beam to support the crane?
Answer This creates an inside tipping point and reduces stability, possibly causing the self-erecting tower
crane to overturn.
Page 5
Question 11
A self-erecting tower crane has been set-up/assembled on a new site, which requires unloading of trucks
from a street over a busy pedestrian footpath. What hazard controls are required to progress with the
operation ensuring public safety?
Answers A hoarding and gantry must be in place that conforms to the relevant standard.
Barricades, detours or pedestrian control could be utilised.
Traffic control may be required.
Practical session
Demonstrate to the trainee the procedure for location of hazard controls before setting up/assembling the
crane.
Demonstrate to the trainee the procedure for set-up/assembly of the particular self-erecting tower crane
used in the training session.
Explain to the trainee the preparations for set-up/assembly of the crane on a new site. The following
points must be taken into consideration.
The position of the self-erecting tower crane is satisfactory in relation to the task to be undertaken.
Outriggers or stabilisers are extended, packed and set-up as per manufacturers specifications.
Base levelled and bearing on all outriggers or stablisers.
Counterweight is erected and adequate as per the manufacturers specifications or according to load
chart requirements.
Reference: Performance assessment section F
Trainers notes
SECTION 6
ASSEMBLY/DISASSEMBLY
Points for trainer
Review this section to ensure the trainee understands the issues involved in assembly and disassembly of a
self-erecting tower crane.

Question 1
What qualification must be held by personnel to assemble a self-erecting tower crane?

Answer An intermediate or advanced riggers certificate
Page 6
Question 2
When can additional counterweight be added to the crane?

Answer As per manufacturers recommendation that apply to the specific self-erecting tower crane.
Practical application
Ensure the trainee understands the following points in assembly of the tower crane.
Self erecting tower crane transported to site
Assess hazards and implement a risk assessment or work method statement
Assess individual environmental conditions such as weather and wind conditions
Check engineers compliance certificate
Erect barricades and ensure public safety
Surface prepared for crane set-up
Adequate clearances to assemble and unfold the crane as per manufacturers specifications
Outriggers positioned and packed
Self erecting tower crane levelled by using jacks
Earth crane to the ground
Connect the power supply
Base counterweights installed or as per manufacturers specifications
Trolley and hook block must be in correct position for unfolding of jib or as per manufacturers
specifications
The crane mast and jib must be unfolded in correct sequence against the prevailing wind. (Note:
Extreme caution is necessary during the unfolding procedure to ensure each section is assembled
correctly.) Follow the manufacturers specifications.
Remainder of counterweights are installed or as per manufacturers specifications
Complete unfolding remainder of jib sections as per the manufacturers specifications
Check all limits and all governors for correct functioning
Load testing self-erecting tower crane under the supervision of a competent person
Reference: Performance assessment section G
Ensure the trainee understands the following points in disassembly of the tower crane.
Note: Particular attention must be considered for the correct sequence of counterweight removal.
Trainers must use manufacturers manuals for each complete crane disassembly.
Reference: Performance assessment section H
Media application
Use a scale model or use OHPS to display the system and procedure involved in assembly and disassembling
of a self-erecting tower crane.
Use a video supplied by the manufacturer to display the assembly and disassembling procedure for a
specific self-erecting tower crane.
Trainers notes
Page 7
SECTION 7
LIMIT SWITCHES
Points for trainer
Explain to the trainee the importance of checking limit switches for correct functioning on each
operational workday of a self-erecting tower crane.

Question 1
Why is it important to check the hoist limit or cut out switch prior to using the crane?
Answer To ensure that it is operating correctly so that double blocking does not occur.
Question 2
Why is it important that all motion limits are checked for correct functioning?
Answer To ensure that all limits are working to avoid causing any damage or injury.
Question 3
If you suspect a load sensor or limit switch is not functioning correctly, what action would you take?
Answer Cease operation, report relevant personnel and await advice regarding action.
Practical session
Demonstrate the role of limit switches and point out the common locations of these switches.
Demonstrate how the limits work by slowly running each motion into the limit activation point.
Trainers notes
SECTION 8
LOAD/RADIUS INDICATORS
Points for trainer
Explain to the trainee the importance of the load movement indicators and load weight indicators being in
correlation with radius indicators. These devices must be accurate and correct for self-erecting tower
crane operation.
Ensure the trainee understands the term operating radius.

Question 1
How often should the load mass (weight) indicator be calibrated?

Answer Every six months or by picking up a known weight in accordance with the manufacturers
specifications.
Page 8
Practical session
Show the trainee the location of load radius indicator both electronic and mechanical where applicable.
Show the trainee the connection between the load chart and the load radius indicators.
Trainers notes
SECTION 9
BRAKES
Points for trainer
Explain to the trainee the importance of checking braking systems before starting operation. Inform the
trainee on the procedure where any slippage or malfunction of braking systems is detected.
Practical session
Show the trainee the location of braking systems for the crane used in the training.
Trainers notes
SECTION 10
SITE/JOB PLANNING
Points for trainer
Explain to the trainee the importance of rules and procedures for industry and how they relate to the
trainees particular area of work.
Explain to the trainee the responsibilities for crane operators and crane crews.
Explain to the trainee the importance of understanding this section as this information relates to the
occupational health and safety (OHS) requirements for industry.
Explain to the trainee the importance of implementing an operational plan before work commences.
Practical session
Perform an onsite hazard assessment of the worksite with the trainee.
With the trainee, draw up an operational plan for the particular crane operation.
Page 9

Question 1
List four job and/or site procedures that should be considered before you set up a self-erecting tower
crane?
Answers Job requirements
Priorities
Workplace rules
Specific site procedures
Identify hazards
Hazard control measures
Site specific induction
Lifting plans including lifting radii requirements
Emergency procedures
Question 2
List six hazards that would need to be taken into account in your crane set up plan?
Answers Powerlines
Trees
Surrounding structures
Overhead service lines (steam, gas, fuel lines)
Underground services (phone, gas, power, drainage, sewage)
Dangerous goods/hazardous substances
Weather conditions
Personnel working around the crane or near the counterweight slewing arc of the crane
Obstructions (scaffolding, ladders, excavations, stored materials and other plant)
Other equipment (cranes, piling rigs, forklifts, elevating work platforms)
Facilities (office, amenities and lunch rooms)
Soil conditions eg recently filled trenches
Inadequate lighting for night operations.
Question 3
List five methods of reducing hazards on site.

Answers Identify/detect all site hazards
Use barriers
Use warning signs
Utilise PPE for crane personnel
Use spotters
Use traffic control
Use risk assessment processes
Utilise hoardings and overhead gantries
Implement adequate lighting for night operations
Use visual identification on powerlines (eg tiger tails)
Ensure awareness of public safety requirements
Obtain relevant information (material safety data sheets, expert advice from councils and statutory
authorities)
Correct siting of crane.
Page 10
Question 4
What precautions must be observed when working near powerlines? List four precautions.
Answers
Never work closer than the minimum distance specified in AS2550.1 or State regulations
Ensure the crane is correctly earthed
Barricades are erected around the work area and crane base for public safety
PPE to be utilised
Traffic signs/cones and barricades should be placed around the work area
Follow procedures in AS2550.1.
Question 5
What is the minimum distance any part of a crane or load is allowed to approach live electrical parts?
Answer Relevant distances must be obtained from State authority regulations.
Note: Assessors must ensure that the applicant is aware of State authority regulations
Question 6
List five essential procedures, which must be followed if the crane was to come into contact with the
powerlines?
Answers
Try to move the crane away from the conductors using the crane cabin/remote controls.
Warn all other people nearby.
Remain in the crane cabin until power is disconnected.
If it becomes essential to leave the crane cabin (if applicable) or the immediate vicinity of the crane,
jump clear as far away from the crane as possible and avoid touching the crane and the ground at the
same. When moving away from the crane, shuffle or hop.
Machine checked prior to future use.
Question 7
A person dogging a load puts a hand on the hook and receives an electric shock. What would be your initial
action and what would you do to ensure the hazard is investigated?
Answers
If possible, lift the hook clear of the person dogging the load to break contact with the earth.
Follow relevant first aid procedure, as required.
If required, get somebody to assist.
Report the hazard to an authorised person.
Report the hazard to the authorities.
Question 8
Why is it important to consult with relevant workplace personnel and OHS officers before commencing
work on sites?
Answer To ensure that the operator is aware of any workplace site rules and procedures.
Question 9
What is the importance of having workplace emergency procedures?

Answer To lay out a sequence that should be followed in case of an emergency.
Page 11
Question 10
What must be provided for the crane working at night or in a darkened area?
Answer There should be sufficient lighting over the whole work area.
Question 11
In the case of an emergency, why is it important to communicate with the person dogging the load prior to
leaving the crane?
Answers
To be made aware of any areas that be unsafe to pass.
To be advised of the nature of the emergency.
To ensure that someone is aware that the crane operator is making their way down to a predesignated
muster point.
To be advised if it is safer to stay in crane cabin until the emergency passes.
Question 12
What is the importance of taking lighting of the workplace into account when planning your job?
Answers
To make sure work can be undertaken safely.
To ensure lighted access and exit locations for emergency situations.
To make sure adequate natural lighting or artificial lighting is provided to work safely under all
conditions.
Practical session
Show the trainee the pre-set up/assembly inspection requirements for the tower crane on arrival to the
worksite for the first time. Included in this list is other information that must be sourced before operation
of the tower crane.
Check the site plan for working radii at given locations from the self-erecting tower crane.
Check the self-erecting tower crane outrigger pad area for proper bearing and adequate packing in
accordance with the manufacturers recommendation.
Identify the maximum free-standing height of the self-erecting tower crane for the particular
worksite.
Obtain the manufacturers manual and daily operational logbook. Familiarise yourself with the
manufacturers manual before operating.
Check for engineers compliance certificate for the crane standing.
Check for commissioning tests for the crane standing.
Check for a dedicated safe operating area for the operator.
Reference: Performance assessment section A
Trainers notes
Page 12
SECTION 11
MAINTENANCE PROCEDURES
Points for trainer
Explain to the trainee the importance of proper maintenance procedures for the crane operation.
Explain to the trainee the maintenance procedures for the particular crane used in the training.
Explain to the trainee that all guards must be in place to restrict personnel from moving and rotating
parts.

Question 1
Why is it important to separate defective equipment?

Answer To eliminate the possibility of further use of unsafe equipment.
Practical session
Show the trainee the lubrication points on the crane; explain how often these points need to be greased.
Trainers notes
SECTION 12
PRE-OPERATIONAL
Points for trainer
Put emphasis in regards to the trainees obligations in performing pre-operational checks and inspections
to ensure the self-erecting tower crane is ready to operate in a safe condition.
Review this section to ensure these points are covered as this section relates also to the performance
assessment.
Before starting the tower crane ensure all motion controls are disabled or in the neutral brake on
position before turning on the main switch or power.
Perform a test of all motion controls, brakes and limit switches before operation.

Question 1
Why should the maintenance service logbook be used?

Answer To record an accurate account of all services, maintenance and repairs of the self-erecting tower
crane.
Question 2
If you found a defect in one of the main controls that would place the crane and/or personnel at risk,
what would you do?
Answers
Secure area and the machine and report to an authorised person.
Ensure the machine is repaired before re-commencing work.
Page 13
Question 3
On checking the tower/mast, you notice a loose bolt at one of the tower/mast connections. What action
should you take?
Answer Immediately stop work and contact an authorised person for a complete inspection of all
tower/mast bolts and pins.
Question 4
On a pre-inspection, you discover the gearbox is leaking oil. What action should you take?
Answer tag the machine and report the defect to the supervisor or authorised person before commencing
operation.
Question 5
What action would you take if the crane is discovered to be out of level during a pre-operational check?
Answers
Check the screw jacks and footings
Check ground conditions
Check for structural damage to stabiliser/outrigger components
Question 6
On checking the control panel you notice water in and around the panel. What action would you take?
Answer Tag the machine and report to the supervisor or authorised person.
Question 7
How do you ensure the self-erecting tower crane level?

Answer By checking the inbuilt level gauge fitted to the self-erecting tower crane or by using a spirit
level on the base section.
Question 8
You notice loose and flaking paint on the mast of the crane. What action would you take?
Answer Cease operation, tag the machine and immediately report to the supervisor or authorised person
to arrange for an inspection of job welds for damage and wear.
Question 9
You noticed that one of the job section connection pins was loose, what would you do?
Answer immediately stop work, tag the machine and contact and authorised person for a complete
inspection of all pins.
Question 10
When interference (tampering) is identified, what action must be taken?

Answer Tag the machine and report to an authorised person or supervisor.
Reference: Oral/written assessment for cranes question 51
Practical session
Demonstrate the use of the service logbook for the particular type of self-erecting tower crane used for
the training.
Reference: Performance assessment section B
Demonstrate the pre-operational checks for the particular type of self-erecting tower crane used for
training. Checks include:
Visually check for any maintenance personnel or servicemen working on or near the self-erecting
tower crane.
Ensure there are no safety tags on the main isolation switch.
Page 14
Inspect the travel mechanism and bogies.

Check for oil leaks on slewing platform or on the ground.
Inspect the travel limits.
Check that the counterweights are in place and secure.
Inspect the slew mechanism.
Check that the tower bolts are secure.
Inspect for any structural damage to the mast or tower.
Identify any structural damage to the crane jib or structure.
Inspect access ladders and kick plates (cabin type).
Access to the cabin (if applicable) is unobstructed.
Disable weather vane mode.
Inspect outrigger footings for adequate bearing.
Connect pendant control (where applicable).
Check that outrigger locking pins are in place.
Check that limits and all governors are in place.
Reference: Performance assessment section C
Demonstrate the checks that should be made before the self-erecting tower crane is started. Checks
include:
Ensure barricades are in position around the counterweight slewing arc.
Perform a visual check of the electrical cabinet and electrical system.
Perform a visual check of the power supply.
Examine all wire ropes, anchorages, splices and hooks.
Check all oil levels eg hydraulic.
Inspect the rope drums.
Examine all brake mechanisms.
Ensure there is adequate lubrication on all moving and rotating parts.
Check the communication systems is operational.
Ensure the rated capacity and manufacturers data plate is on the crane.
Check the load radius indicator is in place.
Check the load chart is in place.
Ensure the fire extinguisher is present.
Visual check of all mechanical equipment.
Reference: Performance assessment section D
Demonstrate the checks that should be made after the self-erecting tower crane is energised or started.
Checks include:
Start up the self-erecting tower crane as per the manufacturers instructions
Emergency stop switch is operational
Check wind gauge is operating correctly
Communication system is operational
The back up signalling system is operational
Travel brakes (rail mounted)
Horn/lights/drive indicator
Clear vision from cabin
All gauges are in correct operating ranges
Radius indicator
Load moment indicator
Load indicator/weight gauge
Slew brake/lock/pin
Page 15
Hoist brake tested

Trolley brake tested
Maximum radius limit tested
Minimum radius limit tested
Hoist limit tested
Warning systems/devices checked for correct operation
Reference: Performance assessment section E
Trainers notes
SECTION 13
CRANE OPERATION
Points for the trainer
Review this section to ensure these points are covered as this section relates to the performance
assessment.
Explain to the trainee the responsibilities of controlled load movement when operating the tower crane.
Explain to the trainee that excessive wind speeds can restrict or abate crane operations. Wind speeds for
in service operations are specified by the manufacturer and can be measured by an on-board
anemometer.
Ensure the trainee understands the limits of operation such as slewing, radii and load limits.
Inform the trainee on worked near radio transmission towers as the crane can become charged thereby
heating up certain components such as lifting slings.
Explain to the trainee the aspects of cabin controlled and remote controlled operation. In cabin controlled
operation the operator is an integral part of the crane with the operator being on board and sensing all
movements whereas the remote control operation deprive the operator of any feel of the crane
movements.
Inform the trainee on keeping a watchful eye in all crane movements where possible. If the operator has
to talk to somebody all crane motions must stop until full attention is back on the crane movements.

Question 4
An outrigger pad sinks when lifting a load on the self-erecting tower crane. What immediate action should
be taken?
Answer Lower the load, assess the situation and seek assistance.
Question 5
What is the maximum wind speed that self-erecting tower cranes can work in?
Answer As per manufacturers recommendations
Question 6
When crane operations are effected by extreme winds what should you do?
Answers
Lower the load to the ground
Put counterweight to the wind
Shut the self-erecting tower crane down as per the manufacturers instructions.
Page 16
Question 7
If you heard abnormal noises coming from the crane what would you check?
Answer Check all lifting gear, running gear, structural and mechanical components.
Question 8
If any signals are observed through warning lights, cut outs or alarms, what actions would you take to have
the problem rectified?
Answer Identify the problem and take appropriate corrective action.
Question 9
The crane will hoist up but will not hoist down. What action should be taken?
Answer Identify the problem and take appropriate corrective action. A competent person may be
required to assist or the load may need to be manually lowered with assistance.
Question 10
What qualification must be held by a person directing a load out of view of the self-erecting tower crane
operator?
Answer A doggers certificate.
Question 11
If you heard a loud noise or felt vibration coming from the jib section, what would do?
Answer Lower the load, cease operation immediately and notify the person dogging the load. Have an
inspection carried out to identify whether damage has occurred during the lift.
Question 12
What hazards exist when using steel ladders or crane towers in wet weather?
Answer The tower access ladder will be slippery and it would be easy for the operator to slip and fall.
Question 13
During operation of the tower crane, electrical power failure/fault occurs. What would you do?
Answer Communicate with the person dogging the load and advise of the problem for rectification.
Question 14
Why is it important to have the jib head positioned correctly over the hook and load?
Answer To reduce the risk of overloading or collapsing the crane and to precent the load from swinging
on the lift.
Question 15
Can you use the jib of a self-erecting tower crane as a ladder to access a worksite or as a work platform?
Explain your answer.
Answer No. Under no circumstances must the jib of a self-erecting tower crane be used as a method of
access or as a work platform because it is unsafe and is not designed as an access route.
Reference: Oral/written assessment for cranes question 73
Question 16
Are you permitted to allow a person to ride upon the lifting hook, sling attachment or suspended load?
Answer No. A person can only be suspended by a self-erecting tower crane in a suitable work box
specifically designed to incorporate the necessary features.
Page 17
Question 17
What would you do if you heard a sudden loud noise and felt a vibration coming from an area lower down
on the base section of the tower crane?
Answer Lower the load, immediately cease operation and communicate with the person dogging the
load. Organise an inspection of the crane base and tower to identify whether some form of heavy plant
has struck the crane. Check for damage and report to an authorised person.
Question 18
List four precautions that must be taken when long travelling a self-erecting tower crane?
Answers
Prior to operating, ensure that there are no obstructions or personnel on the rails.
Ensure that the working radius has been calculated prior to travelling.
When travelling the self-erecting tower crane, siren and flashing lights must be operational.
Ensure that the load is controlled by the person dogging the load with the use of taglines where
necessary.
Ensure that people pushers or wheel guards are in place.
Travel at minimum speeds.
Ensure that the travelling self-erecting tower crane is mechanically stopped prior to reaching end
stops.
Question 19
If you detected a defect in one of the main controls, who would you report this to for rectification and
who would responsible for the rectification work?
Answer To an authorised person or supervisor, who would then contact a competent person for
corrective action.
Question 20
If the hook has landed on the ground, causing a slack rope, what would the correct procedure when respooling the rope?
Answer The weight of the hook or overhauling weight or applied weight must be on the rope when respooling. This can be achieved by luffing the jib or telescoping the angled jib outwards.
Question 21
If the self-erecting tower crane is located near aircraft traffic zones, what action must be taken?
Answers
A red warning light should be installed at the upper most point of the crane.
Directions from airport authority may state operational hours for the crane operation.
Information from the airport authority may state maximum jib elevations for any luffing type
operations.
Question 22
If a heavy load is to be lifted what precautions would you take to work within a given radius?
Answer Ensure the jib or boom deflection is taken into consideration. Adjust boom angle or trolley radius
to maintain vertical lifting application.
Reference: Oral/written assessment for cranes question ?
Media application
Use a whiteboard and make up a list of hazardous occurrences that could effect crane operation.
Practical session
Using close supervision allow the trainee to control the motions of the crane. Note: This must be
performed under strict close supervision.
Demonstrate to the trainee the process of catching the hook. (Use a scale model or other device.)
Page 18
Demonstrate to the trainee the process of crane operation addressing the points below.
Load secure
Load correctly slung
Conduct trial lift
Lift conforms with load chart
Jib positioned over load correctly
Hoist load
Move load
Lower load
Luff up (where applicable)
Luff down (where applicable)
Slew load
Telescope boom
Travel with load
All movements smooth/adequate speed
Tag line used
Signals interpreted correctly
Load placed correctly on dunnage
Load unslung
Raise hook and attachment to safe height.
Reference: Performance assessment section J
Trainers notes
SECTION 14
LOADS AND SELF-ERECTING TOWER CRANES
Points for trainer
Explain to the trainee how the operating radius is displayed on the crane.
Show the trainee the methods of determining the load mass of various materials and loads.
Show the trainee how multiple fall hoist reeving is applied.
Explain to the trainee the dangers associated with snigging and dragging loads.
Sling and lift and load slightly off the ground and show the trainee the checks that must be performed
before lifting further.
Explain to the trainee the application of lifting a personnel lifting box with personnel aboard.
Show the trainee how to read and interpret a load chart on the crane. Explain the deductions required to
calculate the net capacity. Deduct items such as the load mass, the weight of the hook block and
attachments such as spreader beams and slings. Where specified the weight of the hoist rope may be
deducted.
Page 19

Question 1
Explain how the hook radius is indicated on the crane?

Answer The hook radius is displayed on the control device and may also be displayed on flags or signs
installed on the underside of the jib or as per specific crane design.
Question 2
How do you determine the rated capacity if the self-erecting tower crane?
Answer By checking the load chart plate fitted to the crane or control unit.
Question 3
Who should be involved in the process of assessing the load before lifting?
Answer A person dogging a load and the crane operator or rigger if applicable.
Question 4
Who would be responsible for checking all lifting gear for example chains and slings?
Answer The crane operator in conjunction with the person dogging the load.
Question 5
How do you know when the multiple load falls are required?
Answer As per the load cart specifications.
Question 6
Give three different ways in which the mass (weight) of a load can be determined?
Answers
Delivery dockets
Public weighbridge certification
The manufacturers information
Weight may appear on the load itself
Calculate or estimate.
Question 7
State three reasons why you are not permitted to drag or snig a load.
Answers
Load swing may occur
The load may topple
Damage to the sling may occur
Structural damage to the crane by exceeding the rated capacity of the crane may occur.
Question 8
With the load suspended just off the lifting surface, what three observations and checks need to be made?
Answers
The load is securely slung.
All crane equipment is functioning correctly.
Stabiliser/outrigger footing is secure.
Page 20
Question 9
List six requirements that would permit you to lift personnel using the crane.
Answers
The unit must be specifically designed as a workbox.
Tare weight of the workbox must be displayed on the box.
The maximum number of occupants allowed in the box must be displayed on the box.
The maximum mass that can be carried in kilograms must be displayed on the box.
The identification reference must be displayed on the workbox.
The workbox must not contain more than three persons, one of who must be competent in crane
signals.
The workbox must be in a safe working condition.
Slings shall be permanently attached to the workbox by locked shackles or other similar means.
The workbox must have a provision for attachment of safety harnesses for personnel.
The workbox must be painted in high visibility colours.
Where an access door is fitted, it shall open inwards and be provided with means to secure the door.
The workbox is only to be used to lift persons and their equipment.
The crane lifting the workbox shall be fitted with a safety hook.
The crane lifting the workbox shall be equipped with controls that return to the neutral position when
released the motion to stop.
The crane lifting the workbox shall be equipped with power lowering.
The crane lifting the workbox shall be equipped with a lockout control to prevent free-fall of the
workbox and its contents.
The crane lifting the workbox shall be fitted with an up limit switch on the hoist motion.
The crane lifting the workbox shall be fitted with a down limit switch if the workbox is to be lowered
below the cranes supporting surface.
The crane operator shall remain at the controls of the crane when the workbox is suspended with
personnel.
The crane operator shall ensure that at the maximum radius of the task to be performed the crane
has a minimum rated capacity of 1000kgs.
The crane operator shall ensure that when the jib is at the maximum radius for the task to be
performed, the rated capacity for the crane in this condition, when divided by two, is equal or
greater than the total load of the workbox and its contents.
The crane operator shall ensure that they have a means of communication with any person in the
workbox.
Question 10
State three essential items of information you would expect to obtain from a load chart.
Answers
The mass of the hook block
The winch line pull measure in tonnes or kilograms
The rated capacity for an applied crane configuration
Multiple rope fall capacities (eg two fall and four fall hook block configurations).
Note: Other answers may also be considered applicable.
Question 11
List three items that need to be deducted from the (ie stated rated) capacity of a crane to determine its
payload ie the load the crane can lift.
Answers
The mass of the hook block.
The mass of any lifting attachments such as spreader beams, ladies or kibbles.
The mass of the lifting slings.
Page 21
Question 12
When dealing with a crane load chart, what is meant by the term operating radius?
Answer The operating radius is the measurement from the cranes centre of rotation to the vertical
freely suspended hoist line.
Question 13
When the precise reading is between load chart capacities, do you increase or decrease the rated
capacity?
Answer Use the lower rated capacity.
Question 14
If the jib is luffed up to a 10 degree angle does this alter the rated load capacities of the crane? Refer to
load chart Q.
Answer Yes
Question 15
If the jib is in a folded configuration, where only the base section of the jib is available, does this alter
the rated capacities of the crane compared to using a fully extended jib section? Refer to load chart Q.
Answer Yes
Question 16
Refer to load chart Q
A self-erecting tower crane with load chart Q is set up as follows:

Main jib length 30.00 metres
Working radius 21.00 metres
Work area 360 degrees
Fitted with a two-fall hook block
Jib fully extended
i.
What is the maximum load that can be raised on the hook block at the specified radius?
ii.
If the hook block is re-reeved to a four-part configuration, what is the new capacity at the same
radius as question i?
iii.
What is the maximum capacity of the four-fall hook block configuration? (Do not take radius into
consideration.)
Answer Refer to load chart Q: 30.00 metre jib at a 21.00 metre radius with the jib fully extended using
a two-fall hook block configuration.
i.
Rated capacity (SWL):

Hook mass deductions:
ii.
120kgs
Net load:
1410kgs
1480kgs
Deductions:
iii.
1530kgs
205kgs
Net load:
1275kgs
4000kgs
Deductions:
Net load:
205kgs
3795kgs
Page 22
Question 17

Fitted with a four-fall hook block
Jib fully extended
i.
ii.
If the hook block is re-reeved to a two-part configuration, what is the new capacity at the same
radius as in question i?
iii.
What is the maximum capacity of the two-fall hook block configuration? (Do not take radius into
consideration.)
a four-fall hook block configuration.
i.

Net load:
ii.
iii.
1000kgs
205kgs
795kgs
1050kgs
Deductions:
120kgs
Net load:
930kgs

Deductions:
Net load:
2000kgs
120kgs
1880kgs
Question 18

Jib folded
i.
ii.
If the jib is unfolded and fully extended what is the new capacity at the same radius as question i?
iii.
consideration.)
Answer Refer to load chart Q: 30.00 metre jib at a 13.00 metre radius with the jib folded using a fourfall hook configuration.
i.

Net load:
3300kgs
205kgs
3092kgs
Page 23
ii.

Deductions:
2380kgs
205kgs
Net load:
2175kgs
4000kgs
Deductions:
Net load:
205kgs
3795kgs
Question 19

Main jib 24.00 metres
Fitted with a two-fall hook block
Jib fully extended
i.
ii.
If the hook block is re-reeved to a four-part configuration, what is the new capacity at the same
radius as question i?
iii.
What is the maximum capacity of the two-fall hook block configuration? (Do not take radius into
consideration.)
Answer Refer to load chart Q: 24.00 metres jib at a 21.00 metre radius with the jib fully extended using
i.

ii.
120kgs
Net load:
1550kgs
1720kgs
Deductions:
iii.
1670kgs
205kgs
Net load:
1515kgs
2000kgs
Deductions:
Net load:
120kgs
1880kgs
Question 20

Fitted with two-fall hook block
Jib fully extended
i.
ii.
If the hook is re-reeved to a four-part configuration, what is the new capacity at the same radius
as question i?
iii.
What is the maximum capacity if the four-fall hook block configuration? (Do not take radius into
consideration.)
Page 24
i.

ii.
120kgs
Net load:
1380kgs
1550kgs
Deductions:
iii.
1500kgs
205kgs
Net load:
1345kgs
4000kgs
Deductions:
Net load:
205kgs
3795kgs
Reference: Oral/written assessment question ?
Question 21

Jib folded
i.
ii.
If the jib is unfolded and fully extended, what is the new capacity at the same radius as question
i?
iii.
consideration.)
Answer Refer to load chart Q: 24.00 metre jib at a 13.00 metre radius with the jib folded using a fourfall hook block configuration.
i.
Rated capacity (SWL): 3300kgs

Net load:
ii.
205kgs
3095kgs
Rated capacity (SWL): 3180kgs

Deductions:
Net load:
iii.
205kgs
2975kgs
Rated capacity (SW): 4000kgs

Deductions:
Net load:
205kgs
3795kgs
Reference: Oral/written assessment question ?
Question 22

Jib folded
Page 25
i.
ii.
If the jib is unfolded and fully extended, what is the new capacity at the same radius as question
i?
iii.
consideration.)
Answer Refer to load chart Q: 24.00 metre jib at a 14.00 metre radius with the jib folded using a fourfall block configuration.
i.

ii.
205kgs
Net load:
3095kgs
3180kgs
Deductions:
iii.
3300kgs
205kgs
Net load:
2975kgs
4000kgs
Deductions:
Net load:
205kgs
3795kgs
Media application
Use the load chart Q to explain the load chart applications required for written assessment.
Use a variety of other load charts relating to different self-erecting tower cranes to assess the trainees
understanding of load chart interpretation.
Practical session
Show the trainee how to lift loads with the crane, working within the rated capacity specified by the crane
manufacturer.
Explain to the trainee how the radius indicator is displayed. Show the trainee where the load radius is
displayed.
Explain the load chart and its capabilities to the trainee using different jib angles/configurations.
Reference: Performance assessment section L
Trainers notes
SECTION 15
SPECIAL OPERATIONS
Points for trainer
Explain to the trainee the regulations regarding multiple crane lifts.
Explain to the trainee the system of climbing the crane where applicable.

Question 1
How do you lower the load in the event of a power failure?

Answer As per manufacturers recommendations.
Note: This operation differs from crane to crane. Operators must know their particular crane and be able
to describe to the assessor exactly how it is done. Operators have a responsibility to ensure that they can
emergency lower on any self-erecting tower crane that they operate. It is essential for the applicant to
know this. If not, then they should not be assessed as competent.
Page 26
Question 2
Is it permitted to carry out a multiple crane lift with a self-erecting tower crane and another crane?
Answer No.
Question 3
Where is the information found to show how to climb the self-erecting tower crane (if applicable) by
inserting extra tower sections?
Answer In the manufacturers manual for the self-erecting tower crane.
Media application
Show a video or scale model to the trainee regarding climbing of the crane where applicable.
Practical session
Show the trainee how to lower the hook manually using manual lowering techniques in case of an
emergency situation.
Describe to the trainee how to climb (jack the crane vertically) by demonstrating the procedure
appropriate to the self-erecting tower crane, where applicable.
Show the trainee how to unfold and fold the jib on a self-erecting tower crane by demonstrating the
procedure appropriate to the tower crane, where applicable.
Reference: Performance assessment section N
Trainers notes
SECTION 16
SHUTDOWN CRANE
Points for trainer
Explain to the trainee the shutdown procedures for overnight out of service requirements.
Ensure the hook is positioned appropriately for out of service conditions.
Face the crane jib downwind (wind at the back of the crane) on shutdown before engaging weathervane
mode.

Question 1
Can any load remain suspended from the hook following shut down or when the crane is unattended?
Answer No, this is unsafe. If during the course of a lift the crane operator must leave the controls, the
load should be placed on the ground with the crane shut down in the prescribed manner as per the
manufacturers instructions.
Note: No operator, no load.
Page 27
Question 2
How should a self-erecting tower crane be left unattended overnight?

Answers
Load to be removed
Jib folded to manufacturers specifications
Crane is weathervaned to engineers recommendations or manufacturers specifications.
Question 3
What would you do with the platform access hatch (if applicable) on shut down?
Answer Ensure that it is securely closed and locked with a key lock.
Question 4
What must be done to the base of a travelling tower self-erecting tower crane on shut down in regards to
securing the crane.
Answers
Ensure that the blocks are placed at the base of wheels to prevent movement of self-erecting tower
crane.
Make sure that the electric motor to the travelling wheel mechanism is isolated and locked.
Question 5
On shutting down an electric powered self-erecting tower crane, what is an important consideration?
Answer Ensure that all electric circuits are fully isolated and locked off.
Question 6
If the self-erecting tower crane is to be left in free slew, why is it important that you raise the jib and
hook clear of obstructions for the full 360 degrees around the crane?
Answer When in free slew the self-erecting tower crane can paravane (spin rapidly) in a severe storm or
cyclonic winds. The crane must clear surrounding buildings and other obstructions or the jib or crane may
be folded down.
Question 7
You are operating a self-erecting tower crane that is on a travelling base. Why is it essential that travel
locks be clipped to the rails as you leave the crane?
Answer These locks stop the self-erecting tower crane from being blown uncontrollably down the rails by
strong winds.
Question 8
On a self-erecting tower crane why is the trolley and hook brought in close proximity to the tower for
parking?
Answer So that the trolley-hook assembly creates less wind resistance thereby eliminating excessive
forces on the outriggers and foundations.
Question 9
An operational self-erecting tower crane is situated very close to a neighbouring building. The building is
under the jib-slewing radius of the self-erecting tower crane. What special precautions must be
undertaken to shutdown?
Answers
The self-erecting tower crane must not be weathervaned as a collision with the building could occur.
The crane jib may be luffed up to avoid collision with the building.
The self-erecting tower crane may be locked off as per the manufacturers instructions.
The self-erecting tower crane may be packed up as per manufacturers specifications.
Guying of the crane jib may require an engineers approval.
Page 28
Practical session
Explain to the trainee the process of shutting down the tower crane covering these points.
Ensure barricades are in position.
Ensure the hook block/trolley assembly is suitably positioned for stowing as per the manufacturers
specifications.
Lower/retract jib in accordance with the manufacturers specifications.
Slings removed.
Weathervane self-erecting tower crane in accordance with the manufacturers specifications.
Raise hook to maximum height.
Lock and secure remote control unit.
Lock and secure self-erecting tower crane.
Turn the isolator switch off and secure.
Reference: Performance assessment section M
Trainers notes
SECTION 17
RULE OF THUMB AND WORKING LOAD LIMITS
Points for trainer
Explain to the trainee the rule of thumb formulae used to identify working load limits (WLL) for all sling
types such as fibre, flexible steel wire rope (FSWR) and lifting chain.

Question 1
What is the formula or rule of thumb for determining the working load limit (WLL) for an unidentified
synthetic rope?
Answer Diameter in millimetres squared = the WLL in kilograms
Note: If unknown, the formula for fibre rope should apply or be accepted.
Reference: Written assessment for cranes question 1
Question 2
Calculate the WLL for one of the following

i.
12mm diameter unidentified synthetic rope
ii.
15mm diameter unidentified synthetic rope
iii.
20mm unidentified synthetic rope.
Answers
i.
Diameter in mm2 = 12mm = 12 x 12 = 144kg WLL
ii.
iii.
Note: if unknown, formula for fibre rope should apply or be accepted.

Page 29
Question 3
What is the rule of thumb formula used to calculate the WLL of a flexible steel wire rope (FSWR)?
Answer Diameter in millimetres squared x 8 = the WLL in kilograms
Question 4
Calculate the WLL of one of the following:

i.
15mm diameter FSWR
ii.
20mm diameter FSWR
iii.
25mm diameter FSWR
Answers
i.
Diameter in mm2 x 8 = 15 x 15 x 8 = 1800kg WLL
ii.
iii.

Question 5
What is the rule of thumb for calculating the WLL for a grade 80 high tensile chain?
Answers
Diameter in millimetres squared x grade x 0.4 = WLL in kilograms; or
Diameter in millimetres squared x 32 = WLL in kilograms
Question 6
Calculate the WLL of grade 80 high tensile chain at one of the following diameters:
i.
10mm
ii.
12mm
iii.
15mm
Answers
i.
ii.
iii.

Practical session
Demonstrate to the trainee the process of identifying WLLs for a specified sling type used on the tower
crane.
Trainers notes
Page 30
SECTION 18
LOAD FACTORS
Points for trainer
Discuss with trainee the application of utilising load and reeve factors for determining actual sling ratings
on lifting.

Question 1
A sling of 2.0 tonnes WLL is reeved around a circular load. What is the sling now capable of lifting?
Answer 2.0 tonnes x 0.75 load factor = 1.5 tonnes
Question 2
Question 3
Question 4
Question 5
A sling of 5.0 tonnes WLL is reeved around a square load. What is the sling now capable of lifting?
Question 6
Answer 4.0 tonnes x 0.5 load factor = 2 tonnes
Question 7
Answer 1.5 tonnes x 2.00 load factor x 0.5 reduction factor square load = 1.5 tonnes
Question 8
A sling of 1.5 tonnes WLL is used in a basket hitch around a square load. What is the sling capable of lifting
now?
Answer 1.5 tonnes x 2.00 load factor x 0.5 reduction factor square load = 1.5 tonnes
Question 9
A sling of 1.5 tonne WLL is reeved around a square load. What is the sling now capable of lifting?
Page 31
Question 10
A lifting beam with a mass (weight) of 300kg is supported by a two

legged sling shackled to the beam forming an included angle of 90
degrees at the crane hook (see diagram). Two slings are shackled to
the underside of the lifting beam and vertically down to lifting eyes
on a machine if mass 2500kg. What is the minimum WWl required of
each of the four slings?
Answer
Slings between the machine and beam =
Total weight of 2500kg divided by the load factor of 2.00 = 2500
2.00 = 1250kgs for each sling.
The slings between the beam and hook =
A total weight of 2800kg divided by the load factor of 1.41 (for a 90
degree included sling angle) = 2800 1.41 = 1986kg for each of the
upper slings.
Upper slings require a WWL of 1986kgs each.
Lower slings require a WWL of 1250kg each
Question 11
If two slings are spread at an included angle of 90 degrees, what is the load factor applied to the load
being lifted?
Answer For a 90 degree included angle the load factor is 1.41.
Question 12
being lifted?
Question 13
being lifted?
Question 14
being lifted?
Page 32
Question 15
From the drawings below select the included angle closest to 90 degrees.
Answer D is the correct diagram

Question 16
What reduction must be made to the WLL of a FSWR sling when it is reeved on a round load?
Answer A 25 per cent reduction.
Question 17
What reduction must be made to the WLL of a FSWR sling when a basket hitch is used to cradle a square
load?
Answer A 50 per cent reduction.
Question 18
What load factor must be applied to the WLL of a FSWR sling when a basket hitch is used to cradle a
square load?
Answer Load factor of 1 is applied. The rated capacity (SWL) remains the same as the WLL.
Question 19
What safety factor must be applied to the WLL of a FSWR sling when a basket hitch is used to cradle a
round load?
Answer Load factor 2 is applied. The rated capacity (SWL) is double the WLL.
Practical session
Demonstrate to the trainee how load factors effect operations in sling application and sling configurations.
Trainers notes
Page 33
SECTION 19
RULES TO FOLLOW WHEN SLINGING AND HANDLING A LOAD
Points for trainer
Describe to the trainee approved methods of utilising lifting gear and equipment.
Discuss with the trainee the benefits of using tag lines for load control.
Discuss with the trainee the hazards involved with stuck loads such as formwork shutters, sheet pile or
concrete pre-cast panels.
Explain to the trainee the hazards involved with wind affected loads such as shutters, roofing iron and
cladding.
Discuss with the trainee the application of using multiple sling arrangements and which slings are taking
the load.

Question 1
What factors should be considered when using taglines? Give at least four examples.
Answers
Weather conditions
Electrical hazards
Tagline change over may be required at designated point in the lift.
Person holding the tagline should wear PPE.
Ensure that the line is not fouled.
Taglines should be held correctly.
Tagline length requirement.
Tagline size requirements.
Question 2
When lifting concrete formwork shutters in gusting wind conditions, what measures would you ensure are
undertaken to control the load?
Answers
Load must be attached to taglines.
Shutters may be laid down and lifted horizontally with taglines attached.
Operations may have to cease until wind conditions reduce sufficiently.
Question 3
A long load of reinforcement steel bars is to be lifted off a truck close to the sheeted scaffolding
perimeters of the site. How can the load be controlled to prevent contact and subsequent snagging with
the scaffold?
Answer The person dogging the load should control the load with a hand held tagline.
Question 4
An internal lift formwork shutter to green concrete weighing two tonnes is to be lifted. The weight is
taken and the shutter does not budge, what should you do?
Answers
Stop hoisting if the load on the crane is over two tonnes.
The shutter may be jammed; this may require some levering by the formworkers.
Ensure all personnel are clear of the shutter in case the shutter springs off the lift shaft wall.
Page 34
Question 5
List three reasons why packing or dunnage is used when slinging or landing a load.
Answers
To protect the load.
To facilitate the connection/disconnection.
To prevent damage to lifting gear.
Question 6
You have formwork shutters to lower from the top of a building when a strong wind blows up. What are
the hazards?
Answer Shutters are large in area but light in weight, therefore they could flap/spin around in the wind
so will need to be secured. The wind loading with such a large surface area could destabilise the selferecting tower crane.
Question 7
Why must you pack/lag the edges/corners of sharp loads?

Answer To protect load slings and lifting gear from damage.
Question 8
A four legged bridle sling arrangement is attached to a rigid load. How many sling legs would be assumed
to support the load?
Answer two diagonally opposite sling legs must be capable of supporting the load.
Question 9
A three legged bridle sling arrangement is attached to a rigid load. How many sling legs would be assumed
to support the load.
Answer Any two legs of the sling arrangement.
Question 10
A four legged bridle sling arrangement is attached to a flexible load. How many sling legs would be
assumed to support the load?
Answer The entire four sling legs.
Practical session
Demonstrate to the trainee the application of various sling loads. The loads should be lifted using different
sling arrangements to cover this section.
Trainers notes
Page 35
SECTION 20
STACKING
Points for trainer
Explain to the trainee the process of stacking loads allowing for proper clearance whilst ensuring stability
of the load.
Trainers notes
SECTION 21
PERSONNEL PROTECTIVE EQUIPMENT
Points for trainer
Ensure the trainee understands the requirements for personnel protective equipment (PPE) whilst
operating a self-erecting tower crane.
Trainers notes
SECTION 22
COMMUNICATION
Points for trainer
Converse with the trainee regarding the use of communication techniques where a dogger is used with
provide signals.

Question 1
What communication equipment can the crane operator utilise other than two-way radio?
Answers
Hand signals
Whistles, hooters
Light signals
Page 36
Question 2
If given a stop signal by someone other than the person dogging the load, what would you do?
Answer Stop operations immediately and await further directions.
Practical session
Ensure the trainee understands and knows the applicable crane whistle signals for operation.
Reference: Performance assessment section I
Trainers notes
SECTION 23
FLEXIBLE STEEL WIRE ROPE
Points for trainer
Discuss with the trainee the application of wire rope usage in hoist ropes, suspension ropes and sling
configurations.

Question 1
What is the minimum allowable size FSWR for load handling purposes?
Answer 5mm diameter
Reference: Written assessment question 14
Question 2
What is the maximum allowable temperature that FSWR can be exposed to before it is unsafe for lifting
purposes?
Answer 950C
Question 3
What is the formula that indicates the maximum amount of broken wires permitted in FSWR?
Answer Where 10 per cent of the total numbers of wires are broken in one rope lay or in eight diameters
of rope.
Question 4
Using the formula for maximum amount of broken wires in FSWR, work out one of the following:
i.
The construction of the rope is 6/19 and 12mm diameter.
ii.
The construction of the rope of is 6/24 and 20mm diameter.
iii.
The construction of the rope is 6/36 and 54mm diameter.
Answers
i.
6/19 = 6 x 19 = 114 wires

10% x 114 = 11.4 wires
Therefore, in one rope lay 11 wires.
Rope length to inspect = 12mm x 8 = 96mm
Page 37
ii.
6/24 = 6 x 24 = 144 wires

10% x 144 = 14.4 wires
iii.
6/36 = 6 x 36 = 216 wires

10% x 216 = 21.6 wires
Question 5
What is meant by the term core slippage?

Answer Core slippage occurs when the outer wire strands slip over the inner core of the opposite lay.
Question 6
What will condemn a FSWR sling from safe use? List at least six defects.
Answers
Kink or fractures from bending or reeving
Crushed or jammed strands
Damaged splice
Exposure to high temperatures
Core collapse
Bird-caging - where the strands loosen from their proper tight lay
Stretched or overloaded
High stranding
Corrosion loose and springy wires indicate serious corrosion
Knotted sections
Wear caused by badly maintained or aligned sheaves
The number of broken wire exceeding allowable limit.
Question 7
Explain the use and advantages of a wire rope thimble?

Answer Thimbles are designed to protect the load bearing area inside the crown of the eye from chafing
and distortion and to form a hard eye in a rope.
Question 8
Explain the reason for using swaged aluminium alloy fitting or a thimble fitting.
Answer to form an eye splice or thimble eye in a wire rope (FSWR).
Question 9
What are the most obvious indications of a defective swage fitting?

Answers
The tail of the FSWR has slipped inside the swage fitting.
The steel collar thimble is loose on the rope.
The fitting is loose.
There is a broken wire at either end of the swaged fitting.
Page 38
Practical session
Using a number of defective slings, have the trainee determine the defects that cause condemnation of a
FSWR sling.
Trainers notes
SECTION 24
WEDGE ROPE SOCKETS
Points for trainer
Converse with the trainee regarding the proper use of wedge sockets.

Question 1
From the diagrams below, select the correct methods of reeving a hoist rope in a wedge rope socket.
Answer Correct answer is D or E.

Question 2
Are you permitted to use wire rope (bulldog) grips to connect two lengths of wire rope for lifting purposes?
Answer No, the wire rope could crush or pull through the bulldog grip.
Question 3
Should the wedge protrude outside the narrow end of the socket fitting? (As shown in the diagram.)
Answer Under no circumstances should the wedge protrude at the narrow end of the socket.
Question 4
What is the minimum amount of tail projection for the dead end of a rope used with a wedge socket?
Answer In most cases, the tail on the dead end of the rope should project at least 200mm.
Page 39
Question 5
What should be secured to the tail of a rope when in use with a wedge socket fitting to indicate slippage?
Answer A bulldog grip must be applied only to the tail of the rope below the socket.
Practical session
Demonstrate to the trainee the correct assembly of a wedge socket and a bulldog grip.
Trainers notes
SECTION 25
SHEAVES AND DRUMS FOR FLEXIBLE STEEL WIRE ROPE
Points for trainer
Converse with the trainee regarding the application of sheaves and wind drums for FSWR.
Explain the defects that can affect a sheave.
Explain the occurrence of two blocking.
Explain to the trainee the process of inspecting sheaves, drums and running ropes on the crane before
starting the operation.
Show the trainee the process of changing the hook block from a two fall to a four fall reeving
configuration.
Question for trainee/s

Question 1
What will condemn a sheave from safe use? List at least three defects.
Answers
Excessive wear in the groove of the sheave.
Cracks or any damage in the flange of the sheave.
Twisted/deformed or out of shape.
Worn sheave pins, hinge pin wear.
Damaged cheek plates or cheek plate wall/partition is too close to too far from sheave.
Question 2
List two effects double blocking can have on the crane and equipment.
Answers
Can cause the FSWR to break.
Can cause the load to drop.
Can damage the sheave.
Can cause structural damage to the crane.
Question 3
When the rope construction is unknown, what is the rule of thumb method used to calculate a sheave
size?
Answer the basic rule of thumb used to calculate sheave size is rope diameter x 20.
Page 40
Question 4
How much of the FSWR should sit neatly in the base of the groove of a sheave?
Answer one third or 120 degrees.
Question 5
How deep must the sheave groove be in relation to the rope diameter being used?
Answer the sheave groove should not be less than 1.5 times the diameter of the FSWR being used.
Question 6
When the maximum number of turns is wound on a drum, how far must the flange of the drum extend
about the outer layer of rope?
Answer The drum flange must extend above the outer layer of the wire rope by at least two rope
diameters.
Question 7
What is the advantage of using a jockey sheave?

Answer A jockey sheave ensure that the hoist rope remains at the correct fleet angle to the winch drum.
Question 8
What will occur if the sheave groove is too large for the diameter of the given rope?
Answer This will cause rope flattening of the rope.
Question 9
What will occur if the sheave groove is too small for the diameter of the given rope?
Answer This will cause rope pinching and sever abrasion.
Question 10
How is the diameter of a sheave measured?

Answer A sheave is measured across the face of the sheave to the inside of the grooves on either side in
millimetres.
Question 11
When the hook or the block is at the lowest possible point, what is the minimum amount of full turns of
wire rope that must remain on the winch drum?
Answer A minimum of two full turns.
Question 12
What happens if the fleet angle of the hoist rope is incorrect?

Answers
Spooling or uneven coiling of the hoist rope on the hoist drum.
The hoist rope may be pulled off the sheave and subsequently jam.
Question 13
What problem would occur if the jockey sheave seized?

Spooling or uneven coiling of the hoist rope on the hoist drum.
The hoist rope may be pulled off the sheave and subsequently jam.
Page 41
Question 14
What are the approved methods of fixing the hoist wire to the boom head? List two methods.
Answers
By using a hambone wedge socket.
By using hand splice or machine splice with thimble.
By using wire adjusters.
Question 15
List two methods used to secure/fix the tail of the hoist rope to the winch drum.
Answers
Socket and wedge
Clamp and bolts.
Practical session
Have the trainee inspect each sheave on the crane where applicable. The trainee can state which defects
can affect sheaves.
Trainers notes
SECTION 26
LIFTING CHAIN
Points for trainer
Use a high tensile lifting chain set for the trainee to inspect for defects.

Question 1
What is the smallest size diameter chain allowable for safe load handling for:
i.
Grade 30 chain?
ii.
High tensile grade 80 chain?
Answers
i.
Basic grade 30 = 8mm
ii.
High tensile grade 80 = 5.5mm

Question 2
What is the maximum temperature that a sling can be subjected to before the rated capacity (SWL) is
affected for:
i.
Grade 30 chain sling?
ii.
High tensile grade 80 chain sling?
Answers
i.
Basic grade 30 2600C
ii.
High tensile grade 800C 4000C
Note: If 2600C is exceeded, the WLL of the chain is reduced.

Page 42
Question 3
What is the maximum amount of wear permitted in the link of a chain?

Answer The maximum amount of wear permitted in a chain is ten per cent of the diametrical cross
section.
Question 4
Where on a chain link is wear most likely to occur? List two points.
Answers
Links will wear at the link ends from the metal wear down.
Links will wear on the outer sides of the link from being dragged.
Question 5
What will condemn a chain from safe use? List at least four defects.
Answers
Twisted, kinked, knotted
Stretch, locked or does not move freely
Gouged, cut or crushed more than 10 per cent of the links original diameter
Pitting
More than 10 per cent wear in the diameter of the link
Exposed to excessive heat
Cracked or spot welded.
Question 6
What action would you take if a chain has:

i.
no WLL tag?
ii.
no WLL tag and grade marking?
Answers
i.
Check the markings and use accordingly until a new tag is obtained. If unsure about markings,
treat as mild steel grade 30 until manufacturer/supplier or competent person checks chain.
ii.
It should be removed from service immediately as it is not a load chain.

Question 7
What does the marking on a link of chain indicate?

Answers
The marking indicates the grade of a chain.
Note: Most chains are marked with an identification letter or number every 20th link or at intervals of not
more than one metre.
Examples:
Grade (L) indicates 30 mild steel grade /= or 30 or 3.
Grade (M) indicates 40 grade /= M or 40 or 4 or 04.
Grade (P) or 5 or 05.
Grade (S) indicates 60 alloy steel grade /= S or 60 or 06.
If unsure, refer to the manufacturer.
Practical session
Show the trainee the method of detecting the grade of a chain.
Explain to the trainee the defects that affect a lifting chain.
Page 43
Trainers notes
SECTION 27
FLAT WEBBING AND ROUND SYNTHETIC SLINGS
Points for trainer
Explain to the trainee the advantages and disadvantages of using synthetic slugs for lifting.
Question for trainee/s

Question 1
How is the working load limit (WLL) determined for synthetic webbing slings?
Answer By reading the manufacturers tag or by the colour code chart.
Note: If no manufacturers tag, do not use.
Question 2
What factors should be considered when inspecting synthetic webbing slings for safe use? List at least six
points.
Answers
No external wear eg abrasions.
No internal wear. This is often indicated by the thickness of the cling or the presence of grit and dirt.
No damage caused by high temperatures, sunlight or chemicals.
No damage to the label/tag or stitching.
No damage to the eyes, terminal attachments or end fittings.
Check label/tag has not been removed/destroyed or is illegible.
No damage to sleeve or protective coating.
Nylon sling has not come into contact with acid; polyester sling has not come into contact with
organic solvents such as pain, coal tar or paint stripper etc.
No visible cuts or contusions.
Question 3
When should a synthetic webbing sling be discarded? List at least six points.
Answers Label/tag has been removed/destroyed or is illegible.
Damage to sleeve is evident.
Evidence of external wear and abrasions.
Evidence of internal wear.
If damaged by high temperatures, sunlight or chemicals.
Damage to stitching.
Damage to eyes, terminal attachments or end fittings.
Nylon sling has come into contact with acid; polyester sling has come into contact with organic
solvents such as pain, coal tar or paint stripper etc.
There are visible cuts or tears.
Page 44
Question 4
List at least three requirements for the safe storage of synthetic webbing slings.
Stored in a clean, dry and well-ventilated place.
Never store on the ground or floor.
Store out of direct sunlight, ultra-violet light or fluorescent lighting.
Store undercover.
Store away from chemicals.
Store away from oils.
Store away from sand/grit.
Store away from machinery.
Store in a vermin free environment.
Note: The working life of synthetic slings will be shortened if exposed to any of the above.
Practical session
Show the trainee the method of detecting the WLL of a synthetic sling.
Explain to the trainee the defects that affect synthetic slings.
Trainers notes
SECTION 28
FIBRE ROPE
Points for the trainer
Explain to the trainee the advantages and disadvantages of using fibre rope slings for lifting.
Put an emphasis on using fibre ropes of the non-conductive type for use as a tagline for control of loads by
hand.

Question 1
What is the minimum size diameter of a hand-held tagline?

Answer 16mm diameter
Question 2
What is the smallest size diameter synthetic rope allowed for load lifting purposes?
Question 3
What is the smallest size diameter fibre rope allowed for use as a hand-held tagline?
Page 45
Question 4
What will condemn a fibre rope from safe use for lifting purposes? List at least six defects.
Answers
Strands are fraying
Strands are cut
Rope rotted by acid or alkali
Rope affected by mildew
Rope affected by heat or sun rot
Rope has been overloaded
Rope is chafed inside or outside
Unlaid strands
Knotted rope.
Question 5
What is maximum temperature that a fibre rope can be exposed to before it is unsafe for lifting purposes?
Answer 650C
Question 6
Is it safe to use slings to raise or lower loads near or over people?

Answer No, not under any circumstances.
Practical session
Explain to the trainee the defects that affect fibre rope.
Revise the bend and hitches to ensure the trainee can tie a tagline to a load.
Trainers notes
SECTION 29
ACCESSORIES
Points for trainers
Explain to the trainee the use of accessories such as shackles, plate clamps, rings, hooks, spreader beams
and eyebolts.
Explain the application and loads that these accessories are used on.

Question 1
How can the lifting capacity of a hook be identified?

Answer It should be stamped or marked on the hook in WWL.
Question 2
What may be fitted (where applicable) to the hook to prevent slings from dislodging?
Answer A safety latch/device shall be fitted (where applicable) across the mouth of the hook.
Note: Mousing is another acceptable method but should only be used in a temporary situation.
Page 46
Question 3
If the hook spins rapidly what may it indicate? List two examples.
Answers
The rope has been twisted when running onto the drum.
The rope used may be the wrong type (eg rotating FSWR).
The rope may be incorrectly fixed at the head of the boom.
The rope may be incorrectly fixed to the winch drum.
Question 4
Name the two principal shapes of shackles.

Answer The D and bow shackle.
Question 5
What must be marked on a shackle to be used for load handling?

Answer The shackle must be clearly marked with its WLL.
Question 6
Which types of shackle should be used for multi-legged slings? Explain your answer.
Answer The bow shackle should be used, which allows more room around the inside of the crown
for sling legs. Pin section of the shackle to be placed on hook.
Question 7
Why is unsafe to interchange components of a shackle?

Answers
Shackle failure could occur causing a load to drop.
Shackles could be of different WLLs or material grade.
Incorrect fitting or loose fitting.
Question 8
Name two types of lifting eyebolts.

Answer Collared and incollared.
Question 9
Is it permissible to reeve a sling through or two or more eyebolts and what effect does this have on the
eyebolts?
Answer No, slings should never be reeved through two or more eyebolts. The strain on the eyebolt is
doubled. This action could damage or bend the eyebolt.
Question 10
Which type of eyebolt should be used for lifts where the pull on the cling is off centre to the axis of the
eyebolt?
Answer A collared eyebolt.
Question 11
What precautions should be taken when using a single eyebolt for lifting?
Answer Ensure that the eyebolt is firmly tightened and secured to prevent unwinding when load is
suspended.
Page 47
Question 12
Select the correct method of using eyebolts with

a two-legged sling.
Answer Correct answer is C

Question 13
Why is important to mouse a lifting hook or seize the pin of a shackle?

Answer This action will stop the dislodging of loads from the hook and the shackle pin from unscrewing.
Question 14
What should a lifting ring and the slings attached to it have in common?
Answer the lifting ring and the sling should have equal WLL.
Question 15
What defects can occur in lifting rings, eyebolts and shackles? List two defects.
Answers
More than 10 per cent wear
For a lifting ring five per cent wear
Gouged, cut or nicked
Stretched or elongated
Twisted or kinked
No rated capacity (SWL)/WLL displayed and/or legible
Exposure to excessive heat
Fractures
Incorrect fitting pins.
Question 16
If a lifting ring or shackle is placed on a hook and it does not hang freely, what does this indicate?
Answer The shackle or lifting ring is too small for the hook.
Question 17
What will condemn a hook from use? List two defects.

Answers Cuts, gouges more than 10 per cent
Crack, twists and overloaded hook
Exposed to excessive heat (2800C)
The bill has been stretched more than five per cent.
Page 48
Question 18
What details are displayed on a spreader-lifting beam? List at least three.

Answers
Tare weight of the beam
WLL
Approval plate
Registration number
Media application
Practical session
Explain to the trainee the method of determining WLL of a lifting hook.
Explain to the trainee the method to prevent slings dislodging from a lifting hook.
Explain to the trainee the reasons for spinning lifting hook.
Show the trainee the types of shackles used for lifting purposes and the WLL markings required for lifting.
Show the trainee the types of eyebolts used for lifting purposes and the method of use.
Demonstrate to the trainee the method of using shackles.
Trainers notes
SECTION 30
CALCULATION
Points for trainer
Ensure the trainee understands basic mathematics and arithmetic with the use of a calculator.

Question 1
What is the weight of 25mm thick steel plate, 3 metres long and 2 metres wide? Note: Structural steel
weighs 7840kg per cubic metre.
Answer
Weight of steel plate
= 25mm (convert to metres) x 3m x 2m x 7840kg

= 0.025m x 3m x 2m x 7840kg
= 1176kg
Page 49
Question 2
What is the weight of a 25mm thick steel plate, 3 metres long and 3 metres wide? Note: Structural steel
Answer

= 0.025m x 3m x 3m x 7840kg
= 1764kg
Question 3
What is the weight of a 1.5 cubic metre concrete kibble filled with concrete, if the tare weight of the
kibble is 600kg? Note: Concrete weighs 2400kg per cubic metre.
Answer
Weight of concrete kibble
= 1.5 cubic metres x 2400kg + 600kg (tare)

= 4200kg
Question 4
What is the weight of a 2 cubic metre concrete kibble filled with concrete if the tare weight of the kibble
is 700kg? Note: Concrete weighs 2400kg per cubic metre.
Answer
Weight of concrete kibble
= 2 cubic metres x 2400kg +700kg (tare)

= 5500kg
Question 5
Answer

= 0.05m x 5m x 2m x 3m x 7840kg
= 3920kg
Question 6
Answer

= 0.05m x 3m x 3m x 7840kg
= 3528kg
Question 7
Answer

= 0.025m x 5m x 2m x 7840kg
= 1960kg
Page 50
Question 8
One metre of universal beam weighs 125kg. One metre of scaffold plank weighs 7kg. One square metre of
mild steel plate weighs 156kg. Find the total weights of a load made up of the following:
4 universal beams each 8 metres long
15 scaffold planks each 4.4 metres long
2 mild steel plates 4 metres long and 0.5 metres wide.
Answer
Universal beams
= 4 x 8m x 125kg (weight)
= 4000kgs
Scaffold planks
= 15 x 4.4m x 7kg (weight)

= 462kgs
Mild steel plates
= 2 x 4m long x 0.5m wide x 156kg (weight)

= 624kgs
Total weight
= 4000kg + 462kgs + 624kgs

= 5086kgs
Trainers notes
Page 51
APPENDIX (I)
TABLES OF MASSES
Points for trainer
Ensure the trainee understands the table of masses displayed in the learners guide.

Question 1
What is the mass (weight) of a cubic metre of hardwood?

Answer 1.1 tonne or 1000kg.
Question 2
What is the mass (weight) of a cubic metre of water?

Answer 1.1 tonne or 1000kg.
Question 3
What is the mass (weight) of a cubic metre of aluminium?

Answer 2.7 tonnes or 2700kgs.
Question 4
What is the mass (weight) of a cubic metre of dry sand?

Answer 2 tonnes or 2000kgs.
Question 5
What is the mass (weight) of a cubic metre of concrete?

Answer 2.4 tonnes or 2400kgs
Media application
Practical session
Point out some items and loads on site and estimate their mass or weight in kilograms using calculation
and the table of masses.
Trainers notes
Page 52
Catalogue No. 4807 WorkCover Publications Hotline 1300 799 003

WorkCover NSW 92-100 Donnison Street Gosford NSW 2250
Locked Bag 2906 Lisarow NSW 2252 WorkCover Assistance Service 13 10 50
Website www.workcover.nsw.gov.au
Copyright WorkCover NSW 0206. Production and printing by Salmat 02 9743 8777

Self Erecting Tower Crane Operators Guide

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Self Erecting Tower Crane Operators Guide

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A GUIDE FOR SELF-ERECTING

TOWER CRANE OPERATORS

TRAINERS EDITION 2005

WorkCover. Watching out for you.

A GUIDE FOR SELF-ERECTING TOWER CRANE OPERATORS

Both booklets are required to be utilised hand in hand.

SECTION 2 Types of self-erecting tower cranes

SECTION 3 Features of self-erecting tower cranes

SECTION 4 Crane controls

SECTION 5 Set-up crane

SECTION 7 Limit switches

SECTION 8 Load/radius indicators

SECTION 10 Site/job planning

SECTION 11 Maintenance procedures

SECTION 13 Crane operation

SECTION 14 Loads and self-erecting tower

SECTION 15 Special operations

SECTION 16 Shutdown crane

SECTION 17 Rule of thumb and working load limits

SECTION 18 Load factors

SECTION 19 Rules to follow when slinging and handling a load

SECTION 21 Personal protective equipment

SECTION 23 Flexible steel wire rope

SECTION 24 Wedge rope sockets

SECTION 25 Sheaves and drums for flexible steel wire rope

SECTION 26 Lifting chain

SECTION 27 Flat webbing and round synthetic slings

SECTION 28 Fibre rope

APPENDIX (I) Tables of masses

Explain to the trainee the different types of self-erecting tower cranes.

Use overhead transparencies to explain terminology for a self-erecting tower crane.

Questions for trainee/s

List three points that should be considered when setting up outriggers?

Why must the self-erecting tower crane be set-up/assembled level?

Questions for trainee/s

What qualification must be held by personnel to assemble a self-erecting tower crane?

When can additional counterweight be added to the crane?

Questions for trainee/s

Ensure the trainee understands the term operating radius.

Questions for trainee/s

How often should the load mass (weight) indicator be calibrated?

Perform an onsite hazard assessment of the worksite with the trainee.

Questions for trainee/s

List five methods of reducing hazards on site.

What is the importance of having workplace emergency procedures?

Questions for trainee/s

Why is it important to separate defective equipment?

Questions for trainee/s

Why should the maintenance service logbook be used?

How do you ensure the self-erecting tower crane level?

When interference (tampering) is identified, what action must be taken?

Inspect the travel mechanism and bogies.

Hoist brake tested

Questions for trainee/s

Show the trainee how multiple fall hoist reeving is applied.

Questions for trainee/s

Explain how the hook radius is indicated on the crane?

A self-erecting tower crane with load chart Q is set up as follows:

Rated capacity (SWL):

Rated capacity (SWL):

Rated capacity (SWL):

A self-erecting tower crane with load chart Q is set up as follows:

Rated capacity (SWL):

Rated capacity (SWL):