Failure analysis mtn526

Presented by:- Vaibhav Jain Failure Analysis, MTN 526
International norms of safety for Cranes.
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TYPES OF CRANE
 Fixed crane which lift the loads without any appreciable movement.
 Mobile or movable crane which moves from one place to another as well as movement of
the crane basic tools.
Fixed
• 1.TOWER CRANE
• 2. SELF-ERECTING CRANE
• 3.HAMMERHEAD CRANE
• 4.GANTRY CRANE
• 5.DECK CRANE
• 6.JIB CRANE
Mobile
• 1.TRUCK MOUNTED CRANE
• 2.TERRAIN CRANE
• 3.CRAWLER CRANE
• 4. RAILROAD CRANE
• 5. FLOATING CRANE
• 6.AERIAL CRANE

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Specification :-
Lifting Capacity: max 25t
Working Radius: 70 m to 75m
 Used for high rise infrastructure
and project
Specification:-
Lifting Capacity: max 6t to 8t
Working Radius: 45m
Used on construction site to
transport the material from one
place to other place.
Specifications:-
Lifting capacity –max 350 tons
Working radius-up to 70m
Used Ship-yard work including construction of
ship and heavy duty building construction.
Tower Crane Self Erecting Crane Hammer head Crane

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Specifications:-
Lifting Capacity: 5 tones to 10 tones
Working Radius: 23 m
Used in the construction of Bridge
superstructure for lifting heavy girder.
In Ship manufacturing industry ,for
lifting heavy parts of ships.
Deck CraneGantry Crane
Specifications:-
Lifting Capacity:25 to 36 tones
Working Radius: 20m to 30m
used for cargo operations or boat
unloading and retrieval where no
shore unloading facilities are available
Deck Crane
Specifications:-
Lifting Capacity: 1 to 300 tones
Working Radius: 70m
Use: Jib crane used in ship yards for lifting
heavy machinery and equipment, weighing
100 to 300 tons.

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Specification :-
Lifting capacity: 20 to 30 tones
Working Radius: 15m to 20m
used for the loading and unloading of
motor vehicle rolling stock, for cargoes
primarily of a heavy and single-item nature,
and also for construction and repair work
Truck Mounted Crane
Specification :-
Lifting capacity: up to 300 tons
Working radius: 34m
use in places where ground is uneven
or not very accessible like a beach or a
rocky expanse.
Crane
Terrain Crane Crawler Crane
Lifting capacity 35 to 40 tones
Working in confined or small area
where a big crane can not reach.
Crawler crane command their position
at many of power plants, thermal plants
and at big infra projects.

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 For lifting the goods at station yards.
 It may be used for installing signalling
equipment or pointwork, for example,
while more specialised types are used
for track laying.
Float CraneRail road Crane
 Capable of carrying whole sections of
bridge through the water and installing it in
position due to their loads capacity which
exceeds 10,000 ton.
 Used in ports, in protected waters, in
coastal waters and on the open sea.
Aerial Crane
used in remote and accessible places
where it is very hard to get any crane type.
Places like buildings tops, hill or mountain
top

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7 CAUSES OF CRANE FAILURE
The main causes of crane failure are listed as:
1.Struck by Load
2.Electrocution
3.Crushed During Assembly/Disassembly
4.Failure of Boom/Cable
5.Crane Tip Over
6.Struck by Cab/Counterweight
7.Falls

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ASME B30
Safety Standards for Cableways, Cranes, Derricks,
Hoists, Hooks, Jacks, and Slings
B30.1 Jacks
B30.2 Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder,
Top Running Trolley Hoist)
B30.3 Construction Tower Cranes
B30.4 Portal, Tower, and Pedestal Cranes
B30.5 Mobile and Locomotive Cranes
B30.6 Derricks
B30.7 Base Mounted Drum Hoists
B30.8 Floating Cranes and Floating Derricks
B30.9 Slings
B30.10 Hooks
B30.11 Monorails and Underhung Cranes
B30.12 Handling Loads Suspended From Rotorcraft
B30.13 Storage/Retrieval (S/R) Machines and Associated Equipment
B30.14 Side Boom Tractors

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B30.15 Mobile Hydraulic Cranes Note: B30.15-1973 has been withdrawn.
The revision of B30.15 is included in the latest edition of B30.5.
B30.16 Overhead Hoists (Underhung)
B30.17 Overhead and Gantry Cranes (Top Running Bridge, Single Girder,
Underhung Hoist
B30.18 Stacker Cranes (Top or Under Running Bridge, Multiple Girder With Top or
Under Running Trolley Hoist)
B30.19 Cableways
B30.20 Below-the-Hook Lifting Devices
B30.21 Manually Lever Operated Hoists
B30.22 Articulating Boom Cranes
B30.23 Personnel Lifting Systems
B30.24 Container Cranes
B30.25 Scrap and Material Handlers
B30.26 Rigging Hardware
B30.27 Material Placement System.
B30.28 Balance-Lifting Units

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This Standard is designed to
(a) guard against and minimize injury to workers, and otherwise provide for the protection of life,
limb, and property by prescribing safety requirements
(b) provide direction to owners, employers, supervisors, and others concerned with, or
responsible for, its application
(c) guide governments and other regulatory bodies in the development, promulgation, and
enforcement of appropriate safety directives

Daily Operator Inspection Requirements
 Daily inspections should be performed at the beginning of each shift or before initial use of
the crane each shift by the operator or appointed person.
 Make sure crane or hoist is not tagged out. If a tag is in place, it is usually located at the
power disconnect to the runway or on the pushbutton station.
 Check the load block to make sure all sheaves are running freely and sheave covers/guards
are in place.

 Inspect the hook for the following:
1. Is the safety latch in place? Does it operate correctly?
2. Is the hook bent or twisted? The twist cannot exceed 10° from the plane of the unbent
hook or as recommended by the manufacturer.
3. Check the bowl conditions. Are there any gauges, nicks or cuts that could damage
synthetic slings and etc.?
4. Check the rotation of the hook. Does it rotate freely the whole 360°?

 Inspect the wire rope to make sure it is lubricated and that none of the following conditions
exist:
1. No kinks
2. No broken or cut strands
3. No bird caging
4. No corrosion
5. No core protrusion
6. No crushed sections of rope
1.
2.
3.
6.

 Inspect the system conditions
1. Visually inspect the runway system. Are all bolts in place? Are there any obstructions on
the runway?
2. Visually inspect bridge, trolley and hoist connections. Does everything appear normal?
 Check Operational Functions
1. Do all the directional buttons and motions function correctly?
2. Test the hoist limit switches and any travel limit switches, if present, to ensure they are
operating correctly. This should be done without load.
3. If there are any horns or lights present, do they function properly?
4. Do all motions of travel run smoothly with no unusual sounds present?
5. Check the ground for any signs of oil leakage.
6. Pick up a load and make sure the brakes are functioning properly.

Periodic Inspection
 A periodic inspection is a detailed visual and operational inspection whereby individual
components are examined to determine their condition.
 The periodic inspection is performed as often as quarterly and is based on service, environmental
and application factors as determined by a qualified person.

Periodic Inspection Items
 Signs and Labels
 Check for proper capacity labels. Are they
legible from the floor? Are warning signs in
place and legible?
 Were cranes load tested? Did you record
this in your records? All new cranes must
be load tested after installation.
 Connection Points
 Check for loose/broken bolts or rivets. Check for
cracked or insufficient welds.

 Sheaves and Drums
 Check for worn grooves, worn groove lands, sharp edges and
cracks.
 Shafts, Axles, Wheels, Couplings
 Check for worn, cracked, bent or broken parts. Check for loose/
missing hardware.

 Brakes (Holding and Control)
 Check for excessive wear and proper adjustment on brake
system parts, linings, pawls and ratchets.
 Check for proper functioning of electric control brake.
 Indicators, Gauges or Other Devices
 Check for load, wind and other indicators over their
full range. Re-calibrate as required.
 Transmissions
 Check for excessive wear of chain drive sprockets
and excessive chain stretch.
 Open gearbox inspection covers and check for gear
teeth wear and proper lubrication.

 Electrical Components
 Check all electrical apparatuses for signs of pitting or any
deterioration of controller contactors, limit switches, pushbutton
stations, motor slip rings, brushes or resistors.
 Check for any loose wire connections for damaged wiring.
 Check for evidence of overheating.
 Bumpers and End Stops
 Check all bumpers and end stops for damage. Check for
proper restraints and obvious undersizing or improper energy absorption capabilities.

 Trolley and Runway Rail
 Check rails and fastening devices for looseness, gaps,
misalignment or wear.
 Runway Structure
 Check runway structure for proper anchors, loose bolted
connections, corrosion, cracked or deformed members.

Operational Safety
 Do not overload the crane or hoist. Make sure the combined weight of the lifter and load does not exceed the rated
load capacity of the crane or hoist.
 Refuse to make lift if you are unsure of any issues.
 Do not proceed until all issues are resolved.
 Take instructions only from the person designated to give signals.
 Do not ride or allow other people to do so.

Operational Safety
 To pick up a load, move the crane and hoist/hook directly above the load to
eliminate the possibility of side loading and minimize load swing.
 Before lifting, ensure that everyone is clear of any
pinch or crush zones.
 When starting to lift the load, only lift it a few
inches off the ground to verify hoist brake is
functioning properly before continuing with the lift.
Make sure the rigging is in good condition and that
safe rigging practices are applied
Ensure rigging is appropriate for the load size,
shape and weight.

Operational Safety – Moving a Load
 Do not lift loads over people. Stay out from under the load and make sure other people
remain at a distance.
 Do not become distracted while traveling. If you need to speak with someone, cease
operation of the crane.
 Stay clear while moving a load. Do not allow the load to swing.
 Use a rod to push the load or a tag line to pull the load.
 Exercise particular caution with sheet lifters. Be sure to keep
the load level.
 Tilting the lifter could cause the load to slide off the lifter.

Operational Safety
 Never leave a suspended load unattended. If you must leave
the area, lower the load to the ground before doing so.
 When the crane is not in use, always raise the
crane hook above head level.

Recommended Forms
 Maintenance Log
 Frequent Daily Check List
 Operator Training Questionnaire

 Periodically read the manual and review the rules.
 Examine the load chain for damage or twists, or the wire rope for kinks or fraying.
 Check the hook. If it's out of shape, don't use it. This may indicate internal damage.
 Avoid shock loads. Don't run the hook with a slack chain. Bring the chain or wire to a taut position before lifting.
 To avoid damage to the hoist, the rope or chain should always be in a straight line from hoist to hook.
 Avoid snagging a load while lifting.
 Avoid jogging a load.
 When using a wire rope hoist, check the wire on the drum. Don't let it get out of the grooves and pile upon itself.
 Side pulls with a wire rope hoist may fray the rope and make it unsafe and/or damage the hoist.
 Never leave a suspended load unattended. That load is your responsibility.
 Never carry a load over another person...or get under a load yourself.
 Never lift people with a hoist.
 When moving a load, look where you are going. Push, don't pull.
Crane Safety Tips
Conclusion

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Case Study Big Blue crane collapse
 July 14, 1999
 Occurred during the construction of Miller Park in Milwaukee
 3 people were killed as a result
 One of the most serious heavylift crane accidents
 Big Blue crane with 340 ft main boom, 200 ft jib, and 190 mast lattice truss structures.
 It was powered by 11 diesel engines, had six miles of wire rope, 1150 tons of counter weights,
and weighed in at 2100 tons total.
 Cause: The effect of side winds was not calculated for the 450 ton load
 Several environmental factors contributed to the accident including the wind and soft soil.
 The wind speeds that day were 20-21 mph with gusts to 26-27 mph, and the boom on the
crane was rated to 20 mph.
 Also, the crane sank about a foot into the soil when it initially lifted the roof section earlier
that morning.

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Figure a & b - Big Blue Crane components diagrams. (Ross, 2007)

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 When designing a crane, job of the engineer to create a machine that can maintain equilibrium with varying load weights at
different arm distances from the crane’s operating hub.
 On this particular crane, a 1150 ton counter weight was used to offset the load weight on the opposite side of the hub
 On the day of the incident, the crane operator inspected the data tables provided by Lampson in reference to the relevant load
weight a 510 ton roof section. The 510 ton load 155 feet from the hub was 97% of the next highest safe lift reading on the
reference chart.
 This might lead a layman to assume that the lift was safe—but it is common practice in crane operation to take into account wind
effects, something that, under pressure from Mitsubishi, he neglected to do.
 The technical specifications provided by Lampson clearly warned that the data from the load tables fully neglected wind effects
and that wind should always be analyzed on a lift-by-lift basis.
 On top of that, the specifications clearly stated not to use the crane at all in wind conditions above 20 mph, a condition that was far
surpassed that day.
 Ultimately leading to the dangerous decision to make the lift that day regardless of the 26 mph average wind speed with gusts in
the mid 30s (Ross, 2007).
 Lampson specified that the crane can only withstand a side load that is two percent of the total weight being lifted.
 The large force of wind on the roof piece created a side load far surpassing the 2% maximum.
 This force caused the carefully balanced crane to fall out of equilibrium.
 As a result, the connection where the “Boom” and “Mast” met the “Front Crawler,” (Figure 1a), began to bend, leading to an even
greater break in equilibrium as the weight-forces shifted out of their carefully balanced locations.

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After the accident and investigation, several changes were implemented for the completion of the project
A new crane was installed with anemometers at the tip of the boom and computerized load monitoring
Mats were installed to ensure safe foundations
Anemometers were mounted on the crane boom tip and stadium roof for continuous recording
Wind loads and specific site parameters were calculated for all lifts
Employers should implement designed by professional engineers based on
 rated capacity,
 measured weight of the load,
 study of the wind speed and its effect on the load, and
 consideration of ground conditions and dynamic forces on the crane's stability.
Suspended personnel platforms should not be used in adverse weather conditions which may endanger workers.
Provide alternate observations methods for locations not easily visible from the ground.
Only use personnel necessary to safely complete the lift in hoisted platforms.
Designers and erectors should evaluate worker risk when figuring out construction and hoisting methods.

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 A crane operator moved the crawler crane from one location to another with in the worksite
 Operator raised the crane boom to a near maximum boom angle of 80 degree to avoid the nearby
building and site office as the site was small
 Crawler crane boom tipped over backwards while it was being swung towards the front and back of
crawler crane began to sink,
Case Study 2

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 Ground conditions was soft due to sunken hardcore
 Steel plates were placed sparsely apart for crane travel route
 Only 2 steel plates were found under the crane track

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• Lifting supervisor and crane operator did not make a proper assessment of
ground condition
• Wrong method of laying steel plates on soft ground

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• Steel plates must be placed closely together

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Case Study 3:- The overturn of the transportable crane which
happened in lift work in construction
Date July 10, 1997
Place Niigata Prefecture
Location The construction field of the incinerator plant
Incident
The overturn of the transportable crane by the subsidence of the outrigger in the
ground
Background

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Primary Scenario :-
1. Insufficient Analysis or Research,
2. Insufficient Environment Study,
3. Planning and Design,
4. Poor Planning,
5. Usage,
6. Operation/Use,
7. Failure,
8. Fracture/Damage
 The ground was weak in the cohesive soil.
 The size and rigidity of the overlay board which was used to
disperse the load which affected the outrigger were
insufficient.
 The unsuitable work by sliding and drawing was carried out.
Cause:-

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Response:-
 To carry out the appropriate countermeasure such as laying a covering plate as
a prevention of subsidence of outrigger.
 To decide work planning.
 To decide work method.
 To examine the work condition of transportable crane including the ground condition.

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Case Study 1:- The overturn of the transportable crane which
Date July 10, 1997
Place Niigata Prefecture
Location The construction field of the incinerator plant
Incident
The overturn of the transportable crane by the subsidence of the outrigger in the
ground
Background

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 When it was intended to move the load by the method of what is called "sliding and drawing" which raises the jib
while lowering the complementary roll,
the outrigger float located in the rear (the suspension load side) of the crane subsided and slid horizontally on the
overlay board. It dropped and more and more greatly subsided.
 It overturned. Damage to the jib etc was generated in the transportable crane.
In order to lift the load far from the crane, the jib was expanded and the hook was rolled.
However, the operator who judged that it was difficult to lift it by the big radius of operating intended to give the load
access to the crane side.
He intended to move it by the method of "sliding and drawing".
However, the outrigger subsided, slid, dropped from the overlay board and sank in the ground because the
horizontal load with sliding affected the outrigger which supported the vertical load. As the result, the crane
overturned.

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Primary Scenario :-
1. Insufficient Analysis or Research,
2. Insufficient Environment Study,
3. Planning and Design,
4. Poor Planning,
5. Usage,
6. Operation/Use,
7. Failure,
8. Fracture/Damage
 The ground was weak in the cohesive soil.
 The size and rigidity of the overlay board which was used to
disperse the load which affected the outrigger were
insufficient.
 The unsuitable work by sliding and drawing was carried out.
Cause:-

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 To carry out the appropriate countermeasure such as laying a covering
plate as a prevention of subsidence of outrigger.
 To decide work planning.
 To decide work method.
 To examine the work condition of transportable crane including the
ground condition.

Case Study:- The overturn of the transportable crane which
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 Determining whether a rope failure was primarily due to an overload event, or to fatigue.
Background
 A wire rope broke while lifting a load of reinforcing steel estimated to weigh 2.5 - 3 tonnes.
The rope was 2 years old and was stated to be maintained by regular lubrication.
 The rope was a general engineering 18 strand non-spin type designed as 12x7(6/1)/6x7(6/1)
 This rope had an inner layer of 6 strands of wires,
 with each strand comprising 7 wires wrapped as 6 outer wires around 1 inner wire,
while the outer layer is formed by 12 strands of wires wrapped in the same way.
The rope sheave diameter was 520 mm, and it was known to have been in service longer than the rope.
 Three pieces of rope were supplied to assist in this investigation - these comprised the two broken ends together with
a section of rope taken well away from the failed ends.
The purpose of this latter piece was to check the load capacity of the rope, via tensile testing, at the time of failur

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Figure 1 shows the 2 broken
ends of the rope.
Figures 2 & 3 . Close inspection of the rope near to the fracture plane showed
that a number of wires were cracked in outer and inner strands
Figure 4 Cracks on both inner and inner layers were associated with
flattened regions on the wires. Cracking was also observed on wires
well away from this region
Visual Inspection

Failure analysis mtn526

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