C761
C761
This guide is intended to promote the safe design and construction of foundations for tower cranes
through an improved understanding of temporary works design and health and safety issues.
Tower cranes are a vital element in the construction process. There are around 1500 tower cranes in the
UK and at any time around 1000 are in use. Tower cranes are often in use on construction sites in urban
areas and, although rare in the UK, any collapse of the crane is likely to result in injury to members of the
public outside the boundaries of the site as well as those working inside the site. Collapse of tower cranes
also presents a risk to adjacent railways and roads. There is a risk of a catastrophic event occurring.
The initial sections of the guide are aimed at those who need to understand the issues related to the safe
use of tower cranes (eg planners, architects, permanent works engineers and site supervisors). It also
highlights key situations where a specialist should be consulted.
Specific guidance for designers of temporary works involving tower cranes is given. Issues include the
understanding of wind effects, other loading and support considerations, factors of safety and design of
foundations (eg example calculations for typical situations).
This guide aims to bring together important practical and design issues that affect health and safety
and to present a current understanding of good practice based on the experience of a wide cross-section
of the industry. Readers of this guide may also wish to refer to the Lifting Operations and Lifting
Equipment Regulations (LOLER) 1998, HSE (2014), BS 7121-5:2006 and Lloyd (2003).
Watson, T, Marchand, S
CIRIA
A catalogue record is available for this book from the British Library
Keywords
Construction process, ground engineering, health and safety, planning, temporary works design and construction
Reader interest Classification
Design and construction of tower Availability Unrestricted
cranes, temporary works design, Content Advice/guidance
health and safety
Status Committee-guided
User Temporary and permanent works engineers, site managers and
supervisors, geotechnical engineers, architects, planners
This publication is designed to provide accurate and authoritative information on the subject matter covered. It is sold and/or
distributed with the understanding that neither the authors nor the publisher is thereby engaged in rendering a specific legal or any
other professional service. While every effort has been made to ensure the accuracy and completeness of the publication, no warranty
or fitness is provided or implied, and the authors and publisher shall have neither liability nor responsibility to any person or entity
with respect to any loss or damage arising from its use.
All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, including photocopying
and recording, without the written permission of the copyright holder, application for which should be addressed to the publisher. Such
written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature.
If you would like to reproduce any of the figures, text or technical information from this or any other CIRIA publication for use in
other documents or publications, please contact CIRIA publishing for more details on copyright terms and charges at: publishing@
ciria.org, Tel: 020 7549 3300.
ii CIRIA, C761
Acknowledgements
This guide has been produced by CIRIA as a result of Research Project (RP) 999 and has been written
by Tim Watson and Stuart Marchand. This guide supersedes CIRIA C654 Tower crane stability, published
in 2006.
Authors
Tim Watson BTech CEng MIMechE
Tim is an independent engineering consultant, specialising in cranes, hoists and powered access. He
previously worked for the Laing Group for 33 years, and was engineering director of Laing Plant until
he left in 2001. Tim has written many crane-related industry standards and guidance publications in his
role as technical consultant at the Construction Plant-hire Association (CPA). His work on this guide has
been supported both technically and financially by the CPA’s tower crane interest group.
Project funders
Bowmer and Kirkland Ltd
Other contributions
The authors would like to thank HTC Plant Ltd and Mace who have provided images for the guide, and
Dr Hitesh Halai and Brett McKinley of City, University of London, and Paul Trewavas for their helpful
comments and suggestions during the editing process.
Members of the PSG provided guidance and assistance throughout the project.
Syd Appleyard and Mick Donovan sadly passed away during the update.
While not part of the PSG, significant assistance was also received from the Steel Construction Institute
and Christoph Eiwan of Liebherr. Charles Goodchild, Craig Hook, Tim Lohmann and Hilary Skinner
in particular provided valuable help.
iv CIRIA, C761
Contents
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Abbreviations and acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Notation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Causes of failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2.1 Erection, climbing or dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.3 High wind loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.4 Structural failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.5 Load failures or impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.6 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.7 Overhead power lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Health and safety legislation, standards and guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Catastrophic events in construction – factors to consider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Loads applied to the foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Loading information from manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Obtaining information where the crane manufacturer is no longer in existence . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Partial factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Regulation and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.1 Principles of factors recommended in this guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.2 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.3 Structural members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6 Influence of siting on design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.7 Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.1 Foundation selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.7.2 Site investigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7.3 Foundation design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7.4 Tower cranes mounted on the building core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Lightning protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.9 Tying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.9.1 Types of tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9.2 Internally climbing tower cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.10 Guying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.11 Erection, climbing and dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Managing the design, construction and maintenance of foundations and ties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.1 Design checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Procurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Foundation construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5 Erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.7 Maintenance and thorough examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.8 Reconfiguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.9 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.10 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.11 Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Case studies
Case study 2.1 Tower crane foundation designers require appropriate experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Case study 3.1 Need for early communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Case study 3.2 Effects of shrinkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
vi CIRIA, C761
Case study 3.3 Importance of early planning for dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Case study 4.4 The importance of retaining the cube from the base concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Case study A2.1 Planning for tie loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figures
Figure 1.1 Tower crane erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 1.2 Nearby hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 2.1 Loading applied to tower crane foundation on cast-in anchorages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2.2 Loading applied to tower crane foundations on ballasted cruciform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2.3 Design issues relating to crane siting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 2.4 Typical tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 2.5 Proprietary tie system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 2.6 Restraining tie for crane tower passing through slab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 2.7 Typical internal climbing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 4.1 Tower crane foundation pre-erection inspection report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure A1.1 Basic types of tower crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure A2.1 Typical tie loads and reaction forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure A2.2 Main types of foundation anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure A2.3 Foundation anchor setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure A2.4 Bolt grip length and diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure A3.1 Loading applied to base by a tower crane on cast-in anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure A5.1 Nearby buildings can alter wind speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Tables
Table 1.1 Factors tending towards or away from events with catastrophic potential . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2.1 Checklist for crane loading information required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 2.2 Types of foundations and fixings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table 3.1 Base and tie design and construction responsibility assignment matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 3.2 Categories of design check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 4.1 Pre-erection inspection checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 4.2 Foundation monitoring checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table A1.1 Tower crane types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table A3.1 EQU limit state applied to stability of tower crane gravity base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table A3.2 Partial factors for GEO/STR combinations 1 and 2 where loads supplied do not include second order
and dynamic effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table A3.3 Partial factors for GEO/STR combinations 1 and 2 where loads supplied do include second order and
dynamic effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Appointed person Person with the training, practical and theoretical knowledge and experience
required to comply with clause 3.3 of BS 7121-1:2016.
Competent person Person who has such practical and theoretical knowledge and such experience of
the crane, the equipment used in the lifting operation, the design of supporting
structures and other related tasks as is necessary to carry out the function to which
the term relates in each particular context.
Cruciform A steel structure, normally in a cruciform shape, carrying loads from the tower
crane mast out to concrete pad footings.
Equilibrium Loss of static equilibrium of the structure or any part of it considered as a rigid
body, where:
minor variations in the value or the spatial distribution of permanent actions
from a single source are significant
the strengths of construction materials or ground are generally not governing.
Eurocodes Eurocodes are supported by a suite of testing and execution standards covering site
practice that become requirements when they are published.
Fatigue Fatigue failure of the structure or structural members.
Foundation anchor An embedded fixing between a tower crane and its foundation.
Geotechnical Failure or excessive deformation of the ground where the strengths of soil or rock
are significant in providing resistance.
Hydraulic heave Internal erosion and piping in the ground caused by hydraulic gradients.
Owner The company, firm or person owning the crane for their use or letting the plant out
on hire.
Permanent works Competent person with responsibility for the design of permanent works.
designer
Principal contractor A contractor appointed by the client to control the construction phase of any project
involving more than one contractor (CDM2015).
Principal designer A designer who is an organisation or individual (on smaller projects) appointed
by the client to manage and monitor the design stages (including design changes
and modifications) of a construction project from concept to completion to
ensure that relevant health and safety risks are properly identified, considered
and controlled (CDM2015).
Reconfiguration A change in the crane configuration after the crane has been installed (for example
raising the crane height or altering the jib length).
Second-order effects These result from the deflection of structures under load and increase the
deflections, moments and forces beyond those calculated by first-order analysis.
Strength Internal failure or excessive deformation of the structure or structural members,
including footings, piles, basement walls etc, where the strength of construction
materials of the structure governs.
Temporary works Competent person with responsibility for the co-ordination of all activities related
co-ordinator to the temporary works (BS 5975:2008+A1:2011).
Temporary works Competent person with responsibility for the design of temporary works (BS 5975:
designer 2008+A1:2011).
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Notation
While the authors have endeavoured to include most of the common notation in this section, not all notation
has been provided especially partial factors because of the extensive use of them throughout the guide.
e Eccentricity
d Effective depth of base
d
Design (ultimate)
er
Erection
F Vertical load from tower crane including permanent, variable etc loads
h Overall depth of base
H Horizontal load from tower crane including wind, dynamic effects etc
k
Characteristic
L Length of side of pad base or pile cap (see Worked examples 1 and 2)
Length of ‘nominal pad base’ for rail-mounted bogie (see Worked example 3)
M Moment from tower crane
Ω Ohm (unit of electrical resistance)
s Spacing of piles
T Torque moment from tower crane
TC
Tower crane (where required)
Ψ Factor for combination value of a variable action
γF Partial factor for actions, also accounting for model uncertainties and dimensional variations
It has been revised to take account of the Eurocodes and the tower crane design standard BS EN 14439:
2006+A2:2009, together with the revision of the BS 7121 series on installation, maintenance, inspection,
examination and use of tower cranes. Foundation design examples that relate to the Eurocodes are
included.
While this guide articulates good practice based on the experience of a wide cross-section of the
industry, it does not deal with daily lifting operations. Its remit is limited to temporary works design and
the interface with the permanent works, taking account of the process of planning, communicating and
managing the use of tower cranes.
1.2 HAZARDS
Operations that involve erection, reconfiguring and dismantling cranes are particularly hazardous.
When a crane is in use, poor operation or failure of warning devices or structural members are most
likely to result in a serious incident.
All workers involved in specifying, procuring, planning, erecting and operating tower cranes, as well as
those on site around it, should understand the major hazards associated with their safe use and stability.
Some safety critical devices may require a tower crane to have an uninterrupted power source (UPS) and
this must be taken into account early in the planning.
The hazards described in the following sub-sections are not exhaustive. Further hazards may
be identified by a site-specific risk assessment. See Appendix A4 for risks relating to foundation
construction.
Notes
It is vital that site workers carrying out the erection, reconfiguration, use and dismantling of tower cranes have the
necessary knowledge, skills and experience to ensure competence.
The particular hazards associated with tower cranes alongside railways are addressed in CPA (2014a).
Crane components may be lifted by a second crane (Figure 1.1) and may be in an inherently unstable
condition until properly bolted together or when unbolted and disassembled. The correct sequence of
component assembly or dismantling is vital to ensure that the part-completed crane remains stable.
Climbing a tower (increasing its height) using an external frame involves particular hazards relating to
the carrying of an unbalanced load during the operation. These hazards are described in a HSE (2003)
discussion paper.
1.2.2 Overload
The use of rated capacity indicators or limiters has reduced cases of overload. However, the structure of
the crane and its stability can be impaired when loads are lifted that are in excess of the rated capacity
at the given radius, or are inappropriate in the wind conditions or for the crane configuration, such as
lifting objects with a large wind area/mass ratio. So it is vital that all lifts are covered by a lifting plan and
that such activities are controlled by an appointed person (BS 7121-1:2016).
It is important that luffing jib tower cranes are left OOS at a radius not less than that specified by the
manufacturer, unless they have allowed a smaller radius in specified circumstances. For saddle jib tower
cranes the trolley should be parked at the jib foot. For both types of crane, loads should not be left
attached to the hook block.
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1.2.4 Structural failure
Tower crane collapse could be caused by the failure of elements of the structure and its foundations.
For example:
The tower crane foundation not being correctly designed or errors made during the foundation
construction.
Incorrect assembly of the tower crane.
The tower crane being subjected to overloading, either through exceeding the rated capacity or
storm wind load.
Issues with manufacturing quality of the tower crane.
Fatigue damage. According to standard classification, tower cranes are generally designed for
moderate use according to typical construction work. Fatigue failure can happen in less than a year if
a brand new tower crane lifts at or near its rated capacity with a very high frequency (see CPA, 2014b).
It is important that the magnitude and frequency that loads will be lifted is established at the planning
stage to assist selection of a suitable crane.
1.2.6 Hazards
Tower crane collapses or failures have been caused by crane impacts with other cranes (Figure 1.2),
plant or buildings. It is critical that the crane’s operational procedures take into account the location of
hazards and that a safe choice of crane and system of work have been developed. It is important not to
rely on anti-collision systems alone to warn of a crane’s location in relation to other cranes and plant.
Zoning systems are a useful aid in preventing the load and/or parts of a tower crane from entering a
prohibited space or striking structures (see BS 7121-5:2006).
At the time of writing, a new European standard related to anti-collision and zoning system is under
preparation by a CEN/TC147 sub-commitee (CEN, in prep).
Devices are available that are designed to be fitted on cranes to determine the presence and give
warning of overhead electric lines and cables. Such devices should not be used as a substitute for a safe
system of work and safe clearances as set out in HSE (2013).
Other requirements, such as those applied by the rail network and operating companies, airports, ports,
underground railway or tram owners and operators, must also be adhered to where relevant.
Table 1.1 sets out factors tending towards or away from events with catastrophic potential in order to
ensure attention and resources can be focused where they are most needed. A single factor may be
sufficient to indicate catastrophic potential but it may also arise from a combination of factors.
Ultimately, tower crane companies will have to make appropriate judgements and record significant
issues, for each project.
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Table 1.1 Factors tending towards or away from events with catastrophic potential (from Cross, 2013)