TRAINING MODULE FOR SIGNALMAN

(TOWER CRANE)

Prepared for:

Jabatan Keselamatan dan Kesihatan Pekerjaan

Kementerian Sumber Manusia

Prepared by:
30 October 2017 Training Module for Signalman (Tower Crane)

Training Module for Signalman (Tower Crane)

Prepared by:

UKM Pakarunding Sdn Bhd

Universiti Kebangsaan Malaysia
43600 Bangi
Selangor
Tel: 03-89213142
Fax: 03-89252469
Website: http://www.pakarunding.ukm.my/

Prepared for:

Jabatan Keselamatan dan Kesihatan Pekerjaan

(Kementerian Sumber Manusia)
Arasl 2, 3 & 4, Block D3, Kompleks D
Pusat Pentadbiran Kerajaan Persekutuan
62530 W. P. Putrajaya
Tel: 03-8000 8000
Faks: 03-8889 2443
Website : http://www.dosh.gov.my
30 October 2017 Training Module for Signalman (Tower Crane)

CONTENTS
PAGES
1.0 ROLES AND RESPONSIBILITIES OF SIGNALMAN 1
1.1 Introduction To Signalman 1
1.2 Responsibilities of Personnels During Lifting Operation 1
1.2.1 Lifting Supervisor 1
1.2.2 Tower Crane Operator 2
1.2.3 Rigger 3
1.2.4 Signalman 4
1.3 Signalman Roles during Crane Operation 4
1.4 Planning and Preparation by Signalman 5
1.5 Criteria as a Signalman 5

2.0 LEGISLATION 7
2.1 Introduction 7
2.2 Occupational Safety and Health Act 1994 (OSHA) 8
2.3 Regulations and Special Orders under the Factories and
13
Machinery Act, 1967
2.4 Construction Industry Development Board (CIDB)
16
(ACT 520)
2.5 Other Regulations and Code of Practice in relation to
17
Tower Cranes

3.0 INTRODUCTION TO CRANES 19

3.1 Main Functions of Cranes 19
3.2 Types of Tower Cranes 22
3.3 Tower Crane Terminology and Structures 28
3.4 Conditions for the Selection of Tower Cranes 30

4.0 STATISTICS AND CAUSES OF CRANE ACCIDENTS 33

4.1 Introduction 33
4.2 Factors Giving Rise to Accidents Worldwide 33
4.3 Statistics on Tower Crane Accidents 34
4.4 Previous Accident Cases 38
4.5 Measures to Prevent Accidents 41

5.0 BASIC CALCULATION FOR WEIGHT OF A MASS 44

5.1 General Formula for Calculation 44

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5.2 Calculation of Area and Volume of Various Shaped

Objects 46
5.3 Basic Calculation for Finding the Weights of Objects of
Various Shapes 49
5.3.1 Calculated weights of several materials 50
5.3.2 Calculation of weight of load/mass 50
5.3.3 Tonnes to pounds 52
5.3.4 Calculation of weight of load/mass for circular
objects 53

6.0 SAFE OPERATION OF TOWER CRANES 61

6.1 Safe Load Control 61
6.2 Work load Allowed 62
6.2.1 Reach distance of load 62
6.2.2 Luff angle (only for luffing tower cranes) 62
6.3 Handling of loads close to where people are working and
public routes 64
6.4 Control of tower crane operations 65
6.5 Weather conditions 65
6.6 Tower Crane Security Devices 66

7.0 COMMUNICATION 69
7.1 Communication Signals 69
7.2 Hand Signals 70
7.3 Flag Signals 76
7.4 The Use of Two-Way Radios and Other Signals 81
7.4.1 Sending Information by Two-Way Radio 81
7.5 Whistle 83

8.0 PERSONAL PROTECTION EQUIPMENT 85

8.1 Introduction 85
8.2 Types of Personal Protective Equipment 85

GENERAL SAFETY AND RESPONSE TO ACCIDENTS AND
9.0
EMERGENCIES 93
9.1 Identification and Assessment of Hazards at Construction
Sites 93
9.2 Main Hazards/Risks in the Construction Industry 94
9.3 Examples of hazards at construction sites 95

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9.4 Ways to reduce the risk of injury due to collisions between

cranes and other structures 95
9.5 Emergency procedure during contact with overhead
power lines 99

10.0 PRACTICAL TRAINING 102

10.1 Demonstration of the Tower Crane Control 102
10.2 Communication Using Hand 102
10.3 Communication Using Flag 102
10.4 Communication Using Walkie-Talkie 102

11.0 WRITTEN ASSESSMENT 103

11.1 Written training 103
11.2 Communication Using Hand 103
11.3 Communication Using Flag 104
11.4 General Question for Signalman 105

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LIST OF FIGURES
PAGES
Figure 1.1 Safety wear of a rigger 3
Figure 1.2 Safety wear of a signalman 4
Figure 2.1 Acts that apply in Malaysia 8
Figure 3.1 Example of a mobile crane 19
Figure 3.2 Example of a crawler crane 20
Figure 3.3 Example of a derrick crane 21
Figure 3.4 Example of a tower crane 22
Figure 3.5 Saddle top hammerhead tower crane 23
Figure 3.6 Luffing tower crane 23
Figure 3.7 Topless hammerhead tower crane 24
Figure 3.8 Example of a tower crane with a static base installation 24
Figure 3.9 In-situ cast base 25
Figure 3.10 Static base (own base type) 25
Figure 3.11 Installation of crane with external climbing base 26
Figure 3.12 Installation of a crane with an internal climbing base 27
Figure 3.13 Travelling base (type of platform) 27
Figure 3.14 Travelling tower crane 28
Figure 3.15 Design of a hammerhead tower crane 29
Figure 3.16 Design of luffing tower crane 30
Statistics on the number of tower crane accidents
Figure 4.1
worldwide 34
Statistics on the percentage of factors that are the
Figure 4.2
causes of tower crane accidents 34
Figure 4.3 Statistics on accidents involving tower cranes 35
Percentage of causes of tower crane accidents (through
Figure 4.4
surveys) 36
Figure 4.5 Percentage of factors that cause tower crane accidents 36
Figure 4.6 Luffing tower crane accident in Bangsar 39
Figure 4.7 Condition of the tower crane after the incident 40
(a) Luffing tower crane, and (b) iron hook of crane that
Figure 4.8
fell on the victim’s car 41

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Figure 5.1 Oil Tank 54

Figure 6.1 Increase in boom range during lifting of load 63
Figure 6.2 Effect of luff angle on the stability of a tower crane 64
Figure 6.3 Position of the safety device on the hammerhead crane 66
Figure 6.4 Luffing limit switch position 67
Figure 7.1 Hand Signals 76
Figure 7.2 Flag Signals 81
Safety helmet for the construction industry; 1 – shell, 2 –
Figure 8.1 harness, 3 – harness adjuster, 4 – headband, 5 –
sweatband, 6 – peak, 7 – chin strap 86
Figure 8.2 Safety shoes 87
Figure 8.3 Safety gloves 88
Figure 8.4 Reflective vest 89
Figure 8.5 Safety glasses 89
Figure 8.6 Glasses with a direct and indirect ventilation system 90
Figure 8.7 Ear protection devices 90
Figure 8.8 Safety harness 91
Figure 8.9 Safety harness 91
Figure 8.10 Correct method of use and climbing 92
Figure 9.1 Flowchart for HIRARC process 93
Figure 9.2 Collisions and operating radius of tower cranes 95
Figure 9.3 Zone for cranes and mobile machinery working close to
overhead power lines 97
Figure 9.4 Safety observer zone for overhead power lines on pillars
and towers 97
Figure 9.5 Affected area around the crane when in contact with an
aerial conductor 108

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LIST OF TABLES
PAGES
Differences between the requirements of hammerhead and
Table 3.1 31
luffing tower cranes
Table 6.1 The type and weight of the materials for construction 61
Table 7.1 Example of codes by two-way radio 89
Table 7.2 Key to whistle-blowing symbo 83
Table 7.3 Whistle Blowing Standards 91
Table 9.1 Total voltage and safe distance from overhead power lines 99

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ABBREVIATION

FYK - Approved Firm (Firma Yang Kompeten)

DOSH - Department of Occupational Safety and Health
OYB - Orang Yang Bertanggungjawab
PTW - Permit to work (permit-menjalankan-kerja)
SWL - Safe working load (Beban kerja selamat)
WWL - Working load limit (Had beban kerja)

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(1) MODUL: Training Module for Signalman (Tower Crane)

(2) OBJECTIVE: To produce a competent signalman for a tower crane

operation.

(3) LEARNING PERIODS: 3 days (2 days lecture and 1 day practical)

(4) PREREQUISITE: None

(5) SYNOPSIS:
The duty of attending the training is to determine the skill level and also to enable
the signalmen to learn the correct and clear signals to the tower crane operator.
This training is important for obtaining a valid working certificate issued by DOSH.
A signalman is a qualified person to guide the crane operator using a hand signal,
flag or communication tool for providing a direction and also to monitor the
movement of lifting, suspending, dropping and moving operations. The decision
for all crane operations is depending on the signal given to the operator. A
signalman should have a relevant qualification and able to communicate using
standard hand signal, flags and any communication device tools. It is important
to ensure the uniformity of understanding between the signalmen and operators.
In hope, the trend of crane accidents in Malaysia can be reduced with the
combination of a good tower crane forformance with an efficient and ethical
signal communication.

(6) LIST OF TOPICS

Chapter 1 Legislations
Chapter 2 Roles and Responsibilities of Signalmen
Chapter 3 Introduction to Cranes
Chapter 4 Statistics and Causes of Crane Accidents
Chapter 5 Basic Calculation for Weight of a Mass
Chapter 6 Safe Operation of Tower Cranes
Chapter 7 Communication
Chapter 8 Personal Protection Equipment

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General Safety and Response to Accidents and

Chapter 9
Emergencies
Chapter 10 Practical Training
Chapter 11 Written Assessment

TOTAL LECTURE : 14 hours

TOTAL PRACTICAL : 6 hours

(7) REFERENCES (selected):

Akta Keselamatan dan Kesihatan Pekerjaan dan Peraturan-Peraturan. Published
Printers Sdn. Bhd. (Act. 514).
Factories and Machinery Act and Regulation . Published By: Mdc Publishers Sdn.
Bhd. (Act 139).
Peruntukan Utama Akta Keselamatan dan Kesihatan Pekerjaan 1994. Di
Terbitkan oleh Jabatan Keselamatan dan Kesihatan Pekerjaan (JKKP).
Safe Lifting, 2002 Occupational Safety & Health Council, Hong Kong, 2002.
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Bachok, Kelantan, 2004.
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Chembong, Negeri Sembilan, 2003.
Nota Tower Crane Operator, Gamuda Plant Operator School (GPOS), Shah
Alam, Selangor, 2002.
Peruntukan Utama Akta Keselamatan dan Kesihatan Pekerjaan 1994. Di
Terbitkan oleh Jabatan Keselamatan dan Kesihatan Pekerjaan (JKKP).
Guidelines For Public Safety And Health At Construction Sites (1st Revision:
2007), Department of Occupational Safety and Health, Malaysia.
BS 7121-5:2006 Code of practice for safe use of cranes-Part 5: Tower cranes
Code of Practice for Safe Use of Tower Cranes, Hong Kong, 2012.
PN12040 Tower Crane-Code of Practice, Autralia, 2017.

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CHAPTER 1

ROLES AND RESPONSIBILITIES OF SIGNALMAN

1.1 Introduction to Signalman

Signalman is a person who provides a guide to crane operators by using hand

signals, flags or communication tools for direction and supervision of lifting,
suspending, dropping and moving operations. The decision for all crane
operations depends entirely on the signal guide to the crane operator. The
information and instructions provided by the signal engineer must be clear and
understandable by the crane operator to avoid any accident. Signalman should
have the qualifications in practicing the right way and according to hand signal
standards, flags and any communication using device tools during crane
operation. This is important to ensure the uniformity of understanding between
the instructor which is signal operator and crane operator.

Signalman also need to work with lifting members consisting of lifting supervisors,
crane operators and rigger to ensure safe directions can be given to crane
operators. Additionally, signalman should carry out work under supervision of
lifting supervisors to ensure that workplace safety and working conditions are
controlled and monitored.

1.2 Responsibilities of Personnels During Lifting Operation

1.2.1 Lifting Supervisor

Lifting supervisor is responsible for planning and

supervising safe lifting operation using tower crane
at worksite. Lifting supervisor is also responsible in
ensuring all loads were lifted as per safety
procedure, under allowable load limit and in
accordance to the respective load chart of the Sumber: Safe lifting (2002)

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specific tower crane. Among the responsibilities of a lifting supervisor are as

follows:
(a) Possesses the adequate theoretical knowledge, technical and practical
training, plus the experience and knowledge in lifting operations
(b) Prepares and plans for the lifting work
(c) Coordinates and executes the lifting work according to plan
(d) Brief all lifting workers (crane operator, signalman and rigger) regarding the
lifting plan, risk controlling measures and safe lifting procedures prior to
lifting operation
(e) Identifies types and weight of the loads to be lifted
(f) Ensures periodic inspections on the lifting appliances and lifting gear
(g) Ensures safe working load (SWL) markings for all lifting appliances and
lifting gear, and with valid test certificates
(h) Ensures all crane operators are registered with DOSH, while the signalman
and riggers are adequately trained
(i) Evaluates risk and prepare controlling measure accordingly to avoid risks
(j) Attends all lifting operations
(k) If unsafe condition is reported, suitable steps must be taken to rectify the
situation to ensure safe lifting operation
(l) To stop all works if lifting activities lead to unsafe condition

1.2.2 Tower Crane Operator

Tower crane operator must be responsible to

handle crane safely based on orders and work
system provided by the owner or tower crane
contractor. The responsibilities of tower crane
operator are as follows:
(a) To own a log book
(b) To perform daily inspection on crane
Sumber: Safe lifting (2002)
system such as handling mechanisms,
controlling switches, hydraulic hose, hydraulic oil level and various others
(c) To correctly respond to the signalman and rigger during lifting operation

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(d) Only giving lift to allowable loads in accordance to the load chart provided
by crane manufacturer, and to ensure loads lifted do not exceed allowable
load limits
(e) To ensure no lifting activities to be carried out without the risk assessment
by authorised individual or parties
(f) Understand hand signal and verbal communication codes when
communicating using hand signal or walkie-talkie respectively
(g) Understand emergency procedure and know how to react in the event of
accidents during lifting operation

1.2.3 Rigger

Rigger is resposible to tie and release load from crane,

and utilize lifting equipments and gears properly
according to operation plan. Safety wear of a rigger must
be complete and visually distinct (refer Figure 1.1). A
rigger must be:
(a) Adequately trained in slinging and hoisting, able to
estimate load, and safe distance, and height of lifted
load
(b) Able to select suitable lifting equipments and gears
that is safe for the lifting operation
(c) Able to perform visual inspection on the lifting
equipments and gears before use
(d) Avoid using damaged lifting equipments and Figure 1.1 Safety wear of a
gears rigger (Worker’s Safety
Handbook 2011)
(e) Record defected lifting equipments and gears in
suitable documents and report to lifting supervisor
(f) Understand hand signal and verbal communication codes when
communicating using hand signal or walkie-talkie respectively
(g) Understand emergency procedure and know how to react in the event of
accidents during lifting operation

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1.2.4 Signalman

Signalman is responsible to give clear signals as a mean of

communicating with the crane operator after rigging is
completed and the load is ready to be lifted. Signalman is
also responsible to coordinate safe crane movement with
the crane operator. Safety wear of a signalman must be
complete and visually distinct (Figure 1.2). A signalman
must:
(a) Understand hand signal and verbal communication
codes when communicating using hand signal or
walkie-talkie respectively
(b) Able to give instruction to the crane operator and
coordinate movement of crane and load safely Figure 1.2 Safety wear of a
signalman (Worker’s Safety
(c) Able to estimate safe distance between the lifted Handbook 2011)
load and the surrounding objects during lifting
operation
(d) Understand emergency procedure and know how to react in the event of
accidents during lifting operation

1.3 Signalman Roles during Crane Operation

The role of a signalman is very critical during crane operation especially under the
following conditions:
(a) The crane operator’s view on the lifted load is not clear during lifting and
bringing the load down
(b) The crane operator’s view on load is completely blocked
(c) The crane operator is not able to see the load clearly due to large distance
involved
(d) The crane operator is not able to make an informed decision due to the
nature of the loads (e.g. abnormally shaped load, etc).
(e) The crane operator is not able to clearly see the load because lifting
operation is carried out at night
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(f) Lifting activities nearby to public road

(g) Lifting activities nearby to electric cable

1.4 Planning and Preparation by Signalman

Planning and preparation prior to lifting activities need to be considered carefully

by lifting team including signalman. The planning and preparation by signalman
must include as follows:
(a) Wear personal protective outfit
(b) Ensure location is viewable by crane operator
(c) Ensure communication tools are in good condition
(d) Plan the type of signal to be used with the crane operator, such as using
hand signal, flag or other communication devices
(e) Ensure the standard communication signals or codes is understood by both
himself and the crane operator
(f) Cooperate with lifting team to ensure orders given to crane operator is well
received and accurate
(g) Ensure there is no obstacle or hazard interfering with the lifting operation.
Information on such possible interference must be relayed to the crane
operator
(h) Inform the crane operator on the decision made by lifting team with regards
to the lifting plan

1.5 Criteria as a Signalman

A signalman is responsible to give clear signal to a crane operator after rigging is

completed and the load is ready to be lifted. Criteria to become a signalman are as
follows:
(a) Must be a person of the age of 18 years old and above, and possess a valid
certification by an entity (e.g. a training provider) recognised by DOSH.
(b) Visually, hearing and reflection wise in good health condition
(c) Understand and able to use the various communication codes, such as hand
signals, flags, walkie-talkie, etc.

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(d) Able to give clear and precise instructions that will ensure safe movement of
the crane and loads
(e) Wear outfit with clear distinct colours easily seen by the crane tower operator
(f) Must undergo signalman training at DOSH certified training centre
(g) Must going through a signalman refreshment course every 2 years after
obtaining training certificate as signalman

Bibliography

Perintah Kilang dan Jentera (Kepada Pengurus Projek Berkenaan Pengurusan dan
Pengendalian Selamat Kren Menara) 2017.
Guidebook for Lifting Supervisors, Workplace Safety and Health Council, Ministry of
Manpower, Singapore, 2011.
Guidelines for Creating Lifting Plan for Lifting Operations In Workplaces, Workplace
Safety and Health (WSH) Council, Singapore, 2014.
http://www.mytowercrane.com/safeliftingguide.htm [11 September 2017].
Safe Lifting, 2002 Occupational Safety & Health Council, Hong Kong, 2002.
BS 7121-5:2006 Code of practice for safe use of cranes-Part 5: Tower cranes.
Code of Practice for Safe Use of Tower Cranes, Hong Kong, 2012.
PN12040 Tower Crane-Code of Practice, Autralia, 2017.
SS 559: 2010 Code of practice for safe use of tower cranes.

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CHAPTER 2

LEGISLATION

2.1 Introduction

Any action by the enforcement authorities, whether under OSHA or the FMA, should
be in accordance with the existing legislative provisions. Similarly, any directive, action
and decision to be taken by DOSH must be based on clear sources of authority and
stipulations of the law, whether it be OSHA or FMA and the regulations contained
therein. Any unauthorized action can jeopardise the work of DOSH or its enforcement
officers, especially if the case is challenged in court.
For Malaysia, the major legislations enacted to address occupational safety and
health issues at the workplace are the Occupational Safety and Health Act (OSHA)
1994 and the Factories and Machinery Act (FMA) 1967, as shown in Figure 2.1. Under
these Acts, there are Regulations and Rules made by the Minister and which are
enforced by the Department of Occupational Safety and Health (DOSH), Ministry of
Human Resources.

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MINISTRY OF
HUMAN
RESOURCES

DEPARTMENT OF OCCUPATIONAL
SAFETY AND HEALTH

FACTORIES AND PETROLEUM

MACHINERY ACT OCCUPATIONAL
SAFETY AND ACT (Safety
(FMA) 1997 Measures)
HEALTH ACT
(OSHA) 1994 1984

Mining
Manufacturing
Construction
Quarrying Manufacturing
Mining and Quarrying
Construction
Agriculture, forestry and fisheries
Facilities: Electricity, Gas, Water and Hygiene
Services
Transportation, storage and communication
Wholesale and retail trade
Hotels and restaurants
Finance, Insurance, Real Estate and Commercial
Services
Public Service and Statutory Authorities

• Figure 2.1 Acts that apply in Malaysia

DOSH enforces all three Acts. Before a further explanation is given about OSHA
1994 and FMA 1967 (both these Acts are widely used for tower crane issues), a little
clarification should be made with regard to the Petroleum Act (Safety Measures)
1984.

2.2 Occupational Safety and Health Act 1994 (OSHA)

The main purpose of this Act is to inculcate an attitude of concern for safety and health
at the workplace, and to create effective safety measures through self-regulatory
schemes, consultation, collaboration and involvement of employees, that are tailored
to the industry or relevant organization. The long-term objective of this Act is mainly to
produce a healthy and safe work culture among all employees and employers in
Malaysia.

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Aims of OSHA (Act 514)

(Part I; Section 4 Paragraphs (a),(b),(c) and (d)) Act 514 )
1) To secure the safety, health and welfare of employees;
2) To protect employees and others against activities that involve risks;
3) To promote a safe and healthy workplace environment;
4) To provide occupational safety and health legislations with industrial
codes of practice approved under the provisions of the Act (not limited
to Acts and regulations).

Scope of Act 514

FOR EMPLOYEES:
in all sectors in Malaysia is as follows:
(a) Manufacturing
(b) Mining and quarrying
(c) Construction
(d) Agriculture, forestry and fisheries
(e) Facilities: Electricity, Gas, Water and Hygiene Services
(f) Transportation, storage and communication
(g) Wholesale and retail trade
(h) Hotels and restaurants
(i) Finance, Insurance, Real Estate and Commercial Services
(j) Public Service and Statutory Authorities

Except:
Work on ships (enshrined under the Merchant Shipping Ordinance 1952) and in the
Armed Forces.

General Duties of Employers and Self-Employed Persons (Part IV)

Summary of the Relevant Provisions:
Section 15. General duties of employers and self-employed persons to their
employees

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It is the duty of the employer and self-employed person to ensure the safety, health
and welfare of his employees while they are at work. The general duties of employers
are summarised as follows:
Paragraph (1) and Paragraph (2);
(a) To provide a safe plant and system of work.
(b) The use or handling .... plant and substances;
(c) To have and provide information, instructions, training and supervision
in relation to safety and health.
(d) To provide safe means of access to and egress from the workplace
(e) To maintain a safe work environment for employees.

For the purposes of this section, “employees” include independent contractors and the
employees of that independent contractor.

Section 16. Duty to formulate safety and health policy

It is the duty of the employer to prepare and revise a written statement of his general
policy with respect to the safety and health of his employees, and to bring it to the
notice of all his employees.

Section 17. General duties of employers and self-employed persons to persons

other than their employees
It is the duty of the employer and the self-employed person to conduct his undertaking
so as to ensure that other persons who are not his employees are not exposed to risks
to their safety or health as a consequence of his undertaking.

Section 18. Duties of an occupier of a place of work to persons other than his
employees
It is the duty of the occupier of non-domestic premises to ensure that the premises,
plant or substances used by persons who are not his employees are safe. This duty
includes any maintenance or repairs to the place and the access to and egress from
that place.

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Section 19. Penalty for an offence

A person who contravenes the provisions of section 15, 16, 17 or 18 shall be guilty of
an offence and shall, on conviction, be liable to:
(a) A fine not exceeding RM 50,000.00; or
(b) Imprisonment for a term not exceeding 2 years; or
(c) Both.

Section 20. General duties of designers, manufacturers, importers and suppliers

with regard to plants for use at work
It is the duty of a person who designs, manufactures, imports or supplies any plant to
ensure that it is so designed and constructed as to be safe and without risks to safety
and health.
In this case, a plant includes any tool or device or machine (tower crane). A designer
or manufacturer or importer of tower cranes can be charged under this section if he
commits a related offence.

“So far as is practicable”

The duties set out in sections 15, 17 and 18 of OSHA are so far as is practicable. The
phrase “so far as is practicable” means by giving due consideration to and taking into
account four factors that are provided for in section 3(1):
(a) the severity of the hazard or risk in question;
(b) the state of knowledge about the hazard or risk and any way of removing or
mitigating the hazard or risk;
(c) the availability and suitability of ways to remove or mitigate the hazard or risk; and
(d) the cost of removing or mitigating the hazard or risk.

(To further understand the meaning of the phrase ‘so far as is practicable’, please refer
to the Guideliness to the General Provisions of OSHA 1994).

General Duties of Employees (Part VI)

Section 24. General duties of employees at work
Paragraph (1) sub-paragraph (a),(b),(c) and (d), and Paragraph (2)

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(a) To take care of the safety and health of himself and of other persons.
(b) To co-operate with his employer and other persons in implementing the
requirements of the Act.
(c) To wear the personal protective equipment provided.
(d) To comply with instructions and measures on occupational safety and
health.

A person who contravenes the provisions of this section shall be guilty of an offence
and shall, on conviction, be liable:
(a) to a fine not exceeding RM 1,000.00; or
(b) to imprisonment for a term not exceeding 3 months; or
(c) to both.

Section 25. Duty not to interfere with or misuse things provided pursuant to
certain provisions
A person who intentionally, recklessly or negligently interferes with or misuses
anything provided or done in the interests of safety, health and welfare in pursuance
of this Act shall be guilty of an offence and shall, on conviction, be liable:
(a) to a fine not exceeding RM 20,000; or
(b) to imprisonment for a term not exceeding 2 years; or
(c) to both.

The regulations under OSHA 1994 are as follows:

1. Occupational Safety and Health (Classification, Labelling and Safety Data
Sheet of Hazardous Chemicals) Regulations 2013;
2. Occupational Safety and Health (Notification of Accident, Dangerous
Occurrence, Occupational Poisoning and Occupational Disease)
Regulations 2004;
3. Occupational Safety and Health (Use and Standards of Exposure of
Chemicals Hazardous to Health) Regulations 2000;
4. Occupational Safety and Health (Safety and Health Officer) Regulations
1997;

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5. Occupational Safety and Health (Classification, Packaging and Labelling

of Hazardous Chemicals) Regulations 1997 (Revoked);
6. Occupational Safety and Health (Safety and Health Committee)
Regulations 1996;
7. Occupational Safety and Health (Control of Industrial Major Accident
Hazards) Regulations 1996;
8. Occupational Safety and Health (Employers’ Safety and Health General
Policy Statements) (Exception) Regulations 1995.

ORDERS:
- Occupational Safety and Health (Safety and Health Officer) Order 1997
- Occupational Safety and Health (Prohibition of Use of Substances) Order
1999

2.3 Regulations and Special Orders under the Factories and Machinery Act,
1967

The Regulations and Orders under the Factories and Machinery Act, 1967 pertaining
to the safety of machinery and the construction of buildings are as follows:
1. Factories and Machinery (Exemption of Certificate of Fitness for Hoisting
Machine) Order 2015;
2. Factories and Machinery (Building Operations and Works of Engineering
Construction) (Safety) Regulations 1986;
3. Factories and Machinery (Notification of Fitness and Inspections)
Regulations 1970;
4. Factories and Machinery (Safety, Health and Welfare) Regulations 1970
(Amended - 1983); and
5. Chief Inspector Special Order (To The Project Manager On the
Management and Safe Operation of Tower Cranes) 2017.

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In exercising the powers conferred on him by subsection 27(1) of the

Factories and Machinery Act 1967 [Act 1391], the Chief Inspector of
Factories and Machinery issued the following special orders:

Project managers must ensure that tower cranes:

(a) Have approved designs and comply with the requirements for design approval
by the Department of Occupational Safety and Health;
(b) Have an installation permit and comply with the requirement for installation
approval by the Department of Occupational Safety and Health; and
(c) Have a valid certificate of fitness.

The Regulations from No. 1 to No. 4 are indirectly related to the use of tower cranes,
hence they are not described here. Meanwhile, the Chief Inspector Special Order (To
The Project Manager On the Management and Safe Operation of Tower Cranes) 2017
is very relevant to the use of tower cranes at the sites of construction projects, and the
special order makes it the primary duty of the project manager. The Order was made
under the power of subsection 27(1) of the Factories and Machinery Act 1967.
The responsibilities of the project manager are as follows:
1. The project manager must ensure that the tower crane has:
(a) An approved design and complies with the requirements for a design
approval by DOSH;
(b) A permit for its installation, and complies with the requirements for the
approval of installation by DOSH; and
(c) A valid certificate of fitness.

2. The project manager should ensure that during the operation, handling and
maintenance of the tower crane:
(a) The operator who is appointed is registered with the Department of
Occupational Safety and Health to operate the crane;
(b) The appointed lifting supervisor, signalman and rigger have relevant and
adequate knowledge, experience and competency;
(c) A permit-to-work system is implemented;

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(d) All the lifting gear is inspected and maintained according to the specifications
of the manufacturer and good engineering practices;
(e) All safety devices are maintained to function properly at all times and are not
easily disrupted; and
(f) Records relating to the use, inspection, maintenance and permit-to- work are
kept at the construction site for checking purposes at any time..
The project manager must ensure that any person appointed by the occupier has a
valid contract that is legally binding to:
(a) Carry out works to inspect, install, mount, test, maintain and dismantle a tower
crane;
(b) Conduct regular inspections on each tower crane at least once a month;
(c) Carry out works to inspect, install, mount, test, maintain and dismantle a tower
crane according to the specifications of the manufacturer and good engineering
practices; and
(d) Perform repairs or modofications to the tower crane structure or components
after obtaining the written approval of the Department of Occupational Safety
and Health, and in accordance with the specifications of the manufacturer and
good engineering practices.

Penalty:
“Any person who violates this special order shall be guilty of an offence and can be
charged under section 8(g) of the Factories and Machinery Act 1967 (Act 139) and, if
convicted, shall be liable to a fine not exceeding two hundred thousand ringgit or to
imprisonment for a term not exceeding five years or to both”.
However, no specific Regulations have been made under either of the two Acts (OSHA
1994 and FMA 1967) regarding the correct use or operation of tower cranes at work
sites. This can be found in the following guidelines and standards:
1. Guidelines of Occupational Safety and Health (OSH) in the Construction
Industry (Management) 2017;
2. Guidelines for Public Safety and Health at Construction Sites, 2007;
3. Guidelines for the Prevention of Falls at the Workplace, 2007;

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4. Guidelines for the Prevention of Falling Objects at the Workplace,

Department of Occupational Safety and Health, Ministry of Human
Resources, Malaysia, 2007.
5. Standard Malaysia, MS 1803:2008: Cranes - Safety - Tower Cranes;
6. Standard Malaysia MS ISO 4310:2014 Cranes - Test code and procedures
(First revision) (ISO 4310:2009, IDT); and
7. Standard Malaysia MS ISO 4306-1:2014 Cranes – Vocabulary - Part 1:
General (First Revision) (ISO 4306-1:2007, IDT).

2.4 Construction Industry Development Board (CIDB) (ACT 520)

The Construction Industry Development Board of Malaysia is a department under

the Public Works Ministry. The history of its establishment is as follows:
• Tabling of the Construction Industry Development Board Act in
Parliament in May 1994.
• Gazetted as Act 520 in July 1994.
• Came into effect officially on 1 December 1994.

Objectives of Act 520:

1) To register contractors/workers in the construction sector according to

their class/skills.
2) To accredit and certify skilled construction workers and construction site
supervisors according to the methods and forms specified.
3) To conduct investigations into any offence and inspections.

Jobs that require skills and certification

1) Blaster and painter
2) Air-conditioning and mechanical ventilation specialist
3) Drywall installer
4) Ceiling installer
5) Petrochemical fitter
6) Roof truss installer
7) Precast concrete installer
8) Formwork system installer
9) Block system installer
10) Bar bender
11) Wireman
12) Bricklayer
13) Plant operator
14) Crane operator
15) Chargeman
16) Cable jointer
17) Slinger and rigger
18) Painter

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19) Tiler
20) Carpenter
21) Welder
22) Plasterer
23) Plumber
24) Scaffolder

Why is it necessary for construction site workers and supervisors to register with
the Malaysian Construction Industry Development Board (CIDB)?

1) To gain recognition for their skills.

2) To enhance their career opportunities.
3) To acquire opportunities to improve their skills.
4) To enjoy the benefits of protection through the Takaful scheme.
2.5 Other Regulations and Code of Practice in relation to Tower Cranes

Occupational Safety and Health (Control of Industrial Major Accident Hazards)

Regulations 1996

PART I
Regulation 1: Preliminary
These regulations may be cited as the Occupational Safety and Health (Control
of Industrial Major Accident Hazards) Regulations 1996, and take effect on 1
February 1996.

Regulation 5: Obligations of Manufacturer and Employee

(1) Every manufacturer who undertakes an industrial activity shall -
(a) comply with the requirements of these Regulations;
(b) take immediate action to rectify the situation as soon as he becomes
aware of an imminent danger which may affect the safety of persons or
the environment; and
(c) establish and maintain a good management system for controlling any
major accident, as described in the report made under sub-regulations
14 (1) and regulation 16.

(2) Every employee shall:

(a) cooperate with the manufacturer in complying with the requirements of
these Regulations;
(b) act in such manner so as not to endanger himself or to cause or be likely
to cause bodily injury to himself or to other persons, or damage to life
and property; and
(c) notify the manufacturer as soon as he becomes aware of any potential
hazard he considers is capable of generating a major accident, and shall
have the right to notify an officer of the potential hazard.

PART II:
Regulation 9: Demonstration of Safe Operation

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A manufacturer who has control of an industrial activity to which this Part applies
shall, at any time, at the request of the Director General, provide evidence,
including the production of documents, to show that he has:

(a) identified the possible major accident hazards; and

(b) taken adequate steps to -
(i) prevent any major accident or minimize its consequences to persons and
the environment; and
(ii) provide persons working on the site with the information, training and
equipment necessary to ensure their safety; and
(c) prepared and kept up-to-date an adequate on-site emergency plan detailing
how major accidents will be dealt with.

PART III:
Regulation 23: Notification of Major Accident
Where a major accident occurs on a site, a manufacturer shall notify the nearest
Occupational Safety and Health office of the accident by the quickest means
available and the manufacturer who makes the notification shall provide:-
(a) the following information relating to the accident as soon as it occurs:
(ii) the circumstances of the accident;
(iii) the hazardous substances involved;
(iv) a suitable date for assessing the effects of the accident on persons and
the environment; and
(v) the emergency measures taken; and
(b) a statement of the steps envisaged to alleviate the medium or long-term
effects of the accident (if any), and prevent the recurrence of such an
accident.

PART IV:
Regulation 24: Penalty
(a) A manufacturer who commits an offence against any of the provisions of
these Regulations shall, on conviction, be liable to a fine not exceeding fifty
thousand ringgit (RM 50,000.00) or to a term of imprisonment not exceeding
TWO (2) years or to both.

(b) An employee who commits an offence against any of the provisions of these
Regulations shall, on conviction, be liable to a fine not exceeding one
thousand ringgit (RM 1000) or to a term of imprisonment not exceeding
THREE (3) months or to both.

Bibliography

Akta Keselamatan dan Kesihatan Pekerjaan (AKKP) 1994 (Akta 514), dan Peraturan-
Peraturan di bawah AKKP.

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Akta Kilang dan Jentera (AKJ) 1967 (Akta 139), dan Peraturan-Peraturan di bawah AKJ.
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Bachok, Kelantan, 2004.
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Chembong, Negeri Sembilan, 2003.
Nota Tower Crane Operator, Gamuda Plant Operator School (GPOS), Shah Alam,
Selangor, 2002.
Peruntukan Utama Akta Keselamatan dan Kesihatan Pekerjaan 1994. Di Terbitkan oleh
Jabatan Keselamatan dan Kesihatan Pekerjaan (JKKP).
Lembaga Pembangunan Industri Pembinaan Malaysia, Akta 520.

CHAPTER 3

INTRODUCTION TO CRANES

3.1 Main Functions of Cranes

Cranes are included in the load lifting equipment category. A crane is a

mechanical tool that is used for raising or lowering a load and to move the load
horizontally to the required location. Its use is also aimed at facilitating and
speeding up the construction of tall, huge and wide structures such as buildings
and bridges. There are also several types of cranes, namely mobile cranes,
crawler cranes, derrick cranes and tower cranes. The selection and use of a
crane depend on its suitability for the work requirements at a construction site.

(a) Mobile Cranes

A mobile crane is a type of crane on wheels that is be powered by its own engine
and can be driven on the road. It is used to raise and lower loads from a
moderately high place and is easy to handle for work in a confined space (Figure
3.1).

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Figure 3.1 Example of a mobile crane (Occupational Health and Safety Code
2009, Alberta Canada; www.cccme.org.cn)

(b) Crawler Cranes

A crawler crane is a type of crane for climbing. It moves by means of tyres or on

crawler tracks, and it can be manually driven. However, its movements are
restricted to the appropriate roads only. Crawler cranes are suitable for use on
all types of land and earth surfaces. This type of crane also has the power to
raise and lower loads from a height (Figure 3.2).

Figure 3.2 Example of a crawler crane (OSHAcademy Occupational Safety

and Health Training, US; www.directindustry.com)

(c) Derrick Cranes

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A derrick crane is a type of crane that is used on high-rise buildings, where it is

placed in a static position on the building structure and cannot be moved (Figure
3.3). This type of crane is usually used to lower a tower crane structure that is to
be dismantled after having completed works to raise or lower loads.

Figure 3.3 Example of a derrick crane (OSHAcademy Occupational Safety

and Health Training, US; http://jaipur.all.biz)

(d) Tower Cranes

Tower cranes are designed using high-strength iron shaped into a tower. They
are used for industrial works and for the construction of high-rise buildings. Tower
cranes can raise and lower heavy loads, and are better than other cranes. They
are installed in a static position or move along rails (Figure 3.4).

Almost the entire tower crane structure is made of solid iron, and it is divided
into several parts. These parts can be separated and joined back again. This
technique of joining and separating the crane section by section is used to
facilitate the process of installing and dismantling the tower crane. It is also meant
to facilitate the transportation of the crane from one construction site to another.

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Figure 3.4 Example of a tower crane (Occupational Health and Safety Code
2009, Alberta Canada; www.ictinpractice.com)

3.2 Types of Tower Cranes

Tower cranes are one of several types of cranes in the heavy machinery category
that are commonly used to raise and move any heavy and massive load from one
place to another. A tower crane is a rectangular tower fitted with several important
components such as bolts, nuts, and pins, and its base is made of cast concrete
supported by beams or mounted on rails. The slewing platform, hoist, mast and
boom are mounted on the base of the tower.

Before a tower crane is installed, safety inspections should be carried out

first, and these must be carefully planned according to the established
procedures. The installation of the boom and counterweight is a hazardous job,
and if it is not carefully planned or studied, it can result in the failed installation of
the tower crane. Generally, there are many types of tower cranes, but among the
popular types used in Malaysia are the hammerhead (saddle top), hammerhead
(topless) and luffing cranes. These cranes can be divided into several categories
depending on their size and manufacturer.

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Crane structure

Crane base foundation

Concrete

Figure 3.5 Saddle top hammerhead tower crane (Occupational Safety and
Health Program, A Guide to Cranes and Derricks, US)

Boom angle

reach out

Figure 3.6 Luffing tower crane (Occupational Safety and Health Program, A
Guide to Cranes and Derricks, US)

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Figure 3.7 Topless hammerhead tower crane (www.nftcrane.com)

In general, tower cranes can also be categorized according to their base

installation. There are three main types of base installations for tower cranes,
namely: -
(a) Static Base
This type of crane is generally popular and is the tallest among all the other
types of cranes. It is suitable for installation in open sites, and is usually
placed at the front or in any place where there is enough space for the boom
to move/rotate (Figure 3.8).

Figure 3.8 Example of a tower crane with a static base installation

(Environmental, Health and Safety (EHS) Departments, US)

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For the static base category, there are two methods of installation for the tower
crane base, namely:

(i) In-situ cast base

This type of base requires a special anchor (known as an expandable
anchor) to be embedded in a concrete block (Figure 3.9).

Top crane parts

Concrete

Fixed structure
of anchors in
concrete base
sites

Figure 3.9 In-situ cast base

(i) Own base

The base of the crane is constructed by placing ballast at the crane base with
the chassis as the weight (Figure 3.10).

Ballast Crane structure

Crane foundation Anchors

Figure 3.10 Static base (own base type)

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(b) Climbing base

Tower cranes with this type of installation are usually used for the
construction of high-rise buildings. The installation process involves installing
the base starting from one level to a higher level. There are two methods for
the installation of a climbing base, namely: -

(i) Externally supported static crane

The base is supported by a construction/building structure joined by a
climbing frame. The height of the crane can be extended, depending on
the height of the building structure, and it should be aligned with the
climbing frame (Figure 3.11).

Figure 3.11 Installation of crane with external climbing base

(www.dcm.milgromandassociates.com)

(ii) Internal climbing crane

This type of tower crane installation is usually designed for tall buildings,
and it is placed in a location where it can be supported by structures
within the building that is under construction (Figure 2.12). The crane can
be adjusted from one level of the building under construction to a higher
level.

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Figure 3.12 Installation of a crane with an internal climbing base

(www.dcm.milgromandassociates.com)

(c) Travelling rails

This type of tower crane moves on heavy-wheeled bogies placed on rails.
The bogies have no fixed grade but change according to the height of the
mast mounted on the tower crane (Rajah 2.13-14).

Crane structure

Ballast

Bogies/
wheel

Rail stopper Rail

Figure 3.13 Travelling base (type of platform)

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Rajah 3.14 Travelling tower crane (Environmental, Health and Safety (EHS)
Departments, US)

3.3 Tower Crane Terminology and Structures

(a) Saddle top hammerhead tower crane

This type of tower crane is adapted for industrial projects that have certain
criteria, such as a wide load area, and it is driven by electrical power. If the
area or site meets the specified criteria, then the hammerhead tower crane
would be suitable for use (Figure 3.15).

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6 4
8 9
1

11 2

12 10 3
7 5
13 No Terminology
14
SLEWING UNIT
1 Boom
15 2 Trolley
3 Hook block
4 Counter jib
16 5 Ounter weight
6 Hoist unit
17 7 Hoist drum
8 A-frame
9 Pendant bar
10 Hoist rope
11 Operator cabin
12 Slewing installation
13 Slewing pivot
TOWER
19 14 Middle climbing unit
15 Telescopic cage
20 16 Mast
18 17 Inner tie
21 BASE
18 Base chassis of tower
22 19 Crane support
23
20 Center of ballast
21 Crose frame
22 Pad
23 Anchors

Figure 3.15 Design of a hammerhead tower crane (saddle top)

(http://www.morrow.com/crane101)

(b) Luffing tower crane

This type of tower crane, which is able to lift heavy loads and is powered by
electricity, can be adapted for industrial projects with criteria such as limited
load or rotation span. If the area or site meets the specified criteria, then the
luffing tower crane is suitable for use (Figure 3.17).
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6 5 4

2
8
3
1
9 7

10
11 12

No. Terminologi
1 Jib/bum
2 Combine
13 3 Hook
4 Jib tie
5 Pendent
6 Block
7 Installation luffing
8 Luffing wire
9 Hoisting rope
10 A- frame
11 Counter weight
12 Slewing Ring
15 14 13 Cabin
14 Jib/boom angle
15 Tower
Anchor
Concrete

Figure 3.16 Design of luffing tower crane (http://www.morrow.com/crane101)

3.4 Conditions for the Selection of Tower Cranes

Each tower crane design is reasonably based on the requirements of its use. The
explanation for the suitability of two main types of tower cranes is as follows:
(a) Hammerhead tower crane
This type of tower crane is suitable for industrial projects that have the
following criteria:
• wide load area or reach
• limited strength of load to be lifted
• this type of tower crane is driven by electric power
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If the area or site meets the above criteria, then the type of tower crane that is
suitable for use is the hammerhead.

(b) Luffing tower crane

This type of tower crane is adapted for industrial projects that have the
following criteria:
• limited load area or span
• a high load strength to be lifted
• most of these cranes use engine power

If the area or site meets the above criteria, then the luffing tower crane
should be used. Table 3.1 gives a clearer picture of the differences in the
suitability of these tower cranes.

Table 3.1 Differences between the requirements of hammerhead and luffing tower
cranes

HAMMERHEAD LUFFING
• Wide span of radius or • Limited span of radius or
rotation. rotation.
• Load strength that can be • Load strength that can be
hoisted is limited. hoisted is higher.
• Uses electric power • Most tower cranes use
electric power

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Bibliography

Environmental, Health and Safety (EHS) Departments, US

http://www.cccme.org.cn
http://www.cranecrews.com
http://www.ictinpractice.com
http://www.jaipur.all.biz
https://sddahan.en.alibaba.com
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Bachok, Kelantan, 2004.
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Chembong, Negeri Sembilan, 2003.
Nota Tower Crane Operator, Gamuda Plant Operator School (GPOS), Shah Alam,
Selangor, 2002.
Occupational Health and Safety Code 2009, Alberta Canada
Occupational Safety and Health Program, A Guide to Cranes and Derricks, US
OSH Academy Occupational Safety and Health Training, US
Shandong Minglong Construction Machinery Co., Ltd.

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CHAPTER 4

STATISTICS AND CAUSES OF CRANE ACCIDENTS

4.1 Introduction

The construction industry has been identified as one of the largest and most
dangerous industry in the world, based on the rate of job-related deaths, workers’
compensation, injuries and fatalities. The construction industry also involves the
use of cranes, especially tower cranes, to help speed up the construction of
buildings. In this industry, consideration to safety and health requirements is
widely recognised as a useful approach in managing occupational safety and
health as hazards at the workplace can be eliminated or minimised by placing
greater emphasis on these factors. With regard to hazards to the safety of
workers, high risk activities, including working at heights and hoisting works, have
been identified as causes of accidents in the construction sector.

With the increase in the number of tower cranes in Malaysia each year, the
accident rate may rise if safety factors and regulations/codes on the standard
use of tower cranes are not complied with. According to a study by Chong and
Low (2014), during the period 2000 to 2009, as many as 69,126 accidents
occurred in the construction industry, of which 653 cases involved tower cranes.
With reference to the statistics by DOSH (2017), the states with a high number
of tower cranes are Kuala Lumpur, Selangor, Johor and Penang. To date, there
are 1434 tower cranes and 1614 registered and active tower crane operators in
Malaysia. A large number of these tower cranes (1120) are being used in Kuala
Lumpur, Putrajaya, Selangor and Johor.

4.2 Factors Giving Rise to Accidents Worldwide

From the year 2000 until now, more than 1125 tower crane accidents have
occurred involving 780 deaths worldwide. According to the data from surveys,

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many accidents go unreported, and these are estimated to be twice as many as

the reported cases. In 2009, there were 188 cases involving 78 deaths, while a
total of 154 accidents with 113 deaths were reported in 2010. The statistics on
the number and causes of such accidents are shown in Figures 4.1 and 4.2.

Statstik Kemalangan Kren Menara di Seluruh Dunia (2009)

53 Kemalangan 27 Kemalangan
52 Kematian 4 Kematian Semasa operasi

Memasang/meninggi
Menegak/menaik/
/merombak
merombak
Angin

Tidak diketahui

24 Kemalangan
2 Kematian
72 Kemalangan
21 Kematian

Figure 4.1 Statistics on the number of tower crane accidents worldwide

(www.towercranesupport.com)

Statistik Kemalangan Kren Menara di Seluruh Dunia (2010)

31% (48 kes) Semasa operasi

Memasang/meninggi
Menegak/menaik/
23% (35 kes) /merombak
merombak
Angin
38% (59 kes)
8% (12 kes) Tidak diketahui

Figure 4.2 Statistics on the percentage of factors that are the causes of tower
crane accidents (www.towercranesupport.com)

4.3 Statistics on Tower Crane Accidents

Based on surveys that have been conducted, the accident statistics show that
deaths and hazardous incidents at the workplace involving tower cranes and

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hoisting equipment are increasing every year (see Figure 4.3). Among the
causes of the accidents are:
(a) failure of the crane structure or components,
(b) failure of the hoisting equipment (such as the wire rope, pulley, hook block,
etc.),
(c) falling objects,
(d) swinging object during the hoisting of a load.

Based on the causes of accidents mentioned, it is necessary for the

construction industry to improve its practices for the safe operation of tower
cranes. Therefore, the stakeholders in the operation of tower cranes (such as
crane manufacturers, crane contractors, engineers and designers, project
managers, lifting supervisors, operators, signalman, riggers and construction
workers) should play their respective roles and carry out their responsibilities to
ensure that the hoisting operations are conducted safely.

The Total Cases Reported Related to Tower Crane from 2000-2016

16
14
14
12 11
Number of cases

10
8
8
6
6 5 5
4 3
2 1 1 1 1 1 1
0
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16

Year

Figure 4.3 Statistics on accidents involving tower cranes

Among the factors identified as being the cause of accidents during hoisting
operations are the following:
(a) damage to a single mechanical system (such as the hoisting system,
hook block, electronic system and the brake system),

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(b) the lackadaisical attitude of the hoisting crew,

(c) unsafe working environment for cranes,
(d) defective lifting equipment or tools,
(e) abnormal load types and shapes, and
(f) improper rigging and slinging methods.

More than 80% of the respondents to a questionnaire agreed that crane accidents
were due to the negligence of the crane operator, poor communication,
mechanical issues and the lifting of excessive loads, as shown in Figure 4.4.
Referring to reports from the Department of Occupational Safety and Health
(DOSH) from 2000-2017, among the main factors that contributed to tower crane
accidents were mechanical or structural issues, and those that occurred during
the operation of the crane, as shown in Figure 4.5.
100%
83.7% 85.3%
90% 79.1% 81.2% 78.9% 75.5% 77.5%
80% 72.7% 69.5% 69.5% 69.0%
70%
60%
Percentage (%)

50%
40%
30%
20% 12.8%
10%
0%
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en

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ai
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ha

aa
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ik

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kr
en

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ik
rk

an

n-
bi

am

ar
un
ek
li

as
m

i
rle

tu

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ek

n
da

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el

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as
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be

en
en

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ba

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om

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is

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Is
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Is
Is

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/m
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ka

ak
ai

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en

Accident Factor
en

M
M

Figure 4.4 Percentage of causes of tower crane accidents (through surveys)

21 % (12 kes)
12% (7 kes)
Isu-isu mekanikal atau struktur
Semasa operasi
Lain-lain
Isu-isu elektrik/sistem kawalan
Isu-isu asas tapak
Cuaca lampau

43% Menegak/menaik/merombak
Memasang/meninggi/merombak
(25 kes) 4% 5% 5% 10%
(2 kes) (3 kes) (3 kes) (6 kes)

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Figure 4.5 Percentage of factors that cause tower crane accidents (Abdullah &
Wern, 2010; DOSH investigation files; www.dosh.gov.my)
With reference to Figure 4.5, out of 58 accidents that occurred, 43% were due to
mechanical or structural issues with the crane, i.e. damage to the crane
components, such as:
(a) bent boom,
(b) snapped crane cable,
(c) broken pin/bolt, and slewing table,
(d) snapped luffing wire rope,
(e) broken or cracked boom pin,
(f) gear/brake problems,
(g) hoisting drum problems,
(h) snapped wire rope hoist,
(i) bent or cracked crane mast.

The factors that occurred during the operation of the crane contributed to 21% of
the accidents, and these were due to the negligence of crane operators and
signalman, and the failure of the management in ensuring that the hoisting team
comprised members who were competent. The other factors were electrical or
control system issues, where 10% of the accidents were due to failure in the
crane control system, such as:
(a) hoist limit switch,
(b) hoisting system,
(c) failure of the luffing system.
In addition, crane accidents were also caused by the failure of the tower crane
base, where 4% were due to the installation/mounting/dismantling of tower
cranes, 5% to extreme weather (wind and lightning), and 12% to other
factors/unknown causes. Among the factors that affected safety during the
installation, mounting or dismantling of tower cranes were:
(a) inadequate knowledge and skills of the installer/dismantler,
(b) incomplete instructions or manuals regarding safe work procedures,
(c) damage to tower crane parts due to improper storage.,
(d) poor supervision at the workplace,
(e) work pressure, space and time constraints.

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To control hazards associated with hoisting equipment and operations, the

members of the hoisting crew should take note of the following:
(a) the selection of the hoisting equipment,
(b) the position of the hoisting equipment,
(c) the determination and identification of a safe work load for each
hoisting equipment,
(d) safe storage of hoisting aids,
(e) maintenance of hoisting equipment,
(f) planning of hoisting operations,
(g) slinging and rigging methods,
(h) adequate training for personnel involved in hoisting.

4.4 Previous Accident Cases

Examples of Cases
Case 1:
The incident occurred on 15 April 2016 at a construction site at Lot 422, Jalan
Bangsar, Section 96, Kuala Lumpur. At approximately 11:50 a.m., a tower crane
at the construction site adjacent to Dataran Maybank toppled over, where the tip
of the crane fell onto the road in front of Dataran Maybank (as shown in Figure
4.6). No fatalities were reported. The details of the accident were as follows:
(a) the luffing tower crane was manufactured in 1994;
(b) according to the logbook, it was first used at the construction site in
November 2015;
(c) the crane was lifting an iron elbow weighing 1.5 tonnes, where the boom
was lifted up to 82 degrees (according to the meter reading, it had
exceeded the permissible safe limit). The boom then toppled over in the
opposite direction, while the tip of the boom dropped off and fell on the
adjacent road, causing damage to a lorry.
(d) The cause of the accident was the failure of the luffing limit switch.

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Figure 4.6 Luffing tower crane accident in Bangsar

Case 2:
The incident took place in Johor Bahru, Johor on 24 July 2016. The tower crane
became unstable when it was lowering sand, and the front part of the boom broke
first, followed by the jib balancer. The boom toppled over and got stuck on the
13th floor, as shown in Figure 4.7. The details of the accident were as follows:
(a) the tower crane was unloading sand using a bucket with a capacity of
approximately 1 m3 from ground level to the 10th floor;
(b) when the load was at a height equivalent to the 5th floor and the trolley
was at the mid-point of the boom, the crane suddenly experienced failure;
(c) this failure caused the boom to fall backwards and the buffer weight to fall
to the ground;
(d) from the results of the preliminary investigation and based on the
surrounding evidence, it was found that the accident probably occurred
when the bucket got caught on the scaffolding;
(e) the cause of the accident was the wire rope hoist, which got caught on the
scaffolding.

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Figure 4.7 Condition of the tower crane after the incident

Case 3:
The incident involving a luffing tower crane occurred in Bukit Bintang, Kuala
Lumpur on 25 August 2016, as shown in Figure 4.8. The details of the accident
were as follows:
(a) the hook block of the crane, weighing more than 300 kg, fell from a height
of more than 100 metres, and crashed onto a car on the road, resulting in
the death of a 24-year-old woman.
(b) members of the public claimed that they saw the boom moving across the
road beyond the operating boundary of the crane before the hook block
fell and crashed onto the victim’s car.
(c) the position of the crane also violated the rules of safety because it was
operating beyond the site fence for the building project.
(d) the incident could have been caused by the lifting limit switch being
diverted when lowering or raising the hook, thereby causing the hook to
jerk on the tip of the boom and to cause the wire rope to snap.

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Figure 4.8 (a) Luffing tower crane, and (b) iron hook of crane that fell on the
victim’s car

4.5 Measures to Prevent Accidents

Preventive measures must be taken by the responsible parties to ensure that
such accidents involving tower cranes are not repeated. Among the preventive
measures that can be taken are the following:
(a) When encountering difficulties in hoisting a load, the crane operator must
avoid using force, and the hoisting work must be stopped immediately. An
inspection should be carried out, and the parties concerned should be
informed so that further action can be taken,
(b) Ensure the pulley sheave is in good condition, without any defects or
damage,
(c) Ensure the luff wire rope that is used is according to the specifications set by
the manufacturer,
(d) Conduct inspections from time to time to ensure that the crane is being
handled safely by the operator,
(e) Perform regular checks on the luff wire rope, and if it is damaged, defective
or a few strands of the wire rope have given way, change the rope
immediately,
(f) Carry out checks on safety devices such as the overload limit switch and the
hoisting speed limit before use,
(g) Carry out a risk assessment around the area of operation of the crane and
take the appropriate steps to reduce such risks,

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(h) The crane operator should handle the crane in the correct manner, and
comply with the procedures outlined in the operating manual,
(i) The crane operator should identify the inherent risks around the crane when
lifting or lowering a load,
(j) Periodic inspections should be carried out on the crane structure,
(k) Regular inspections and maintenance of the pulley and trolley should be
performed at frequent intervals,
(l) Owners must ensure that all tower cranes are handled by competent and
registered operators,
(m) Crane owners must ensure that the cranes are safe for use,
(n) Crane owners must ensure that cranes are maintained and checked
regularly,
(o) Contractors should conduct a risk assessment of every work activity that is
carried out using a tower crane,
(p) The brake components should be carefully inspected. Among the brake
components requiring attention are:
(i) brake lining
(ii) hydraulic oil supply
(iii) electrical wiring or related component of the brake system, etc.
(q) If the crane stops operating for a short period of time, the crane operator
must comply with the procedure concerning ‘leaving a crane unattended’
by ensuring:
(i) the load has been removed from the hook,
(ii) the electricity supply has been switched off,
(iii) the brake lock has been engaged.
(r) The boom should be parked according to the angle outlined in the crane
manufacturer’s manual.

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Bibliography

Chong, H. Y. & Low, T. S. 2014. Accidents in Malaysian Construction Industry: Statistical
Data and Court Cases. International Journal of Occupational Safety and
Ergonomics (JOSE) 20(3): 503–513.
Saifullah, N. M. & Ismail, F. 2012. Integration of Occupational Safety and Health during
Preconstruction Stage in Malaysia. Procedia - Social and Behavioral Sciences 35:
603-610.
Abdullah, D. N. M. A. & Wern, G. C. M. 2010. An Analysis of Accidents Statistics in
Malaysian Construction Sector. 2010 International Conference on E-business,
Management and Economics, IPEDR vol.3 (2011) © (2011) IACSIT Press, Hong
Kong, pg. 1-4.
Laporan dan fail kemalangan Jabatan Keselamatan dan Kesihatan Pekerjaan.
http://www.towercranesupport.com [21 March 2016]
http://www.dosh.gov.my [23 Ogos 2017]

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CHAPTER 5

BASIC CALCULATION FOR WEIGHT OF A MASS

5.1 General Formula for Calculation

(I) Basic unit of measurement for a load

Quantity Unit Symbol
Mass kilogram kg
ton tan
Length millimetres mm
centimetres cm
metre m

(II) Measurement unit

a) 1 ton = 1000 kilogrammes

b) 1 metre = 100 centimetres = 1000 millimetres

(III) To convert the unit of measurement

a) Tons to kilogrammes

Example: 2 tons x 1000 = 2000 kg

b) Kilogrammes to tons

Example: 2000 kg / 1000 kg (divided) = 2 tons

c) Metres to millimetres

Example: 2 m x 1000 = 2000 mm

d) Millimetres to metres

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Example: 2000 mm / 1000 (divided) = 2 m

e) Metres to centimetres

Example: 5 m x 100 = 500 cm

f) Centimetres to metres

Example: 300 /100 (divided) = 3m

Examples of unit conversions for length:

(IV) Calculations Using a Calculator

If there is a decimal in the calculated figure, then, three digits should be
taken after the decimal point.

Example:

123.456778 tons is taken as 123.456 tons (Example in the picture)

100.87651 tons is taken as 100.877 tons

100.1111 tons is taken as 100.111 tons

Example: 200.9999 kg is taken as 201.000 kg

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Example: 200.1111 kg is taken as 200.111 kg

5.2 Calculation of Area and Volume of Various Shaped Objects

(a) Surface Area

The calculation of the surface area depends on the shape. Several basic
calculations, such as the areas of squares and circles, must be known.

i) Surface area of a square ( m2 ) = Length x Width

Example: 2m

m2 = 2mx2m 2m
= 4 m2 (square metres)

ii) Surface area of a Circle (m2) = Radius x Radius x 0.79

Example:

m2 = 1.2 x 1.2 x 0.79

= 1.138 m2 (square metres)

Garis Pusat
(b) Volume
The volume is the quantity of space that is taken up by a component. In this
syllabus, 5 types of volumes must be known, namely:-

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i) Volume of a Rectangular Object (m3) = Length x Width x Height

4m
3m 2m

Example:

m3 = 4m x 3m x 2m

= 24 m3 (cubic metres)

ii) Volume of a Cylinder (m3) = Radius x Radius x Length x 0.79

20 m

Diameter
20 mm

Example:

m3 = 0.02m x 0.02m x 20m x 0.79

= 0.00632 m (cubic metres)

Note: Pi (π) = 3.142 = 3.142/4 = 0.79

iii) Volume of a Cone (m 3) = Radius x Radius x Height x 0.79

(divided) 3

Example :

m3 = 1.6 m x 1.6 m 3 x 3.142 3.0 m

(divide) 3 Diameter

1.6 m
3
= 2.022 m (cubic metres)
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iv) Volume of a Metal Pipe (m3) = Radius x Thickness x Length x Pi (π)

Pi = 22 /7 = 3.142

6 m (length )

Diameter
800 mm Thick wall
250 mm

Example:

m3 = 0.8m x 0.25m x 6m x 3.142

= 3.770 m 3 (cubic metres)

v) Volume of Iron Board (m3) = Length x Width x Thickness

6m
1.5 m 60 mm

Example:
m3 = 6 m x 1.5 m x 0.06 m

= 0.54 m 3 (cubic metres)

• Summary of Formulas

CODES FOR UNITS OF MEASUREMENT

L Length mm Millimetre
W Width M Metre
H Height M2 Square metres

D Diameter M3 Cubic metres

R Radius Kg Kilograms
Circ Circumference T Tonnes

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Th Thickness Pi 3.142

Diameter

Circumference
W
Radius

Diameter Rx2
Circumference 3.142 x D2
Area of a square LxW=m
Area of a circle D x D x 0.79 = m2
Area of a cylinder 3.142 x D x L = m2
Volume of a round tank D x D x 0.79 x L = m3
Volume Area x H = m3

5.3 Basic Calculation for Finding the Weights of Objects of Various Shapes

There are several ways of knowing the weights of construction materials, among
which are:

a) The weight may be marked on the item.

b) Ask your supervisor or any person who might know.
c) If the item appears in a catalogue, perhaps the weight of the item can be
obtained from the catalogue that comes together with the item.

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d) The weights of machines might be obtained more clearly from the business
records or Operator’s Manuals.
e) Through the Engineer’s Manual
f) Calculations

5.3.1 Calculated weights of several materials

MATERIAL WEIGHT
Aluminium 2.7 tonnes/m3
Bricks, Clay, Common (2.5t/1000) 1.6 tonnes/m3
Cast Iron 7.2 tonnes/m3
Cement (20 bags/T) 1.0 ton (50 kg per bag)
Concrete, wet or set 2.4 tonnes/m3
Concrete Panel (Steel reinforced) 3.0 tonnes/m3
Petrol 0.7 tonnes/m3
Diesel 0.8 tonnes/m3
Earth, Loose 1.8 tonnes/m3
Glass 2.6 tonnes/m3
Hardwood 1.1 to 1.4 tonnes/m3
Lead 11.3 tonnes/m3
Road metal (Crushed rock) 1.9 tonnes/m3
Sand, Dry 1.7 tonnes/m3
Sand, Wet 1.9 tonnes/m3
Softwood (average) 0.6 tonnes/m3
Steel 8.0 tonnes/m3
Mild Steel 7.84 tonnes/m3
Water, fresh (1 Kg per litre) (1 m3) 1.0 tonne/m3 (1000 litres/m3)
Scaffold fittings (4.9 mm thick) (Frame) 0.5 kg/m; AST Rigging
Handbook, 1.5 kg/m (for
Australian scaffolds)
Scaffold Tubes (tubular type) (Steel) 4.41 Kg/m
Karri Scaffold planks 7 Kg/m
Steel H-Beam 45 kg/m
Steel Pipe (20 mm thick) 2.4 tonnes/m3; From
material catalogue

5.3.2 Calculation of weight of load/mass

Throughout our study, we worked with rectangular and square shapes. The
formula below is used to find the surface area:

Surface Area = Length x Breadth = m2 (square metres)

The volume can then be calculated from the above surface area:
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Volume = Surface area x Height = m3 (cubic metres)

If the weight of the material is given, the weight of the load/mass can be
calculated from the above volume:

Weight = Volume (m3) x Weight of the material

The following makes it clearer:

Weight = Length x Breadth x Height (Thickness) x Weight of the Material
= Tonnes

You should be able to calculate the measurements including the parts in metres
(1.30 x 2.5 x 1.75 and so on) or in millimetres alone.

1 Meter

1000 Milimeter
mm. 0 250 500 750 1000
m 0 .25 0.5 0.75 1.0

One metre is equivalent to 1000 mm

1 mm is equivalent to one-thousandth of a metre or 0.001 metres (1/1000)

10 mm is equivalent to one-hundredth of a metre or 0.01 metres (1/100)

100 mm is equivalent to one-tenth of a metre or 0.1 metres (1/10)

Thousand Hundred Ten One (Unit)

THTU

One metre 1. 0 0 0

One hundred millimetres 0 .1 0 0

Ten millimetres 0. 0 1 0

One millimetre 0. 0 0 1

Measurements in different units cannot be multiplied together. If two different

units are to be multiplied together, the units must be converted to become the
same.
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Example:

1500 mm = 1.5 m
1 m and 30 mm = 1.03 m
5 m and 6 mm = 5.006 m
2072 mm = 2.072 m

5.3.3 Tonnes to pounds

1 US tonne = 2000 Ibs.

1 (M) tonne = 2204 Ibs.
1 kg = 2.2 Ibs
1 metre = 3.28 feet

(a) Plate Formula

There are various types of weight calculations. The Plate formula is based on
the thickness of an object, for example, an iron sheet.

We know that the weight of 1 cubic metre of iron is 8 tonnes or 8000 kg. We
can cut the iron into 1 m3 pieces to become 1000 small pieces, with each
piece measuring 1 m x 1 m x 1 mm and weighing 8 kilograms.

8000 kg/1000 small pieces = 8 kg/piece

Besi is cut as

1m 8 Tan

1m 1m
1m
1 mm thick

Each small piece of iron weighs 8 kilograms

Below is shown how these facts are used:

One piece - 1 m x 1 m x 1 mm, weighs 8 kilograms

One piece - 1 m x 1 m x 10 mm, weighs 80 kilograms
One piece - 2 m x 1 m x 10 mm, weighs 160 kilograms

Each square metre of this piece weighs 40 kilograms.

IRON
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Safety THICKNESS=5mm
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1m

3m

Method for obtaining the weight:

5 mm (thick) x 8 kg (weight of a 1-mm thick piece of iron) = 40 kilograms

Therefore, for 3 square metres (3 x 1 = 3 m2) of this piece, the weight will be:

3 x 40 = 120 kilograms

The formula for calculating the weight of the iron piece is as follows:

Weight = Area (m2) x Thickness ( mm) x Weight of the material = Kg

Example:

Weight = 3 x 1 x 5 x 8 = 120 kilograms

Note:
The advantage of using the Plate formula is that the thickness in mm units need
not be converted to metre units or be in equivalent units in the calculation.

This formula can be used for concrete or any material produced in cubic metres.

5.3.4 Calculation of weight of load/mass for circular objects

(a) Area of circular object

Before working with circular objects, it is important to understand the 3 types of
measurements that are inter-related to each other.

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Circumference

Diameter Radius

The radius (R) is the distance from the centre of a circle to the edge of the circle.
The radius is half of the diameter.
The diameter (D) is the distance across the circle from one edge to another,
passing through the centre of the circle.

The diameter is twice the radius.

The circumference is the distance around the circle along the outer edge of the
circle.

Formula for calculating the area of a circle:

AREA = DIAMETER X DIAMETER X 0.79 = M2

OR
AREA = D X D X 0.79 = M2

Formula for calculating the circumference of a circle:

CIRCUMFERENCE OF A CIRCLE = 3.142 X DIAMETER

(b) Estimated weight of a circle

Figure 5.1 Oil Tank (http://tslack.com)

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1.5m

3.5 m
The weight of this oil tank (diagram), which is made of 3-mm thick steel, needs
to be determined.
Step 1: Calculate the area of this steel tank.

This tank has two circular surfaces at both ends. Obtain the areas of both
surfaces.

Total area of circular surface = D x D x 0.79 = M2 x 2 (both ends) = m2

= 1.5 x 1.5 x 0.79 = 1.77 x 2 = 3.5 m2

The body of the tank is made of a steel piece that has been rolled into a
tube or cylinder. The area of this steel body can be calculated using the formula:

Area = Length x Breadth = m2

If we think of the body of this tank as being in the shape of a rectangle, then its
length would be 3.5 m, i.e. the length of the tank.

We can obtain the circumference for the whole circle by using the following
formula:

Circumference of circle = 3.142 x Diameter (D) = m

Area of the tank body = 3.142 x Diameter (D) x Length (L) = m2

(Area of a cylinder)

Total area of steel = Second area – surface areas of two ends + Area of
the tank body
= 3.5 + 16.5 = 20 m2

Step 2: Calculation of the weight of steel

WEIGHT = Area x Thickness X Weight of Material = Tonnes

Calculation:

Area = 20 m2
The thickness of the body of the steel tank at 3 mm must be changed to 0.003
m.

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Weight of the material = 8 kg (Weight of 1 square metre piece of steel with a

thickness of 1 mm)

Therefore, the Weight of the Tank = 20 x 0.003 x 8 = 0.48 tonnes

EXAMPLES OF CALCULATIONS OF THE WEIGHT OF A LOAD/MASS

1. Find the weight of 2 iron beams, given that:

10 m

the weight of a 1-metre length = 100 kg

the length of 1 piece = 10 m

Answer: 10 m x 100 kg x 2 pieces = 2.0 tonnes

2. Find the weight of 2 pieces of iron board (Soft Iron):

6m
70 mm thick
1.5m

Solution:

Thickness of 70 mm = 0.07 m

Answer: 6 m x 1.5 m x 0.07 m x 7.84 tonnes = 4.939 tonnes x 2 = 9.878

tonnes

3. Find the weight of 2 pieces of iron board.

Given:
Weight of 1 square metre = 100 kilograms
6m
70mm
1.5m

Solution:
Convert the thickness of 70 mm into metres = 0.07 m

Answer: 6 m x 1.5 m x 100 kg = 900 kg x 2 = 1800 kilograms

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4. Find the volume and weight of the pipe below:

Given:
Length = 6 m
Diameter = 1.5 m
Thickness = 20 mm

Solution:
Convert the thickness of 20 mm to 0.020 m

Pi (π) = 3.142
D = 1.5 m
D
d = 1.5 – (0.020 + 0.020) = 1.460 m
d

Volume of pipe = 3.142 x Length x Outer diameter x Thickness = m3

Volume of pipe = 3.142 x 6 m x 1.5 m x 0.02 m = 0.565 m3

or

π (D - d2) 2 x Length
4

3.142 (1.5 - 1.462) 2 x 6 = 0.558 m3

4
Total weight of the pipe = 0.565 x 2.4 tonnes = 1.356 tonnes

Note:
The weight of the pipe with a volume of 1 cubic metre (thickness of 20 mm)
obtained from the weight of the building material = 2.4 tonnes

5. Find the weight of a concrete bucket filled with concrete.

Given:
Weight of the empty concrete bucket = 300 kg
Diameter of the top surface of the concrete bucket = 1.5 metres
Height of the concrete bucket = 2 metres

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1.5 m

2m

Solution:

Convert the weight of the empty concrete bucket of 300 kg to 0.3 tonnes.

Use the formula for the volume of a cone

= 0.79 x Diameter x Diameter x Height
(divide) 3

or πR2 x Height
3

or π D2 x Height
12

Note:
R = Radius D = Diameter π = Pi = 3.142

Step 1

Find the volume of the concrete bucket:

Volume of concrete bucket = 0.79 x 1.5 m x 1.5 m x 2 m / (divide) 3 = 1.185
m3

Step 2

Find the weight of the concrete:

Use the weight of wet concrete = 2.4 tonnes/m3 (obtain from Table 1.0)

Weight of wet concrete in the bucket = Volume of concrete bucket (m3) x 2.4
tonnes/m3 = Tonnes
= 1.185 m3 x 2.4 tonnes/ m3
= 2.844 tonnes

Step 3

Find the weight of the concrete bucket filled with concrete:

Convert the weight of the empty bucket, given as 300 kg, to 0.3 tonnes
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Weight of the concrete bucket filled with concrete = weight of wet concrete in
the bucket + Weight of the empty concrete bucket
= 2.844 tonnes + 0.3 tonnes
= 3.144 tonnes

6. Find the weight of a bucket, ¾ of which is filled with water.

Given:
Weight of the empty bucket = 300 kilograms

1.250m

1.750m

Solution:

Step 1

Obtain the height of the water in the bucket, which is ¾ the height of the
bucket = 1.750 m x ¾ = 1.313 m

Step 2

Obtain the volume of the water in the bucket = Diameter x Diameter X Height
x 0.79 = m3

= 1.250 m x 1.250 m x 1.313 m x 0.79 = 1.621 m3

Step 3

Find the weight of the water in the bucket:

Weight of water in the bucket = Volume of water (m3) x 1.0 tonne/m3

= 1.621 m3 x 1.0 tonne/m3

= 1.621 tonnes

Step 4

Obtain the weight of the bucket that is ¾ filled with water.

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Convert the weight of the empty bucket, which is given as 300 kg, to 0.3
tonnes

Total weight = Weight of bucket + weight of water content

= 1.621 tonnes + 0.3 tonnes

= 1.921 tonnes

Bibliography

Book: Cranes and Derricks,

http://www.petronet.ir/documents/10180/2324297/Cranes_and_Derricks
Canada: Occupational Health and Safety Code 2009,
https://work.alberta.ca/documents/WHS-LEG_ohsc_p06.pdf
New Zealand: Approved Code of Practice for Cranes,
https://www.worksafe.govt.nz/worksafe/information-guidance/all-guidance-
items/acop-cranes/cranes-acop-2009.pdf
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Bachok, Kelantan, 2004.
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Chembong, Negeri Sembilan, 2003.
Nota Tower Crane Operator, Gamuda Plant Operator School (GPOS), Shah Alam,
Selangor, 2002.
US: Environmental, health and safety (EHS) departments,
http://www.ehsdb.com/tower-crane-safety.php
US: Occupational Safety and Health Program, A Guide to Cranes and Derricks,
http://www.nclabor.com/osha/etta/indguide/ig20.pdf
US: OSHAcademy Occupational Safety and Health Training,
http://www.oshatrain.org/courses/mods/820m1.html

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CHAPTER 6

SAFE OPERATION OF TOWER CRANES

6.1 Safe Load Control

Project planning should involve two key points: the estimated load capacity to
be lifted and the overloaded load or the load reduction area. Information on
load weights can be obtained from signs on loads, drawings or project
documentation or cranes load charts. If the load size is known, the material
weight can be calculated from the density information of the material as in
Table 6.1.

Table 6.1 The type and weight of the materials for construction

Materials Weight (kg/m3)

Water 1000
Aluminum 2700
Charcoal 1450
Brick 2100
Iron and steel 7700
Wood 800
Concrete 2400
Soil 1600
Copper 8800
Lead 8500

Lifiting supervisor, signalman and rigger are responsible for ensuring that light
weight materials such as bricks, bricks, tiles, whiteboards or other objects should
be lifted in a sturdy and enclosed container with safe equipment (eg plastic). The

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project manager is responsible for ensuring that lifting work are handled by lifting
supervisor, operator, signalman and rigger have received sufficient training in
terms of operating lifting principles, load weight and appropriate distance of the
materials.
6.2 Work load Allowed

The safe working load (SWL) or lifting load allowed for the tower crane refers to
the load specification on hooks with certain range distance, the use of the
appropriate wire rope, the length of the boom, and the height of the crane and
the location of the load lift site. Each equipment involved in the lifting operation
has its own SWL. The load lifted must be lower than SWL crane tower system
and also take into account the dynamic effects such as impact caused by the
sudden lifting movement. Machinery / equipment specification is suitable to be
referred to the crane manufacturer's manual to find out the usage limit or the limit
the load allowed for each machine / equipment.

6.2.1 Reach distance of load

The reach distance will be displaced forward whenever the crane lifts a heavy
load from ground level because then, the wire rope hoist will be stretched and
will cause the boom and mast to lean forward, as shown in Figure 6.1. Therefore,
the operator plays an important role in determining the lifting of a load for a large
range of reach distances by taking into account the height of the mast and the
length of the crane boom.

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The boom will slip

forward when the
bum range
reaches
boom range

Increase in boom
reach

Figure 6.1 Increase in boom range during lifting of load

6.2.2 Luff angle (only for luffing tower cranes

The luff angle is the angle between the horizontal line of the slew-boom
platform pin and the line of tilt of the boom (Figure 6.2). The maximum luff
angle for a luffing tower crane is determined by the crane manufacturer. The
maximum luff angle of some cranes can be up to 86o. Therefore, every
luffing crane should be installed with a luff limiter switch to stop the boom
from moving once the maximum luff angle is exceeded. This is to prevent the
occurrence of over-luffing. In addition, the crane operator must exercise
caution when a large luff angle is used during the lifting of a load because
this will expose the load to the risk of collision with the mast. The sudden
release of the load at a large luff angle position can also cause the boom to
bounce backwards and hit the jib counter.

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The bum will bounce

back and strike the
balancing jib

Luffing angle

Platform pin slewing-

boom

Load bounce

Figure 6.2 Effect of luff angle on the stability of a tower crane

6.3 Handling of loads close to where people are working and public routes

If loads are to be handled close to where people are working, the following
precautions should be taken:
(a) It should be ensured that the place where the load is to be lowered, raised and
shifted to is safe,
(b) The hoisting crew (operator, signalman, rigger, lifting supervisor) will need to
plan a safe route for the load to avoid lifting it over or across workers,
(c) All workers must stay away from the route along which the load is to be lifted,
(d) Written approval must be obtained from the local authority if any hoisting work
or part of the crane is to extend beyond the construction site,
(e) In danger zones where hoisting works are being carried out, warning signs (see
Figure 10.5) or warning lights should be erected to direct the public or traffic
away from the construction site,
(f) Avoid lifting loads across highways, railway tracks, rivers or public places that
can be accessed by the public.
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6.4 Control of tower crane operations

Before commencing a crane operation, the operator must ensure the following:
(a) He has a clear view of the load and the zone of operation. If not, the crane
operator will have to follow the instructions of a signalman who has a clear
view,
(b) Safety devises that warn of danger should be clearly visible to the operator,
(c) Hand and flag signals by a signalman must be clearly visible,
(d) The signal codes that are conveyed verbally must be clearly audible,
especially when communicating by telephone or two-way radio (walkie-
talkie),
(e) Ensure that hoisting activities do not cause damage to crane components
and the material being hoisted,
(f) Ensure that the operator has a clear view of the load and wire rope hoist,
and is not obstructed by any object,
(g) Ensure that the wire rope hoist is vertical throughout the hoisting work,
(h) The load must be lifted clearly from the surface of the ground/area,
(i) The rigging and counterweight of the load must be inspected before the
hoisting work,
(j) The load should not be left suspended unless a site safety officer or lifting
supervisor is present during the period when it is suspended,
(k) Ensure the brake locks for the hoist and boom (luffing crane) can function
during an emergency.

6.5 Weather conditions

Generally, cranes are designed to operate in normal wind speed conditions, and
they should not be operated during strong winds. An anemometer or tool for
measuring wind speed must be installed in a suitable position on the tower crane.
During the operation of the tower crane, the maximum wind speed as
recommended by the crane manufacturer must be complied with. Besides strong
stormy/windy conditions, other weather conditions can also invite the risk of
accidents. The crane operator must stop operating the crane during severe

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weather conditions such as heavy rain, lightning or situations that are hazardous
for the operator (haze, mist, excessive heat and so on) and for the stability of the
crane (earthquakes, landslides, floods and so on).

6.6 Tower Crane Security Devices

All tower cranes must be equipped with a limit switch and safety device that
operate automatically to prevent crane damage; if crane operators make
mistakes during operation. Figures 6.3 and 6.4 respectively show the limiting
switches and safety devices installed on hammerhead and luffing cranes.

Moment limiting Extreme moment breaker

bar

Suis pengehad
Slewing gerakan troli
limit switch
Overhead
wire Hook block limit
breakers switch

Figure 6.3 Position of the safety device on the hammerhead crane

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Luffing limit switch

Figure 6.4 Luffing limit switch position

(note: additional limiting switch for luffing cranes)

Crane safety devices such as limiting switches and load indicators need to be
installed on the cranes and ensured functioning well during operation. Warning
issued by security device is in the form of warning lights and / or sound alerts to
crane operators.

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Bibliography

BS 7121-5:2006 Code of practice for safe use of cranes-Part 5: Tower cranes

Code of Practice for Safe Use of Tower Cranes, Hong Kong, 2012.
Guidebook for Lifting Supervisors, Workplace Safety and Health Council, Ministry of
Manpower, Singapore, 2011.
Guidelines for Creating Lifting Plan for Lifting Operations In Workplaces, Workplace
Safety and Health (WSH) Council, Singapore, 2014.
Guidelines For Public Safety And Health At Construction Sites (1st Revision: 2007),
Department of Occupational Safety and Health, Malaysia.
http://www.manitowoc.com [21 Julai 2017]
http://www.mytowercrane.com/safeliftingguide.htm [11 September 2017].
MS 1803:2008 Cranes-Safety-Tower Cranes.
PN12040 Tower Crane-Code of Practice, Autralia, 2017.
Safe Lifting, Occupational Safety & Health Council, Hong Kong, 2002.
SS 559: 2010 Code of practice for safe use of tower cranes.

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CHAPTER 7

COMMUNICATION

7.1 Communication Signals

Sign language is important for ensuring communication between the signalman

and the operator during crane operations. The signalman will give the signal to
the operator, who must be familiar with the signals to avoid accidents while the
crane is in operation.

Signals that cannot be understood or are misinterpreted will pose a danger

to workers, including the operator and the personnel involved in the hoisting
operations. Hence, a signalman must be competent in the sign language used
for cranes so that the information or signals given to the operator are correct and
can be understood.

A signalman must be able to convey standard signals, such as the

ISO16715: 2014 Crane - Hand Signals Used with Cranes, at all times for the
following cases:
(a) A tower crane operating with a long boom. The signalman is required to
give signals regarding the movement of the boom or trolley,
(b) The operator is unable to see the hook or the load at all times, and
therefore, the assistance of a signalman is required at such moments.,
(c) A tower crane is installed for mobile operations and the operator is unable
to see all the parts of the crane and the platform in order to move.

A signalman must be sure of the following when working on construction

sites:
(a) The place where the signalman stands must be visible to the operator at all
times, and if hand signals are used, the signals must be clearly visible to
the operator. Ensure that the place where the signalman is standing poses
no danger to him.

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(b) The operator must be experienced in the handling of a tower crane and
must be able to understand the sign language used by the signalman.
(c) A signalman must be responsible for all the persons working within the
range of the tower crane, and he must ensure that all persons are beyond
the reach of the boom.
(d) There must be continuous communication with the operator regardless of
whether hand signals, flags or two-way radios (walkie-talkies) are used.
(e) The signalman must wear the proper personal protection equipment such
as a reflective vest, safety helmet, and brightly-coloured gloves for the hand
signals.

There are three types of signal languages that are usually used in tower
crane operations, namely:

(a) Hand signals

(b) Flag signals
(c) Transmission of information by two-way radio

7.2 Hand Signals

Hand signals are the main form of communication used by signalman to convey
information to operators. Figure 7.1 shows the standard hand signals based on
MS2203:2008 Cranes - Training of Operators - Part 3: Tower Cranes or
ISO16715: 2014 Crane-Hand Signals Used with Cranes that are used in crane
operations.

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Signal Signal meaning

1.Lower

2.Raise boom

3.Lower Boom

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Signal Signal meaning

4.Hoist

5.Swing

6.Move slowly

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Signal Signal meaning

7.Use main hoist

8.Retract Boom

9.Extend Boom

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Signal Signal meaning

10. Dog Everything

11.Stop

12.Use Whipline

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Signal Signal meaning

13. Move

14. Raise boom lower the load

15. Lower boom raise the load

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Signal Signal meaning

16. Trolley to the out

17. Trolley to the in

Figure 7.1 Hand Signals

7.3 Flag Signals

When hand signals cannot be clearly seen by the operator, then flag signals
should be used instead. The standard flag signals are shown in the diagram in
Figure 7.2.

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Signal Signal meaning

1.Turn to the left

2. Turn to the right

3.Show position

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4. Raise lufing boom

5. Lower lufing boom

6.Stop emergency

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7.Raise

8.Stop

9.Calling

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10.Moving

11.Lowering

12.Raise slowly

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13.Lowering slowly

14.Thank you

Figure 7.2 Flag Signals

7.4 The Use of Two-Way Radios and Other Signals

7.4.1 Sending Information by Two-Way Radio

Two-way radio communication is used during the operation of all types of cranes.
It not only provides precise directions for the movement of the crane but also
gives the operator more confidence in handling the crane. However, it also has
its disadvantages. For example, the battery power can be depleted, there may
be interference from waves/frequencies, other waves may be combined
simultaneously, and the surroundings may be noisy. Both the operator and the
signalman must agree to the form of communication and the public/authorities
(Police Station, Fire Department and others) in the vicinity must be informed
before they take their respective positions. Communication by two-way radio can
be used when handling all types of cranes.
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When using a two-way radio, make sure the information is clear, and there
must be a specified instruction from the operator for each required term code, for
example, whether to lower a boom/trolley by one metre or the reverse; or to turn
to the left or right, or other instructions. The information must be precise and clear
to avoid any mistakes, such as 5 metres being heard as 25 metres over the two-
way radio. Therefore, the pronunciation must be audible and clear at all times.

It is recommended that Malay and an international language, i.e. English,

be used as the intermediate language between operators and signalman (see
Table 7.1). The use of other native languages for the operation of cranes in
Malaysia is not encouraged.

Table 7.1 Example of codes by two-way radio

MOVEMENT CODE
HOOK/HOIST MOVEMENT HOIST UP AND HOIST DOWN

BUM MOVEMENT BUM UP AND BUM DOWN

TROLLEY MOVEMENT TROLLEY IN AND TROLLEY OUT

SLEWING SLEW LEFT AND SLEW RIGHT

OK TO RAISE ALL CLEAR

DO NOT MOVE STOP

WARNING:

(a) For tower crane operations at night, where the range of vision is limited,
communication must be by two-way radio.
(b) The operator must stop operating the tower crane if communication is lost,
and resume operations once communication is restored.
(c) If a load is lifted to a high place and another to a low place (for example, during
concrete works), two signalman are required, one at the place to which the
load is being hoisted, and the other at the low place where the concrete is
being loaded into the bucket.

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(d) If there are doubts as to the instructions or the language in the delivery of
information to the operator, the operator must cease all hoisting operations.
8.4.2 Whistle

When two or more cranes are in use at the same time, there will be confusion in
the signal communications. Therefore, an alternative signal, like the blowing of
a whistle, can be used.

The key to the symbols and standard whistle-blowing signals are given in
Tables 7.2 and 7.3.

Table 7.2 Key to whistle-blowing symbols

Short blowing once

Long blowing once

Jadual 7.3 Whistle Blowing Standards

SYMBOL MOVEMENT

STOP

HOIST UP

HOIST DOWN

BUM UP or TROLLEY IN

BUM DOWN) or TROLLEY OUT

SLEW LEFT

SLEW RIGHT

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The following tools can also be used as a means of communication between

operators and signalman:
• Speakers
• Horns
• Torchlights

The use of the above tools must be discussed between the operator and the
signalman so that the information conveyed by the signalman can be
interpreted by the operator.

Bibliography

Book: Cranes and Derricks,

http://www.petronet.ir/documents/10180/2324297/Cranes_and_Derricks
Canada: Occupational Health and Safety Code 2009,
https://work.alberta.ca/documents/WHS-LEG_ohsc_p06.pdf
New Zealand: Approved Code of Practice for Cranes,
https://www.worksafe.govt.nz/worksafe/information-guidance/all-guidance-
items/acop-cranes/cranes-acop-2009.pdf
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Bachok, Kelantan, 2004.
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Chembong, Negeri Sembilan, 2003.
Nota Tower Crane Operator, Gamuda Plant Operator School (GPOS), Shah Alam,
Selangor, 2002.

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CHAPTER 8

PERSONAL PROTECTION EQUIPMENT

8.1 Introduction

Personal protective equipment (PPE) means all equipment intended for use or to
be held by persons at the workplace, and that protects them against risks to their
health and safety. PPE is also related to any additional gear or accessories
designed to meet those objectives. PPE must be worn when carrying out work at
construction sites.

8.2 Types of Personal Protective Equipment

(a) Safety helmet

A safety helmet is one of the most commonly used PPE (Figure 8.1). The safety
helmet serves to protect the head of the user against:
(a) The impact from a falling object by rebounding and deflecting the force
(b) Impact from the side and behind
Fire, splashes from molten metal, high temperatures and electric shock
(depending on the standard of the hard helmet chosen. However, standard hard
helmets cannot function to protect the wearer against electric shock). A complete
safety helmet must come with a shell, harness and headband.

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Figure 8.1 Safety helmet for the construction industry; 1 – shell, 2 – harness, 3
– harness adjuster, 4 – headband, 5 – sweatband, 6 – peak, 7 – chin strap

(b) Safety shoes

Safety shoes are designed to protect the feet against various injuries (Figure 8.2).
Knocks, compression and piercings are the most common types of hazards that
can cause foot injuries. The toecap protects the wearer from falling or rolling
objects, as well as compression that can affect the feet in the workplace. Steel
toecaps are the most popular and reliable form. Non-metallic toecaps are also
commonly used because they do not conduct electricity, and are resistant to heat
and cold temperatures, making them more comfortable for the wearer. To prevent
injuries to the foot caused by the penetration of sharp or pointed objects, shoes
that come with soles to withstand penetration should be selected.

The selection of suitable footwear should begin by identifying the risk factors that
may occur in the workplace. The risk factors that should be identified are:

1) Based on the characteristics of the workplace

(a) heavy items that can fall onto or injure the feet,

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(b) type, concentration and physical properties of chemicals (acids, alkalis,

solvents, etc.),
(c) ambient temperature and humidity.

2) Based on the condition of the worker:

(a) working in a standing position
(b) activities involving constant movement
(c) climbing up ladders
(d) moving on smooth surfaces
(e) awkward working posture
(f) working in an open space
(g) working in a confined space (depending on the temperature)

Figure 8.2 Safety shoes

(c) Gloves

According to the hierarchy of control, the priority is to eliminate risks, followed by

engineering aspects, and then the use of PPE such as the wearing of gloves
(Figure 8.3). Gloves must be worn together with other PPE. Protective gloves are
less effective as a control compared to other PPE. The selection of protective
gloves should be based on the type of work, the wearer and the workplace
environment. The following factors must be taken into consideration in the
selection of gloves:

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(a) The material being handled

(b) The risk of danger to the hands
(c) The type and period of contact
(d) The size of the hand and the comfort of the wearer
(e) The type of task

Figure 8.3 Safety gloves

(d) Reflective vests

The purpose of reflective vests (Figure 8.4) is to enable the wearer to be clearly
seen in an environment that is compatible to the situation at the workplace. To
ensure that the vests can be easily seen during the day, they must be in
fluorescent colours (yellow, orange-red or red). The vests should be maintained
according to the rules and instructions of the manufacturer. The proper selection
and use of reflective vests are as follows:

(a) Reflective vests should be worn in dim workplaces so that the wearer can
be easily seen
(b) The colour of the vest must be in contrast to the work environment so that
the personnel will be clearly visible
(c) The selection of the appropriate vest should be determined through
discussions with the employer.
(d) The vests should carry a valid label by the manufacturer, and be
recognized by the authorities.
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Figure 8.4 Reflective vest

(e) Safety glasses

Safety glasses (Figure 8.5), face shields, and welding helmets are used to protect
the eyes and face. This type of protection needs to be worn when power tools
are being used or to prevent liquid from splashing onto the eyes or face. Glasses
are the most widely used eye protection equipment.

Figure 8.5 Safety glasses

Figure 8.6 shows three types of eye protection devices, namely, a face shield,
safety glasses, and goggles. The face shield provides the best protection against
droplets and splashes of hazardous substances.

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Figure 8.6 Glasses with a direct and indirect ventilation system

(f) Ear protection devices

Earplugs and ear muffs are ear protection devices (Figure 8.7) that are used to
protect the hearing of the wearer. Ear muffs are more comfortable and effective
in reducing noise, while earplugs are more effective in terms of their use, although
some workers find them uncomfortable.

Figure 8.7 Ear protection devices

(g) Safety harness

A safety harness (Figure 8.8) is a protective equipment that is designed to protect

aperson who is performing a climbing activity or is coming down from a height. The
harness connects a moving object to a stationary object, and it is usually designed
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with a rope and cable, together with a lock that can be easily opened (Figure 8.9).
Figure 8.10 shows the correct way to use a harness when climbing a tower crane.

Figure 8.8 Safety harness

Figure 8.9 Safety harness

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Figure 8.10 Correct method of use and climbing

(https://www.123rf.com/photo_13536201_worker-builder-at-facade-construction-
works.html)

Bibliography

EN ISO 20345:2011
https://oshwiki.eu/wiki/Protective_helmets_%E2%80%93_requirements_and_selection)
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Bachok, Kelantan, 2004.
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Chembong, Negeri Sembilan, 2003.
Nota Tower Crane Operator, Gamuda Plant Operator School (GPOS), Shah Alam,
Selangor, 2002.
www.afscme.org
ASME B30.5 – Mobile Crane Hand Signals
http://theatresafetyblog.blogspot.my/
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Bachok, Kelantan, 2004.
Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Chembong, Negeri Sembilan, 2003.
Nota Tower Crane Operator, Gamuda Plant Operator School (GPOS), Shah Alam,
Selangor, 2002.
Worker's Safety Handbook for Rigger and Signalman

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CHAPTER 9

GENERAL SAFETY AND RESPONSE TO

ACCIDENTS AND EMERGENCIES

9.1 Identification and Assessment of Hazards at Construction Sites

Hazard identification is the process of examining every work and task area for
the purpose of identifying all the hazards that “exist on the job”. The work area
includes the machine workshops, laboratories, and agricultural, industrial or
construction equipment. This process is about finding what can pose a hazard in
a task or area.

Hazard identification, risk assessment and risk control

When planning work methods, an appropriate and adequate assessment should

be carried out and recorded. Methods, materials and equipment should be
selected to eliminate or reduce the risk at work.

• Employers are responsible for conducting a risk assessment. A

flowchart for the Hazard Identification, Risk Assessment and Risk Control
(HIRARC) process is shown in Figure 9.1.

• The risk assessment principles below should be complied with when

determining the method and sequence of work:
a) identify the hazards involved in the proposed works;
b) risk assessment (possibility and severity) of any hazards that may arise;
c) elimination of the risks, perhaps by changing the proposed method or
process;
d) control of remaining risks;
e) review, and where appropriate, updating of the information.

Figure 9.1 Flowchart for HIRARC process (Guidelines for Hazard Identification,
Risk Assessment and Risk Control (HIRARC), 2008)
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9.2 Main Hazards/Risks in the Construction Industry

The hazards/risks that occur most frequently in the construction industry can be
divided into two main categories:
a) hazards/risks that can cause work accidents, sometimes leading to
death immediately or not long after it occurs;
b) hazards/risks that can cause sickness at the workplace, sometimes also
leading to death in the medium or long term (from several hours to
several years later).

(a) The main hazards/risks of accidents in the construction industry in

most countries are:
(a) falls from a height (from floors without guardrails, platforms,
scaffolding, roofs, etc.);
(b) trapped (in or between damaged machinery, building materials, etc.);
(c) confined (due to damaged shoring system, missing during
excavation, etc.);
(d) electric shock (by touching a power line, power tool, etc.); and
(e) hit by an object (falling object, etc.).

(b) The hazards/risks of disease in the construction industry in most

countries are:
(a) back injuries (carrying heavy loads, working in an inappropriate
position, etc.);
(b) respiratory diseases (inhalation of dust, toxic fumes, etc.);
(c) musculoskeletal disorders (due to muscle tension and strain, injuries
to the hands and wrists, shoulders, neck and upper back, knees,
etc.);
(d) hearing loss (prolonged exposure to noise); and
(e) skin diseases (handling of toxic substances, exposure to ultraviolet
rays).

(c) There are nine general principles for the prevention of the
hazards/risks of accidents, namely:
(a) avoid risks;
(b) assess those risks that are unavoidable;
(c) combat a risk at its source;
(d) adapt the work to the individual, especially with regard to the design
of the workplace, the choice of working tools, and the selection of the
work methods and production, with the aim of reducing work
boredom;
(e) adapt to technical progress;
(f) replace hazardous materials with non-hazardous or less hazardous
ones;
(g) develop an overall prevention policy that covers technology, work
organisation, working conditions, social relationships and the
influence of factors that are relevant to the work environment;
(h) give priority to collective protective measures rather than individual
protective measures;

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(i) give appropriate instructions to employees.

9.3 Examples of hazards at construction sites
Collisions between cranes, other objects and structures
The placement of the tower crane must take into account hazards (Figure 9.2)
such as:
(a) overhead power lines
(b) adjacent structures
(c) other cranes or concrete placement booms (including those at adjacent
sites)
(d) surrounding airfields and flight paths.
(e) concrete placement booms functioning within the operating radius of the
tower crane.
(f) tower cranes located at adjacent sites that are operating in the same
airspace.

(g) Figure 9.2 Collisions and operating radius of tower cranes

(http://www.opticrane.com/tac-3000)

Collisions between cranes or with other structures/objects can cause injury to

those who are within the vicinity of the crane due to:
(a) Falling loads,
(b) Collapse of the crane,
(c) Failure in a crane component, such as the boom section.

The risk of injury due to collisions between cranes and other structures is greater
when the crane crew members are unable to communicate directly.

9.4 Ways to reduce the risk of injury due to collisions between cranes and
other structures

• The relevant procedures with regard to the location/space where the tower
crane might collide with other structures must be documented. For example,
safe work method statements must be established in the early planning
stage to ensure that there are proper controls at the site to reduce the risk
of injury due to collisions.
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• These procedures should identify the persons responsible for the

implementation of the safe work method statements. All those involved in
the operation of the tower crane and other structures must be trained in the
procedures concerned.
• These procedures should handle the following issues:
- The placement of the crane to give the crane/other machinery the
space to operate within the operating radius of the crane.
- The placement of the crane and other machinery with counterweights
so that the counterweights do not collide during slewing operations.
- The method of communication between the crane crew and other
crane operators.
- Work scheduling to reduce the time for which the crane and other
machinery are required to operate in the same area or at the same
height.
- The procedure for climbing a tower crane to ensure it remains at an
appropriate distance/height from any other structure or machinery.
- The frequency of meetings to monitor and review the effectiveness
of the control measures and who should attend such meetings.

b) Location of access/entry to area

When placing a tower crane, the following should be taken into

consideration:
(a) the normal access to the worksite for workers and other persons.
(b) public access such as pedestrian walks, roads and paths between
buildings around the crane.

c) Working close to overhead power lines

(a) Contact with an overhead power line while operating a machine may
cause an electric shock (Figures 9.3 and 9.4). It can be very difficult for
a crane operator to spot power lines and to estimate the distance from
them.
(b) Before erecting a tower crane where there are overhead power lines,
there must be consultations between the main contractor and the tower
crane operator regarding the work and the related risks.
(c) When a crane and high-range machinery are to be used in an area
where there are overhead power lines, the following steps should be
taken:
a) the operations must be properly planned by a competent person
b) the work should be supervised accordingly by a competent
person
c) the work should be implemented in a safe manner.
(d) There are two options when working close to overhead power lines:
a) cut the power supply to the power lines, or
b) remain outside the exclusion zone
• If the power lines are to be switched off, discuss with the person who is
controlling the lines as early as possible when planning a job. The

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process of shutting down the power supply may take some time and may
depend on the situation, and this can lead to delays in the work.

Figure 9.3 Zone for cranes and mobile machinery working close to overhead
power lines (Work Near Overhead Power Lines, Code of Practice 2006,
Australia)

Figure 9.4 Safety observer zone for overhead power lines on pillars and
towers (Work near Overhead Power Lines, Code of Practice 2006, Australia)

• If the crane or load touches an aerial conductor, inform the electrical

supervisor immediately of the situation, and the competent person (Safety
Officer) should remain in his position to warn of the danger of an electric
shock (Figure 9.5).

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Actions and measures that should be complied with and carried out by the
crane operator:

a) Remain in the cabin of the crane until the power line is disconnected.
b) Warn others (signalman) to stay away from the crane and not to touch
any part of the crane, rope or load.
c) Without anyone approaching the crane, handle the crane (boom) in any
way to break contact.
d) When unable to move the crane or break contact with the aerial
conductor, remain in the cabin or with the crane, and wait until the
situation is confirmed to be safe.
e) If it is necessary to exit the cabin or crane due to a fire or for other
reasons, to avoid electrocution, jump clear of the crane (except for a
tower crane), and do not touch the crane and the ground at the same
time.
f) When moving from the crane, walk slowly through the affected area to
avoid coming into contact with other high-voltage capacity areas (see
Figure 9.7). The actions recommended by the competent person should
be completed/carried out before the crane is put into operation once
again.

Figure 9.5 Affected area around the crane when in contact with an aerial
conductor (AS 2550.1—2011 Australian Standard ® Cranes, hoists and
winches-Safe Use Part 1: General requirements, 2011)

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• Electrical power and working close to overhead power lines

Table 9.1 shows the voltage range and the safe working distance for
positioning machinery from overhead power lines for construction works, as
recommended by several countries.

Table 9.1 Total voltage and safe distance from overhead power lines

Recommended distance from overhead power

Voltage (V)
lines (m)
Australia Hong Kong Ireland
0 – 33,000 3.0 3.0 3.0
33,000 – 132,000 3.0 6.0 4.5
132,000 – 330,000 6.0 7.0 (275 kV) 6.0
Above 330,000 8.0 7.0 (400 kV) 8.0
Code of Practice
Avoiding danger
Work Near for Networks
from overhead
Overhead Avoiding Danger
power lines
Power Lines, from Overhead
Source Guidance Note
Code of Electricity Lines,
GS6 (Fourth
Practice, Health and
edition), Hong
Australia, 2006 Safety Authority,
Kong, 2013
Ireland, 2008

9.5 Emergency procedure during contact with overhead power lines

If a person or object comes in contact with overhead power lines, the

following should be carried out:
a) never touch the power line concerned;
b) assume that the power line is live, even if it does not emit sparks or
appears to be dead;
c) it should be remembered that even though the power line is dead, it can
come to live again either automatically after several seconds or after
several minutes or hours if the owner of the line is not aware that the line
has been damaged:
d) if possible, call emergency services/TNB;
e) if you happen to touch/are close to a damaged wire, move and distance
yourself as quickly as possible until the line is confirmed to be safe;
f) it must be remembered that if the live wire touches the surrounding area
(ground) it may be live. Ensure that you are at a safe distance from the
wire or anything that can come in contact with it.

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Bibliography

Abdul Rahim Abdul Hamid, Wan Zulkifli Wan Yusuf and Bachan Singh, Malaysia
Hazards at Construction Sites, Proceedings of the 5th Asia-Pacific Structural
Engineering and Construction Conference (APSEC) 2003.

Abdullah, D.N.M.A. & Wern, G.C.M. 2010. An Analysis of Accidents Statistics in

Malaysian Construction Sector. 2010 International Conference on E-business,
Management and Economics, IPEDR vol.3 (2011) © (2011) IACSIT Press, Hong
Kong, pg. 1-4.

AS 2550.1—2011 Australian Standard ® Cranes, hoists and winches-Safe use Part 1:

General requirements, 2011.

Code of Practice for Networks Avoiding Danger from Overhead Electricity Lines, Health
and Safety Authority, Ireland, 2008.

Code of Practice for Safe Use of Tower Cranes, Occupational Safety and Health Branch,
Labour Department, Hong Kong, 2011.

Concise Manual Tower Crane STT293, Bigge Crane and Rigging Co.

Ground Conditions for Construction PlantStrategic Forum for Construction, Good

Practice Guide, London, 2014.

Guidance Note GS6 (Fourth edition), Hong Kong, 2013.

Guidelines for Hazard Identification, Risk Assessment and Risk Control (HIRARC),
Department of Occupational Safety and Health, Ministry of Human Resources,
Malaysia, 2008.

Guidelines for Public Safety and Health at Construction Sites, Department of

Occupational Safety and Health (DOSH) Ministry of Human Resources, 2007.

Guidelines for the Prevention of Falls at Workplaces, Department of Occupational Safety

and Health Malaysia, Ministry of Human Resource, 2007.

Guidelines on Safety of Tower Cranes, Construction Industry Council (CIC), Hong Kong,
2010.

Hazard Identification, Risk Assessment and Control Measures for Major Hazard
Facilities, Booklet 4

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Hazard Identification, Risk Assessment and Control Procedure, Western Sydney

University, 2015.

Hazards of Confined Spaces, Workers’ Compensation Board of British Columbia, 2008.

Hoisting and Rigging Safety Manual, Infrastructure Health & Safety Association,
Canada, 2012.

http://blog.fieldid.com/2010/08/fall-protection-inspection-harnesses

http://chainsawjournal.wpengine.netdna-cdn.com

http://fieldshomecenter.com/projects/stair-landing-construction

http://howtospecialist.com/structure/how-to-build-concrete-stairs

http://simplifiedsafety.com/blog/what-are-the-different-types-of-fall-protection-for-the-
construction-indust/

http://speeddemon2.com/viewing-ohio-river-bridges-project-tower-crane-pier-four/

http://www.craneblogger.com/crane-resource-library/how-are-tower-cranes-built

http://www.howtospecialist.com

http://www.ihsa.ca/pdfs/safety_manual/Fall_Protection.pdf

http://www.nzmachinery.com/news_nc1_7

http://www.opticrane.com/tac-3000)

http://www.superiorscaffold.com/blog/page/7/

https://www.peri-usa.com/projects/highrise-buildings-and-towers/555-10th-avenue.html

Luis Alves Dias, Inspecting Occupational Safety and Health in the Construction Industry,
International Training Centre of the International Labour Organization, 2009.

Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Bachok, Kelantan, 2004.

Nota Operator Kren Menara, Institut Kemahiran Tinggi Belia Negara (IKTBN),
Kementerian Belia dan Sukan, Chembong, Negeri Sembilan, 2003.

Nota Tower Crane Operator, Gamuda Plant Operator School (GPOS), Shah Alam,
Selangor, 2002.

Richard L. Neitzel, Noah S. Seixas, and Kyle K. Ren, 2001. A Review of Crane Safety
in the Construction Industry, Applied Occupational and Environmenta l Hygiene
Volume 16(12): 1106–1117.

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Tower crane Code of Practice 2006 Workplace Health and Safety Queensland
Department of Justice and Attorney-General, Australia, 2012.

Work near Overhead Power Lines, Code of Practice 2006, Australia.

CHAPTER 10

PRACTICAL TRAINING

10.1 Demonstration of the Tower Crane Control

Cranes must be handled with trainers. The signalman must have a clear
communication signal that will be used to the operator. The operator will see how
the tower crane moves as taught. The signalman must give signal to the operator
about the all appropriate movements formoving items from one location to
another.

10.2 Communication Using Hand

The signalam must indicate the appropriate hand signal for the process of moving
the load to the operator. The involved operator must handle the crane by relying
entirely on the hand signal by signalman.

10.3 Communication Using Flag

In addition to hand gestures, practicality must also be made for flag signers using
the flag. Only by using flag signals, signalman give directions to operators for
every crane and loading of goods.

10.4 Communication Using Walkie-Talkie

For voice communication using walkie-talkies also monitored by the trainers.

Some instructions by the signal interpreter should be provided to the operator
using the prescribed standard language. If this communication is clear and

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capable of assisting each movement properly, the signal engineer may be

deemed successful, and is entitled to be awarded a signal certificate.

CHAPTER 11

WRITTEN ASSESSMENT

11.1 Written training

Written training is a form of assessment to assess the level of understanding

of candidates who take the course of signalman. Candidates will be assessed
for understanding in signaling hands and flags (all should be compulsory) as
well as general questions (50% correct enough to pass).

11.2 Communication Using Hand

Signalman must identify hand signal. Examples of questions are as follows:

a) What is this signal? :-

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b) What is this signal? :-

11.3 Communication Using Flag

Signalman must identify flag signal. Examples of questions are as follows:

a) What is this signal? :-

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b) What is this signal? :-

11.4 General Question for Signalman

General questions of the signalman authority, legal and personal protection

tools can be addressed to candidates applying for a signalman certificate. For
this question, the candidate must successfully answer 50% correct to be
successful.

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