CRANE SAFETY ASSESSMENT OF DESIGN CRANE RISK

ASSESSMENT WORKING PERIOD (DWP) ASSESSMENT

Cranes — Monitoring for crane design working period

ISO 12482 & AS 2550.1
HAMIDREZA HOJAT
CRANE AND HOIST DESIGNER
INSPECTION, ASSESSMENT, SERVICE AND REPAIR
EMAIL: J.HOJJAT@GMAIL.COM
LinkedIn: linkedin.com/in/hamidreza-hojat-14a918198

Author Profile:

Senior Mechanical Design Engineer with over 9 years of experience in steel

structure, crane and hoist industries (Overhead, Gantry, Jib, Underslung and Wall
cranes, double-girder and single-girder hoists). Considerable working experiences in
Machines design, Steel Structures calculation, Solution Engineering, and Mechanical
Calculations. Excellent communicator with the ability to explain complex design
ideas and concepts effectively. Skilled engineering leader with the ability to build
and motivate high-performing engineering team. Proficient in AUTOCAD,
SOLIDWORKS, ANSYS WORKBENCH, CATIA, ARTCAM, MATHCAD. Skilled
in English as a Second Language (ESL). Certified as a Professional Mechanical
Engineer by Engineers Australia (EA).

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 CRANE SAFETY ASSESSMENT OF DESIGN CRANE RISK
ASSESSMENT WORKING PERIOD (DWP) ASSESSMENT

A INTRODUCTION

A.1 GENERAL

Cranes are designed for a finite lifetime duty, which is specified in load cycles and load
spectrum and is not principally related to calendar working time. Classification of crane duty
provides the crane owner a means to specify the intended duty in order to achieve the
intended useful operational lifetime of the crane.
Typically the operational period for industrial cranes is from 10 to 20 years. However, a
specified crane classification may be related to any calendar time depending on the
application, e.g. 5 to 10 years for a special limited use or 40 years for a long-term
investment.
Monitoring of crane use does not in any way change requirements for periodic inspections
of the cranes, independent of whatever type of instruments are used for the monitoring.
Neither does it remove the requirement for regular maintenance of cranes. Inspections and
monitoring of use are methods, which complete each other, giving different information of
the condition.
The design working period (DWP) calculation in in this report is based on the ISO
12482:2014, and is derived from the design classification of cranes and is not to be
considered as a guaranteed operational period in any respect. Due to the probabilistic nature
of metal fatigue and other influencing factors, premature failures during the DWP cannot be
ruled out. However, the DWP represents a reliable estimate of a safe operational period of
the crane, with due consideration to specified design regulations and standardized design
safety factors.

A.2 THE PURPOSE OF THE ASSESSMENT OF DWP

The purpose of the assessment of DWP is to estimate accumulated duty of the crane and
assess its remaining life. The DWP calculation shall cover both the crane as a whole
(structures) and the mechanisms.
It is assumed that:
--- all periodic inspections scheduled for the crane have been carried out,
--- any damage suffered during the operation is recorded and appropriately repaired, and
--- maintenance work, as well as replacement of worn parts, is carried out in accordance
with the manufacturer’s instructions.

A.3 DWP CALCULATION METHOD

The applied DWP calculation method should follow the specification and classification of
the original design Standard, as closely as possible. ISO 12482-1 give DWP calculation
methods for cranes classified and designed in accordance with ISO 4301-1.

A.4 DESIGN DATA

Pmax = rated capacity Pmax ≔ 40 tonne

PA is the sum weight of the fixed and non- PA ≔ 3 tonne

fixed load lifting attachments;

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 CRANE SAFETY ASSESSMENT OF DESIGN CRANE RISK
ASSESSMENT WORKING PERIOD (DWP) ASSESSMENT

H = Height Of Lifting H≔3 m

m
Vh = Hoisting Speed Vh ≔ 2.0 ――
min

Ls_yrs = Structure Lifetime in years Ls_yrs ≔ 25

Lm_yrs = Mechanisms Lifetime in years Lm_yrs ≔ 10

Crane Design Group A ≔ “A4”

Crane Design Class of Utilization U ≔ “U4”

Q “Q1”

Crane Design Load of Spectrum Class Q ≔ “Q2”

Mechanism Design Classification M ≔ “M5”

Mechanism Design Class of utilization T ≔ “T5”

Mechanism Design Load of Spectrum Class L ≔ “L2”

A.5 ACTUAL DATA

ACTUAL TOTAL NUMBER OF WORK CYCLES AT A POINT OF INSPECTION

T
Ni = number of load cycles that occur at the N ≔ [[ 0 2000 260 200 200 494 ]]
individual load levels

Ca = is the actual total number of work

cycles at a point of time of inspection = ΣNi

length ((N))
Ca ≔ ∑ N = 3.154 ⋅ 10 3
i
i=1

Pi = individual load magnitudes (load levels)

characteristic of the duty of the crane.

P T = [[ 0 8 16 24 32 40 ]] tonne

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 CRANE SAFETY ASSESSMENT OF DESIGN CRANE RISK
ASSESSMENT WORKING PERIOD (DWP) ASSESSMENT

B- DWP CALCULATION FOR CRANES DESIGNED TO ISO 4301-1

B.1 GENERAL

Two basic duty factors and the crane classification as a combination of the two duty factors
are given in the applicable Part of FEM 1.001, as follows:

1. Number of operating cycles ( U ), grouped into classes “U0” to “U9” .

2. Load spectrum factor ( Kp ), with spectrum Classes Q1 to Q4 .

Group classification of the crane into Classes A1 to A9 is derived as a combination of the

two duty factors U and Q.

The two duty factors are of equal relevance. The DWP of the crane is reached when any
criterion reaches its design value. It is then an issue for the special assessment to find out
which of the crane components are critical in respect to each duty factor.

B.2 NUMBER OF WORK CYCLES

In cases where the manufacturer has specified the class of utilization for the crane, the
design limit for the number of work cycles, DN , shall be taken from Table A.1, ISO
12482-1.

The DWP of the crane is reached — i.e. the actual duty has reached the design limit in
respect of the total number of working cycles — when:

f1 ⋅ Ca ＝ DN

f1 is the safety factor for duty counting f1 ≔ 1.2

according to Table 1, ISO 12482;

Design Class of Utilization (being specified by U = “U4”

crane manufacturer

DN is the design limit for the number of work DN = 2.5 ⋅ 10 4

cycles according to Table A.1, ISO 12482;

Ca is the actual total number of work cycles Ca = 3.154 ⋅ 10 3

at a point of time of inspection;

Result = “The DWP of crane has not reached ”

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B.3 CUMULATIVE LOADING

A starting point of this clause is that design limits for the parameters, number of work cycles
and load spectrum factor, are specified separately.
In cases where the manufacturer has specified the load spectrum class for the crane, the
design value for the load spectrum factor, Kp , shall be taken from Table A.2, ISO 12482.

For calculation of the load spectrum class from the actual operation history, values of
payloads from each working cycle must be recorded or estimated.

The DWP of the crane is reached — i.e. the actual duty has reached the design limit in
respect of cumulative loading — when:

Ca
⎛ Pi ⎞ 3
f1 ⋅ ∑ ⎜―⎟ ＝ KP ⋅ DN
i=1 ⎝ P ⎠

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Design Load of Spectrum Class Q = “Q2”

is the design value for the load spectrum KP = 0.25

factor according to Table A.2, ISO 12482

Result = “The DWP of the crane has not reached”

B.4 CRANE CLASSIFICATION

This clause applies to cases where the basic duty factors or their classes are not specified
separately and the crane classification only is known. In the DWP calculation, the load
spectrum and the number of work cycles are combined and converted to correspond to the
state of loading, KP ＝ 1 .
The DWP of the crane is reached, that is the actual duty has reached the design limit in
respect to crane classification, when:

Ca
⎛ Pi ⎞ 3
f1 ⋅ ∑ ⎜―⎟ ＝ DC
i=1 ⎝ P ⎠

DC the design limit for converted number of DC = 6.3 ⋅ 10 4

work cycles according to Table A.3, ISO 12482

Result = “The DWP of the crane has not reached”

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B.5 CALCULATION OF REMAINING LIFE OF CRANE

In this step we assume that crane continue working with

α The relative number of working α T = [[ 0 0.634 0.082 0.063 0.063 0.157 ]]

cycles for each load

length ((N))
⎛ P ⎞3 length ((N))
⎛ P ⎞3
⎜ i ⎟ ⎜ i ⎟
f1 ⋅ ∑ N ⋅ ⎜―― ⎟ ＝ KP ⋅ DN f1 ⋅ ∑ α ⋅ AN ⋅ ⎜―― ⎟ ＝ KP ⋅ DN
i=1
i
⎝ Pmax ⎠ i=1
i
⎝ Pmax ⎠

AN is the actual limit for the number K P ⋅ DN

of work cycles based on the recorded AN ≔ ―――――――
actual load. length ((N))
⎛ P ⎞3
⎜ i ⎟
f1 ⋅ ∑ α ⋅ ⎜―― ⎟
i=1
i
⎝ Pmax ⎠

AN ≔ min ⎛⎝DN , AN⎞⎠

AN = 2.444 ⋅ 10 4

Remaining Life of the crane if it Remaining_lifecrane ≔ AN - Ca

continues to work with current relative
loads.
Remaining_lifecrane = 2.128 ⋅ 10 4

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C DWP CALCULATION FOR HOIST DESIGNED TO ISO 4301-1

C.1 GENERAL

Two basic duty factors and the class of mechanism as a combination of the two duty factors
are dealt with as follows:

total operation time, T;

load spectrum factor, K , representing the state of loading, L, of the mechanism;
class M of the mechanism as a combination of the two duty factors.

C.2 CRANE'S SPECIFIC DESIGN DUTY FACTORS ARE KNOWN

In cases where the manufacturer has specified the state of loading through the L-class of the
load spectrum factor, the design value for this shall be taken from Table B.1, ISO 12482
Otherwise a crane-specific value of KmD shall be used.

Design Load of Spectrum Class L = “L2”

is the design value for the load spectrum KmD = 0.25

factor according to Table B.1, ISO 12482:

In cases where the manufacturer has specified the total duration of use through the
classification, the design limit for the total duration of use, DT , shall be taken from Table
B.2., ISO 12482 Otherwise, a crane-specific value of DT shall be used.

Design Class of Utilization (being specified by T = “T5”

crane manufacturer

DT is the design limit for total duration of use DT = ⎛⎝6.3 ⋅ 10 3 ⎞⎠ hr

Table B.2. ISO 12482

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 CRANE SAFETY ASSESSMENT OF DESIGN CRANE RISK
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For calculation of the cumulative loading for a hoist mechanism, values of total hoisted
loads from each work cycle must be recorded or estimated. Both the effective, working part
of the load cycle and the return part of the work cycle shall be considered.

The DWP of the hoist mechanism is reached — i.e. the actual duty has reached the design
limit — when:

⎛ 3 ⎞
Ca
⎜ ⎛ Pi + PA ⎞ ⎛ PA ⎞3 ⎟
f1 ⋅ ∑ t ⎜―――― ⎟ + tRi ⎜―――― ⎟ ⎟ ＝ KmD ⋅ DT
⎜i
i=1 ⎝ ⎝ Pmax + PA ⎠ ⎝ Pmax + PA ⎠ ⎠

f1 is the safety factor for duty counting f1 = 1.2

according to Table 1, ISO 12482;

Ca is the actual total number of work cycles Ca = 3.154 ⋅ 10 3

at a point of time of inspection;

Pi is the handled payload in work cycle i; P T = [[ 0 8 16 24 32 40 ]] tonne

Pmax is the rated value of the payload for the Pmax = 40 tonne
crane

PA is the sum weight of the fixed and non- PA = 3 tonne

fixed load lifting attachments;
2H
ti is the hoist mechanism running time during ti ≔ ――
Vh
a loaded part of work cycle i (Length of
average cycle);

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ti = 3 min

tRi is the hoist mechanism running time during tRi ≔ 0 min

a return part of work cycle i;

DT is the design limit for the total operation

time, see Table B.2, ISO 12482; DT = ⎛⎝6.3 ⋅ 10 3 ⎞⎠ hr

KmD is the design value for the load spectrum KmD = 0.25
factor of the mechanism, see Table B.1.

Result = “The DWP of the crane has not reached”

C.3 MECHANISM CLASSIFICATION IS KNOWN

This clause applies to cases where the basic duty factors or their classes are not separately
specified and the mechanism classification only is known. In the DWP calculation, the load
spectrum and the total operation time are combined and converted to correspond the state of
loading, Km ＝ 1 .

The DWP of the hoist mechanism is reached — i.e. the actual duty has reached the design
classification— when:

⎛ 3 ⎞
Ca
⎜ ⎛ Pi + PA ⎞ ⎛ PA ⎞3 ⎟
f1 ⋅ ∑ t ⎜―――― ⎟ + tRi ⎜―――― ⎟ ⎟ ＝ DM
⎜i
i=1 ⎝ P
⎝ max + P P + P
A⎠ ⎝ max ⎠ ⎠
A

DM is the design limit for converted number of the total operation time according to Table B.3,
ISO 12482:

Mechanism classification M = “M5”

The design limit for converted number of the total DM = ⎛⎝1.6 ⋅ 10 3 ⎞⎠ hr

operation time according to Table B.3, ISO 12482:

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 CRANE SAFETY ASSESSMENT OF DESIGN CRANE RISK
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Result = “The DWP of the crane has not reached”

C.4 CALCULATION OF REMAINING LIFE OF HOIST

⎛ 3 ⎞
⎜ ⎛ P + PA ⎞ 3⎟
Ca
⎜ i ⎟ ⎛ PA ⎞
f1 ⋅ ∑ ⎜t ――――
⎜P ⎟ + tRi ⎜―――― ⎟ ⎟ ＝ KmD ⋅ DT
i=1 ⎜
⎝i ⎝ max + PA ⎠ ⎝ Pmax + PA ⎠ ⎟⎠

ti ＝ αi ⋅ Tactual tRi ＝ 0

⎛ 3⎞
Tactual is the actual length ((N)) ⎜
⎛ P + PA ⎞ ⎟
⎜α ⎜―――― ⎟ ⎟
i
limit for the total f1 ⋅ Tactual. ∑ ＝ KmD ⋅ DT
operation time. i=1 ⎜⎝ i ⎝ Pmax + PA ⎟⎠ ⎠⎟
⎜

KmD ⋅ DT
Tactual ≔ ――――――――― = ⎛⎝5.853 ⋅ 10 3 ⎞⎠ hr
⎛ 3 ⎞
length ((N)) ⎜
⎛ P + PA ⎞ ⎟
⎜ i ⎟ ⎟
f1 ∑ ⎜α ⎜――――
i=1 ⎜⎝ i ⎝ Pmax + PA ⎟⎠ ⎟⎠

Tactual ≔ min ⎛⎝Tactual , DT⎞⎠

Tactual = ⎛⎝5.853 ⋅ 10 3 ⎞⎠ hr

Assessing remaining Tremaining ≔ Tactual - Ca ⋅ ti

life of Mechanism

Tremaining = ⎛⎝5.695 ⋅ 10 3 ⎞⎠ hr

C.5 GENERAL OVERHAUL

General overhaul (GO) is a set of repair, replacement and maintenance actions, which are
necessary for the safety of the further use of the crane. Some issues may require immediate
actions; some may be postponed, in which the case these actions shall be scheduled
according to the future duty of the crane.

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INDEX

D.1 Operating hours per

2⋅H⋅N⋅T⋅J
inspection interval, Ti Ti ＝ ―――――
Vh

H = average hoisting height [m] H=3 m

m
Vh = hoisting speed [m/min] Vh = 2 ――
min

T = daily working time [h] Ca ＝ N ⋅ T ⋅ J

J = working days during inspection

interval [days] Ca = 3.154 ⋅ 10 3

N = number of work cycles per hour

[cycles/h] 2 ⋅ H ⋅ Ca
Ti ≔ ―――
Vh

Operating hours per inspection interval, Ti Ti = 157.7 hr

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D.2 CRANE CLASSICATION

D.2.1 CLASSIFICATION OF HOISTING APPLIANCES AS A WHOLE

Appliances as a whole are classified in eight groups, designated by the symbol A1, A2, ...,
A8 respectively (see section 2.1.2.4.), on the basis of ten classes of utilization and four load
spectra.

r
⎛ n ⎞ ⎛ P ⎞3
⎜ i ⎟ ⎜ i ⎟
The Load Spectrum Factor Kp ＝ ∑ ⎜―― ⎟ ⋅ ⎜―― ⎟
i=1 ⎝ nmax ⎠ ⎝ Pmax ⎠

r
⎛ P ⎞3
⎜ i ⎟
Kp ＝ ∑ αi ⋅ ⎜―― ⎟
i=1 ⎝ Pmax ⎠
The relative Percentages of T
working cycles for each load α ≔ [[ 0 60 0 30 10 0 ]]

Load Spectrum Factor Kp = 0.121

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Load Spectrum Class Q = “Q1”

Class of Utilization: U is determined according to number of hoisting cycles (n) during the
life time of crane. Crane lifetime can be determined according to customer's requirements.

Ls_yrs = Structure Lifetime in years Ls_yrs ≔ 7

N = number of work cycles per hour [cycles/h N ≔ 10

T = daily working time [h] T≔8

Dw = Working days/week Dw ≔ 5

Wy ≔ 48 = Working weeks/years Wy ≔ 48

Design number of hoisting cycles nmax_d ≔ Ls_yrs ⋅ N ⋅ T ⋅ Dw ⋅ Wy

nmax_d = 1.344 ⋅ 10 5

Crane class of Utilization U = “U4”

Crane Group:

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 CRANE SAFETY ASSESSMENT OF DESIGN CRANE RISK
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Crane Load Spectrum Class Q = “Q1”

Crane class of Utilization U = “U4”

Crane Group Crane_Group = [[ “A3” ]]

D.2.2 CLASSIFICATION OF INDIVIDUAL MECHANISMS AS A WHOLE

Individual mechanisms as a whole are classified in eight groups, designated respectively by

the symbol M1, M2, ..., M8 (see 2.1.3.4.), on the basis of ten classes of utilization and four
classes of loading spectrum.

r
⎛ t ⎞ ⎛ P ⎞3
⎜ i ⎟ ⎜ i ⎟
Load Spectrum Class Km ＝ ∑ ⎜―― ⎟ ⋅ ⎜―― ⎟
i=1 ⎝ tmax ⎠ ⎝ Pmax ⎠

r
⎛ P ⎞3
⎜ i ⎟
Kp ＝ ∑ αm ⋅ ⎜―― ⎟
i=1
i
⎝ Pmax ⎠

The Percentages of lifting time T

for each load αm ≔ [[ 0 60 0 30 10 0 ]]

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Load Spectrum Factor Km = 0.121

Load Spectrum Class L = “L1”

Class of Utilization: The class of utilization of a mechanism shall be determined by the

assumed total duration of use in hours, and shall be one of the 10 nominal classes shown in
Table T.2.1.3.2, FEM 1.001.

Lm_yrs = Structure Lifetime in years Lm_yrs ≔ 7

N = number of work cycles per hour [cycles/h N ≔ 10

T = daily working time [h] T≔8

Dw = Working days/week Dw ≔ 5

Wy ≔ 48 = Working weeks/years Wy ≔ 48

H = average hoisting height [m] H≔3 m

m
Vh = hoisting speed [m/min] Vh ≔ 2 ――
min

2 ⋅ H ⋅ N ⋅ T ⋅ Dw ⋅ Wy ⋅ Lm_yrs
Total life time [h] Tmax ≔ ―――――――――
Vh

Tmax = ⎛⎝6.72 ⋅ 10 3 ⎞⎠ hr

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Class of Utilization T = “T6”

Individual Classification

Load Spectrum Class L = “L1”

Class of Utilization T = “T6”

Hoist Group Hoist_Group = [[ “M5” ]]

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REFERENCES:

1. ISO 12482:2014, Cranes — Monitoring for crane design working period.

2. ISO 4301-1:2016, Cranes — Classification — Part 1: General.
3. FEM 1.001, 3rd Edition, Revised 1998.10.01.
4. AS 1418.1:2002, Cranes, hoists and winches, Part 1: General requirements.
5. AS 2550.1:2011, Cranes, hoists and winches—Safe use, Part 1: General
requirements.
6. FEM 9.512: 1997, Series of Lifting Equipment, Rules for the Design of Storage and
Retrieval Machines Mechanisms
7. FEM 9.511: 1986, Rules for the Design of Serial Lifting Equipment, Classifications
of Mechanisms
8. FEM 9.682: 1986, Rules for the Design of Serial Lifting Equipment, Selection of
Lifting Motors

Site Inspection

1. CMAA 78: Standards and guidelines for professional services performed on

overhead traveling cranes and associated
2. OSHA 1910.179- Overhead and gantry cranes.
3. ASME B30 Safety standard: cranes and related equipment

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