CSCS Self-Erect Crane cheat sheet

Self-erect (tower) cranes sit under the same regulatory umbrella as other lifting equipment: LOLER 1998 requires thorough examination before first use, after installation/erection, after exceptional circumstances, and at 6-month intervals.

PUWER 1998 covers suitability, maintenance, inspection, and competent persons; it applies to the crane as work equipment regardless of whether it is hired or owned.

A 'competent person' for thorough examination is defined by competence and experience, not by job title; the role is distinct from the 'appointed person' who plans the lift.

The Lifting Operations and Lifting Equipment Regulations require that lifting accessories (slings, shackles) are examined every 6 months, whereas lifting equipment for non-personnel may be 12 months.

Construction (Lifting Operations) and CDM 2015 require a written lift plan and a competent appointed person for complex or tandem lifts.

Manufacturer's instruction manual is the primary technical standard; deviation from it requires written justification from a competent engineer.

EN 14439 covers tower crane safety; self-erect cranes also conform to specific type standards and CE/UKCA marking obligations.

Records of examination, maintenance, and operator training must be retained and made available to the enforcing authority on request.

Reportable dangerous occurrences (e.g., crane collapse, uncontrolled load) must be notified to the HSE under RIDDOR.

Self-erect crane = tower crane designed for rapid erection without a separate mobile crane, typically using a folding mast and jib.

Key components: base/foundation, mast sections, slewing ring, jib, counter-jib, counterweight, hoist winch, trolley, hook block, and operator's cab or remote control.

Slew ring allows 360° rotation; slew brake/limit prevents uncontrolled rotation, and slew lock is applied during erection and out-of-service.

Hoist limit switches (upper and lower) prevent two-blocking and hook over-lowering; trolley limit switches prevent over-travel.

Moment limiter (overload protection) measures load moment and cuts out hoisting/derricking when rated capacity is exceeded.

Self-erect cranes are commonly classified by maximum load moment (tm) and maximum jib length; capacity falls as radius increases.

'Two-blocking' is contact between hook block and jib/trolley - prevented by the upper hoist limit; causes can include operator error or limit failure.

Counterweight is sized to balance the jib; incorrect or missing counterweight invalidates the load chart and stability calculation.

Ground bearing pressure must exceed the crane's imposed pressure at the outrigger/base footprint, including dynamic and wind effects, with a factor of safety typically ≥2.

Check for buried services, drains, basements, and voids within the crane's zone of influence; a survey and service drawings are required before siting.

Proximity hazards to assess: overhead power lines (goal posts/isolation), adjacent structures, public highways, railways, and other cranes (anti-collision).

Siting must consider jib over-sail and the crane's full slewing circle; the out-of-service condition (free-to-slew or locked) must be defined in the plan.

Wind exposure is a siting factor: assess prevailing wind, shielding by buildings, and the crane's rated in-service and out-of-service wind speeds.

Access for erection/dismantling (mobile crane or self-erect sequence), delivery vehicles, and laydown areas must be planned.

A site-specific risk assessment and method statement must precede siting; exclusion zones must be established and communicated.

Foundation design (mass concrete pad or proprietary base) must be signed off by a competent engineer and match the manufacturer's specification.

Erection and dismantling require a written method statement, a competent person in charge, and a permit-to-work or equivalent control.

Self-erect sequence typically: base/foundation → mast sections → slewing unit → jib and counter-jib → counterweights → commissioning checks.

Climbing/jacking uses the crane's own climbing frame; the mast is jacked and a new section inserted - never climb with the jib loaded or in service.

During climbing the crane is in a reduced-stability condition: wind speed limits, slew lock, and exclusion zones are mandatory.

Each mast section, pin, and bolt must be checked for correct fit and torque before the crane is returned to service.

Dismantling is the reverse of erection; the same planning, supervision, and exclusion controls apply, and it is statistically the higher-risk phase.

No personnel may be on the mast or jib during jacking unless the manufacturer's procedure and fall protection permit it.

After erection/climbing, a thorough examination by a competent person is required before first use or return to service.

Weather limits (typically manufacturer-specified wind speed, often around 10 m/s for climbing) must be monitored and enforced.

Load moment = load × radius (plus hook block, slings, and jib/trolley effects); the rated capacity must not be exceeded at any radius.

Gross load = net load + lifting accessories + hook block; always lift against gross load, not the net weight.

Rated capacity decreases with increasing radius; the load chart is specific to jib length, counterweight configuration, and outrigger/base setup.

Stability is governed by the moment of the load about the tipping line versus the restoring moment of the counterweight and base; the chart already incorporates a factor of safety.

Dynamic effects: add for acceleration/deceleration and wind; shock loading can exceed static load several-fold.

Wind load on the load and jib increases with area and wind speed (proportional to v²); the chart's in-service wind limit must be respected.

For pick-and-carry or travel with load (where permitted), capacity is further reduced; most self-erect cranes are not designed for travel with load.

Verify chart units (kg vs. t, radius in m) and confirm the correct chart page for the actual configuration before every lift.

Sling angle affects tension: for a two-leg sling, tension per leg = (load/2) / cos(angle from vertical); flatter angles increase leg tension.

SWL/WLL of each accessory must be ≥ the tension it carries; the assembly rating is limited by the weakest component.

Use tag lines to control load rotation; ensure the load's centre of gravity is under the hook to prevent tilt and swing.

Inspect slings before use: reject for cuts, fraying, broken wires, chemical damage, or missing ID tags; colour coding indicates inspection period.

Shackles must be rated, pin fully engaged, and moused where vibration could loosen; never substitute non-rated hardware.

Load control: know the load weight (calculate or weigh), never guess; unknown loads require a verified weight before lifting.

Avoid side loading of hooks and slings; hooks must have a functioning safety latch and load on the saddle, not the tip.

Landing and setting down: control descent, use guides, and never place hands between load and landing surface.

One designated signaller/slinger directs the lift; only the signaller may give signals, except an emergency stop which anyone may give.

Standard hand signals (e.g., raise, lower, slew left/right, stop, emergency stop) must be agreed and understood before the lift.

Radio communication requires a dedicated channel, tested before the lift, with a backup method (hand signals) agreed.

The operator must stop immediately on loss of communication or on any emergency stop signal from anyone.

Banksman/slinger and operator must maintain line of sight; if not, an intermediate signaller is required.

Exclusion zones and pedestrian control must be coordinated with the signaller; nobody passes under a suspended load.

Brief all personnel on the lift plan, roles, and emergency procedures before starting; confirm understanding.

Use distinctive PPE (e.g., high-visibility) for the signaller so the operator can identify them unambiguously.

Pre-use checks (daily): visual inspection of structure, wire rope, hooks, limit switches, brakes, and warning devices; record and report defects.

Thorough examination by a competent person: before first use, after erection/climbing, after exceptional circumstances, and at 6-month intervals.

Wire rope inspection: check for broken wires (count per lay length), corrosion, kinks, bird-caging, and end termination condition; reject per manufacturer criteria.

Brake test: verify hoist and slew brakes hold the rated load; test before each shift where practicable and after any adjustment.

Limit switch function test: upper/lower hoist, trolley, and slew limits must operate correctly; never rely on the operator to stop the load.

Maintenance per manufacturer's schedule: lubrication, bolt torque checks, pin wear, and electrical inspection by competent persons.

Defects must be logged and the crane taken out of service until rectified and re-examined; do not operate with a known defect.

Keep records: examination reports, maintenance logs, and defect records available for inspection.

Never exceed the rated capacity or the in-service wind speed; stop lifting when wind limits are reached and put the crane into out-of-service condition.

Out-of-service: slew lock or free-to-slew per manufacturer, jib positioned to minimise wind area, and brakes/hook secured.

Lightning: stop operations, lower the jib/hook, and follow the site's lightning plan; the crane is a tall structure and a lightning risk.

Overhead power lines: maintain safe clearance (goal posts or isolation), and never operate within the exclusion zone without formal control.

Emergency procedures: emergency lowering of a suspended load, evacuation, and first aid must be briefed; the operator must know how to lower the load safely if power fails.

Fire and fuel: refuelling and battery charging follow site rules; keep extinguishers accessible and know the isolation point.

Environmental: control dust, noise, and spillage; prevent oil/ hydraulic leaks from contaminating ground and watercourses.

Incident reporting: any near miss, uncontrolled load, or contact with a structure must be reported and the crane inspected before further use.

Fatigue and fitness: operators must be fit, rested, and free from impairment; shift limits and breaks apply.

LOLER 1998: thorough examination before first use, after erection, after exceptional circumstances, and at 6-month intervals for lifting equipment.

PUWER 1998: work equipment must be suitable, maintained, inspected, and used by competent persons.

CDM 2015: construction phase plan and coordination duties apply to crane operations on construction sites.

RIDDOR: report dangerous occurrences such as crane collapse or uncontrolled load release to the enforcing authority.

Manufacturer's manual is the primary technical standard; deviations require written justification from a competent engineer.

EN 14439 covers tower crane safety; self-erect cranes also carry CE/UKCA marking obligations.

Records of examination, maintenance, and training must be retained and produced on request to the enforcing authority.

The appointed person plans the lift; the competent person examines the equipment - these roles are distinct and must not be confused.

Self-erect crane = tower crane designed for rapid erection without a separate mobile crane, typically using folding mast and jib.

Key components: base, mast sections, slewing ring, jib, counter-jib, counterweight, hoist winch, trolley, hook block, and cab or remote control.

Slew ring allows 360° rotation; slew brake/limit prevents uncontrolled rotation; slew lock is applied during erection and out-of-service.

Hoist limit switches (upper and lower) prevent two-blocking and over-lowering; trolley limits prevent over-travel.

Moment limiter measures load moment and cuts out hoisting/derricking when rated capacity is exceeded.

Self-erect cranes are commonly classified by maximum load moment (tm) and maximum jib length; capacity falls with radius.

Two-blocking is contact between hook block and jib/trolley, prevented by the upper hoist limit; causes include operator error or limit failure.

Counterweight balances the jib; incorrect or missing counterweight invalidates the load chart and stability calculation.

Ground bearing pressure must exceed imposed pressure at the outrigger/base footprint, including dynamic and wind effects, with a factor of safety typically ≥2.

Survey for buried services, drains, basements, and voids within the crane's zone of influence before siting.

Proximity hazards: overhead power lines, adjacent structures, public highways, railways, and other cranes (anti-collision).

Siting must consider jib over-sail and the full slewing circle; define the out-of-service condition (free-to-slew or locked).

Wind exposure is a siting factor: assess prevailing wind, shielding, and the crane's rated in-service and out-of-service wind speeds.

Access for erection/dismantling, delivery vehicles, and laydown areas must be planned.

A site-specific risk assessment and method statement must precede siting; exclusion zones must be established and communicated.

Foundation design must be signed off by a competent engineer and match the manufacturer's specification.

Erection and dismantling require a written method statement, a competent person in charge, and a permit-to-work or equivalent control.

Self-erect sequence typically: base → mast sections → slewing unit → jib and counter-jib → counterweights → commissioning checks.

Climbing uses the crane's own climbing frame; the mast is jacked and a new section inserted - never climb with the jib loaded or in service.

During climbing the crane is in a reduced-stability condition: wind speed limits, slew lock, and exclusion zones are mandatory.

Each mast section, pin, and bolt must be checked for correct fit and torque before return to service.

Dismantling is the reverse of erection; the same planning, supervision, and exclusion controls apply, and it is statistically the higher-risk phase.

No personnel on the mast or jib during jacking unless the manufacturer's procedure and fall protection permit it.

After erection or climbing, a thorough examination by a competent person is required before first use or return to service.

Weather limits (typically manufacturer-specified wind speed for climbing) must be monitored and enforced.

Load moment = load × radius (plus hook block, slings, and jib/trolley effects); rated capacity must not be exceeded at any radius.

Gross load = net load + lifting accessories + hook block; always lift against gross load, not net weight.

Rated capacity decreases with increasing radius; the chart is specific to jib length, counterweight, and base/outrigger configuration.

Stability is governed by the load moment about the tipping line versus the restoring moment of counterweight and base; the chart incorporates a factor of safety.

Dynamic effects: add for acceleration/deceleration and wind; shock loading can exceed static load several-fold.

Wind load on load and jib increases with area and with wind speed squared (∝ v²); respect the in-service wind limit.

Pick-and-carry or travel with load is generally not permitted for self-erect cranes; where allowed, capacity is further reduced.

Verify chart units (kg vs. t, radius in m) and confirm the correct chart page for the actual configuration before every lift.

Sling angle affects tension: for a two-leg sling, tension per leg = (load/2) / cos(angle from vertical); flatter angles increase leg tension.

SWL/WLL of each accessory must be ≥ the tension it carries; the assembly rating is limited by the weakest component.

Use tag lines to control load rotation; ensure the load's centre of gravity is under the hook to prevent tilt and swing.

Inspect slings before use: reject for cuts, fraying, broken wires, chemical damage, or missing ID tags.

Shackles must be rated, pin fully engaged, and moused where vibration could loosen; never substitute non-rated hardware.

Know the load weight (calculate or weigh); unknown loads require a verified weight before lifting.

Avoid side loading of hooks and slings; hooks must have a functioning safety latch and load on the saddle, not the tip.

Landing and setting down: control descent, use guides, and never place hands between load and landing surface.

One designated signaller/slinger directs the lift; only the signaller may give signals, except an emergency stop which anyone may give.

Standard hand signals (raise, lower, slew left/right, stop, emergency stop) must be agreed and understood before the lift.

Radio communication requires a dedicated channel, tested before the lift, with a backup method (hand signals) agreed.

The operator must stop immediately on loss of communication or on any emergency stop signal from anyone.

Signaller and operator must maintain line of sight; if not, an intermediate signaller is required.

Exclusion zones and pedestrian control must be coordinated with the signaller; nobody passes under a suspended load.

Brief all personnel on the lift plan, roles, and emergency procedures before starting; confirm understanding.

Use distinctive PPE (e.g., high-visibility) for the signaller so the operator can identify them unambiguously.

Pre-use checks (daily): visual inspection of structure, wire rope, hooks, limit switches, brakes, and warning devices; record and report defects.

Thorough examination by a competent person: before first use, after erection/climbing, after exceptional circumstances, and at 6-month intervals.

Wire rope inspection: check for broken wires (count per lay length), corrosion, kinks, bird-caging, and end termination condition; reject per manufacturer criteria.

Brake test: verify hoist and slew brakes hold the rated load; test before each shift where practicable and after any adjustment.

Limit switch function test: upper/lower hoist, trolley, and slew limits must operate correctly; never rely on the operator to stop the load.

Maintenance per manufacturer's schedule: lubrication, bolt torque checks, pin wear, and electrical inspection by competent persons.

Defects must be logged and the crane taken out of service until rectified and re-examined; do not operate with a known defect.

Keep records: examination reports, maintenance logs, and defect records available for inspection.

Never exceed rated capacity or the in-service wind speed; stop lifting when wind limits are reached and put the crane into out-of-service condition.

Out-of-service: slew lock or free-to-slew per manufacturer, jib positioned to minimise wind area, and brakes/hook secured.

Lightning: stop operations, lower jib/hook, and follow the site's lightning plan; the crane is a tall structure and a lightning risk.

Overhead power lines: maintain safe clearance (goal posts or isolation) and never operate within the exclusion zone without formal control.

Emergency procedures: emergency lowering of a suspended load, evacuation, and first aid must be briefed; the operator must know how to lower the load safely if power fails.

Fire and fuel: refuelling and battery charging follow site rules; keep extinguishers accessible and know the isolation point.

Environmental: control dust, noise, and spillage; prevent oil/hydraulic leaks from contaminating ground and watercourses.

Incident reporting: any near miss, uncontrolled load, or contact with a structure must be reported and the crane inspected before further use.

Fatigue and fitness: operators must be fit, rested, and free from impairment; shift limits and breaks apply.