Maintenance, Inspection and Thorough Examination of Mobile Cranes

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1.0 Introduction and Summary The consequences of any failure of a mobile crane are likely to be extremely serious, with the potential for multiple fatalities. Mobile cranes, which include wheeled and , crawler cranes, compact cranes and mobile tower cranes, are also often one of the primary means of material handling on a construction site and any breakdown will have a serious effect on the construction programme. It is therefore extremely important that mobile cranes are effectively maintained to ensure continued safe and efficient operation over time. In addition to the maintenance process the thorough examination of mobile cranes, periodically and after exceptional circumstances is required to ensure that mobile cranes are safe to take into use and to continue in use. Both the maintenance and thorough examination of mobile cranes are required by law and the purpose of this Best Practice Guide (BPG) is to set out, in clear and concise terms, both the requirements and Best Practice for meeting these requirements. The document is split into two sections – Maintenance and Thorough Examination, to emphasise that these are separate, although complimentary, activities. The document is aimed primarily at mobile crane owners, and those managing and carrying out the maintenance and thorough examination of mobile cranes. However the document will also be of benefit to other groups such as mobile crane users. Maintenance There are a number of equipment maintenance management techniques that can be employed, including “Breakdown Maintenance” where maintenance is only carried out after faults or failures have occurred, and “Planned Preventive Maintenance” which involves routine inspection replacing parts and consumables or making necessary adjustments at preset intervals, so that risks do not occur as a result of the deterioration or failure of the equipment. In the case of mobile cranes the “Breakdown” approach is inappropriate, as any failure presents an immediate risk. The Best Practice Guidance is therefore the “Planned Preventive Maintenance” management technique. Maintenance of mobile cranes should be managed in the same way as any other business activity as, if not carried out effectively, it can have severe financial and safety implications for a business. An effective management structure is required to ensure that everyone involved in the maintenance activity is aware of their responsibilities, properly briefed on their duties and that systems are in place to enable effective feedback, including the monitoring of maintenance data. Mobile crane maintenance activities should be carried out, as a minimum, at the intervals specified in the mobile crane manufacture’s maintenance manual. Varying circumstances on site may however require the frequency to be increased. Once a mobile crane has been set up on a site, the user of the crane has a duty to ensure that it is adequately maintained. The actual undertaking of the maintenance is generally delegated to the crane owner by the user; the user however, retains the responsibility for ensuring that the maintenance is carried out. Clear lines of responsibility for maintenance operations should be established from Board level downwards, ensuring that those appointed and responsible have sufficient knowledge and experience to carry out their duties in a way which will ensure that risks are properly controlled. 2
Each mobile crane should have a documented preventive maintenance schedule which is targeted at the parts of the equipment where failure or deterioration could lead to health and safety risks and which specifies the frequency of inspection and test of relevant parts, taking account of the manufacturer’s instructions, the age of the crane and its in-use history. Mobile crane owners may not have access to expert professional engineering advice in-house. If this is the case arrangements should be made for securing such advice externally where this is necessary for the purposes of health and safety and clear guidelines should be established for when this advice should be sought. For a preventive maintenance system to be fully effective it is essential that comprehensive records of daily checks, intermediate inspections, breakdown reports, maintenance work sheets (including details of parts replacement) and reports of thorough examination are kept. These should be filed in an individual machine history file which should be kept for the life of the crane. An extremely important aspect of a planned preventive maintenance system is the continuous and systematic review of all maintenance records, inspection reports and reports of thorough examination to ensure that the maintenance is effective, defects are found and worn components are replaced well in advance of any possible failure. Should this review indicate that maintenance is not fully effective, the frequency may have to be increased and maintenance practices amended. Maintenance should only be carried out by those who are competent and have adequate training and information to carry out the work required. A number of general maintenance training courses and qualifications are available for personnel carrying out and supervising maintenance operations. Training is offered by a number of training providers including the National Construction College, whilst qualifications are available through the NVQ/SVQ scheme. All maintenance personnel should have received machine specific training, traceable to the mobile crane manufacturer, before carrying out maintenance tasks on any mobile crane. Maintenance operations on mobile cranes require adequate facilities and equipment to enable them to be carried out effectively, efficiently and safely. The size and sophistication of the facilities will depend on the degree of maintenance tasks to be carried out. Thorough Examination Thorough examination of lifting equipment is a fundamental requirement of the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER). Regulation 9 of the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) requires employers to ensure that mobile cranes are thoroughly examined at prescribed intervals. In the case of a hired-in mobile crane the actual undertaking of thorough examinations is often delegated to the crane owner by the user. The user however, retains the legal responsibility for ensuring that thorough examinations are carried out. The primary purpose of a thorough examination is to ensure that a mobile crane is safe to be taken into, or to continue in, use. It is in addition to any inspection carried out as a part of the maintenance regime and is a statutory requirement. Mobile cranes operate in a high risk environment which includes lifting loads over people. These factors must be taken into account by the competent person when determining the scope and nature of the thorough examination. As with maintenance, the thorough examination of mobile cranes should be managed effectively, irrespective of whether thorough examination is carried out in-house or by 3
Page 1 and 2: HSE Logo When Approved Maintenance,
Page 3 and 4: Contents Foreword 1 1. Introduction
Page 5: Foreword Every year, the constructi
Page 9 and 10: Other Issues In addition to the iss
Page 11 and 12: overload testing (dynamic) operatio
Page 13 and 14: 2.1 3.6 The Provision & Use of Work
Page 15 and 16: 4.0 Approaches to Maintenance 4.1 M
Page 17 and 18: competent person at the time of the
Page 19 and 20: 5.0 Maintenance Intervals 5.1 Intro
Page 21 and 22: 6.0 Maintenance Personnel - Attribu
Page 23 and 24: working life. This is a joint respo
Page 25 and 26: of work (risk assessment, method st
Page 27 and 28: All the defect reports, including t
Page 29 and 30: � Records of unusual applications
Page 31 and 32: 11.0 Site Issues For Maintenance 11
Page 33 and 34: This means that those planning work
Page 35 and 36: “as new” condition. Care should
Page 37 and 38: 13.0 Maintenance Facilities and Equ
Page 39 and 40: 13.10 Lifting Equipment Maintenance
Page 41 and 42: NOTE: Further information is given
Page 43 and 44: The Working Time Regulations limit
Page 45 and 46: � Mobile cranes will be used for
Page 47 and 48: � Repeated overloads may have a d
Page 49 and 50: different perspective than someone
Page 51 and 52: 16.0 Competent Persons - Attributes
Page 53 and 54: An individual training plan should
Page 55 and 56: 17.0 Developing the Defined Scope o
Page 57 and 58:
17.3.3 Generic Information Competen
Page 59 and 60:
18.0 Reports of Thorough Examinatio
Page 61 and 62:
19.0 Management Review of Thorough
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equirements of usage this is unavoi
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21.0 Practical Issues for Thorough
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The planning process for work at he
Page 69 and 70:
22.0 Lifting Accessories Lifting Ac
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Domestic Premises Sole responsibili
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Figure 1 - Work Restraint System Wo
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A1.3.6 Anchor Points Figure 4 - Lan
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� A system provided by the Princi
Page 79 and 80:
4.1 Anticipating the Consequences o
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Prior to examination of cranes: 5.1
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crane if they have any doubt as to
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6.12 Crushing Keep hands, arms, fee
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Examination Areas Area Element Requ
Page 89 and 90:
Operation Power Unit:- Controls:- B
Page 91 and 92:
Structures Slew section structural
Page 93 and 94:
A5.5.0 Availability of Operators Ma
Page 95 and 96:
A5.13.0 Communication Equipment Per
Page 97 and 98:
Annex 6 - Daily Pre-use Checks and
Page 99 and 100:
Annex 8 - Example of the Use of Key
Page 101 and 102:
Annex 9 - Example of the Use of Key
Page 103 and 104:
The appointed person responsible fo
Page 105 and 106:
A10.10 Wire ropes The examination o
Page 107 and 108:
Annex 11 - Qualifications and Asses
Page 109 and 110:
A declaration of conformity is requ
Page 111 and 112:
BS EN 12385-4:2002, Steel wire rope
Page 113 and 114:
Index (to be fully revised) 109
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Maintenance, Inspection and Thorough Examination of Mobile Cranes

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