SANS522

© SABS.
This non-printable standard is exclusively for approved users of the SABS’ Complete Collection of Standards and Related Documents.
The standard must reside on an internal network or intranet and may only be used for reference purposes in compliance with SABS
copyright rules. The standard or parts thereof may not be distributed in any form without permission from the SABS.
ISBN 978-0-626-30116-3
SANS 522:2007
Edition 1
SOUTH AFRICAN NATIONAL STANDARD
The inspection, testing and examination

of tower cranes
Published by SABS Standards Division

1 Dr Lategan Road Groenkloof Private Bag X191 Pretoria 0001
Tel: +27 12 428 7911 Fax: +27 12 344 1568
www.sabs.co.za
© SABS
© SABS. This non-printable standard is exclusively for approved users of the SABS’ Complete Collection of Standards and Related Documents.
SANS 522:2007
Edition 1
Table of changes
Change No. Date Scope
Foreword
This South African standard was approved by National Committee SABS/TC 096, Cranes, in
accordance with procedures of the SABS Standards Division, in compliance with annex 3 of the
WTO/TBT agreement.
This document was published in October 2007.
A reference is made in 3.3 to the “relevant authority”. In South Africa this means the Engineering
Council of South Africa.
A reference is made in 3.10 to the “relevant national legislation”. In South Africa this means the
Occupational Health and Safety Act, 1993 (Act No. 85 of 1993) (as amended from time to time).
This document is referenced in Regulations of the Occupation Health and Safety Act, 1993
(Act No. 85 of 1993).
Annexes A and B form an integral part of this document. Annex C is for information only.
Reaffirmed and reprinted in March 2014.

This document will be reviewed every five years
and be reaffirmed, amended, revised or withdrawn.
© SABS
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Edition 1
Contents
Page
Foreword
1 Scope ............................................................................................................................................. 3
2 Normative references ..................................................................................................................... 3
3 Terms and definitions ..................................................................................................................... 3
4 Personnel carrying out inspection, testing and examination, and their responsibilities................. 4
5 Facilities and information for inspection, testing and examination ................................................ 5
5.1 Facilities .................................................................................................................................. 5
5.2 Information .............................................................................................................................. 5
6 Provisions for inspection, testing and examination and methods of test ...................................... 5
6.1 Thorough examination of tower cranes .................................................................................. 5
6.2 Overload testing of tower cranes ............................................................................................ 9
6.3 Indicator test ......................................................................................................................... 11
Annex A (normative) Information to be contained in a report on inspection, testing and
examination ............................................................................................... 12
Annex B (normative) Procedure for climbing frame inspection, testing and examinations ......... 14
Annex C (informative) Tower crane foundation pre-erection inspection certificate ....................... 17
Bibliography ....................................................................................................................................... 18
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The inspection, testing and examination of tower cranes
1 Scope
This standard covers requirements for the inspection, testing and examination of tower cranes in
service.
2 Normative references
The following referenced documents are indispensable for the application of this document. All
normative documents are subject to revision and, since any reference to a normative document is
deemed to be a reference to the latest edition of that document, parties to agreements based on
this document are encouraged to take steps to ensure the use of the most recent editions of the
normative documents indicated below. Information on currently valid national and international
standards can be obtained from the SABS Standards Division.
BS 7262, Specification for automatic safe load indicators.
SANS 4306-3/ISO 4306-3, Cranes – Vocabulary – Part 3: Tower cranes.
SANS 4309/ISO 4309, Cranes – Wire ropes – Care, maintenance, installation, examination and
discard.
3 Terms and definitions

For the purposes of this document, the terms and definitions given in SANS 4306-3 and the
following apply.
3.1
crane operator
person who operates a crane for the purpose of positioning loads or for the erection of the crane
3.2
lifting
movement of loads or persons that necessitates, at a given moment, a change of level
3.3
lifting machinery inspector
LMI
person who receives training in, who has knowledge of, and experience in, the operation of lifting
machinery, and who is registered by the relevant authority (see foreword)
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3.4
load radius indicator
device fitted to a crane that shows the radius at which the crane is operating and its corresponding
rated capacity
3.5
non-destructive testing
NDT
non-destructive examination
testing carried out on the structure and components of the crane to establish the presence, location
and extent of any defects that can affect the integrity of that structure
NOTE The techniques employed for non-destructive testing are such that they do not damage or alter the
material under test.
3.6
radius
horizontal distance between the point at which the centre of rotation of the crane meets the ground
and the vertical centre line passing through the load-lifting attachment
NOTE In the case of a non-slewing crane, the horizontal distance from the centre line of a load-lifting
attachment to the centre line of the nearest axle, bogie or track, measured at ground level, may be assumed to
be the radius for the purpose of this definition.
3.7
rated capacity
maximum load that can be safely handled by a crane at a specified position and under specified
conditions
3.8
rated capacity indicator/limiter
RCI/L
device that warns and helps prevent the crane from being overloaded
NOTE This was previously known as an “automatic safe load indicator” and “overload protector”.
3.9
thorough examination
examination by an LMI in such depth and detail as the LMI considers necessary to enable him/her
to determine whether the equipment being examined is safe to remain in use
NOTE The thorough examination is not part of the maintenance regime for the equipment but provides
owners with information which could be used to determine the effectiveness of the regime.
3.10
user
person as specified by the relevant national legislation (see foreword)
4 Personnel carrying out inspection, testing and examination, and

their responsibilities
4.1 Inspection, testing and examination shall be carried out by an LMI.
4.2 After the LMI has identified defects that need to be rectified within a specified timescale,
he/she shall submit a report immediately to allow the user of the crane to take the necessary action
within the required period.
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4.3 If, whilst carrying out a thorough examination, the LMI sees that a crane is not safe for any
reason, he/she shall notify the user of the crane of this finding and also of any defects.
5 Facilities and information for inspection, testing and examination

5.1 Facilities
The user of the crane shall ensure that the facilities required by the LMI for purposes of inspection,
testing and examination, are provided. These may include, but are not limited to, the following:
a) an appropriate area, cordoned off to prevent access by persons not directly involved in the
examination;
b) a crane operator;
c) a person(s) to remove covers or open up parts of the crane; and
d) the preparation of parts or areas of the crane for NDT.
5.2 Information
5.2.1 Information that is necessary for carrying out inspections, testing and examinations shall be
made available to the LMI. Such information may include rated capacities, alterations, maintenance
repairs, renewals, operators’ instructions, etc.
5.2.2 A “Report on inspection, testing and examination after installation” shall be supplied and
retained.
5.2.3 The information to be contained in the report shall be in accordance with annex A.
6 Provisions for inspection, testing and examination and methods of

test
6.1 Thorough examination of tower cranes
6.1.1 General
Tower cranes shall be thoroughly examined on the ground before every erection.
Before thorough examination, the base of the crane shall be cleaned, for example pressure wash,
by appropriate means to remove all spoil/dirt that would otherwise conceal the structure or
mechanisms and prevent an effective examination. The examination shall be carried out in a logical
sequence, for example from top to bottom, to ensure that nothing is overlooked.
6.1.2 Rated capacity indicator/limiter (RCI/L) calibration check
6.1.2.1 Thorough examinations of tower crane shall include confirmation that the RCI/L has been
calibrated to an accuracy within the tolerances given in BS 7262.
6.1.2.2 The RCI/L shall be calibrated at least every 12 months and after the RCI/L has undergone
repairs.
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6.1.2.3 During the calibration check of the RCI/L, the tower crane shall not be loaded
beyond 110 % of its rated capacity. The radius/angle at which the test load corresponds to 110 % of
the rated capacity shall be marked and the test load shall not be taken beyond that point.
6.1.2.4 Test weights shall be calibrated to an accuracy within ± 1,0 %.
6.1.3 Examination scheme approach
6.1.3.1 An examination scheme approach to thorough examinations, if used, shall be based on

regular assessments of the tower crane in accordance with usage. Guidance is given in
SANS 12482-1.
6.1.3.2 The crane manufacturer or manufacturer’s representative shall provide limiting criteria
based on the crane design, for example, the number of load cycles, load spectrum, critical parts,
and exceptional circumstances. These criteria shall not be based on time alone.
6.1.3.3 The user of the crane and the LMI shall take into account the limiting criteria from the crane
manufacturer or its representative when devising an examination scheme. Data logging equipment
greatly facilitates collection of information concerning crane usage for comparison with the crane
design criteria. The data logging equipment needs to be fitted to the tower crane from new to
ensure that a complete record of the usage of the crane is maintained. Without a complete record of
crane usage it is not possible to devise an appropriate examination scheme for a tower crane. A
tower crane shall be subjected to periodic thorough examination in accordance with 6.1.4.
In the case of tower cranes subjected to an examination scheme, a calibration check shall be
carried out on the RCI/L at least once every 12 months as described in 6.1.2.
6.1.4 Specified-period approach
6.1.4.1 Six-monthly thorough examination
6.1.4.1.1 Tower cranes used to lift persons shall either be examined by an LMI at least once every
six months or at lesser intervals if stipulated by the LMI. Any passenger-carrying device such as an
elevating control station, access hoist or climbing frame shall either be examined by an LMI at least
once every six months or at lesser intervals if stipulated by the LMI.
6.1.4.1.2 Lifting accessories shall be thoroughly examined by an LMI at least once every six
months.
6.1.4.2 Twelve-monthly thorough examination
Tower cranes not used to lift persons shall be examined by an LMI at least once every 12 months.
After carrying out the thorough examination the LMI shall specify when the next thorough
examination should be carried out.
6.1.4.3 Items to be checked during the specified-period examination
6.1.4.3.1 Visually examine the crane tower structure, including the cast-in anchors/cruciform
base/chassis/internal climbing collar/grillage, for signs of damage, distortion, cracking and
corrosion.
6.1.4.3.2 If applicable, visually examine the crane travelling base rail track for signs of damage,
distortion, cracking and corrosion.
6.1.4.3.3 Visually inspect any central (base) ballast of the crane for corrosion, damage, cracks and
secureness, and the total mass of the central (base) ballast and positioning of individual weights.
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6.1.4.3.4 Visually inspect all bolts, pins and other fastenings to check that they are not loose or
damaged.
6.1.4.3.5 Visually examine the slewing mechanism for secureness and wear during operation of the
slew motion throughout its full range of movement, and with the tower crane at maximum reach.
6.1.4.3.6 Visually examine all electrical cables on the crane for damage, secureness and fretting.
6.1.4.3.7 Visually examine all electrical enclosures on the crane for corrosion, damage and
secureness.
6.1.4.3.8 Visually examine all pipework on the crane for corrosion, damage, leakage, secureness
and fretting.
6.1.4.3.9 Examine all hydraulic cylinders for leakage, corrosion on the rods and alignment, and end
fixings for wear, secureness and lubrication.
6.1.4.3.10 Visually inspect the counter jib, slewing platform, frame, trolley and jib of the crane for
corrosion, damage, cracks and distortion.
6.1.4.3.11 Visually inspect any trolley rope breaks safety device, if fitted, for corrosion, damage,
cracks and distortion, and any bearings and pivots for freedom of action.
6.1.4.3.12 Visually inspect the counter ballast of the crane for corrosion, damage, cracks and
secureness, and the total mass of the counterweight and the correct position of individual weights.
6.1.4.3.13 Visually examine all pivoting joints on the jib and attachments of the crane for wear,
corrosion, secureness and evidence of lubrication.
6.1.4.3.14 Visually examine all wire ropes to determine whether they are of the size and type
specified in, and reeved in accordance with, the instructions of the manufacturer of the tower crane.
Pay particular attention to the end terminations. Guidance regarding wedge and socket anchorages
for wire ropes is given in EN 13411-6.
6.1.4.3.15 Visually check whether all pulleys/sheaves and drums are free from damage and wear,
whether the rope fits correctly on them, and whether they are effectively lubricated. Check whether
all idler pulleys/sheaves turn freely and all guards are undamaged and in place.
6.1.4.3.16 Thoroughly examine the whole length of the wire ropes for signs of wear, damage,
broken wires and corrosion in accordance with SANS 4309.
6.1.4.3.17 Visually inspect all motors, drive couplings, gearboxes and winch drums for wear,
damage, secureness and leakage.
6.1.4.3.18 Visually inspect the braking mechanisms for wear, damage and adjustment and check
whether they comply with the instructions for the crane.
6.1.4.3.19 Check any means of access for completeness and secureness of ladders, hoops,
walkways, rest platforms, hand rails/hand holds and safety-line anchorages. Examine powered
access including elevating control stations and access hoists in accordance with the instructions.
6.1.4.3.20 Check (for example by debris monitoring) the oil and other fluid for condition and level of
the fluid.
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6.1.4.3.21 Visually inspect the operator’s cab of the crane for corrosion, damage, cracks and
secureness.
6.1.4.3.22 Visually check whether the fixings for the operator’s seat are in place and secure.
6.1.4.3.23 Visually check whether the cab windows (including guard bars) are secure and clean,
and whether any wiper is working correctly.
6.1.4.3.24 Check whether all controls (including those located in remote control stations, where
fitted) are marked with their function and mode of operation.
6.1.4.3.25 Visually inspect the upper and lower hoist limit switches; check whether they are in place
and free from damage or excessive wear.
6.1.4.3.26 Visually examine the hooks, their attachments and safety catches for wear, fretting,
distortion, corrosion and secureness.
6.1.4.3.27 Check whether there is a table displayed in the operator’s cabin that shows the rated
capacities for the crane for all crane operating conditions (free on wheels, free on cushion wheels,
all permitted outrigger positions, etc.).
6.1.4.3.28 Functionally test all controls (including those located in remote control stations, where
fitted) for smoothness of operation and to determine whether they are free from wear and other
damage.
6.1.4.3.29 Check whether warning signs and other important instructions are present and readable,
for example rating plates for load lifting.
6.1.4.3.30 Operate the tower crane and check whether all motions operate smoothly and effectively
without excessive play. The load lifting attachment shall not drop excessively after the motion has
been stopped and all limiters and safety devices shall operate correctly. Climbing frames, whilst not
always part of the crane’s permanent equipment, are devices for lifting persons and should be
thoroughly examined either in accordance with a scheme of examination or at intervals not
exceeding six months. The minimum inspection criteria for examination of climbing frame shall be
as given in annex B.
6.1.4.3.31 Verify the tower crane's identification and plates.
6.1.4.3.32 Verify the presence of the instruction handbook.
6.1.4.3.33 Verify the components, equipment and steel structure. Compare the component installed
on the tower crane with the component listed in the documentation.
6.1.4.3.34 Consider the condition of equipment that indicates the following signs of its deterioration:
• the gear or its components are loose and its oil (lubricant) leaks;
• an unusual noise and vibration are noticeable;
• an unusual high temperature is noticeable; and
• the brake linings are worn or damaged.
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6.2 Overload testing of tower cranes
6.2.1 General
Overload testing of tower cranes shall be carried out after each erection, after reconfiguration
(alteration of jib length), and for cranes that remain on the same site for long periods, at least once
every 12 months.
A visual examination of the crane and the test area shall be carried out before starting the test.
Before the application of a load, a thorough examination of the crane shall be carried out, including
verification that the crane is erected in accordance with the instructions of the crane manufacturer.
The LMI shall check the rated capacity specified on the manufacturer’s certificate of test, the load
radius indicator, the table of rated capacities displayed in the operator’s cab and those used by the
RCI/L. The rated capacities given shall be identical.
A functional test with no load applied shall be carried out to determine whether the controls,
switches, contactors and other devices operate correctly. The adjustments of the brakes and limit
switches shall be checked and tested to ensure that they are operating correctly.
6.2.2 Levelling
The base of the tower crane shall be level in accordance with its manufacturer’s specification.
Annex C gives a typical foundation pre-erection inspection certificate.
6.2.3 Lifting capacities
The load ratings marked on tower cranes and shown on the manufacturer’s rated capacity charts
indicate the net loads, i.e. the loads quoted include the weight of the hook block, but not slings and
lifting gear.
Therefore when the crane is being tested, allowance should be made for the weight of suspended
slings and other lifting gear. The exact weight of these items shall be determined.
6.2.4 Overload tests
6.2.4.1 Preparation
6.2.4.1.1 Examine the previous test certificate, if available, before starting any overload test as this
forms the basis for the test. Seek advice on a suitable test programme (see 6.3) and the ability of
the crane to withstand a 110 % overload from the crane manufacturer (or other suitable design
authority) if no test certificate is available.
6.2.4.1.2 Position a rail-mounted crane at the start of testing on a straight and level track with firm
foundations and that is free from obstructions, and use rubber-tyred crane jacks or outriggers. Set
the jacks or outriggers in accordance with the instructions to completely relieve the tyres of the load.
6.2.4.1.3 Thoroughly examine the crane to determine whether it is in a safe state and condition to
be overload tested.
6.2.4.2 Test procedure
NOTE During the raising of any load it might be necessary to derrick the jib, or trolley in the load, so that the
radius is not exceeded owing to the deflection of the tower.
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6.2.4.2.1 Functionally test the crane without a load applied to determine whether it is working
properly.
6.2.4.2.2 With the trolley or jib at the maximum radius of the rated capacity, raise the test load until
every tooth in the train of gears has been subjected to the load, then lower the test load to
between 100 mm and 200 mm above the ground and operate the crane through all its permitted
motions.
6.2.4.2.3 Increase the rated capacity by 10 % and hoist this load until each tooth in the train of
gears has been subjected to the overload, then lower this load to between 100 mm and 200 mm
just clear of the ground and operate the crane through its permitted motions.
6.2.4.2.4 For horizontal jib cranes with trolleys, set the trolley at the maximum radius of the
maximum rated capacity. Fit suitable devices, for example clamps, to the jib to prevent the trolley
from moving beyond this point. For other cranes, position the load lifting attachments at the
maximum radius for the maximum rated capacity.
6.2.4.2.5 Raise the appropriate rated capacity until each tooth in the train of gears has been
subjected to the load, then lower the test load to between 100 mm and 200 mm above the ground
and operate the crane through all its permitted motions, subject to site limitations. Determine
whether the crane is safe to proceed with the test.
NOTE For most tower cranes it is possible to operate the maximum rated capacity at a number of radii, so for
these cranes the motions include moving the load back to the maximum radius position for that rated capacity,
taking care to stop before the clamp is reached.
6.2.4.2.6 Increase the load shall by 10 % and hoist the load until each tooth in the train of hoist
gears has been subjected to the overload, then lower the load to between 100 mm and 200 mm
above the ground and operate the crane through its permitted motions to ensure the overload is
applied to all parts.
If the tests are limited owing to site conditions, it might be necessary to dismantle and reassemble
the test load at different positions throughout the arc of slew to enable the crane to be thoroughly
tested over its working area. Otherwise duties should be restricted.
6.2.4.2.7 Where the loaded crane can travel on rail tracks, travel the overload the appropriate
length of the track with the jib at right angles, at both sides and in line with it where such duties are
permitted.
6.2.4.2.8 Ensure that, during the overload test, the crane remains stable, structurally sound and fit
for the purpose for which it was designed. Ensure that the brakes on each motion function
effectively.
6.2.4.2.9 During the overload test, test the crane at speeds appropriate to the safe control of the
load, for example the lowest possible speed of the crane.
6.2.5 Major repair or modification
Tower cranes shall be thoroughly examined and overload tested after major repairs or
modifications.
6.2.6 Post-test examination and certification
6.2.6.1 On completion of the test, a thorough examination of the tower crane shall be carried out by
an LMI to determine whether the crane has withstood testing without signs of structural damage that
could affect the safety of the crane, such as:
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a) cracking;
b) permanent deformation;
c) paint flaking; or
d) loosening of, or damage to structural connections.
6.2.6.2 When the testing has been completed, the LMI should issue the appropriate certificate
which shall be appended to the report of inspection, testing and examination.
6.2.7 Non-destructive testing (NDT) of tower cranes
NDT of tower cranes is a valuable aid to the identification of cracks and other defects in tower crane
structures damaged by fatigue, corrosion or overloading. Older cranes are often prone to these
defects and particular care should be taken when carrying out thorough examinations on these
cranes.
6.3 Indicator test
6.3.1 General
During the testing of the indicator it is essential that the crane is not loaded beyond 110 % of its
rated capacity. The radius at which the test load corresponds to 110 % of the rated capacity shall be
marked and the test load shall not be taken beyond that point.
6.3.2 Horizontal jibs with trolleys
Having established the effectiveness of the trolley brake by carrying out the tests in 6.3.3 and 6.3.4,
the clamps shall be removed and a known load, not less than 80 % of the maximum rated capacity,
shall be lifted just clear of the ground at minimum radius and travelled very slowly out until the
indicator gives the rated capacity warning and indicators. The radius shall be between 90 %
and 97 % of the rated capacity for that radius. The load required to cause an overload warning as it
is carefully hoisted from the ground can then be found. This shall be between 102,5 % and 110 % of
the rated capacity for that radius.
6.3.3 Derricking jibs
A known weight of between 80 % and 90 % of the maximum rated capacity for the configuration
shall be suspended at the minimum radius of the crane. Keeping the load as close to the ground as
possible, the radius shall be increased until the indicator gives the approach to rated capacity
warning and indicators.
When the radius is measured, the load on the crane shall be between 90 % and 97,5 % of the rated
capacity for that radius. The radius shall be reduced slightly and the load increased by small
amounts until the load required to cause an overload warning as it is carefully hoisted from the
ground is found.
When the radius is measured, the load on the crane shall be between 102,5 % and 110 % of the
rated capacity.
6.3.4 Repeat tests
The test shall be repeated using a known weight approximately midway between the maximum and
minimum rated capacity for that configuration of the crane.
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Annex A
(normative)
Information to be contained in a report

on inspection, testing and examination
The report shall contain at least the following information:
a) the name and address of the employer for whom the thorough examination was conducted;
b) the address of the premises at which the thorough examination was conducted;
c) particulars sufficient to identify the equipment, including, where known, its date of
manufacture;
d) the date of the last thorough examination;
e) the safe working load of the tower crane or (where its safe working load depends on the
configuration of the tower crane) its safe working load for the last configuration in which it was
thoroughly examined;
f) in relation to the first thorough examination of tower crane after installation or after assembly
at a new site or in a new location, a statement to the effect that
1) it is such a thorough examination, and
2) (if it is the case) the tower crane has been installed correctly and is safe to operate;
g) in relation to a thorough examination of tower crane other than a thorough examination to

which (f) above relates
1) whether it is a thorough examination
i) within an interval of six months,
ii) within an interval of 12 months,
iii) in accordance with an examination scheme, or
iv) after the occurrence of exceptional circumstances, and
2) (if it is the case) a statement to the effect that that the tower crane is safe to operate;
h) in relation to every thorough examination of the tower crane
1) identification of any part found to have a defect which is, or could become, a danger to
persons, and a description of the defect;
2) particulars of any repair, renewal or alteration required to remedy a defect found to be a

danger to persons; and
3) in the case of a defect which is not yet, but could become, a danger to persons
i) the time by which it could become such a danger,
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ii) particulars of any repair, renewal or alteration required to remedy it, and
iii) the latest date by which the next thorough examination shall be carried out;
i) where the thorough examination included testing, particulars of any test such as
1) the date of the thorough examination, and
2) the name and address making the report; and the fact that he/she is self-employed or, if
employed, the name and address of his/her employer;
j) the name and address of a person signing or authenticating the report on behalf of its author;
k) the date and type of the most recent inspection, test or examination (or any combination of the
three);
l) the date and type of the next inspection, test or examination (or any combination of the three);
and
m) the date of the report.
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Annex B
(normative)
Procedure for climbing frame

inspection, testing and examination
B.1 Procedure for the thorough inspection, testing and examination of
frames for top climbing of tower cranes
B.1.1 Procedure for six-monthly thorough inspection, testing and
examination
NOTE The six-monthly thorough inspection, testing and examination may be supplemented by NDT at the
discretion of the LMI.
B.1.1.1 Confirm the identification number of the frame and all corresponding sections, to ensure
that all parts are of the same frame.
B.1.1.2 Carry out a visual check of the frame structure, checking for any damage to structural
members or evidence of cracking in welds. Pay particular attention to the suspension brackets and
the jointing plates.
B.1.1.3 Confirm the free movement of all guide rollers and check for damage.
B.1.1.4 Check the rollers for undue wear and check that all keep plates are in place and secure.
B.1.1.5 Check the hydraulic ram mounting brackets for secureness and check the welds for signs
of cracking.
B.1.1.6 Check the lifting yoke at the base of the hydraulic ram for signs of wear and any cracking
or deformity.
B.1.1.7 Check the hydraulic ram joint pin for lift and that it is correctly locked in position.
B.1.1.8 Check that the rollers are free to rotate (to allow horizontal motion of the ram).
B.1.1.9 Carry out a visual inspection to check that the hydraulic system is free from leaks and has
no damage to the pipework or the connections.
B.1.1.10 Check the travelling platform for damage to itself and its supports.
B.1.1.11 Check the walkways for damage and secureness of fixing. Close off the walkways.
B.1.1.12 Record the results of the inspection, testing and examination on the appropriate form
and retain on file.
B.1.2 Procedure for 12-monthly thorough inspection, testing and

examination
B.1.2.1 This work is to be carried out with the frame on the ground at rest.
B.1.2.2 Carefully inspect, test and examine the main load bearing parts and subject them to NDT
as necessary.
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The inspection, testing and examination shall include the following:
— the jointing plates and associated supporting structures;
— the reaction roller supports and associated structures;
— the main suspension lugs;
— the corner nodes; and
— the main lifting yoke.
B1.2.3 Subject the hydraulic ram and relief valves to a pressure test in accordance with the
manufacturer’s recommendations for that system.
B.1.2.4 Remove the ram-jointing/reaction roller pins and measure them to assess wear. Subject
the pins to NDT.
B.1.2.5 Carry out the six-monthly thorough inspection, testing and examination at this time.
B.2 Procedure for post-installation thorough inspection, testing and

examination report
NOTE The post installation thorough inspection, testing and examination may be supplemented by NDT at
the discretion of the LMI.
B.2.1 Confirm the identification number of the frame and all corresponding sections to ensure that
all parts are of the same frame.
B.2.2 Carry out a visual check of the frame structure, checking for any damage to structural
members or evidence of cracking in welds. Pay particular attention to the suspension brackets and
the jointing plates.
B.2.3 Confirm the free movement of all guide rollers and check for damage.
B.2.4 Check the rollers for undue wear and check that all keep plates are in place and secure.
B.2.5 Check the hydraulic ram mounting brackets for secureness and check the welds for signs of
cracking.
B.2.6 Check the lifting yolk at the base of the hydraulic ram for signs of wear and any cracking or
deformity.
B.2.7 Check the hydraulic ram joint pin for lift and that it is correctly locked in position.
B.2.8 Check that the rollers are free to rotate (to allow horizontal motion of the ram).
B.2.9 Carry out a visual inspection to check that the hydraulic system is free from leaks and has
no damage to the pipework or the connections.
B.2.10 Check the travelling platform for damage to itself and its supports.
B.2.11 Check the walkways for damage and secureness of fixing. Close off the walkways.
© SABS 15
SANS 522:2007
Edition 1
B.2.12 Record the results of the inspection, testing and examination on the appropriate form and
retain whilst the frame is installed for use at that location.
B.3 Procedure for pre-use check of frame for top climbing of tower
cranes
B.3.1 Confirm that the frame undergoes current thorough inspection, testing and examination and
installation reports.
B.3.2 Confirm that the test of the hydraulic system is current.
B.3.3 Confirm that all personnel have been issued with a copy of this procedure or a checklist that
relates to it.
B.3.4 Confirm that all personnel are trained in the operation and that they understand the
procedure.
B.3.5 Confirm that communication means, either by radio or telephone, are available.
B.3.6 Inspect and examine all connecting pins/bolts before erection to determine whether they are
the correct type and undamaged.
B.3.7 Check the frame to ensure the jointing bolts are in place and secure.
B.3.8 Check that the main guide roller pin keep plates are in place and secure.
B.3.9 Check that the walkways are secure with no missing bolts or guardrails.
B.3.10 Check that the hydraulic system is free from leaks.
B.3.11 Check that the apron for the support of the section to be inserted is secure and free to
move.
B.3.12 Engage the slew lock or physically lock the slew and inform the operator of the importance
of maintaining this action.
B.3.13 Obtain authorization of the checklist and permit to climb from an appointed person at the
site.
16 © SABS
SANS 522:2007
Edition 1
Annex C
(informative)
Tower crane foundation pre-erection inspection certificate

Certificate No.:
TOWER CRANE FOUNDATION
PRE-ERECTION INSPECTION CERTIFICATE
Project: Tower crane No./location
Tower crane type
Item (delete where not applicable) Checked by Date

Compliance with design drawings/specification
Level check
Cast-in items within tolerance
Concrete quality/strength
Pile tests
Steel grade
Weld quality
Bolts – grade, torque, tightness, quantity
Track rails – levels, spacing, fixings, ramps, end
stops, earthing
Documents against which foundation has Design certificate No.:

been checked (drawing Nos/document
references):
Design check certificate No.:
Notes and observations:
The above inspections having been carried out satisfactorily, erection of the tower crane superstructure may
proceed.
Signed: Date:
Name:
Position:
Company:
© SABS 17
SANS 522:2007
Edition 1
Bibliography
BS 7166, Specification for wedge and socket anchorages for wire ropes.
EN 13411-6, Terminations for steel wire ropes – Safety – Part 6: Asymmetric wedge socket.
ISO 9927-3, Cranes – Inspections – Part 3: Tower cranes.
SANS 61-1/ISO 10245-1, Cranes – Limiting and indicating devices – Part 1: General.
SANS 615-3/ISO 10245-3, Cranes – Limiting and indicating devices – Part 3: Tower cranes.
SANS 4310/ISO 4310, Cranes – Test code and procedures.
SANS 9927-1/ISO 9927-1, Cranes – Inspections – Part 1: General.
SANS 12480-3/ISO 12480-3, Cranes – Safe use – Part 3: Tower cranes.
SANS 12482-1/ISO 12482-1, Cranes – Condition monitoring – Part 1: General.
18 © SABS
SABS – Standards Division
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© SABS.

SOUTH AFRICAN NATIONAL STANDARD

The inspection, testing and examination

Published by SABS Standards Division

This document was published in October 2007.

Reaffirmed and reprinted in March 2014.

This page is intentionally left blank

The inspection, testing and examination of tower cranes

BS 7262, Specification for automatic safe load indicators.

SANS 4306-3/ISO 4306-3, Cranes – Vocabulary – Part 3: Tower cranes.

3 Terms and definitions

4 Personnel carrying out inspection, testing and examination, and

5 Facilities and information for inspection, testing and examination

c) a person(s) to remove covers or open up parts of the crane; and

d) the preparation of parts or areas of the crane for NDT.

6 Provisions for inspection, testing and examination and methods of

6.1.2 Rated capacity indicator/limiter (RCI/L) calibration check

6.1.2.4 Test weights shall be calibrated to an accuracy within ± 1,0 %.

6.1.3 Examination scheme approach

6.1.3.1 An examination scheme approach to thorough examinations, if used, shall be based on

6.1.4 Specified-period approach

6.1.4.1 Six-monthly thorough examination

6.1.4.2 Twelve-monthly thorough examination

6.1.4.3 Items to be checked during the specified-period examination

6.1.4.3.31 Verify the tower crane's identification and plates.

6.1.4.3.32 Verify the presence of the instruction handbook.

• an unusual noise and vibration are noticeable;

• an unusual high temperature is noticeable; and

• the brake linings are worn or damaged.

6.2 Overload testing of tower cranes

6.2.3 Lifting capacities

6.2.4 Overload tests

6.2.4.2 Test procedure

6.2.5 Major repair or modification

6.2.6 Post-test examination and certification

d) loosening of, or damage to structural connections.

6.2.7 Non-destructive testing (NDT) of tower cranes

6.3 Indicator test

6.3.2 Horizontal jibs with trolleys

6.3.3 Derricking jibs

6.3.4 Repeat tests

Information to be contained in a report

d) the date of the last thorough examination;

1) it is such a thorough examination, and

g) in relation to a thorough examination of tower crane other than a thorough examination to

1) whether it is a thorough examination

i) within an interval of six months,

ii) within an interval of 12 months,

iii) in accordance with an examination scheme, or

iv) after the occurrence of exceptional circumstances, and

h) in relation to every thorough examination of the tower crane

2) particulars of any repair, renewal or alteration required to remedy a defect found to be a

i) the time by which it could become such a danger,

1) the date of the thorough examination, and

m) the date of the report.

Procedure for climbing frame

B.1.2 Procedure for 12-monthly thorough inspection, testing and

The inspection, testing and examination shall include the following:

— the jointing plates and associated supporting structures;

— the reaction roller supports and associated structures;

— the main suspension lugs;

— the corner nodes; and

— the main lifting yoke.

B.2 Procedure for post-installation thorough inspection, testing and