GuidelinesforInspecting

OverheadCraneStructures

May20,2011

PreparedBy:

GaryJ.Davis,P.E.
DirectorofConsultingServices
IntegratedMachinerySolutions(IMS)
FortWorth,Texas

TexasRegisteredEngineeringFirm#11499

www.teamims.com garydavis@teamims.com 8176592399

TableofContents
Section
1.0
1.1
1.2
1.3

2.0
2.1
2.2
2.3

3.0
3.1
3.2
3.3
3.4
3.5

4.0
4.1
4.2
4.3

5.0
5.1
5.2
5.3

6.0
6.1

7.0
7.1
7.1
7.2
7.2
7.3

Description
Introduction
Purpose
Scope
LimitationsofthisGuide

OrganizationandPersonnel
ImplementationofaDisciplinedPlan
PrerequisitesforaQualifiedInspector
RecommendedInspectionTeam

InspectionSafety
PreInspectionSafetyPlan
SafelyManeuveringontheStructure
IdentifyingHazards
HighAmbientTemperatures:PrecautionsandPlanning
PersonalSafetyEquipment

PlanningandPreparation
CleaningtheStructure
AerialWorkPlatforms
OtherInspectionParaphernalia

GeneralInspectionGuidelines
GettingStarted
WheretoLook
OtherInspectionGuidelines

TrolleyStructureInspection
TrolleyStructureInspectionPoints

BridgeStructureInspection
BridgeGirderInspectionPoints
BridgeGirderInspectionNotes
BridgeEndTruckandEndTieInspectionPoints
BridgeEndTruckandEndTieInspectionNotes
BridgeMiscellaneousInspectionPoints

Page
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5
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6
6
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10
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10
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13
13
15
20
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Section
8.0
8.1
8.2
8.3
8.4
8.5
8.6

9.0
9.1

10.0
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
10.10

11.0
11.1
11.2

12.0
12.1
12.2

13.0

14.0

Description
HighStrengthBoltedConnections
BoltedConnections:DescriptionandFunction
HowtoCheckforBroken,Damaged,andLooseBolts
RivetedCraneConstruction
RivetInspection
CautionsforReuseofBolts
CheckingforProperFastenerHardware

InspectionIntervals
WhentoInspect

BasicStructureBehavior
WheretoLook
Tension,Compression,andBending
Shear
DeflectionandCamber
Buckling
EffectofWelding
StressConcentrationandFatigue
AttachmentsCreateDiscontinuities
SingleFailurepoints
ManufacturingQualityandFatigueResistantDesignDetails

TrolleyStructureBehavior
TrolleyStructureDesign
TrolleyDeflection

BridgeStructureBehavior
BridgeStructureDesign
BridgeStructureResponsetoLateralLoadsandSkewing

ExamplesofCraneStructureDamage

References

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29
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32
34
34
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37
37
37
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42

1.0Introduction

1.1 Purpose

This guide provides a comprehensive set of recommendations for structural inspection of

overhead bridge cranes and trolleyhoists. Emphasis is placed on knowing where to look for
structuraldamage.Basicconceptsareintroducedforidentifyinghotspotsonthestructure,
andareaspronetofatigue.Thisguideisintendedforplantmaintenancepersonnelandcrane
service technicians who are responsible for periodic, visual structural inspections. This guide
will also be useful for entry level engineers and experienced engineers who are new to field
inspection.

Because structures are so reliable, it is easy to lose sight of their fundamental importance.
Failure to complete overhead crane and hoist inspections and proper equipment
maintenancecouldleadtoseriousinjury,deathordestructionofproperty1.

Implementationofacomprehensiveanddisciplinedinspectionplanhasthefollowingbenefits:

Reducedchanceoffatalityorinjurytopersonnel.
Reducedliabilityexposure.
Improvesequipmentproductivity.
Prolongsequipmentservicelife.
Ensurescompliancewithlaws,codes,andstandardsincluding:OSHA,ANSI,andASME.

1.2 Scope

Thisguideisforoverheadbridgecranestructuresincluding:

Bridgegirders.
Bridgeendtrucks,endties,equalizersaddles,sillbeams.
Platforms,ladders,stairs,cabs.
Boltedandweldedconnections.
Trolleyframes,trolleyendtrucks.

1.3 LimitationsofthisGuide

This information is not a substitute for prevailing inspection standards for cranes and
structures, or recommended inspection procedures provided by original equipment
manufacturers.

Thisguideisintendedtosupplementthetrainingandexperienceofpersonnelwhoare
alreadyqualifiedtoperformstructuralinspectionsofoverheadcranes.

TheCrane,HoistandMonorailAlliance,anOSHACooperativeProgram,FactSheetNo.1,ProperInspectionand
MaintenanceofOverheadCranes,http://www.mhia.org/industrygroups/osha

Page4of43

Duetothewidevarietyofcraneapplicationsandequipmentconfigurations,thisguide
canonlyprovidegenericguidance.Inspectionprovisionsforspecialapplicationsmay
not be addressed here. Special applications not addressed here include: under
running cranes, patented track systems, stacker cranes, jib cranes, portal cranes,
gantrycranes,packagedtrolleyhoists,cranerunways,andbelowthehookequipment.

2.0OrganizationandPersonnel

2.1 ImplementationofaDisciplinedPlan

Thefirststepindesigningahighqualityinspectionprogramistocreateacontrolleddocument
manualcontainingworkinstructionsandprocedures.Themanualshouldbealivedocument
thatiscontinuouslybeingimproved.Manualsfacilitateasystematicandrepeatableapproach,
and set definite standards. Manuals also facilitate seamless transitions during changes in
personnel. They help train new people, and identify existing plans to new management
personnel.Ataminimum,themanualshoulddefinethefollowing:

Personnelresponsibilitiesandauthorities.
Minimumrequirementsfortrainingandcertificationofinspectors.
Provideinspectionformscustomizedforvariouscranesintheplant.
Standardsfordocumentationandrecordkeeping.
Wheninspectionsshallbemade.
Minimuminspectionintervals.
Levelofdetailtobecarriedoutforvariousinspectionintervals.
Criteriaforreportingsuspectandproblemareastotheresponsibleengineer.

Theentireprogramshouldbecloselymonitoredandsupervisedbyanengineerwhoisqualified
to design and inspect structures. Each inspection should be reviewed and approved by the
responsibleengineer.Toensurethatinspectionsaremeetingminimumqualitystandards,the
responsible engineer should perform inspections of recently inspected cranes (periodically at
randomintervals).

For longinterval inspections of major process cranes, hire a consulting engineer to do the
inspection. It is important that the selected firm specializes in inspection and design of
overheadmaterialhandlingequipment.Byperiodicallyhiringanoutsideexpert,itprovidesa
goodcheckonthequalityofyourinhousesystem.

2.2 PrerequisitesforaQualifiedInspector

Onlyproperlytrainedandqualifiedpersonnelshouldperforminspections.Aformaltraining
andcertificationprogramshouldbeimplementedtoensurethatinspectorsarequalified,and
remain qualified. For additional guidance on minimum requirements for crane inspectors,

Page5of43

refer to CMAA Specification No. 782002, Standards and Guidelines for Professional Services
PerformedonOverheadandTravelingCranesandAssociatedHoistingEquipment.

2.3 RecommendedInspectionTeam

Theinspectorshouldhaveanassistantpresentatalltimes.Assistingtheinspectorisidealfor
trainingandqualifyingnewinspectors.

Primarydutiesfortheassistant:

Monitortheimmediateareaforhazards.
Operatetheaerialplatform.
Assisttheinspectorbytakingnotesandmeasurementsasrequired.
Handletools,flashlight,camera,notepads,etc.
Communicatewithpersonnelonthefloorandelsewhereviaradio.
Intheeventofaninjurytoeithertheassistantortheinspector,theotherwillprovide
assistance.

3.0InspectionSafety

3.1 PreInspectionSafetyPlan

Beforestartingtheinspection,followthesafetyproceduresrequiredbyyourcompany,OSHA,
andstateandlocalauthorities.Generallyrecommendedsafetyproceduresinclude:

Notifyplantpersonnel(inadvance)thataninspectionwilltakeplace.Personnelwho
worknearthearea,orpassthroughtheareashouldbenotified.
Locatethebridgeawayfromcraneactivityinthesameandadjacentcraneaisles.
Ifothercranesonthesamerunwaymuststayinserviceduringtheinspection,provide
ameanstopreventthemfromhittingthecranebeinginspected.
If the mainline conductor system must remain energized during the inspection, all
inspection personnel must remain aware of this hazard and stay clear of the
conductors.
Iftheinspectionrequirespersonnelmaneuveringandpotentialexposuretocraneson
anadjacentrunway,installaguardorabarrierorprovideothersafemeanstoprotect
theinspectorfromcontactwithadjacentcranes.
Removeallsourcesofstoredmechanicalenergyincludingsuspendedloadblocks.
Disconnect,tag,andlockoutallelectricalpowertothecrane.

3.2 SafelyManeuveringontheStructure

Safe,comfortable,andcloseaccessisrequiredtoallpartsofthecrane.Ifpossible,thecrane
should be moved to an area that has good lighting, comfortable temperature, and is away
fromproductionprocesses,andadjacentcraneactivity.

Page6of43

Inspectorsmaybestanding,sitting,kneeling,bending,squatting,climbing,orlayingdownto
facilitatetheinspection.Theinspectormusthavephysicalagilitytoclimbtallladders,walkon
partsoftherunway,andclimboverallpartsofthebridgeandtrolley.

Theinspectormustbeabletosafelymaneuverandpositionhimselfinareasthathavelimited
footingandspace.Onecommonlyencounteredexampleoflimitedfootingissteppingonto
runwaybeamswherenoplatformsexist.Dependingonthespecificbuildingdesignandcrane
location,accesstotherunwaymayberequiredtoexaminetheconditionofbridgeendtrucks,
end ties, sill beams, equalizer saddles, squaring plates, girder connections, and bumper
extensions.

3.3 IdentifyingHazards

Itisimpossibletocreatealistofallpossiblehazards,butafewcommonsenseguidelinesfor
safeinspectionsareofferedhere:

Neverrushthetask.
Nevermovetoalocationwhereyoucannotclearlyseethatyouwillhavesafefooting
andifrequired,stablehandholds.
Observe the condition of the walking surface and avoid walking on surfaces covered
withlubricantsordebris.
Continuouslymonitoractivitiesinallthreedimensionsofyoursurroundings.
Whenclimbingandmaneuveringonthestructure,bothofyourhandsshouldbefree
forgraspinghandholds.Taketimetothinkaboutyourmovementsinadvance.
Makesurethatothersknowwhereyouare.Dontassumethatothersareawareof
your nearby presence. When passing behind someone, be sure to announce your
presence.
Even if power is disconnected and locked out from the crane, its a good habit to
remainawareofexposedconductorsurfacesandnottouchthem.
Youshouldbeaccustomedtoheights.
Be familiar with the OSHA definition of a confined space. Never enter a confined
spacewithoutapermit.
Identifypotentialpinchpointsandlocationswhereyoucouldbecrushed.
Watchforunguardedopeningsinfloorsandhandrailings.

3.4 HighAmbientTemperatures:PrecautionsandPlanning

Special attention and planning are required for inspecting cranes in hot areas. Due to the
adverseenvironment,thesecranesmaynotreceivetheinspectiontimetheydeserve.Theair
temperature on melt shop cranes in a steel mill can exceed 140 Fahrenheit. The crane
structuremaybehot,andglovesarerecommendedformaneuveringonthestructureduring
aninspection.

Consider inspecting high temperature cranes at night, early morning, or on cloudy days.
Whentemperaturesatthecraneelevationareextremelyhot,inspectiontimeisconsiderably

Page7of43

longer. When air temperatures are 120 to 140 F., inspection personnel should limit their
exposure time. Productive inspection time may be limited to 15 or 20 minute increments
beforedescendingtothefloorlevel,orenteringanairconditionedcaborcontrolroom.For
extremelyhotenvironments,60%cooldowntimeand40%inspectiontimemaybeusedasa
roughguideforestimatinginspectiontime.

3.5 PersonalSafetyEquipment

In addition to safety equipment mandated by OSHA, and if not already furnished by your
company,thefollowingarticlesshouldbeconsidered:

Twowayradio.
Dustmask.
Coverallswithzipperpockets.
Gloves(lightcanvastype).

4.0PreparationforInspections

4.1 CleaningtheStructure

Thesurfaceofthecraneshouldbecleanbeforestartingtheinspection.Forhighproduction,
process cranes, it iscommon for structuralelements to be obscured by a thickcoat of dust
andlubricants.Areascoveredbythicklayersofundisturbeddebris,mayindicatelongterm
neglectofinspection.

Over time, accumulated debris may harden into a thick crust that requires vigorous
mechanicalcleaning.Thenatureandextentofthedebrismustbeevaluatedforplanningthe
cleaningmethod,equipment,andmanpower.Donotunderestimatehowtightly thedebris
maybebondedtothesurfaces,crevices,andcornersofthestructure.Crevicesandcorners
are important areas of interest and must be thoroughly cleaned for inspection. In extreme
cases,pneumaticchiselingisrequiredtoremovedebris.

When it is not feasible to clean the entire crane before an inspection, it becomes more
important for the inspector to know where to look. The inspector must have a basic
understandingofstructures.Refertosection10foranoverviewofstructurebehavior.

4.2 AerialWorkPlatforms

An aerial work platform (or manlift) is required for hard to reach areas, including the
underside of the trolley and bridge girders. When planning for the aerial lifting apparatus,
considerthefollowing:

Identifyareasofthecranethatcanbesafelyinspectedwithoutanaeriallift.
Determinethehighestelevationandfarthestlateralreachrequiredfortheapparatus.

Page8of43

Considerwherethebaseoftheapparatusmustbemaneuveredtoreachthelocations
previouslyidentified.
Consider the travel path required to bring the apparatus through the plant, into the
aisle,andunderthecrane.
Useatrainedequipmentoperator.
Theaerialliftshouldbeoperatedbysomeoneotherthantheinspector.

4.3 OtherInspectionParaphernalia

Thefollowingitemsarerecommendedforlocalcleaningareasofinterest,markingsuspected
areas,anddocumentingareasforreports:

Camera.Useacompact,rugged,goodqualitycamera.Thecameramustbesuitable
forsharpcloseupsandshouldbeweatherproof.
Mini audio recorder. For dictating verbal descriptions that can be transcribed and
editedforreports.
Mirror.Asmallinspectionmirrorwithanextensionhandle,ora4x5acryliclocker
mirror.
Flexible borescope with optical or video display. A borescope allows closeup
inspectionofinaccessibleareassuchastheinteriorofboxgirders,endtrucks,andend
ties.
Paintstick(whiteoryellow)foridentifyingareasofinterest.
Extrapensandpencils.
Notepadforsketches,measurementsandnotes.
Blackmarkerforidentifyingareasofinterest.
Flashlight.Useagoodqualityflashlight(Magliteorequalquality).
Puttyknifeforscrapingdebristocleanareasofinterest.
Smallwirebrushforcleaningareasofinterest.
Tapemeasure.A16or25isadequate.Useawidebladetapemeasureformaximum
reachtoinaccessiblelocations.
Ballpeen hammer. Asmall (2 oz. or 4 oz.) hammercan be used for tapping on the
face of girder webs or other weldments to determine the locations of internal
stiffeners.Ahammercanalsobeusedtotapontheheadsofrivetsandboltstohelp
determineiftheyarelooseorbroken.
Torpedolaserlevelwithmagneticbaseorasmalllasercrosslevel.Astraight,level
reference line is required to measure the elevation profiles of trolley rails. Use the
brightest laser available (at least 100 working range) so the beam will be visible for
usewithatapemeasure.

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5.0GeneralInspectionGuidelines

5.1 GettingStarted

Starttheinspectionatthetopandworkyourwaydown.Thismeansstartingatthetopofthe
trolley.Thenproceedtothetopofthebridge.Inspectasmuchaspossiblewithoutusingthe
aeriallift.Noteareasthatarenotaccessibleforlaterviewingfromtheaeriallift.

5.2 WheretoLook

Overheadcraneshavethesamebasicconfigurations,andagenericlistofbridgeandtrolley
inspectionpointsissuggestedinsection6and7.Sincetherearesomanydesignvariations
forcustomcraneapplications,itisnotpossibletoidentifyallpointsofinterestinthisguide.A
basic understanding of structure behavior canhelp to identify other inspection points. This
guide includes a section on basic structure behavior to help technicians identify points of
interestthatmaynotbelisted.Acustomlistofinspectionpointsshouldbemadetosuiteach
craneinyourplant.

5.3 OtherInspectionGuidelines

Whenacrackisdiscoveredatonelocation,allothersimilarortypicallocationsmust
becarefullyinspected.Oneexamplewouldbewhenacrackisdiscoveredinthegirder
webadjacenttoplatformconnections.Theremaybeseveralotherconnectiondetails
identicaltowheretheoriginalcrackwasdiscovered.Itisefficienttofocusattention
ontypicallocationsthatarediscovered.

Aviewingdistanceofnotmorethantwofeetisrecommendedforvisualinspections.

Routinelyinspectareasthathavebeenrepairedormodified.

Previously repaired areas that use patch plates present a problem for inspection.
Thepreviouslyrepairedareacannotbeinspectedbecauseitiscoveredbythepatch
plate.Patchplatedareasshouldbereportedtotheresponsibleengineerasdamaged
areas that require action. The patch plate should be removed and an engineered
repair should be made. The engineered repair procedure should be completed by a
qualifiedstructuralengineer.

All areas of structural damage must be documented and reported to a qualified

structuralengineerforassessmentbeforeplacingthecranebackintoservice.

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6.0TrolleyStructureInspections

Item
1

4
5

6
7
8
9

10

11

12
13
14

Table6.1:TrolleyStructureInspectionPoints
Description
PointsofInterestforInspection
Wherestiffenersarewelded togirtsorwhere
Mainandauxiliaryhoistload
othermembersareweldedonornearthelower
girts:bottomflange.
flangeofgirt.Checkweldsandadjacentbase
metal.
Mainandauxiliaryhoistload
Edgesofmembersadjacenttorunningwireropes.
girts:bottomedgesof
Lookforscuffing,erosion,andsawingaction
members.
fromwireropecontactwithstructure.
Weldsandadjacentbasemetalwheregirtsare
weldedtoendtrucks.Whenthedepthofthegirt
Mainandauxiliaryhoistload
memberislessthantheendtruck,checkfor
girts:endconnections.
flexingofthewalloftheendtruckatthebottom
edgeofthegirt.
Sheaveboxes
Weldsandbasemetal.
Similartoitems1and2.Lookforotherload
Otherloadgirts.
carryinggirts,includingsupportsforhoistdrums,
drumpinionsupports,andequalizersheaves.
Whereloadgirtsare weldedtotheendtruck,
Trolleyendtrucks:frame
especiallyonornearthelowerflange.Check
connections
weldsandadjacentbasemetal.
Trolleyendtrucks:wheel
For90and45MCBtypewheelassemblies,check
assemblymounting.
forcrackingatstiffenersandcorners.
Trolleyendtrucks:bumper
Weldsandbasemetal. Checkboltedconnections
attachments,bumperchocks.
persection8.0.
Trolleyendtrucks:bolted
Checkboltedconnectionspersection8.0.Check
splicefortrolleyframe.
weldsandbasemetalforconnectionplates.
Damagefromjacking onedgesofendtruck
Trolleyendtrucks:jackingpads flangesordirectlyonthebottomflangeplateof
orjackingbrackets.
theendtruck.Checkweldsandbasemetal
aroundjackinglocations.
Lookforcracksatcornersornotches.Checkwelds
Trolleydrivemounting
andbasemetalwherebracketsareweldedtothe
brackets.
trolleyframe.
Lookforcracksatcornersornotches.Checkwelds
Hoistreducersupportbracket.
andbasemetalwherebracketsareweldedtothe
trolleyframe.
Torquearmbracketsfor
Inspectbracketarmandweldtoendtruck.
hollowshafttrolleyreducers.
Bearingsupportsfordrum,
Checkweldsandbasemetalatconnectionto
bearingsupportforexternal
trolleyframe.
drumpinion.

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15

Handrails,guardrails,ladders,
platforms,stairs,cantilevered
platformsupports.

16

Cabattachments,cantilevered
cabsupportstructures.

17

Towarmforconductors.

Checkweldsandbasemetal.Checktightnessof
allfasteners.Lookforloose,broken,ormissing
bolts.Checkforproperfastenerhardware.Check
formissingordamagedgatesorchains.Checkfor
sharpedgesorcornersnearpersonnelpassage
ways.
Checkboltedcabconnectionspersection8.0.
Weldsandbasemetalforconnectionplates.For
cabssuspendedoutsidethebridgegirder,inspect
thecantileveredsupportstructure.
Checktowarmandtheboltedorwelded
connectiontothetrolleyframe.

Figure61
Seesection6.1fortrolleyinspectionpoints.

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Figure62
Viewunderneathtrolley, showingtypicalstructureinspectionpoints.

7.0BridgeStructureInspections

Item

2
3
4

Table7.1: BridgeGirderInspectionPoints
Description
PointsofInterestforInspection
Looseandmissingsplicebolts,checkforimproper
hardware.Jointbarboltshavestraightshankstothehead
Trolleyrailbolted
andaremadeperASTMA449.NutsareperA563gradeB.
splices.
A325boltsandnutsmayalsobeused.Check/tighten
spliceboltsevery3months.Fastenersshouldincludea
helicalspringlockwasher perAREAspecification.
Trolleyrailclampsor
Checkforfracturedclamps,crackedwelds,looseand
clips.
brokenbolts.Seenote2.
Trolleyrail:erosion
Underthebaseoftherail,checkforerosionofthegirder
underrailbase.
flangeorthewearplate(ifpresent).Seenote3.
Checkfortopflangecrackingattheedgeoftherailbase.
Trolleyrailsupport.
Checkfortackweldsattheedgeoftherailbase.Seenote
4.

Page13of43

Trolleyrailelevations.

Girdercamber.

Torsionboxrail
support.

Trolleyendstops.

Bridgedrivemounting
bases.

10

Lineshaftbearing
supports.

11

Platformconnections
togirder.

12

Festoon/span
conductorsupports.

14

Pendantfestoon
supports.
Rivetedgirders.

15

Girderwelds.

13

Fromoneendofthetrolleyrail,sightdowntherailhead.
Sightovertheentirelengthoftherailfordipsinelevation.
Checkforlocaldeformationofthegirderflangethat
supportstherail.Dishingordipsinthegirderflange
mayindicatebrokenintermediatediaphragmsorbroken
welds.Checkthisconditionatbothtrolleyrails.See
Figure71.
Positionthetrolleyattheextremeendofthebridge.From
theendofthebridgeoppositethetrolley,positionyour
lineofsighttobeinlinewithoneofthetrolleyrails,and
nearlyatthesameelevationastherailhead.The
elevationoftherailnearthemiddleofthebridgespan
shouldbevisiblyhigherthanneartheends(positive
camber).Ifconditionsdonotpermitthisobservation,orif
positivecamberisnotobserved,detailedmeasurements
arerequired.Repeattheprocedurefortheothertrolley
rail.Seenote6.
Forboxgirdersthatsupportthetrolleyraildirectlyover
theinsidewebplate,checkforcrackingofthegirder
flangetowebweld.
Welds,basemetal,andattachmenttogirder.Confirmthat
trolleybumpersmakesimultaneouscontactwiththeend
stopsatbothendsoftrolleytravel.
Checktheconditionofgirderwebwherebridgemachinery
isattached.Lookforoutofplanedeformationofthe
girderweborcrackingofthematerialadjacenttowhere
barsarewelded.SeeFigure72.
Checktheconditionofgirderwebwherebearingsupports
areattached.Lookforoutofplanedeformationofthe
girderweborcrackingofthematerialadjacenttowhere
barsarewelded. SeeFigure72.
Checktheconditionofgirderwebwhereplatformsupport
gussetplatesareattached.Lookforoutofplane
deformationofthegirderweborcrackingofthematerial
adjacenttogussetattachments.SeeNote11.SeeFigure
73,74,75.
Checktheconditionofgirderwebwhereconductor
supportsareattached.Lookforoutofplanedeformation
ofthegirderweborcrackingofthematerialadjacentto
wheregussetsorbarsarewelded.
Checksupportmembers,weldedandboltedconnections.
Inspectrivetedconstructionpersection8.
Longitudinalflangetowebwelds.Inspectthelocationof
shopsplicesforwebandflangeplates.Seenote15.

Page14of43

16

Girderlowerflange
andweb.

17

Walkingirders.

18

Boltedgirdersplices.

19

Girderconnection
notch.

20

Equalizersaddles.

21

Platformtruss.

Insideedgesofthebottomflanges,includingtheadjacent
webareafordamageduetowireropeabrasion,impact
fromloadblocks,orliftingbeams.Forcraneswithlifting
beams,alsochecktheconditionofthebottomsurfaceof
thebottomflangeforimpactfromtwoblockingaccidents.
Ifropeguardsarepresent,inspecttheropeguard
attachmentstothegirder.
Weldsandbasemetalforintermediateandfulldepth
diaphragms,girderwebs,girderflanges.Seenote17.
Checkboltsintopandbottomflangesplicesandweb
splicespersection8.
SeeFigure7.6. Checkweldsandbasemetalatcornersand
whereweldsmeetatcorners.Checkweldswheregirder
websareweldedtohorizontalshelfplate.
SeeFigure77.Checkweldsandbasemetalwherethe
verticalsaddleplatesareweldedtothehorizontalsaddle
plate.Alsocheckweldedconnectionstogirder.
Weldsandbasemetalforalltrussmembersandgusset
plates. SeeFigure74.

7.1 BridgeGirderInspectionNotes

ThefollowingitemnumberscorrespondtotheitemsinTable7.1.

2.
Railclipsresistasmallupliftforcefromthetrolleyrail.SeeFigure71.Theraildeflects
downwarddirectlyunderthetrolleywheel.Oneithersideofthetrolleywheel,therail
reactsbydeflectingupward.Theupwardforceisresistedbytherailclips.Theclipsor
weldsmaybreakduetofatigue.

3.
Erosionofgirderflangematerialundertherailbaseismorelikelyinwet,corrosive,or
abrasiveenvironments.Theerosioniscausedbytheslidingandcreepingactionofthe
railrelativetothegirder.Thisactionisnormalandcannotbepreventedunlessarail
padisused.Erosionundertherailsisaveryslowprocess.Itmaytakeseveralyears
beforemateriallosscanbeobserved.

4.
Duetohighcarboncontent,ASCEcranerailsarenotreadilyweldable.Tackwelding(or
anyotherwelding)oncranerailsmustberemovedbygrinding.NDTthegirderflange
basemetalforcrackingafterrailweldsareremoved.

6.
Whencambercannotbevisuallyobserved,elevationmeasurementsarerequired.The
preferredmethodistosetaselflevelinglaserlevelnearthecenterofthespanonone
of the girders. At 5 foot increments along the span, measure and record the vertical
distancefromthelaserlinetothetopoftherailhead.Measurementsforbothgirders
shouldbetakenfromoneinstrumentsetup.Alternately,asmalltorpedolaserlevel

Page15of43

can be used to obtain the rail camber elevations on each individual girder. With this
methodhowever,theelevationdifferenceofthegirderscannotbemeasured.

11.

15.

17.

Forcranesthatuseatrusstosupporttheoutsideedgeoftheplatform,theplatform
connections to the girder are prone to fatigue damage. See Figure 73. The bridge
girderdeflectsduetothetrolleyload,buttheoutriggertrussdoesnot.Theplatform
connectionthat frames into the girder web is forced to translate vertically relativeto
the truss end. The forced vertical translation causes a large bending action at the
platformconnectiontothegirder.Figures74and75showtypicalgirderwebcracks
nearthegirdertensionflangecausedbyoutofplaneflexingofthegirderweb.
Shopsplicesaresometimesdifficulttolocate.Theexternalappearanceofshopspliced
materialmayvarybyOEM.Shopsplicesmaybefoundbynotingsubtlechangesinthe
profile of edges and surface texture. This is difficult to detect under a thick coat of
paint.Bottomflange(tensionflange)splicesshouldhave beengroundflushwiththe
basematerialbytheOEM.
Beforeenteringawalkingirder,reviewandfollowapplicablesafetyrequirementsfor
enteringandworkinginconfinedspaces.

Figure71
Schematicillustrationofhowthetrolleyraildeflects.Theupwardforceproducedby
leveragefromthetrolleywheelisresistedbytherailclipsorclamps.

Page16of43

Figure72
Bridgemachinerysupports.
Checkgirderweb andwelds forverticalbarstoweb.

Page17of43

Figure73
Cranewithanoutriggertruss.Thediagonalmembersarepartofthetrussthatsupportsthe
platform,bridgemachinery,andfestoontrack.

Figure74

Thegirderwebiscrackedat

thetoeofthefilletweldfor

platformconnectionbar.

Figure75
ThisisacloseupviewofFigure74.Thearrowpointstotheendofthecrack.Thecrackis
propagatingtowardthebottomflangeofthegirder.Cracksinthebottomflangeofagirder
cancauseacatastrophicgirderfailure.

Page18of43

Figure76
GirderEndConnection

Figure77
Equalizedbogietruckswithrigidendtie

Page19of43

Item
1

2
3
4

5
6
7

Table7.2:BridgeEndTruckandEndTieInspectionPoints
Description
PointsofInterestforInspection
SeeFigure7.6.Checkboltedconnectionsforloose,broken,
Squaringplate
ormissingbolts.Looseboltsshouldberemovedand
connection.
replacedwithnewboltsofthesamegrade,size,andlength.
Seesection8 forboltedconnections.
SeeFigure77.Theendsoftherigidendtieareboltedto
Rigidendtie
thegirdersinonehorizontalplaneandtwoverticalplanes.
connections.
Seesection8forboltedconnections.
Compensatingendtie SeeFigure78forcompensatingendtieconnection. Check
connections.
boltspersection8.
Checkflangetowebwelds,checkweldsandbasemetalat
Sillbeams.
corners,abruptchangesingeometry,andwherewelds
meetatcorners.
For90and45MCBtypewheelassemblies,checkfor
Endtrucks:wheel
crackingatstiffenersandcorners.SeeFigure7.6.Check
assemblymounting.
weldforshoeplatetoendtruckweb.
Endtrucks:equalizer
Checkweldsandbasemetalaroundthedoublerplate
pinsupports.
supportingtheequalizerpin.
Torquearmbrackets
forhollowshaft
Inspectbracketarmandweldtoendtruck.
trolleyreducers.

7.2 BridgeEndTruckandEndTieInspectionNotes

ThefollowingitemnumberscorrespondtoTable7.2.

3. Compensatingendtiesshouldbeflexibleforbendingintheverticalplane,andrigidfor
bending in the horizontal plane. Improper design, crane service misapplication, and
runway misalignment can make compensating end ties prone to cracking, especially at
theirverticalendconnections.Thefatiguecracksarecausedbycompletereversalofthe
bendingstress.

Page20of43

Figure78
Boltedconnectionsforcompensatingendties

Page21of43

Item

Table7.3:BridgeMiscellaneousInspectionPoints
Description
PointsofInterestforInspection
Weldsandbasemetal.Checkboltedconnectionsper
section8.Lookforloose,broken,ormissingbolts.Check
Handrails,ladders,
forproperfastenerhardware.Checkformissingor
stairs,gates.
damagedgatesorchains.Checkforsharpedgesor
corners.
Checkcondition ofplatformdeck,decksupportmembers,
Platforms.
andweldedconnections.Checkboltedconnectionsper
section8.
Checkforbrokenmembersandbrokenwelds.Check
boltedconnectionspersection8.Bentmembersare
acceptableifatleast3clearanceremainsbetweenthe
Mainlineguard.
guardandnearestobstruction.Checkconditionofsafety
tieoffcables.Ifcablesarenotpresent,theyshouldbe
installed.
Checkforbrokenmembersandbrokenwelds.Check
Mainlinecollector
boltedconnectionspersection8.Checkconditionof
support.
safetytieoffcables.Ifcablesarenotpresent,theyshould
beinstalled.
Hangerconnectionsandcageframe.Checkladderper
item1.Checkforbrokenmembersandbrokenwelds.
Mainlinerepaircage.
Checkboltedconnectionspersection8.Checkcondition
ofsafetytieoffcables.Ifcablesarenotpresent,they
shouldbeinstalled.
Checkconditionofsafetytieoffcables.Itemsthatcould
falltothefloorshouldhavesafetycablesinstalled.These
Safetycables.
itemsinclude:mainlineguards,mainlinecollector
supports,bumpers.
Hangerconnectionsandcabframe.Checkforbroken
Operatorcabstructure
membersandbrokenwelds.Checkboltedconnectionsper
andsupports.
section8.Checkladders,stairsandhandrailsperitem1.

Page22of43

8.0HighStrengthBoltedConnections

8.1 BoltedConnections;DescriptionandFunction

High strength bolted connections are used for primary load path members including girders,
end ties, and bolted field splices. They may also be used for cab and platform connections.
High strength bolts are tightened to develop a high tensile stress in them which results in a
predictableclampingforceonthejoint.Theactualtransferofloadsthroughthejointisdueto
thefrictionforcedevelopedinthepiecestobejoined.

8.2 HowtoCheckforBroken,Damaged,andLooseBolts

Applypenetratingoiltothefastenerstobeinspected.Usingahandwrenchwithatleasta16
handle,applyfullefforttotightentheelement.Theelementtobeturned(eitherthenutorthe
bolthead)shouldbethesameelementthatwastightenedduringtheoriginalinstallation.The
turnedelementshouldhaveahardenedflatwasherunderit.Iftheelementturns,theboltis
consideredtobeloose.

Whenalooseboltisfound,itmustbereplacedwithanewboltorremovedandinspected.For
inspection,thoroughlycleantheboltandcheckfordamageincludingdeformation,elongation,
wear,cracks,orstrippedthreads.Elongationcanbedetectedbyusingyourfingerstoinstallan
unused nut on the bolt threads. If the nut stops turning after a certain point, the bolt has
elongatedandshouldbediscarded.

Primary connections are designed to resist the crane rated capacity (the live load) plus the
weightofthebridgeandtrolleystructure(thedeadload).Sincetheliveloadisusuallyseveral
times greater than the dead load, it is usually safe to remove one or two fasteners from a
connection containing several bolts under dean load only. Consult with a qualified person
before removing any fasteners. Do not release the crane for service until the replaced or
inspectedboltshavebeenproperlyinstalled.

Broken, damaged, and very loose bolts may be found using the hand wrench procedure
suggested here. The formal procedure for inspection of high strength bolted connections is
giveninRCSCSpecificationforStructuralJointsusingASTMA325orA490Bolts,(seereference
6).Theabovemethodispresentedasanalternativeforsituationswheretheformalmethod
cannotbeusedduetolimitedspaceorotherpracticalconsiderations.Consultwithaqualified
structuralengineertodetermineiftheformalmethodofcheckingbolttightnessiswarranted
foryourinspectionplan.

8.3 RivetedCraneConstruction

Manyrivetedcranesarestillinservice.Beforeelectricarcwelding,bridgegirders,endties,and
end trucks used builtup riveted construction, and some trolley frames consisted of large
castings.Whenproperlyinstalled,rivetsareveryeffectiveconnectorsforcranecomponents.
Duringinstallation,arivetissqueezedfromeachendcausingthebodyoftherivettoexpand

Page23of43

andcompletely(ornearly)fillitshole.Rivetsareinstalledafterheatingtoalightcherryred.
Whentherivetcools,itshrinksandprovidesaclampingforce.Eveniftheclampingforcewas
notgreatenoughtocarrytheload,thebodyboundrivetstillmaintainsjointalignment.

8.4 RivetInspection

Examinetheconditionoftherivetheads.Thefullcircumferenceoftherivetheadshouldbein
firmcontactwiththematerial.Usingasmallballpeenhammer,taptherivetheadatabout45
to the rivet axis. If the hammer impact sounds like a dull thud or if any movement is
observed,therivetisloose.Tightrivetswillhaveasolidringwhenhitbyahammer.Mark
thelooserivetswithapaintstickanddocumenttheirlocation.

8.5 CautionsforReuseofBolts

It may be tempting for maintenance and inspection personnel to simply retighten loose
fastenersonthespot,butA325boltscanonlyberetightenedonceortwice.Ifyoudontknow
how many times the bolt has been retightened after the original installation, it should be
replaced.Retighteninghighstrengthboltscausesthemtolosetheabilitytostaytight.A490
bolts shall not be retightened. In general, touching up or retightening previously tightened
boltswhichmayhavebeenloosenedbythetighteningofadjacentboltsisnotconsideredtobe
reuse.HighstrengthboltsshallbetightenedperRCSCSpecificationforStructuralJointsUsing
ASTMA325orA490Bolts,(seereference6).

There should be no excessive elongation of the bolt in the threaded area which would be
presentifthebolthadbeenovertightened.Theboltcanbereusedifthenutcanbeinstalled
by hand for the full thread length, and the bolt is not otherwise damaged. When in doubt,
replacetheboltwiththesamegrade,size,andlengthastheoriginal.

8.6 CheckingforProperFastenerHardware

Figure81showstypicalhardwareusedforhighstrengthboltedconnections.Wheninspecting
primaryboltedconnections,notethefollowing:

Confirm that high strength bolts are installed in connections for primary members,
including girders, end ties, and trolley splices. See Figure 82 for standard head
identificationmarksforhighstrengthbolts.

Hardenedflatwashersshallbeinstalledundertheturnedelement.

Lockwashersshallnotbeusedinhighstrengthboltedconnections.

When bolting to sloped surfaces such as Sbeam flanges and channel flanges, beveled
washersmustbeused.Figure83illustratesatypicalinstallationforbeveledwashers.

Page24of43

Figure81
Typicalhardwareforhighstrengthboltedconnections.
(FromReference11.)

Figure82
Standardheadidentificationmarksforhighstrengthbolts

Page25of43

Figure83
Exampleofbeveledwasherinstallation
(FromReference11)

Page26of43

9.0InspectionIntervals

9.1 WhentoInspect

Checktheoriginalmanufacturersmanualforrecommendationsaboutinspections.Ifacopyof
themanualisnolongeravailable,refertothefollowingreferencedocuments:

ASMEB30.22005,OverheadandGantryCranes(TopRunningBridge,SingleorMultiple
Girder,TopRunningTrolleyHoist)

OSHA29CFR1910.179(j)forOverheadandGantryCranes

CMAA Specification No. 782002, Standards and Guidelines for Professional Services
PerformedonOverheadandTravelingCranesandAssociatedHoistingEquipment

10.0BasicStructureBehavior

10.1WheretoLook

Knowledgeofwheretolookforstructuraldamageisveryimportantfortheinspector.When
inspectiontimeislimited,andthestructureiscoveredbydebris,knowledgeaboutwhereto
lookbecomesveryvaluable.Sincestructuresrespondtoloadsinpredictibleways,someof
themostlikelyplacestoinspectcanbeidentified.

Abasicunderstandingofcranestructurebehaviorgivesfocustotheinspection.Thissection
provides basic concepts and guidelines to help determine the locations most likely to have
damage.

10.2Tension,Compression,andBending

For beam members, look for cracks in the tension zone and at the end connections. See
Figure101.Forsimplebeams,thebottomsurfaceisintension.Themiddle2/3ofthelength
of the tension zone should be checked first. Material near the top surface of the beam is
compressed, and the bottom is pulled into tension. If there are cracks in the compression
zone, they will not grow. Cracks in the tension zone will grow, but the speed of growth
dependsonthemagnitudeoftheloading,andthenumberofloadingcycles.

Page27of43

10.3 Shear

InFigure101,thehighshearzonesarenearthebeamends.Failuresinthehighshearzones
aremorelikelytobesuddenandcatastrophic.Shearfailurescanoccurinboltedconnections
and welds. The connected base material can also fail by shear but usually the shear is
combined with tension and compression. Shear can be visualized as the tendency of the
materialtoslideonitself.Figure102illustratesthedifferencebetweenshearandtension.A
scissorscutspaperbyapplyingashearforce.Horizontalshearinabeamcanbeillustratedby
astackofboardsspanningbetweentwosupports.Whenyoupushdownonthemiddle,the
stackdeflectsandthesurfaceofeachboardslidesrelativetotheother.Thetendencyforthe
boardstoslideiscausedbyshear.

Figure101

Internalforcesanddeformationofasimplebeam

Figure102

Page28of43

10.4 DeflectionandCamber

There is a common misconception that deflection indicates weakness of a structure. A

structure can have low strength and little deflection, or high strength and large deflection.
Deflectioniscausedbystretchingand/orcompressingthematerial.Theactualdeformation
that causes visible deflection is too small to be seen with the unaided eye because it is
distributedoverthelengthofthemember.Localelongationorcompressionofthematerial
may only be a few thousandths of an inch long, but the cumulative effect is visible as
deflection. The beam assumes a bowed shape because the length of the top material gets
shorterandthebottombecomeslonger.

Sometimes paint will crack from these small deformations. Areas of cracked paint can
indicatehighstress,anddeserveacloselookduringaninspection.

10.5 Buckling

Somevisibledeformations/deflectionsarecausedbybuckling.Bucklingiscausedbyexcessive
compression.Inplatematerial,bucklingcanalsooccurfromexcessiveshear.Thesurfaceofa
buckled plate will appear wavy or rippled. Free edges of plates and bars are subject to
buckling.Whenviewedalongtheedge,thebuckledplateappearswavy.Forstraight(non
plate) members such as building columns or legs of a gantry crane, buckling appears as a
bowingofthenormallystraightmember.

10.6 EffectofWelding

In general, welding creates an internal, local restraint that creates biaxial and triaxial stress
and strain conditions. Triaxial stress can be visualized as a solid cube with a perpendicular
load applied to each face. Structural steel is very ductile, i.e., it will undergo a very large
deformationbeforefailing.Butwhensteelisloadedtriaxially(orbiaxially),itbehaveslikea
brittlematerial.Whenweldscool,theyshrinkinalldirections.Internalreactionforcesare
createdwhenweldsshrink.Thisisbecausethebasemetaloutsideoftheheataffectedzone
resiststheweldshrinkageforce.Oneexampleforthisiswhenthreeweldsmeetatacommon
cornerasshowninFigure108.Eachlineofweldshrinksinitslongdirection.Thepointatthe
corner is subjected to tension forces in three perpendicular directions. Since this corner
wouldbethemostlikelyspotforacracktoform,itshouldbeapriorityforinspection.Refer
to Figures 103 and 104 for common examples of welded connections that are prone to
fatiguecracking.Theseillustrationsalsoshowtheexpectedcrackpattern.Thisinformation
canhelptheinspectoridentifylocationsthataremostlikelytocrack.

Page29of43

10.7 StressConcentrationandFatigue

Cracking will eventually occur in hardworked cranes with poor engineering details and/or
poorweldquality.Inorderofimportance,keepaneyeonthefollowingconditions:

1) Previouslyrepairedareas.
2) Girderandendtieconnections.
3) Locationswherecyclicflexingofthinwalledelementsmayoccur.
4) Sharpcorners.
5) Weldedattachmentstothetensionflange.
6) Jaggedorflamecutedgesnotgroundsmooth.
7) Weldsthatmeetincorners.SeeFigure108.
8) Arcstrikes&tackwelds.
9) Abruptchangesinstructuregeometry(stressconcentrations).
10) Locationswherethestateofstressregularlyfluctuatesbetweentensionand
compression(stressreversals).

Page30of43

Figure103
Examplesofconditionsthatmayresultinfatiguecracking
(FromReference13)

Page31of43

Figure104
Examplesofconditionsthatmayresultinfatiguecracking
(FromReference13)

Page32of43

10.8 AttachmentsCreateDiscontinuities

InFigure105,thereisatackweldatthebottomoftheverticalconnectionplate.Thisisthe
mostlikelyplacewherethecrackstarted.Tackweldscoolrapidly,makingtheadjacentbase
metalhard,brittle,andpronetocrack.

InFigure105,stressisconcentratedatthecornersformedbythesquaringplateweldedto
thebottomflangeoftheendtruck.Thestressfieldmaybevisualizedasasetofstreamlines
analogoustofluidflowingthroughaduct.Figure106illustratestheanalogyforstressand
fluid flow. Abrupt geometry changes, inclusions, gouges, or notches create stress
concentrationsthatarepronetofatiguecracking.Figure107showshowthestressintensity
variesintheflange.Redrepresentsthehighestlevelofstress.

Figure105
Thebluearrowspointtoacrackthroughthebottomflangeofabridgeendtruck.Thiscrack
mayhavebeencausedbytheeffectofthetackweld(pinkarrow)combinedwiththestress
concentrationshowninFigure106.SeeFigure76foraviewofthecompleteconnection.

Page33of43

Figure106
Lookforsharpcorners,notches,andabruptchangesingeometry

Figure107
Thisisaqualitativeillustrationofincreasedstresscausedbyasuddenchange
inthegeometryoftheloadpath.Theredareasindicatethehigheststress.

Page34of43

Figure108

Atriaxialstressconditioniscreatedfromlongitudinalshrinkageofthree

weldsthatmeetatacorner.

10.9SingleFailurePoints

Be able to recognize single failure points. Look for areas in the main load path where no
redundancyexists.Theloadpathisredundantifthefailureofoneelementdoesnotcause
completefailure.Redundantloadpathshaveabackupstructurethatcansupporttheload.
Achainisanexampleofanonredundantstructure.Ifonelinkinthechainfails,theentire
chainhasfailed.Aredundantstructureislikeaparallelcircuit,anonredundantstructureis
likeaseriescircuit.Inspectionprioritiesshouldbeforelementsofthemainloadpaththatare
singlefailurepoints.

10.10ManufacturingQualityandFatigueResistantDesignDetails

Preferenceshouldbegiventocranebuildersthathaveaproventrackrecordfordesignand
manufacture of hardworked cranes. The crane vendor must have knowledge of the
application,andexperiencewithfatigueresistantdesign.

High quality welding is important for dynamically loaded crane structures. Geometric
imperfections such as undercut, porosity, slag inclusions, incomplete fusion, craters, melted
corners,andhydrogenentrapmentcreatestressconcentrations.Theseflawsmaycausethe
adjacentmaterialtoyieldandcrack.

Page35of43

11.0TrolleyStructureBehavior

11.1TrolleyStructureDesign

Thetrolleystructureisaframeworkofbeams.Figure111showstheconstructionofasimple
trolleyframe.EachbeammemberintheframebehavesasshownisFigure101.Locations
withthehighesttensionandshearstressshouldbeinspected.Thehighesttensionstressis
located on the bottom surface of each member, at the midpoint of its length. The highest
shear stress is at the end of each member. The maximum shear stress in the girt is at the
weldedconnectiontotheendtruck.

Figure111

Illustrationofasimpletrolleyframe

Page36of43

11.2TrolleyDeflection

When loaded, the trolley frame will deflect as shown in Figure 112. Each girt that spans
betweentheendtruckswilldeflectasshowninFigure112.Whengirtsdeflect,theirends
rotateandthiscausesthetrolleyendtruckstotilttowardeachother.Thealignmentofhoist
machinerymaybeadverselyaffectedifthetrolleyframeistooflexible.Thisisespeciallytrue
fortrolleyframeswitharelativelylargespanbetweenthetrolleyrails.

Figure 11-2

Page37of43

12.0BridgeStructureBehavior

12.1BridgeStructureDesign

Viewed from the top, the bridge structure is a rectangular frame with rigid corners. The
bridge girders support the trolley load by bending in a vertical plane between the runway
rails.Theendtrucksorendtiesalsobendinaverticalplane.Forverticalloading,thebridge
structurebehavessimilartothetrolleyframeshowninfigure112.Thebridgeendtruckstilt
towardeachotherwhenthegirdersbend.

12.2BridgeStructureResponsetoLateralloadsandSkewing

The purpose of the bridge frame is to keep the end trucks parallel. See Figure 121.
Unbalancedaccelerationsfromthebridgedrivesandlateralbridgewheelforcesfromtracking
causetheframetoskew.Lateralgirderbendingfromtrolleyinertia(andwindloads)along
withskewing,causethecornersoftheframetorotate.Thecornerrotationsteersthewheels
intothesideoftherailandtrackingperformanceisaffected.Thebridgegirdersandendties
(orendtrucks)musthaveenoughstiffnesstopreventexcessivecornerrotationoftheframe.

Figure 12-1

Page38of43

13.0ExamplesofCraneStructureDamage

Figure131

Thespanforthisbridgewasincreasedbyinsertingadeepersectionatthecenterofthenewspan.

The
dashed lines show the original girder. The horizontal dashed lines show where the original
girder
flange overlaps the web of the new section. The splice at the other end of the added

sectiondidnothaveaflangeoverlap,andthisiswherethefailureoccurred.Theflangeoverlap

creates
a transition for the sudden change in girder depth. Without the flange overlap, the

reactionforceinthebottomflangeoftheoriginalgirderdoesnothaveenoughofananchor.In

thiscase,thelowerflangeforcewasdistributedintothediagonalflangeplateandthewebofthe

addedsection.Theweldedjointintheoverlapbetweentheflangeoftheoriginalsectionandthe

webofthenewsectionmustbelongenoughtocarry100%oftheforceinthebottomflangeof

theoriginalsection.

Page39of43

Figure132
ThisisacloseupofFigure141showingtypicalcrackingatthesplicebetweenthe
originalandaddedsection.Theoriginalgirderflangewasterminatedabruptlyand
weldedtothediagonalflangeoftheinsertedsection.

Figure132
Itislikelythatthecrackstartedattheflangesplice,andthen
propagatedintotheweboftheinsertedsection.(FromFigure141)

Page40of43

Figure133
ThisisacloseupfromFigure141showingthecrackpropagatingintothewebplate
oftheinsertedsection.Aholewasdrilledattheendofthecracktostop
propagation.Therespannedcranehadbeeninserviceforabout5years.

Figure134
Theseverticalbarssupport
the bridge drive for a high
productioncrane.Asimilar
configuration is shown in
Figure 72. The bars were
trimmed to install the
grease lines. The cutting
created a notch at the
corner which initiated a
crack that propagated into
the girder web. Due to
multiple repairs that could
nolongersupporttheload,
largesectionsofthegirder
webwerereplacedandthe
drive mounting was re
designed.

Page41of43

Figure135

This is a bridge girder looking up from

below. The vertical edge of a full depth
diaphragmisshown.Thisgirderwasbeing
usedforaclassFbuckethandlingcrane.
The girders were in service only one year
beforetheyfailed.Thisfailurewasdueto
improper welding and detailing. The
girder web consisted of individual plates
welded between full depth diaphragms.
The vertical edges of the web segments
were connected to the full depth
diaphragms by intermittent fillet welds.
For box girders, most of the bending is
carried by the flanges, but web material
neartheflangesissubjectedtonearlythe
same strain. In this case the strain was
tensilenearthebottomflange.Thetensile
force in the web was carried by a single
sided fillet weld to the diaphragm. This
causedacyclicandeccentricloadingabout
the throat of the weld that resulted in
rapidfailureoftheweld.Thecrackedweb
welds propagated into the lower flange
which caused a complete failure of the
girder.

Page42of43

1.
2.

3.
4.

5.

6.

7.

8.

9.

10.

11.
12.

13.

14.

14.0References
OmerW.Blodgett,DesignofWeldedStructures,JamesF.LincolnArcWeldingFoundation,
Cleveland,Ohio,1976.

Kulak, Fisher, Struik, Guide to Design Criteria for Bolted and Riveted Joints, American
InstituteofSteelConstruction,Chicago,Illinois,2001.

AmericanInstituteofSteelConstruction,SteelConstructionManual,9thed.,Chicago,1989.

American Welding Society, Specification for Welding of Industrial and Mill Cranes and
OtherMaterialHandlingEquipment,ANSI/AWSD14.1:2005,Miami,Florida,2005.

American Welding Society, Structural Welding CodeSteel, ANSI/AWS D1.1:2010, Miami,

Florida,2010.

ResearchCouncilonStructuralConnections,SpecificationforStructuralJointsUsingASTM
A325orA490Bolts,AmericanInstituteofSteelConstruction,Chicago,2004.

Charles G. Salmon, John E. Johnson, Steel Structures, Design and Behavior, Intext
EducationalPublishers,NewYork,NY,1971.

U.S.DepartmentofTransportation,HighStrengthBoltsforBridges,reportNo.FHWASA
91031,May,1991.

American Society of Mechanical Engineers, Overhead and Gantry Cranes (Top Running
Bridge,SingleorMultipleGirder,TopRunningTrolleyHoist),ASMEB30.22005,NewYork,
NY,2005.

OccupationalSafety&HealthAdministration,29CFRPart1910.179OverheadandGantry
Cranes.

AmericanInstituteofSteelConstruction,DetailingforSteelConstruction,Chicago,1983.

Crane Manufacturers Association of America, Inc., CMAA Specification No. 782002,

Standards and Guidelines for Professional Services Performed on Overhead and Traveling
CranesandAssociatedHoistingEquipment,Charlotte,NC,2002.

American Institute of Steel Construction, ANSI/AISC 36005, Specification for Structural

SteelBuildings,Chicago,2005.

S. Timoshenko, Strength of Materials, Part II, 2nd edition, D. Van Nostrand Co., Inc., New
York,1941.

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