TOWER CRANES

ASSESSMENT INSTRUMENT

NATIONAL OCCUPATIONAL HEALTH AND SAFETY CERTIFICATION STANDARDS FOR USERS AND OPERATORS OF INDUSTRIAL EQUIPMENT [ NOHSC: 1006 (1995) ]

June 1994
Level 4, Lutwyche Shopping Village, 543 Lutwyche Road, Brisbane Qld 4030 PO Box 820 Lutwyche Qld 4030. Telephone: (07) 3247 9444; Facsimile: (07) 3247 9426

Cranes
Tower Cranes

ASSESSMENT INSTRUMENT

Part 1 Part 2 Part 3

Performance Oral/Written Written

June 1994

Contents
Page

Assessor guidelinesgeneral guidelines for Schedule B Part onePerformance Assessment Part twoOral/Written Assessment Assessment Summary

i 1 10 20

Note: Part threeWritten Assessment for Cranes provided as a separate document.

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Assessor guidelinesgeneral
1
1.1

Introduction
Scope These general guidelines apply to all the assessment instruments for the certificates of competency prescribed by Schedule B of the National Occupational Health and Safety Certification Standard for Users and Operators of Industrial Equipment. Assessors should also be familiar with the publication Assessment guidelines for National Occupational Health and Safety Certification Standard for users and operators of industrial equipment.

2.3 Equipment availability The availability of equipment, materials and a suitable working area must be organised and confirmed, prior to the assessment. 2.4 Workplace factors Because procedures and processes vary greatly between workplaces, it is important for assessors to plan their approaches to meet the requirements of the individual workplace. Make sure you take the timeframe into account when planning the assessment and also make applicants aware of any time limits. 2.5 Selecting questions Questions for the written/oral assessment should be randomly selected, either by hand or using the computer system, if applicable.

1.2 Additional guidelines Guidelines which provide additional specific information to certificate assessors are also included in each assessment instrument. Included, where appropriate, are specific instructions on the usefulness of training records (such as logbooks) and other certificates with overlapping competencies. 1.3 Evidence of competence Evidence of competence is established in a number of ways. The methods used in the following instruments involve: assessment of practical performance written and/or oral answers to questions on underpinning knowledge.

Conducting the assessment

3.1 Provide an explanation Begin by explaining clearly to the applicants what is required of them. Check that applicants have provided (or have been provided with) the necessary tools and equipment. 3.2 Practical performance Complete the performance checklist, as the applicant works through the required tasks. Wherever possible, this should be done in a normal working environment. Do not ask the applicant questions while he or she is performing a task, as this can be distracting, and may affect the time taken to complete the assessment.

Preparing for the assessment

2.1 Study the instruments You need to read the assessment instruments and specific instructions carefully before beginning an assessment. 2.2 Confirm appointments Prior to an assessment, you need to confirm the date, time and location of the assessment with the applicants and any other relevant people.

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If, at any time, the applicant is endangering 4 Determining competencies himself/herself or others, stop the 4.1 Assessment summary assessment immediately. This indicates A specific assessment summary is given for that the applicant is not yet competent and each certificate class. This is to be filled in may require further training, before being and signed by the assessor, and reassessed. countersigned by the applicant. Assessments should also be stopped, if equipment or property are likely to be damaged. The original and duplicate are given to the applicant. The applicant provides the original to the certifying authority. The triplicate is retained by the assessor.

3.3 Knowledge The knowledge assessment covers both 4.2 Competency requirements oral and written exercises. The model In order for you to deem an applicant answers provided with the knowledge competent, he or she must have completed assessment instruments are not each section of the assessment to the necessarily exhaustive. Use your own standard required. You should note any judgement when scoring alternative time constraints when arriving at your answers. decision. 3.4 Written assignment As well as providing a means to determine the applicant's competence in solving workrelated problems, the written assignment will clearly demonstrate whether or not the applicant can work without direct supervision. The assessor may assist by reading out a question, but should not prompt or interpret for the applicant. 3.5 Recording responses Each item and question on the assessment forms you use is accompanied by a box. Assessors must complete every box as follows:
CORRECT PERFORMANCE/ANSWER NOT YET ACHIEVED NOT APPLICABLE

The standard required for each instrument is specified in the specific guidelines and/or on the summary page at the end of each assessment. In the case of a repeat assessment, the assessor can decide to apply the whole or only part of the assessment. 4.3 Additional comments Where an applicant fails to meet the standard of competence, you should add a written comment on the Assessment Summary, which briefly explains the problem. Advice to the applicant, on the appropriate remedial action should also be included. This will also assist the certificate assessor, in the event that the applicant undergoes future reassessment. Likewise, if an applicant demonstrates outstanding or remarkable performance, this should be noted.

If a box is marked incorrectly, cross out the mistake, mark the correct response alongside, and initial the change.

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4.4 Further investigation As a certificate assessor, it is your role to determine whether or not an applicant has achieved the standard necessary for the certifying authority to be able to grant a certificate of competency. Whenever you are unsure of the applicant's performance or knowledge or performance, ask additional questions, and obtain additional evidence, before making your final decision.

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National OHS Certification Standard

Cranes and Hoists

Tower Cranes

Performance Assessment

May 1994

TOWER CRANES
5. In item 11, the assessor is to use the load chart for the crane being used for the assessment, and to select either: 1) The working conditions of the crane including number of counterweights and ask the applicant to determine the maximum permissible load, or, 2) the load and crane configuration and ask for number of counterweights, or, 3) another load chart problem typically encountered, for 4 different crane configurations that cover the scope of operations for that crane. The applicant should be able to identify whether the load is limited by structural strength. Items 13 to 15 can be achieved by presentation of adequate records of training/experience or by answering the questions.

Assessor Guidelines Specific

1. The assessment comprises 15 items covering the following operating areas1) 2) 3) 4) 5) 6) 7) Pre-operational checks Start up crane Site/job planning Operate crane Shut down crane Set up and dismantle crane Special operations

The applicant must undertake all performance items. All critical components must be demonstrated/answered correctly. An assessor must use his/her discretion in assessing competence of non-critical items, at least 75% being ticked for a competent person. 2. The answers provided are only typical of this type of equipment, eg. in shutdown, the sequence varies between different types of crane. The assessment should be conducted in an area 1) With sufficient space to operate freely, without obstruction. 2) Without undue interference from nearby operations. The applicant should provide (or be provided with) appropriate personal, protective equipment and clothing.

6.

3.

4.

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PRE-OPERATIONAL CHECKS: 1. Demonstrate checks to be made on the base/foundation/track system and tower sections. Foundation attachments Tracks are clear of obstructions (where applicable) Rail travel clamps have been removed (where applicable) Visually check that no maintenance personnel are working on or near the crane Main isolation switch (where applicable) - ensure no safety tags Travel mechanism (where applicable) Travel limits (where applicable) Counterweights Tower bolts are secure Ties (where applicable) Structural damage to tower section Access ladders and kickplates Slew mechanism Lighting (where appropriate) 2. Demonstrate checks that should be made before you start the motor (walk around check on carrier and machine deck). Visual check of motor Radiator water Fuel level All oil levels eg. motor, gearbox, hydraulic Lubrication (grease) Battery Water Oil/water leaks on machinery deck and carrier Communication system SWL and manufacturers data plate of crane Load radius indicator Load chart Examine all ropes, wires, anchorages, splices and hooks where practical Any structural damage of crane Rope drums Examine all brake mechanisms Access to machinery deck Controls identified and use explained Fire extinguisher is present Cabin windows are clean Guard railings Pneumatic system

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Visual check of all mechanical equipment Machinery deck drainage

Horn/lights/drive indicator Travel brake (where applicable) Radius indicator Trolley brake (where applicable) Counterweights and attachments Trolley travel limits (where applicable)

Lock to access manhole Electrical system

START UP CRANE:
3. What checks should be made after the motor has been started? (Critical where applicable.) Throttle control Check boost pressure gauge - must read 100 PSI or 700 KPa or 7 BAR, ie to manufacturer's specification

SITE/JOB PLANNING:
4. On arrival to the workplace what pre-erection inspection must be made? Check site plan for working radii at given locations from tower. Check tower crane foundation anchorages. Sight engineer's certificate. Maximum free standing height of the crane.

Caution: Do not move any motion until boost pressure is raised to correct pressure.Do not move any motion until after a warm up period for hydraulic and engine oils. Hoist brake Luff brake Maximum radius limit Minimum radius limit and deceleration limit Hoist limit and deceleration limit Cavitation switches Deadman operation on all controls Communication system "Back up" signalling system

5. What is the function of the service log book? It explains the service maintenance carried out and any defects found and repaired. 6. Produce the service log book and explain critical entries. Log book produced and explained.

OPERATE CRANE: 7. Demonstrate all of the following signals. Stop - hand Stop - whistle Hoist up - hand

Slew brake

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Hoist up - whistle LOAD Hoist down - hand Working Radius Hoist down - whistle Angle/trolley position Luff boom down - hand Luff boom down - whistle Luff boom up - hand Luff boom up - whistle Slew left - hand LOAD Slew left - whistle Working Radius Slew right - hand Angle/trolley position Slew right - whistle Jib/trolley extend - hand Jib/trolley extend - whistle Jib/trolley retract - hand Jib/trolley retract - whistle Creep - hand 9. Demonstrate all crane movements. Secure load Load correctly slung Conduct trial lift Lift conforms with load chart Jib positioned over load correctly Hoist Move load Lower Luff up Luff down Slew load Note: An assessor can give the load and ask for the other items to be calculated or else give the working radius and angle/trolley position and ask for the load to be calculated. LOAD Working Radius Angle/trolley position

Note: Whistle signal for trolley extended or retracted can be utilised by using the boom extend or retract signal.

8.

Explain the load chart and its capabilities at the following 4 boom angles or trolley positions.

LOAD Working Radius Angle/trolley position

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Trolley travel Travel with load All movements smooth/adequate speed Tag line used (where applicable) Signals interpreted correctly Load placed correctly on dunnage (where applicable) Load unslung Cabin Controls Power pack Counter weight & attachments `A' Frame Boom Sheaves and bearings Ropes and attachments Climbing frame equipment Hook and attachment raised to safe height Erection Sequence Anchors Tower sections Slew ring Machine deck Note: Question only relates to the crane driver's involvement.

SHUT DOWN CRANE: 10. Demonstrate shut down procedures. Hazard lights (aircraft warning) Slings removed Raise hook to maximum height Shut down as per manufacturers instructions and as per site conditions Free slew (where applicable) Lock and secure crane

SET UP AND DISMANTLE CRANE: 11. Demonstrate competence either through record of training or by answering the following: Record of training shows erection procedure completed. List the sequence of events involved in the erection procedure.

14. Demonstrate competence in special operations either through record of training, by presentation of Rigging Certificate, or by answering the following: Record of training/Rigging Certificate internal and external climbing sequences completed. List the sequence of events involved in the climbing for both internal and external climbers. Note: Question only relates to the crane driver's involvement.

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 Climbing Sequence (Internal) Ensure climbing cylinders are full of oil and no air is trapped in cylinders Safety throttling valves on both cylinders are checked and adjusted Before commencement of climbing, ensure that tower will be guided at two positions throughout the whole operation until completion Guides must be at least 6 metres apart It is important to ensure the guides are accurately placed It is important to ensure the crane is balanced It is important to ensure clearance of tower leg (at least 3mm)

Place a steel bearing plate under the climbing rams to distribute the load over the concrete surface. Connect special climbing hoses to the quick release connections on the climbing frame (care must be taken to prevent dust and foreign matter entering the system) Set engine throttle at 1,500 Rpm The climbing control valve located at the front of the winch unit can then be operated The crane should commence to rise slowly If there is no visible movement check for obstructions or an out of balance condition of the tower Raise the crane sufficiently to enable the outer climbing support beams to be extended on the higher floor Lower the crane by reversing the climbing control valve until the load is taken on the outer support beams Retract the cylinders until the centre climbing support beam can be extended as well Care must be taken to equalise the retraction rate of the cylinders This can be achieved by the manually controlled balancing valve located at the base of the tower Ensure that the support beam remains in the horizontal position

Equilibrium of the crane is achieved by: Locking the travelling counter weight Luff the crane into the minimum radius

Secure the lock plates on counter weight trolleys to special lugs located on the underside of the counter weight trolley track Luff out slowly, the lugs will anchor the trolley and counter weights will tay in the minimum radius position Luff the boom out with caution until the crane is in equilibrium

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Climbing Sequence (External) Mono rail fitted Tower sections placed at base of tower ready for use in climb Tower section placed on the monorail Boom up Disconnect counter weight and locate close to tower Equilibrium of crane can now be achieved by luffing up and having first tower section ready on mono rail Lock slew ring, when in position to climb "Fitter" will disconnect slew hose and attach them to the climbing rams. Climb the crane "Rigger" then pulls in tower section on mono rail Crane is then lowered slightly, not more than 15mm Drifts fitted

the lock plates release this allowing the counter weight to travel in relation to the boom. 15. List the sequence of events involved in the dismantling process. Note: Question only relates to the crane driver's involvement. Dismantling Sequence (Crane driver has very little involvement in the dismantling operation) External and internal tower crane sequence for dismantling is identical to that of erection and climbing procedure. But, in the reverse order. After the slew ring is locked and the "Fitter" has disconnected the slew hose and attached the lines to the climbing reins. The crane is then removed from the workplace with the assistance of another crane. Special Operations Covered in knowledge assessment. Warnings Before operating the crane in new position always ensure that the crane is checked at two levels of lateral support. Where tower passes through penetration in floor ensure tower section are checked with fox wedges to improve stability near the base.

Note: Crane should only work to 50% of its rated capacity while on drifts Climb down until mount is just clear of tower section pad Bolts inserted and tightened to specified torque

On Completion of Climb Place mono rail beam on ground Disconnect climbing hose and coil on machine deck "Fitter" re-connects slew hose to slew motor Re-connect counter weight trolleys; this can be achieved by luffing into minimum radius and

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Tower Cranes - Performance RELATIONSHIP TO THE NATIONAL CERTIFICATION STANDARD THE UNITS OF COMPETENCE 4. The items in the practical performance assessment are intended to assess the competencies of the applicant in the safe use of Tower Cranes as described in Schedule B of the National Occupational Health and Safety Certification Standard for Users and Operators of Industrial Equipment. These are as follows: 1.0 Assess and secure equipment and work area. 2.0 Secure and transfer load. 3.0 Set up and dismantle mobile or tower cranes. 4.0 Carry out special operations with mobile or tower cranes. Each unit of competence is subdivided into elements of competence, for which performance criteria are prescribed. The questions in each section of the assessment cover the following competencies. 1. Pre-operational checks Performance Criteria 1.1.1, 1.1.3, 1.3.4. 2. Start up crane Performance Criteria 1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.5. 3. Site/job planning Performance Criteria 1.1.2, 1.2.1, 1.2.2, 1.2.3. Operate crane Performance Criteria 1.2.1, 1.2.2, 1.2.6, 1.2.7, 1.3.1, 1.3.2, 1.3.5, 2.1.1, 2.1.2, 2.1.3, 2.2.1, 2.2.2, 2.2.3, 2.2.4, 2.2.5, 2.3.1, 2.3.2, 2.3.3, 2.3.4, 2.3.5. 5. Shut down crane Performance Criteria 1.4.1, 1.4.2, 1.4.3, 1.4.6. 6. Set up and dismantle crane Performance Criteria 3.1.1, 3.1.2, 3.2.3, 3.4.1, 3.4.2, 3.4.3, 3.4.4. 7. Special operations Covered in knowledge assessment.

THE RANGE STATEMENT The performance assessment takes into account factors described in the range statements, including relevant standards and relevant State/Territory occupational health and safety legislation.

Tower CranesGuidelines

June 1994

National OHS Certification Standard

Cranes and Hoists

Tower Cranes

Oral/Written Assessment

June 1994

Tower Cranes Oral/Written

June 1994

TOWER CRANES

Assessor Guidelines Specific

1. The knowledge assessment consists of 70 questions, with 18 compulsory questions. The compulsory questions are identified under each operational area heading. Compulsory questions have part or all of the answers identified as critical. All critical components must be answered correctly, and at least 75% of other components answered correctly, for the applicant to be assessed as competent. 2. Fifteen questions from the other 52 questions are to be randomly selected (manually or by computer) with at least one question from each of the following operational areas 1) 2) 3) 4) 5) 6) 7) Pre-operational checks Start up crane Site/job planning Operate crane Shut down crane Set up and dismantle crane Special operations
No. critical questions No. noncritical questions to select Total question s selected

3.

The knowledge assessment may be given orally, or as a mixture of oral and written. In the Operate Crane planning section the questions, including compulsory questions, are grouped in general subject areas.

4.

Operational area

1 2 3 4 5 7 Total

0 2 3 8 4 1 18

1 1 2 8 ) 3 ) 15

1 3 5 16 8

33

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PRE-OPERATIONAL CHECKS: 6. 1. Explain the function of the mechanical boom radius indicator, and how it works. Applicant shows all connections from base of boom to final position on control panel. 7. 2. On checking the fuel systems, you notice a leak at one of the hose connections. What action should you take? If unable to repair report to authorised person. 8. 3. You noticed that one of the tower frame connection bolts was loose, what would you do? Immediately stop work and contact an authorised person, who would arrange for a competent person to inspect the remainder of the tower bolts. Why does the trap door which leads to the machine deck have to be locked with a chain and padlock if necessary? So that unauthorised persons cannot gain access to the machine deck and start the crane. What happens when the luff out ultimate is actuated? The limit de-energises the luff out solenoid and stops the luff out motion, the brake is automatically applied.

What happens when the luff in ultimate is actuated? The luff in limit when actuated, provides a complete shut down of the crane including engine and all brakes are applied

What limits are on the hoist and how do they work? Hoist up and hoist down limits are usually of the hunting tooth type. The hoist down limit should stop the hoist hook from hitting the ground and should stop the motion when there are two full turns of rope remaining on the drum. Note: The hoist down limits should be adjusted after every climb. Hoist up limit is set with jib at maximum radius. Declaration limit is set to trip at approximately 5 metres below jib head. Up limit is set at approximately 2 metres below jib head. Ultimate limit is set approximately 1 metre below jib head.

4.

START UP CRANE: Questions 9 and 10 are compulsory 5. You are working in cold conditions, why would you have to take special care when starting up? Extra time would have to be taken to allow the engine and hydraulic oils to warm up. 9.

What is cavitation and what is the anticavitation device and why is it important? Cavitation is when the pumps are dragging hydraulic oil faster than it can be supplied and the pumps suck air allowing a free-fall. The anti-cavitation device senses cavitation and applies the brakes.

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10. How do you check the anti-cavitation device? Note: All limits are important but the anti-cavitation device is of extreme importance. Assessors must see the applicant crack the anti-cavitation device. There is a small pressure line which simulates cavitation if it is cracked. An air release is heard and brakes will be applied and controls will return to neutral

13. What hazard control strategies would need to be included in the plan for the crane procedures? A hazard control strategy plan shall address the following areas: Task being performed Any site hazards - filled ground; power lines; obstructions in the working radius of the boom, scaffold, ladders; access and exit points. PPE required by tower crane personnel Traffic controls Lights/lighting Public safety Hoardings

SITE/JOB PLANNING: Questions 11, 12 and 13 are compulsory 11. What procedures should you follow in preparing an operational plan for a tower crane? Job requirements, priorities, workplace rules and procedures, identified hazards and hazard control measures. 12. What types of hazards would you consider for incorporation into your workplan? Powerlines Trees Overhead service lines Surrounding structures Obstructions Facilities Other equipment Dangerous materials

14. What is the importance of having workplace emergency procedures? In the case of an emergency that may arise in the workplace (fire, collapses, serious accident to individual/s) a plan should be developed and put in place in the workplace that lays out a sequence of events that should be followed. 15. What matters should be considered when developing emergency procedures? Raising of the alarm. Location of fire fighting equipment. Location of first aid facilities/equipment. Location of first aid personnel box. Location of telephones and emergencies numbers. Location of evacuation muster area.

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16. In the case of an emergency situation, a set of procedures should be developed specifically relating to your crane. Why?

Note: Assessor may need to give an example of emergency situation. The tower crane in most cases is fixed in one position, has to a certain extent an element of isolation. The crane driver's means of escape in an emergency is in most cases by climbing down the tower to a level where the personnel hoist is operating or all the way to the ground by means of the tower. Most workplaces have an alternate emergency escape route, due to the fact that the personnel hoist may beaffected by the emergency situation. It is essential to notify the person dogging the load prior to leaving the crane cabin. 17. In the case of an emergency why is it important to communicate with the person dogging the load prior to leaving the crane? To find out the area or areas that may be unsafe for the crane driver to pass. The person dogging the load will inform the driver as to the nature of the emergency and also make someone aware at ground level that you are making your way down. The person dogging the load can give instructions as to whether it may be safer to stay in the cabin until the situation has eased. 18. Your crane is set up very close to a building which is next door to the site where you are working. If you slew too far, your counter weight will hit the building. What special precautions must be taken when you park the crane?

The crane cannot be left in free slew as is normally done when parking tower cranes. With the long boom crane, an engineer's permission should be obtained to ensure that it is safe to leave the slew locked when parking the crane. 19. You notice that scaffolders are erecting a scaffold which is close to the crane - what should you do? Have them stop until you check whether the scaffold will be hit by the counterweight or other part of the crane when you slew.

20. What equipment should be provided for the crane operations working at night or in darkened areas? There should be sufficient lighting over the whole work area.

21. What is the importance of having an operations plan that ensures the correct lighting for the workplace? The importance of having an operations plan with regards to lighting is task/job scheduling, taking environmental factors into account can greatly improve conditions in the workplace. working directly into the sun, which includes the hottest hours of the day working at night using artificial light sources access and exit limited visibility during rain conditions etc.

22. If power failure is to be of a long term problem, what needs to be done? An authorised electrician investigates the problem and where necessary has a danger tag placed on the main switch board until rectified.

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OPERATE CRANE: Questions 27, 29, 37, 43, 44, 50, 51 and 52 are compulsory

29. (i)

23. When interference (tampering) is identified, to whom should the crane driver report any faults? To an authorised person. 24. What warnings are indicated by the enunciator panel? Low engine oil Low coolant level Low boost pressure Hydraulic filter bypass warning 25. Concrete form work shutters have to be stripped and lowered to the ground. While the carpenters are releasing a shutter, a very strong wind blows up. What should you do? Lay the shutter down. If the wind is very strong do not take it down. Inform an authorised person regarding the wind condition. 26. What would you do if a very strong gale force wind blows up? As per manufacturers recommendations. 27. The crane will boom up but will not boom down. When you push the controller to boom down the motor starts to fade. What action should be taken? Cease operation. Check for cause and take appropriate action.

What is the minimum distance any part of the crane and load is allowed to set-up near overhead powerlines? 2 metres from distribution lines on poles, 6 metres from transmission lines on towers, closer if lines are covered.

(ii) If you want to work closer than these distances what can you do? Must seek an exemption from the relevant authority. 30. The crane hoist rope is 2.5 metres away from distribution lines on poles. The load you are to pick up is steel and over 5 metres long. The load could spin and hit the power lines. What should be done? The person dogging the load should control the load with a hand held tag line 31. The building next to your construction site is one of the new mirrored glass buildings. At a certain time of day, the glare is such that you cannot see in positions where it could be assumed that you can see the job. What should you do? Inform the person dogging the load that you cannot see because of the glare. Treat the job as you would normally when working out of sight. Wear personal protective equipment (AS approved tinted glasses). 32. You have to lift an internal lift shaft formwork shutter. You know it weighs two tonnes. The person dogging the load slings it and you take the weight. The weight gauge shows an increasing strain over two tonnes. What should you do? Stop hoisting immediately if the strain goes over two tonnes, the shutter could be jammed. If it freed suddenly it could be a hazard and injure people.

28. A tower crane has been set up on a new site. Your truck unloading position requires you to lift from the street. People walk along that footpath, what should be done so that work can progress? The walkway should be covered with a pedestrian hoarding which conforms to relevant standards. Do not lift over pedestrians/public.

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33. What is the maximum wind speed that tower cranes can work in? As per manufacturers recommendations. 34. You have some formwork shutters, to lower from aloft. While the carpenters are freeing them a strong wind blows up. What should you do? Shutters are large in area but light in weight, therefore they could flap around in the wind. Inform the supervisor that you will bring them down when the wind drops.

39. If you heard abnormal noises coming from the machine deck, what main components would you check? Hoist brake, luff brake, slew brake, main engine, hydraulic pumps ie hoist,luff, slew, gear box, hoist and luff drive, spur wheels and drive pinions. 40. What action would you take and what would you look for if you heard a sudden loud noise just underneath the machine deck? Cease operation immediately and look for any broken gears on the slew ring, report to an authorised person. 41. What would you do if you heard a loud noise and felt vibration coming from an area lower down on the tower section? Cease operation immediately and communicate with the person dogging the load to have an inspection carried out to identify whether some form of heavy plant has struck the main tower and check for damage, report to an authorised person. 42. You have hit the luff in limit and the engine has stopped. How do you restart the motor? Manufacturers require that the mechanic be called to re-start the crane if the luff-in limit is actuated. This is to ensure that the luff pump is not in stroke while the controller is in neutral. Some owners have fitted luff override buttons to allow the motor to be started and boom down to take place, but manufacturers believe that a mechanic should be called. 43. Why is it important that all motion limits are checked for correct functioning? You could overrun and cause structural, personnel and property damage.

Note: Some applicants may say place them together and bring them down on the flat. This is a correct method if the wind is not too strong. 35. What hazard exists when accessing and egressing steel ladders in wet weather? The access ladder will be slippery, it would be easy to slip and fall. 36. If the work takes longer than expected and natural lighting is fading, what steps/action should you take? At the instance where natural lighting has faded to the point where it is unsafe to operate the crane, inform the person dogging the load that work will cease until artificial lighting has been set up. 37. If the boom length is lengthened, what needs to be done to the load radius indicator chart? Ensure that the load chart calibration is readjusted to the new boom length. 38. During operation of the crane, electrical power failure/fault occurs. What would you do? Communicate with the person dogging the load and advise of the problem for rectification.

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44. What precautions must be taken when long travelling? Prior to operating, ensure that there are no obstructions in the tracks. Ensure that working radius has being calculated prior to travelling. Ensure that there are no people, for example, people fishing on wharfs, who could be in danger of travelling crane. When travelling long distances, siren and flashing lights must be fitted. Ensure that load is controlled by the person dogging the load and/or tag lines where necessary. Ensure that "people pushers" or wheel guards are in place. Travel at minimum speeds. Ensure that crane travelling is mechanically stopped prior to reaching end stops.

46. If any signals are observed through warning lights, alarms or gauges, what action would you take to have the defect rectified? Cease all operations, investigate where the problem is and report problem to an authorised person, for action. 47. Why do you have to have a machine deck well and rain water storage, which can be drained by opening a cock? This is to ensure that oils and greases which may leak are not washed down all over the job/crane access. 48. You are driving a tower crane which is fitted on to a travelling base. Why should access to the travel motor in the base be locked off? So that unauthorised persons cannot gain access to the base start, the travel motor and drive the crane along the rails. 49. What action would you take if the boom struck a power line? Attempt to break contact with the power by controlling the main boom. 50. A person dogging a load puts a hand on the hook and starts to jump as though they are getting an electric shock. What should you do? If possible, lift hook clear of the person dogging the load to break contact with earth. Follow relevant first aid procedure as required. If possible, get somebody to assist. 51. Are you permitted to allow a person to ride upon the lifting hook, sling attachment or suspended load?

Note: Some hydraulic tower cranes are put on a travelling base which is counterweighted to engineers/manufacturers specifications, they run on rails and have end stops. When fitted as a travelling crane, they have a separate travel motor which is near the base, these are usually fitted so that it can be driven from the base or the drivers cabin. 45. If you observed a defect in one of the main controls, who would you report this to for rectification and who would be responsible for rectification work? To an authorised person, who would then contact the mechanic for corrective action.

No.
52. Explain the requirements that would permit you to lift personnel using the crane? Any requirements specified by crane manufacturer.

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Any requirements covered by workplace conditions. Applicant to explain requirement for the work box -refer Clause 7.16.2 of AS 2550 Part 1. Applicant to explain requirements for the crane - refer Clause 7.16.3 of AS 2550 Part 1. Applicant to explain the operator requirements - refer Clause 7.16.4 of AS 2550 Part 1.

55. On a luffing boom crane what is the ideal radius to leave the boom in during shut down? With the head sheave on the boom, approximately level with the head of the`A' frame. 56. If the boom cannot be left at the desired radius because of the obstruction of surrounding buildings etc. and must be left at the minimum radius, what procedure would you follow? Have a qualified engineer assess the situation, taking into account the effects on the crane caused by wind loadings. 57. If the crane is located near aircraft traffic zones, what must be switched on at night? The red warning light at the uppermost point of the crane.

Note: Statutory authorities may have other conditions. 53. Explain the use of packing or dunnage when slinging a load. To protect the load. To facilitate the connection/disconnection. To prevent damage to lifting gear.

58. What would you do with the platform access hatch on shut down? Ensure that it is securely closed and locked with a key lock. 59. What must be done to the base of a travelling tower crane on shut down? (i) Ensure that blocks are placed at base of wheels to prevent movement of crane. (ii) Make sure that the electric motor to the travelling wheel mechanism is isolated and locked. 60. On shutting down an electric powered ie hammerhead type crane, what is the most important thing to be done? Ensure that all electric circuits are fully isolated - locked off.

SHUT DOWN: Questions 61, 62, 63 and 64 are compulsory 54. When shutting down the crane, what check is most important with the pawl to the luff drum, and how would you ensure this procedure was done? The pawl `must' be fully engaged. Firstly by observing the light on the control panel, then by physically proceeding to the luff drum and sighting that the pawl if fully engaged.

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61. Is it permitted for any loads including slings to remain suspended from the hook following shut down? No. 62. Why is it essential that you check whether the pawl is fully engaged before leaving the crane overnight? To ensure that the pawl is not riding on the top of the tooth on the ratchet. 63. If the crane is to be left in free slew, why is it important that you raise the hook clear of obstructions for the full 360o around the crane? When in free slew the crane can paravane. 64. Why do you have to connect the machine deck water drain to a system that can take water away during periods of shut down? This is to ensure that oils and greases which may leak are not washed down all over the crane and job. 65. You are driving a crane which is on a travelling base. Why is it essential that travel locks are clipped to the rails as you leave the crane? These locks stop the crane from being blown down the rails by strong winds. 66. On an electric hammerhead type, why should you bring the trolley back to near the tower for parking? So that the trolley-hook assembly creates less wind resistance. 67. Do you leave hammerhead type cranes in free slew for parking? Yes. Or as otherwise required for site conditions.

SET UP AND DISMANTLE CRANE: Covered in performance assessment.

SPECIAL OPERATIONS: Question 69 is compulsory 68. How often should the load mass (weight) indicator be calibrated? Six monthly, by picking up a known weight, or in accordance with manufacturer's specifications. 68. How do you lower the load in an emergency? 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 crane that they operate. It is essential for the applicant to know this. If not, then they should not be assessed as competent. 70. Is it permitted to carry out a multiple lift? Refer to the statutory authority.

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Tower Cranes - Oral/Written RELATIONSHIP TO THE NATIONAL CERTIFICATION STANDARD

THE UNITS OF COMPETENCE The items in this part of the knowledge assessment are intended to assess the competencies of the applicant in the safe use of Tower Cranes as described in Schedule B of the National Occupational Health and Safety Certification Standard for Users and Operators of Industrial Equipment. These are as follows: 6. Set up and dismantle cran 1.0 2.0 3.0 4.0 Assess and secure equipment and work area. Secure and transfer load. Set up and dismantle tower cranes. Carry out special operations with tower cranes. Covered in performance assessment. 7. Special operations Performance Criteria 4.3.1, 4.3.2, 4.3.3. Each unit of competence is subdivided into elements of competence, for which performance criteria are prescribed. The questions in each section of the assessment cover the following competencies. 1. Pre-operation checks Performance Criteria 1.1.1, 1.1.3. 2. Start up crane Performance Criteria 1.3.1, 1.3.2, 1.3.3, 1.3.4. 4. Operate crane Performance Criteria 1.2.1, 1.2.2, 1.2.4, 1.2.6, 1.2.7, 1.3.1, 1.3.2, 1.3.5, 2.1.1, 2.1.2, 2.2.1, 2.2.2, 2.2.3, 2.2.5, 2.3.2, 2.3.3, 2.3.5. 5. Shut down crane Performance Criteria 1.4.1, 1.4.2, 1.4.3, 1.4.6, 3.3.1.

THE RANGE STATEMENT This part of the knowledge assessment takes into account factors described in the range statements, including relevant standards and relevant State/Territory occupational health and safety legislation.

3. Site/job planning Performance Criteria 1.2.1, 1.2.2, 1.2.3, 1.2.4, 1.2.5, 1.2.8, 1.3.4.

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Assessment summary
! Tower Cranes

Form of assessment

Total number of items in the assessment

Number of items given ! or NA

Number of items required to meet standard

Were all critical boxes given ! or NA?

Assessment standard requirements achieved *

Performance Oral/ Written Written

15 33 22

13 29 17

Yes Yes Yes

No No No

Yes Yes Yes Yes

No No No No NA

Assessment completed within time allowed

* Performance standard Knowledge standard = =

Number of items required to meet standard (including all critical boxes) Number of questions required to meet standard (including all critical boxes)

Summary
Candidate is:
(circle the result obtained)

COMPETENT NOT YET COMPETENT

Date: ........................................

Name of ................................................. assessor ................................................. Signature ................................................ Comments/feedback

Name of candidate .................................................. Signature ..................................................

(assessors to make any additional comments which clarify the assessment) .......................................................................................................................................................................... .......................................................................................................................................................................... .......................................................................................................................................................................... .......................................................................................................................................................................... .......................................................................................................................................................................... ..........................................................................................................................................................................

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