REPUBLIC OF KAZAKHSTAN SAFE WORK IN INDUSTRY SUPERVISION

AND MINING SUPERVISION COMMITTEE

(REPUBLIC OF KAZAKHSTAN GOSGORTECHNADZOR [GGTN])












REGULATIONS
FOR CRANE DESIGN AND SAFE OPERATION








Binding for Ministries, Agencies, Industries, Associations, Companies (irrespective
of their ownership types) and Individuals.















KRANENERGO SCIENTIFIC AND PRODUCTION ASSOCIATION
ALMATY
1997
2
These Regulations have been developed on the basis of Crane Design and Safe
Operation Regulations approved by the USSR Gosgortechnadzor on the 30
th
of
December 1969.

Some amendments and additions introduced in the Russian Federation Crane Design
and Safe Operation Regulations and approved by Gosgortechnadzor of Russia on the
30
th
of December 1992, as well as comments and suggestions of the Republic of
Kazakhstan Gosgortechnadzor (GGTN), the Republic of Kazakhstan Ministry of
Housing Construction and Development of Areas (Minstroy), the Institute of Kaz
Project Steel Structure and other concerned organisations and companies were taken
into consideration in the course of the Regulations development and editing.

The Regulations have been reviewed and amended accounting for the experience of
crane operation. Changes that have taken place on the engineering level of hoisting
units, requirements of current Construction Standards and Regulations (SNIPS),
Standards, legislative acts, resolutions and other regulatory documents were also taken
into account.

The compilers of the first revision hereof will appreciate any remarks and suggestions
related to provision of crane safety during its operation to be received from ministries,
industries, research and development, as well as designing institutions, companies,
GGTN bodies, crane owners and individuals. Such comments will be considered in
further revisions of the Regulations.

These Regulations shall come into effect on 01.08.1994. The Crane Design and Safe
Operation Regulations approved by the USSR Gosgortechnadzor on the 30.12.1969
shall be invalid since the above date.


ISBN 5-620-01085-6 Republic of Kazakhstan
Gosgortechnadzor

Official Publication Kranenergo State Owned
Scientific and Production
Association.

Any reprint is prohibited
3
TABLE OF CONTEXT

1. General Provisions 5
2. Engineering Requirements
3. Cranes and Gripping Devices Production,
Reconstruction, Maintenance and Installation
4. Hoisting Equipment Design and Assemblage
4.1. Gripping Parts
4.2. Ropes
4.3. Chains
4.4. Drums, Blocks and Sprockets
4.5. Brakes
4.6. Running Wheels
4.7. Supporting Parts, Limit Stops and Bumpers
4.8. Counterweight and Ballast
4.9. Safety Instruments and Devices
4.10. Control Mechanisms and Devices
4.11. Control Cabins
4.12. Guarding
4.13. Galleries, Platforms and Ladders
4.14. Installation of Hoisting Equipment
4.15. Crane Track
5. Cable Type Cranes
6. Hoists and Winches to Lift People
7. Operation of Hoisting Equipment
7.1. Registration
7.2. Commissioning Permit
7.3. Technical Examination
7.4. Supervision and Servicing
7.5. Operation
8. Responsibility for Breaches of the Crane Design
and Safe Operation Regulations
9. Emergency and Accident Investigation Procedures
10. Final Provisions
Appendix 1. Terminology and Determinations
Appendix 2. List of Regulatory Documents to be Applicable for Hoisting
Equipment Designing, Fabrication, Maintenance and Operation
Appendix 3. List of Head Organisations in Crane Production
Appendix 4. Estimation of Tension in a Sling String
Appendix 5. Crane Certificate Form
Appendix 6. Chain Block Certificate Form
Appendix 7. Maximum Permissible Deviations of Rail Tracks
(Plane and Profile Views) from the Designed Position
Appendix 8. Statement Form for a Crane Rail Track Acceptance
at Commissioning
Appendix 9. Work Permit Form (for the right of access to crane track and
passage galleries of overhead travelling and mobile cantilever
cranes to carry out maintenance and other types of work)
4
Appendix 10. Standards to Reject Ropes of Hoisting Equipment
Appendix 11. (Reference) International Standards ISO 4301/1,
4302, 4308/1, 4308/2, 4310 and 8087
Appendix 12. Threshold Standards of Load-Lifting Equipment
Component Rejection
Appendix 13. Standards for Rejection of Detachable Load-Gripping Devices
Appendix 14. Knowledge Assessment Certificate Form for engineering
and technical personnel responsible for supervision of
load-lifting equipment safe operation, engineering and
technical personnel responsible for load-lifting equipment
maintenance in good serviceable conditions, and persons
responsible for safe performance of work by cranes.
Appendix 15. Threshold Standards to Reject Basic Components of
Rail Tracks
Appendix 16. Knowledge Assessment Certificate Form for operating
personnel (crane operators, their assistants, mechanics,
electricians, safety device adjusters, and slingers)
Appendix 17. Shift Logbook of a Crane Operator Form
Appendix 18. Recommended Signals when Moving Loads by Cranes
Appendix 19. Form of a Work Permit for a Crane Operation
Close to an Overhead Power Line

List of Regulatory Documents Applicable to Facilities Supervised
by the Regional State Mining and Technical Supervision Inspectorates
(GGTN) of the Republic of Kazakhstan State Emergency Committee.
(The Documents are Available at Kranenergo Research and
Development Association)
5

1. GENERAL PROVISIONS

1.1. These Regulations shall set forth the requirements to hoisting machines and
units, as well as load gripping devices, appliances and containers design, set-up,
fabrication, installation, maintenance, reconstruction and operation.
1.2. The Regulations shall be applicable for the following:

a) Cranes of all types, including crane-manipulators;
b) Power driven trucks (trolleys) travelling along ground rail tracks together
with the control cabin;
c) Cranes-excavators designed to operate with a hook on a steel line or electric
magnet only;
d) Power hoisting tackle;
e) Winches to hoist loads or people;
f) Removable gripping devices (hooks, clamshells, load-lifting electromagnets,
etc.);
g) Detachable load gripping appliances (slings, shackles, spreader bars, etc.);
h) Load containers, with the exception of special containers applied in
metallurgy (dippers, bowls, moulds, etc.), as well as at sea and river ports,
requirements for which shall be provided by the industry standards and
regulations.

1.3. The Regulations shall not be applicable for the following:

a) Hoisting units installed in mines, on sea and river boats and other floating
structures, where specific requirements shall apply;
b) Excavators designed to operate with earth-moving equipment or clam-shells;
c) Cranes designed to operate with attached implements only (silent pile
drivers, pile draw-out devices, cradle hoists, drilling equipment, etc.);
d) Hoisting units for special purposes (e.g. floor, charging and planting
machines, boom-cats, electric and combustion engine forklift trucks, pilers,
tracklayers and bridge construction units, manipulators, etc.);
e) Mounting polyspasts (block and tackle) and structures they are suspended on
(masts, shavers, beams, etc.);
f) Specific military hoisting units;
g) Hand tackle units;

1.4. Basic terminology and definitions used in the text hereof are described in
Appendix 1. The list of standard documents and International standards
applicable in Kazakhstan is given in Appendix 2.

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2. ENGINEERING REQUIREMENTS

2.1. Designing and main research and development organisations (Appendix 3) shall
develop standardising and regulatory documentation for hoisting units.
Designing, research and development, and specialised organisations authorised
(licensed) by Gosgortechnadzor (GGTN) shall develop designs of hoisting units
to be fabricated.
2.2. Designs, requirements specifications and other standard documentation for
hoisting units to operate in explosive and inflammable environment shall be
developed accounting for the requirements of Electric Unit Design Regulations
(PUE) and the following standard documents: RD 24.090.96 and RD 24.090.91,
Operation Safety Regulations and Safety Regulations. The design shall provide
for arrangements to ensure safe working conditions of such hoisting units in the
above environment.
The ability of a hoist to operate in an explosive and inflammable environment
(with the particular environment category stated) shall be noted both in the
certificate and operation instructions.
2.3. Hoisting units to operate in the areas with the design temperatures below -40C
shall be designed and produced in accordance with the HL (cold) type on the
basis of GOST (State Standard) 115150.
Hoisting units to operate in seismic areas (above 6 degrees) shall be designed
and produced in accordance with SNIP 11-7, as seismic proof equipment.
2.4. The company that carries out the corresponding work shall be held responsible
for the quality of the design, production, installation, reconstruction and
maintenance of a hoisting unit, removable gripping devices and detachable load
gripping appliances, as well as for their compliance herewith.
2.5. Hoisting mechanisms and their parts supplied from abroad shall comply with the
requirements hereof.
Prior to conclusion of a contract for any hoisting unit supply from abroad, a
company (client) shall obtain the certificate of compliance herewith from the
certification authority. The certificate, instructions and any other operation
documentation supplied with hoists shall be translated into the language of
international communication in Kazakhstan
1
and comply with the requirements
hereof.
The client shall get all the possible deviations from these Regulations approved
by the Republic of Kazakhstan Gosgortechnadzor prior to signing of the
contract. Copies of the approval and certificate shall be attached with the
Hoisting Unit Certificate.

1
Russian.
7
2.6. The capacity and other characteristics, as well as the sizes shall comply with
State Standards and specifications, and in case they are unavailable, such
parameters shall be established in the requirements specifications or other
documents in accordance with GOST 15.001.
2.7. Hoisting units shall be designed in accordance with ISO 4301/1 and other
standard documents.
2.8. Self-propelled, railway and pull-type cranes with booms, cranes-excavators,
tower and frame cranes shall be stable in both operating and stand-by conditions.
Stability of a crane shall be estimated under conditions of a test load, under the
load (loaded stability), absence of load (inherent stability), sudden load removal
and mounting (dismounting).
If operation conditions of a crane require lowering of an unloaded boom in the
horizontal position, the boom stability in such position shall be ensured.
Stability of a crane shall be estimated in accordance with regulating documents
developed by appropriate institutions and approved by the Republic of
Kazakhstan Gosgortechnadzor.
2.9. The track gradient of a frame or cantilever crane truck (trolley) shall not exceed
0.003 at the worst position of the truck, and with the greatest operating load.
The above rated gradient shall not refer to cranes, which the mechanism of the
truck travelling is equipped with an automatic braking system of a closed type,
or when the truck is moved with the help of cable haulage.
2.10. The devices for load lifting and crane radius alteration shall be designed so as
the load or boom are lowered with the help of the engine solely.
2.11. Hoisting unit devices equipped with jaw, friction or other mechanical appliances
to switch them on, or to switch over their operating speeds shall be designed in
such a way that spontaneous switching or unclenching of the mechanism is
impossible. In addition, the possibility of the drive disengagement without the
brake application shall be eliminated for load and boom lifting winches.
Application of friction and jaw actuating clutches shall be inadmissible in
mechanisms designed to lift people, melted metal or slag, noxious and explosive
substances, as well as in power driven mechanisms, with the exception of the
following:
a) Movement or turning mechanisms with several ranges of speeds to switch
from one of them to another;
b) The mechanism for a caterpillar crane movement, with a common drive for
both tracks designed for their separate control.
In cases stated in clauses "a" and "b", the brake shall have an uninterrupted
kinematical link with the revolving section of the crane, caterpillar tracks or
wheels.
8

2.12. Spline, keyed and bolted joints shall be applied in the assemblies of a hoisting
unit that serve to transmit the torque.
2.13. Spline, keyed and bolted joints of a hoisting unit shall be protected from
arbitrary unscrewing or release.
2.14. Provision for secure fixation for sliding structures of cranes with telescopic
booms and towers shall be made.
2.15. Lifting mechanisms of forging cranes shall be provided with damping devices.
2.16. Cable and chain tackle and polyspasts of a hoisting unit shall be designed to
eliminate spontaneous falling of the cable (chain) off the tackle, as well as the
cable (chain) jam between the block and the pin (the sprocket and pin).
2.17. Installation of an equalising block or balancer is required if a double polyspast is
applied.
2.18. Traction wheels of hoisting units with a hand drive shall be provided with guides
to prevent the chains on them from falling off. The traction chain shall be long
enough for its lower part to be at the height of 500 mm from the surface, on
which the worker operating the unit is located.
2.19. Steel structures and steel parts of hoisting units shall be protected from
corrosion.
Arrangements to prevent moisture accumulation shall be provided in box and
tubular steel structures of cranes operating in the open air.
2.20. Safe access shall be provided to the mechanisms, protection devices, power
equipment, steel structure components of hoisting units requiring maintenance.
Galleries, platforms and ladders shall be arranged for the purpose. If there are
no platforms and ladders to serve blocks and safety devices, the possibility of the
boom lowering shall be provided.
2.21. Power equipment of hoisting units, its installation, wiring and grounding shall
comply with the requirements of the Power Unit Design Regulations (PUE).
Power equipment of hoisting units shall be operated in accordance with the
Consumer Power Unit Operation Regulations and Safety Regulations for
Consumer Power Unit Operation.
2.22. Automatic shutdown and fixation of mechanisms (the turning mechanism, those
of the load and boom winches, boom and bracing jacks lifting, boom sections
advancing) shall be provided for cranes with hydraulic drives, to be applied in
case of a pipeline break or pressure drop in the hydraulic system. The same
shall be provided for crane-manipulators to be applied in case of flexible
pipeline breaks.
9
2.23. The hydraulic system of cranes shall comply with the requirements of GOST R
50046 and provide the possibility of pressure control in each operating contour,
as well as the possibility to replace hydraulic units, hoses and filters without any
liquid discharge from the tank.
2.24. Steel line slings shall be designed accounting for the number of the line strings
and their incline to the vertical line angle (Appendix 4).
In case of general-purpose slings with several strings modelling, the design
angle between them shall be assumed as equal to 90. When slings designed for
a particular load is modelled, the actual angle may be taken as the basis for
calculations.
The strength margin factor for sling modelling shall be assumed as at least 6.
The design of multiple-strand slings shall provide for uniform tension of all the
strands.

2.25. Slings of hemp, caperone and cotton ropes (tapes) shall be modelled accounting
for the number of rope strings and the angle of their incline towards the vertical
line. The strength margin factor in that case shall be at least 8.


3. CRANES AND GRIPPING DEVICES PRODUCTION, RECONSTRUCTION,
MAINTENANCE AND INSTALLATION

3.1. All the hoisting units shall be designed and produced in compliance with these
Regulations and standard documentation.
3.2. Cranes and their elements shall be produced at plants with appropriate technical
facilities and qualified personnel to provide their production in full compliance
with the requirements of the Regulations, standards and specifications, and such
plants shall possess a permit (license) for such production issued by
Gosgortechnadzor bodies.
The Republic of Kazakhstan Gosgortechnadzor shall be the authority to issue the
above permits. The number and the date of the permit for crane production, as
well as the description of the Gosgortechnadzor body issuing the permit shall be
stated in the Crane Certificate.
Production of hoisting units not liable for registration in accordance with clause
7.1.2 hereof requires no permit from Gosgortechnadzor bodies.
3.3. Executive officers and experts involved in production of cranes, steel structures
for them and crane winches, as well as in crane installation and maintenance,
shall pass their knowledge hereof assessment in accordance with the Regulations
for the Knowledge of Standards and Guidelines Assessment issued by the
Republic of Kazakhstan Gosgortechnadzor (GGTN).
10
3.4. A permit for a non-specialised plant to produce a hoisting unit for their own
needs shall be issued by Gosgortechnadzor bodies in the order described below.
The company shall submit the following documents for consideration:
a) Assembly drawings of the crane and its basic units;
b) Specifications for production approved in the established order;
c) A certificate to confirm availability of welders attested in accordance with
the Welders Attestation Regulations.
3.5. The company shall submit the following documents to Gosgortechnadzor bodies
in order to obtain a permit to produce designed crane steel structures, winches
and safety devices made at the plant as separate elements (overhead beams,
booms, etc.):
a) Assembly drawings of units to be produced, cinematic, hydraulic and electric
diagrams;
b) Specifications for production approved in the established order;
c) A certificate to confirm availability of welders attested in accordance with
the Welders Attestation Regulations.
3.6. Gosgortechnadzor bodies shall issue permits to produce cranes and their separate
steel structures, winches and safety devices on the basis of the producer
inspection results, revision of the documents submitted, and after successful
testing of a pre-production model. Deviations from designs and other standard
documents may be accepted on an agreement with the authority that has issued
their approval. If it is the RoK Gosgortechnadzor that has issued the approval,
the deviations shall be agreed with that particular body.
The producer shall attach a copy of the agreement with the certificate of each
crane.
3.7. If a crane is assembled of units and parts produced at several plants, the
assembling plant shall be made responsible for the quality of the product as a
hole, and for compliance with these Regulations and State Standards, as well as
for the documentation. The crane certificate shall be compiled on the basis of
the documents certifying separate units. Such documents shall be kept at the
plant that assembles the crane.
3.8. Welding quality control requirements and rejection parameters accounting for
these Regulations and the procedure of units and the final product acceptance
shall be provided by the requirements specifications for the crane or separate
steel structures alongside with other conditions. The specifications shall also
include information about the material applied in production and welding
materials.
3.9. The producer shall carry out preliminary (mill), acceptance and recurring tests to
control the quality of cranes and their compliance with regulations, standards
11
and specifications. Every pre-production model of a crane shall undergo
preliminary and acceptance testing.
3.10. The producer shall arrange preliminary (mill) testing of the pre-production
model in accordance with the programme and methods developed by the crane
designers.
Participation of the crane designers and Gosgortechnadzor representatives in
crane testing shall be obligatory.
3.11. Acceptance testing of the crane pre-production model shall be carried out in
accordance with the programme developed by the designers, approved in the
established order and agreed with the RoK Gosgortechnadzor.
3.12. The programmes of the crane pre-production model mill and acceptance testing
shall be developed accounting for the requirements of ISO 4310. The
programmes shall provide testing of cranes for their compliance with the
certificates, visual inspection, static and dynamic testing, as well as testing of
boom self propelled cranes for stability.
3.13. The results of pre-production models preliminary and acceptance tests shall be
presented in Minutes and Statements, where the Committees' suggestions and
conclusions shall be stated.
3.14. The producers shall carry out recurrent tests of stock-produced cranes in
accordance with the programme they develop and get approved by
Gosgortechnadzor. Gosgortechnadzor's representative shall participate in crane
testing.
3.15. The programme of recurrent tests shall provide for testing in compliance with
the requirements hereof including visual inspection, idle stroke testing, static and
dynamic tests, testing of safety devices and crane characteristics.
3.16. One of stock-produced cranes shall undergo recurrent testing (once in 3 years).
3.17. The results of recurrent crane tests shall be entered in a Statement including
suggestions and conclusions of the Committee.
3.18. Every produced crane or its units shall undergo acceptance tests at the QA/QC
Department of the producer in accordance with a developed and approved
programme. The testing results shall be entered in the Crane Certificate.
3.19. The programme of acceptance testing shall provide for visual inspection, idle
stroke testing, static and dynamic tests in compliance with the requirements
hereof, testing of safety devices and crane characteristics, as well as testing of
the crane running gear. For cranes dispatched in the non-assembled state, that
programme shall be developed in accordance with the standard documents.
3.20. Every produced hoisting unit shall be supplied with the following:
12
a) Certificate;
b) Specifications;
c) Operation instructions;
d) Assemblage instructions (if required);
e) Other documents provided for by appropriate state standards and
requirements specifications.
If separate steel structures, mechanisms and safety devices for cranes are
produced, they shall be supplied with appropriate certificates.
3.21. The producer shall record every newly produced hoisting unit in a production
logbook and provide it with a nameplate fastened at a visible place. The
nameplate shall state the name of the producer or its trademark, the capacity of
the crane, the date of production, the serial number and other information in
accordance with the documentation. The nameplate with the data shall be kept
on the crane for the whole of its life span.
Cranes with a movable truck shall have such nameplates fastened either on the
crane or on the truck; and jib, tower and frame cranes shall have the producer's
trademark on each of the tower and boom sections in addition to the nameplate
bolted at an easily seen place.
If separate steel structures and units are produced, their data shall be entered into
a logbook.
3.22. The Crane Certificate shall be compiled in accordance with the Form given in
Appendix 5, and the certificate for a telpher shall be drawn up in accordance
with the Form shown in Appendix 6.
3.23. Hoisting unit operation guidelines shall be developed by a specialised
organisation or producer in accordance with the requirements hereof and GOST
2.601.
The Guidelines shall state the following:
a) The frequency of units and mechanisms maintenance and service;
b) Potential steel structure damages and the ways of their repairs;
c) The frequency and methods to test safety devices;
d) Methods of brakes adjustment;
e) The list of highly wearing-out parts and tolerances for their wear-out;
f) The procedure of technical examination;
g) The conditions of a clam-shell and magnet application for clam-shell and
magnet cranes;
h) A rail track for cranes set-up and operation requirements;
13
i) The instructions to bring the crane into a safe position in stand-by
conditions;
j) Safety requirements in case of emergency;
k) The criteria of the crane's threshold conditions to dispatch it to major repairs;
l) The life-span of the crane;
m) Other instructions on the crane maintenance and operation accounting for its
design specificity.
3.24. The producer shall take into account the deficiencies in a hoisting unit design
and production revealed in the course of its operation and make arrangements to
eliminate them. In cases, when the deficiencies revealed may impact the safety
of a hoisting unit application, the producer must notify all the companies
operating such units about the requirement and methods to eliminate such
deficiencies. They shall also send technical documents and materials, parts and
units required for the replacement. The body of Gosgortechnadzor that has
issued the permit to produce the hoisting unit shall approve recommendations
related to elimination of deficiencies.
3.25. On identification of deficiencies in a hoisting unit in the course of its assembling
or operation, or its incompliance with the requirements hereof, the owner shall
send a complaint letter to the producer. A copy of it shall be dispatched to the
certifying body and the Gosgortechnadzor body that has issued the permit for the
unit production.
If the hoisting units had been imported, the complaint letter shall be sent directly
to the producer and the body that has issued the certificate.
3.26. On receiving the complaint letter, the producer shall undertake to eliminate the
deficiencies and incompliance herewith stated in the letter, if no permit of
Gosgortechnadzor has been issued for related deviations from these Regulations.
The producer shall maintain a special logbook of claims, where the information
of the claimant, the unit serial number and the claim in brief shall be entered.
The producer shall also record other notifications of crane design and production
deficiencies in the same logbook.
3.27. Production of detachable gripping devices and containers shall also comply with
the standard documentation and assembly charts; and there must be a permit
(license) of the local Gosgortechnadzor body available.
If welding was applied during production, the production documents shall
include information about it and its quality control.
3.28. Detachable gripping devices (slings, chains, spreader bars, clamps, etc.) shall be
tested at the producing plant after they are manufactured, and after their
overhaul, the same shall be carried out at the factory having repaired them.
14
Detachable gripping devices shall be visually inspected and tested with the load
exceeding their rated capacity 1.25 times.
Containers for small items, loose and other loads shall be visually inspected after
their manufacturing. Containers have no need to be tested with loads.
3.29. Information related to detachable gripping devices and containers manufacturing
shall be entered into a logbook. The logbook shall state the description of the
device or container, its capacity, the number of the standard document (assembly
chart), the number of the certificate of materials applied, welding quality control
results and the results of the gripping device testing or container visual
inspection.
3.30. Detachable gripping devices shall bear a trademark or securely fastened metal
labels, with the number, lifting capacity and testing date stated on. Detachable
gripping devices produced for other companies shall be supplied with a
certificate in addition to the trademark (label).
3.31. The purpose, number, dead weight and capacity shall be marked on containers.
3.32. Companies with permits (licenses) from Gosgortechnadzor bodies may only
carry out reconstruction of cranes with welding application, as well as safety
device overhaul and adjustment. Permits for such work to be carried out shall be
issued in accordance with the procedure established by the Republic of
Kazakhstan Gosgortechnadzor.
3.33. Crane reconstruction and maintenance shall be carried out in accordance with a
design developed by a specialised company.
The actual state of a crane (wear-out degree, damages, etc.) shall be taken into
consideration while the design is developed.
The tower or boom may be shortened without any design on an agreement with a
specialised company if the crane certificate or its operation instructions do not
provide for the possibility of such change.
Special purpose equipment (excavators, boom-cats, etc.) may be reconstructed
into cranes on a permission of Gosgortechnadzor bodies, given they comply with
the requirements hereof.
A specialised company shall confirm the possibility of special purpose
equipment use as cranes.
3.34. The company that repairs and reconstructs cranes shall be provided with
requirements specifications including instructions on metals and welding
materials to be applied, welding quality control methods, welded joint rejection
rates and the procedure of separate units and items acceptance, as well as on
paperwork procedures.
15
3.35. After the overhaul and reconstruction is completed, the company that has carried
the work out shall state the character of work in the crane certificate and enter
the information about materials applied into it stating the number of the
certificate for the material.
The documents certifying the quality of materials and welding applied shall be
kept with the company, which has carried out the welding.
3.36. A specialised company only may carry out repairs and reconstruction of steel
structure load-bearing members with welding application. The owner may be
permitted to repair or reconstruct such crane steel structures on a permit of a
Gosgortechnadzor body only.
3.37. Repairs, assemblage or other work related to crane design or specifications
modification shall be carried out on an approval of the producer or specialised
company.
3.38. Companies engaged in production, maintenance and assemblage of cranes and
their units shall be certified in accordance with the Provisions of Hoisting
Equipment Certification.
3.39. Materials for production, maintenance and reconstruction of hoisting equipment
and their units shall be applied in compliance with state standards and standard
documentation developed by the main crane production organisations.
3.40. Quality of materials applied in hoisting equipment production, reconstruction
and maintenance shall be confirmed with a certificate provided by the supplier,
and that of incoming quality control.
If no certificate is available, materials may be applied after their testing in
accordance with standard documentation. Materials shall be selected accounting
for the ambient air temperature lowest threshold values for operational and
stand-by conditions, the extent of the elements being loaded and the aggressive
character of the environment. The data of the applied material type and the
lowest threshold temperatures for operational and stand-by conditions shall be
stated in the crane certificate.
3.41. Cast iron with the quality of at least 15 type in accordance with GOST 1412
may be applied to produce the following:
a) Tooth gear, worm and running wheels of hoisting equipment with a hand
drive;
b) Worm wheels of hoisting units with mechanical drives designed for the
classification (mode) group of at least M5, with the wheel peripheral speed
not exceeding 1.5 m/sec;
c) Worm wheels with bronze rims irrespective of the drive type and the
hoisting unit mechanism classification (mode) group;
16
d) Drums, bodies, reducers and blocks, with the exception of boom and tower
crane blocks;
e) Brake shoes, drum cantilevers and bearing housings.
Mouldings with the quality of at least 20 type in accordance with GOST 1412
may be applied to manufacture brake pulleys of hoisting equipment movement
and turning mechanisms. Types of moulding are not regulated for
counterweights and non-forced parts.
3.42. Materials, which previously have not been applied to manufacture, reconstruct
and repair hoisting equipment, may be used on the recommendation of a
specialised company and approval of the RoK Gosgortechnadzor.
3.43. Bearing elements of hoisting equipment steel structures shall be welded and
welding joints quality shall be controlled in accordance with standard
documentation developed by specialised companies.
3.44. Welders certified in accordance with the Regulations of Welders Attestation
only shall be allowed to weld and tack critical elements of steel structures, weld
on platforms, railing and stairs of a crane.
3.45. Welding shall be carried out in accordance with flow sheets developed by the
producer or specialised company on the basis of state standards and standard
documentation of main crane production organisations, and accounting for
characteristics of the structures to be welded.
3.46. Welding materials applied in crane structure welding shall ensure that
mechanical properties (the ultimate stress limit, yield point, extension strain,
flare angle and impact strength) of welding seam metal and that of welded joint
are not below the lowest limit values of the same basic metal features established
for the appropriate steel type in the state standard or specifications. The
requirement shall be also applicable for welding of railings, ladders and
platforms.
If steel of different types is applied in one joint, the mechanical properties of the
weld metal shall correspond to the properties of the steel with the higher ultimate
strength value.
Types of additive materials, fluxing agents and protective gases shall be stated in
specifications for crane fabrication, overhaul or reconstruction.
3.47. All cutting methods may be applied to prepare structure elements out of sheets,
section steel, pipes, etc. to provide quality in obtaining the shape and sizes of the
elements required in accordance with shop drawings.
Materials and half-finished products shall be cut in accordance with a
technology that will ensure absence of cracks or will avoid deterioration of steel
quality at the rims and within the areas of thermal impacts.
17
3.48. Precision of joints within the range of sizes and tolerances set forth in drawings
and by process requirements shall be ensured in the course of structures
assemblage for welding.
3.49. Crane steel structures shall be welded inside covered areas to eliminate adverse
impacts of weather conditions on the quality of welded joints.
Welding in the open air may be permitted in accordance with a specific
technology and on condition that appropriate arrangements are made to protect
welding from precipitation and wind.
3.50. The possibility of and procedure for welding at the ambient air temperature
below 0C shall be established in the standard documents.
3.51. Fabrication of welded steel elements with different welding methods application
within one and the same unit may be accepted given it is provided for by
specifications.
3.52. Tacks made in the course of a structure assemblage may remain if they are
completely melted during welding. Slag shall be removed from tacks prior to
welding.
3.53. Welded joints shall have a stamp or other mark on to identify the name of the
welder. The method of welded joints marking shall not impair the items marked.
Marks shall be applied by way of techniques that will ensure their preservation
in the course of the crane operation. The technique and location of the mark
shall be stated on drawings.
3.54. The requirement of post welding heat treatment for crane structure bearing
elements shall be identified in requirements specifications for crane production,
repairs or reconstruction.
3.55. Welded joint quality control carried out by the QA/QC Department during crane
production, assemblage, reconstruction and maintenance shall be performed by
way of visual inspection and measuring, mechanical tests and NDT provided for
by standard documents.
3.56. The quality of welded joints shall be tested after their heat treatment (if it is
required for the particular welded joint).
Welded joint quality control results shall be recorded in appropriate documents
(logbooks, charts, sheets, etc.).
3.57. All the welded joints shall be visually inspected and measured in order to
identify the following possible outer deficiencies:
a) Ruptures or failures to achieve the perpendicularity of the connected section axes;
b) Displacement of connected element rims;
18
c) Deviations from drawings in seam dimensions and shapes (seam height, leg
and width, regularity of intensification, etc.);
d) Cracks of all types and directions;
e) Bulges, cuts, burns through, non-welded dimples, porosity and other
deficiencies.
Prior to inspection, the surface of the seam and basic metal sections for at least
20 mm both ways adjoining the seam shall be cleaned from slag, drops and other
contamination.
Visual inspections of welded joints and their measurements shall be carried out
from both sides along the whole length of the joint. If the inside surface of a
weld is not available for inspection, it may be examined at the outer side only.
3.58. Inspection of welded joints with the help of radiological methods shall be carried
out in compliance with GOST 7512, and ultrasound testing shall be performed in
accordance with GOST 14782.
Welded joints at designed elements of steel structures shall be tested after
elimination of deficiencies revealed by visual inspection only. The initial and
the end parts of butt-joint seams at box-like beam, column, boom, and
gooseneck structures shall be inspected without fail.
The summarised length of welded sections to be tested shall be established by
standard documents, and shall be at least as follows:
a) 50% of the joint length at each joint of a box-like or grid steel structure
tensile chord;
b) 25% of the joint or compression wall section length at each joint of a
compression chord or at compression wall sections;
c) 75% of the joint length at each joint of boom and gooseneck structures, and
rack boxes of frame cranes;
d) 25% of the joint length for all the other butt-joints not stated in clauses a), b)
and c);
e) 25% of the joint length for other welded joints tested with the ultrasound
technique. Prior to X-ray or gamma tests, the appropriate sections of the
welded joint shall be marked so that they may be easily identified at X-ray or
gamma films.
3.59. Welded joint quality estimation on the basis of visual inspection and NDT
results shall be carried out in accordance with requirements specifications for
crane production, assemblage, repairs or reconstruction. The specifications shall
include the standards of welded joint quality estimation, which shall prevent
production of defective units of reduced safety and operational reliability.
3.60. The following deficiencies shall be unacceptable for welded joints:
19
a) Cracks of all types and directions in the metal of the seam, along the fusion
line and in the close to the seam area of basic metal including micro-cracks
revealed by microscopic analyses;
b) Faulty fusion (inadequate penetration) located at the surface along the cross
section of the welded joint;
c) Faulty fusion at the top (root) of angle and T- welded joints made without
bevelling;
d) Pores located as a continuous grid;
e) Cuts and bulges
f) Non-welded dimples;
g) Blowholes;
h) Non-welded burns-through in the metal of the seam;
i) Burns-through and sub-melts of basic metals (in case of pipe contact butt
welding);
j) Rim bias above rated values provided by drawings.
3.61. If NDT reveals unacceptable deficiencies in welded joints, the whole joint shall
be inspected. Defective sections of welds identified shall be mechanically
removed and welded anew.
3.62. Mechanical tests shall be carried out to check welded joints for their compliance
with the strength and plastic characteristics. They shall be made at control
samples welded in conditions, which completely correspond to those of steel
structure welding (the same basic and adding materials, the same welding
techniques and welding positions).
3.63. Mechanical tests at specialised plants fabricating, repairing and reconstructing
cranes shall be carried out from time to time in accordance with specifications.
When the above work is completed at a specialised plant, mechanical tests shall
be carried out with control samples to be welded by each welder participating in
crane steel structures assemblage. The number of samples shall be at least two
for each type of test (strain, bending).
3.64. Mechanical properties of control sample welded joints shall be tested
irrespective of the welded joint type by way of straining and bending of butt-
welded joints.
The results of mechanical testing shall be considered satisfactory if:
a) The point of maximum load is not below the lowest value of that of the
appropriate steel type provided by state standards or specifications;
b) The bend angle of carbon steel types is at least 120, of low-alloy types with
the element thickness up to 20 mm - at least 80, above 20 mm - at least 60.
20
3.65. The quality of welded joints shall be considered unsatisfactory if any type of
inspection identifies inner or outer deficiencies exceeding the standards set forth
hereby and by standard documentation for cranes production, assemblage,
reconstruction and repairs.

4. HOISTING EQUIPMENT DESIGN AND ASSEMBLAGE

4.1. Gripping Parts

4.1.1. Forged and pressed load hooks shall be produced in accordance with the
requirements of GOST 2105 and other standard documentation. The sizes and
basic parameters of forged and pressed hooks shall depend on the hook type and
the drive type of the hoisting unit in accordance with GOST 6627 and GOST
6628.
Safety locks for single hooks of climatic type "V" according to GOST 15150
applied in general-purpose hoisting equipment (with the exception of hoisting
units designed for operation in explosive environments) shall comply with the
requirements of GOST 12840.
Plate-type hooks shall be designed and manufactured in accordance with GOST
6619.
4.1.2. Steel forged and pressed hooks shall comply with standard documents.
4.1.3. Hooks with the capacity of above 3 tonnes shall be installed on frictionless
bearings, with the exception of hooks at specific purpose cranes.
4.1.4. A forged or pressed hook with the capacity of 5 and above tonnes, as well as a
clevis of a plate-type hook in a spreader bar, shall be mounted so that
spontaneous nut screwing is avoided. The nut shall be fixed with a locking plate
for the purpose. Locking of nuts with dowels, pins and locking bolts shall be
unacceptable.
4.1.5. Load hooks of cranes and telphers shall be equipped with a safety lock to
prevent the detachable gripping device from spontaneous falling off. Hooks of
cranes carrying melted metal or liquid slag may be installed without safety locks.
4.1.6. Forged and pressed hooks for loads shall be marked in accordance with GOST
2105 or GOST 12840. Marks on plate-type hooks shall accord with GOST
6619.
If a plate-type hook is fastened on a spreader bar with a clevis, the latter shall be
marked in the same way as the hook.
4.1.7. Hooks of specific design shall be supplied with a certificate, where the producer,
hook number, capacity and material it is made of shall be identified.
21
4.1.8. Rope grip buckets for bulk materials shall be manufactured in accordance with
GOST 24599. They shall be designed so that spontaneous opening and the
possibility of ropes leaving block grooves are avoided.
Clamshell capacity shall be estimated by way of material weighing after test
scooping to be carried out by the clamshell owner prior to its application for a
particular type (sort, kind) of load transhipment.
4.1.9. The clamshell shall be provided with a nameplate stating the producer, number,
capacity, dead weight, and the type of material it is designed for and the
maximum permissible weight of scooped material. If such nameplate is
damaged, the owner shall restore it.
Clamshells manufactured separately from cranes shall be provided with a
certificate in addition to the nameplate.

4.2. Ropes

4.2.1. Steel ropes applied as load, boom, guy, track and hauling cables, and as material
to fabricate slings shall comply with current State Standards and be supplied
with a certificate of the cable producer or its copy certifying their successful
testing in accordance with GOST 3241 and GOST 18899. Ropes manufactured
in accordance with ISO 2408 are also acceptable. If ropes are received without
certificates, they shall be tested in accordance with the above Standards.
Ropes without testing certificates shall not be accepted for operation.
4.2.2. Ropes shall be located and fastened on a hoisting unit in such a way that shall
eliminate the possibility of their falling off drums and blocks, as well as
minimise their abrasive wearing due to contacts with structure elements or ropes
of other polyspasts.
4.2.3. A loop at the end of a rope to fasten it on a hoisting unit, as well as sling loops
connecting them to rings, hooks and other parts shall be made with a thimble,
with the free end plaited or clamped, a steel forged, pressed or cast bushing
secured with a cotter, by way of cast moulding with fusible alloy or otherwise in
accordance with standard documents. Application of welded bushings shall be
unacceptable (with the exception of a rope fastening in the bushing of a telpher).
Housings, bushings and cotters shall have no sharp edges to wear the rope out.
4.2.4. The number of the rope punches with each strand while plaiting shall correspond
to that of Table 1.

Table 1
Humber of Rope Punches with Strands while Plaiting

Rope Diameter, mm Minimum Number of Punches with Each Strand
up to 15 4
from 15 to 28 5
from 28 to 60 6
22

The last punch with each strand shall be made with half of its wires (half section
of the strand).
The last punch may be made with a half of the rope strands. The number of
clamps shall be identified while designing, but it shall be at least three. The
spacing between clamps and the length of the rope free end after the last clamp
shall be equal to at least six rope diameters. Cramp irons shall be installed at the
free end of the rope.
Hot (forged) installation of clamps shall be prohibited.
4.2.5. The rope shall be securely fastened to the drum providing rope replacement
when required. If clamping bars are applied, their number shall be at least two.
The length of the free rope end from the last clamp on the drum shall be equal to
at least two rope diameters. It shall be prohibited to bend the free end of the
rope under the clamping bar or at the distance of less than three rope diameters
away from the bar.
4.2.6. Steel ropes of hoisting units transporting melted or glowing metal and liquid slag
shall be protected from the direct impact of radiant heat and metal drops with
appropriate guarding.
4.2.7. Steel ropes to be applied as load, boom, guy, track and hauling cables, shall be
selected in accordance with ISO 4308/1 and other standard documents, and those
for boom self-propelled cranes shall be selected in accordance with ISO 4308/2.
When designing, as well as prior to their installation of hoisting equipment,
ropes shall be checked with the help of calculation utilising the following
equation:
p
SxZ F >
0
, where:

F
0
is the breaking strength of ropes in general () taken from the certificate;
Z
p
is the minimum factor of the rope usage (the minimum factor of the rope
safety margin), to be identified from Tables 2 and 3;
S is the maximum tension of the rope strand () given in the crane certificate.
If the testing certificate gives a summarised breaking strength of the rope
threads, the value of F
0
maybe obtained by way of the summarised breaking
strength multiplied by 0.83.
Table 2
Minimum Factors of Rope Usage, Z
p

Unit Classification (Mode) Group Moving Ropes Stationary Ropes
ISO 4301/1 GOST 2583S Z
p

M1 1 3.15 2.5
23
2 1 3.35 2.5
1 3.55 3.0
4 2 4.0 3.5
5 3 4.5 4.0
6 4 5.6 4.5
7 5 7.1 5.0
8 6 9.0 5.0

Table 3

Minimum Factors of Rope Usage, Z
p

for Boom Self-Propelled Cranes

Crane
Classifi
cation
(Mode)
Group
Acc. to
ISO
4301/21
(GOST
27553*)
Moving Ropes Stationary Ropes
Load lifting Boom lifting / lowering Telescoping Mounting Operation Mounting
Mechanism
Classification
(Mode)
Group
Zp Mechanism
Classification
(Mode)
Group
Zp Mechanism
Classification
(Mode)
Group
Zp Zp
1 3.55 2 3.35 5 3.15 3.05 3.0 2.73
A3 4 4.0 3.55 2 3.35 3.05 3.0 2.73
4 5 4.5 3.55 M1** 3.15 3.05 3.0 2.73

* - Classification (Mode) group "A3" is assumed for truck cranes, with the
capacity up to 16 tonnes inclusive.
** - Without load.
Classification (mode) group below M5 shall not be applied for operations in
hazardous conditions (transportation of melted metal, slag, noxious substances
and explosives). Z
p
shall be calculated as for classification (mode) group M8 for
ropes on winches to lift people.
4.2.8. Hemp and cotton ropes used to make slings shall comply with GOST 483,
GOST 1088 and other standard documents.
4.2.9. Loop plaiting in case of a hemp or cotton rope shall have at least two complete
and two half punches, and shall be caged.
4.2.10. Application of synthetic and other materials to fabricate slings may be admitted
in accordance with standard documents.

4.3. Chains

4.3.1. Leaf chains used at hoisting equipment shall comply with GOST 191. Welded
and pressed chains applied as load lifting ones and to make slings shall comply
with GOST 228 and other standard documents. Anchor chains may be applied
either with spacer bars or without them.
24
4.3.2. Chains used at hoisting units as slings shall be supplied with the producer's
certificate about their testing in accordance with the State Standard applied in
their production.
If such certificate is not available, a sample of the chain shall be tested to assess
the critical load and check its compliance with the State Standard.
4.3.3. The strength margin factor of leaf chains applied in crane units shall be at least 3
with respect to the breaking load value for classification (mode) groups of M1
and M2, and at least 5 for other groups of unit classification.
Strength margin factors of welded load chains and chain slings with respect to
the breaking load value shall be taken from Table 4.
Table 4

Minimum Strength Margin Factors of Welded Chains

Chain Purpose Unit Classification (Mode) Group
1. 2 3 - 8
Load chain operating on a smooth drum 3 6
Load chain operating on a sprocket
(calibrated)
3 8
For slings 5 5

4.3.4. Chains may be joined by way of electric welding of inserted links, or with the
help of special connecting links. When joined, the new chain shall be tested
with a load exceeding its designed tractive force 1.25 times for 10 minutes.

4.4. Drums, Blocks and Sprockets

4.4.1. The minimum diameter of drums, blocks and compensation blocks rounded with
steel ropes shall be estimated in accordance with the following equation:
,
1 1
d h D >

,
2 2
d h D >


,
3 3
d h D >
where:
d is the diameter of the rope, in mm;
D
1
. D
2
. D
3
- are the diameters of the drum, block and compensating block
respectively at the centre line of the rope coiled, mm;
h
1
. h
2
. h
3
are factors of diameter selection for the drum, block and compensating
block respectively (Table 5).
Factor h
1
. may be changed, but not above two steps according to the
classification group either way (see Table 5), with an appropriate compensation
by way of the Z
P
. value (see Table 2) shifting to the same number of steps the
opposite way.
25

Table 5

Diameter Selection Factors for a Drum (h
1
), Block (h
2
) and
Compensation Block (h
3
)

Unit Classification Group Diameter Selection Factor
ISO 4301/1 GOST 25835 h
1
h
2
h
3

M1 1 11.2 12.5 11.2
2 1 12.5 14.0 12.5
1 14.0 16.0 12.5
4 2 16.0 18.0 14.0
5 3 18.0 20.0 14.0
6 4 20.0 22.4 16.0
7 5 22.4 25.0 16.0
8 6 25.0 28.0 18.0

4.4.2. When operating on a sprocket, welded calibrated and leaf chains shall be in a
complete clutch with at least two teeth of the sprocket at the same time.
4.4.3. The rope capacity of a drum shall provide that at the lowest possible position of
the gripping device at least one and a half turns of the rope or chain remain
coiled on the drum in addition to the turns under the gripping device.
4.4.4. Hoisting equipment drums for one layer of wound rope shall be provided with
helical grooves. Clamshell cranes, if the rope is wound in one layer, and special
cranes, if their operation is accompanied with jerks and rope slackening, shall
have drums with a groove at least half of the rope diameter deep. Otherwise
they shall be equipped with a device ensuring proper winding of the rope on the
drum.
Drums with the smooth surface may be used in cases, when design purposes
require many layers of rope to be wound on the drum, or if a chain is applied.
4.4.5. Smooth drums and grooved ones for many layers of rope shall be provided with
ledges from both sides of the drum. Grooved drums for one layer of two rope
strings may have no ledges if the strings are wound from the sides of the drum
towards its centre. There may be no ledge at the side where the rope is fastened
to the drum if one string of rope is wound on the drum with grooves. Drums of
electric hoists (telphers) equipped with a device to prevent the rope from falling
off the drum (a cable layer) may be produced without ledges.
Ledges of a drum for rope shall rise over the top layer of the rope for at least two
rope diameters, and for chains - at least for the width of the chain link.
4.4.6. If several layers of rope are laid on a hoisting unit drum, proper placing of each
rope layer shall be ensured.
26
4.4.7. Blocks of boom and load polyspasts shall be equipped with a device to prevent
the rope from getting out of the block pass.
The gap between the above device and the block ledge shall not exceed 20% of
the rope diameter.

4.5. Brakes

4.5.1. Load lifting and crane radius changing mechanisms of hoisting units with a
mechanical drive shall be equipped with brakes of the normally closed type
automatically releasing at the drive actuation, with the exception of cases
provided for by clause 4.5.2.
Lifting mechanisms with a hand drive shall be equipped with automatically
operating load thrust brakes.
A device (check valve) to prevent the load or boom from going down if pressure
in the hydraulic system drops shall be provided for the mechanisms of load
lifting, radius changing and boom telescoping with a hydraulic cylinder.
4.5.2. Regulated normally closed brakes interlocked with the actuation coupling shall
be applied for the mechanisms of load lifting and crane radius changing with
regulated mechanism actuation couplings. The brakes shall prevent the load or
boom from spontaneous going down.
4.5.3. Clamshell double-drum winches with separate electric drives shall have brakes
installed on each drive.
A treadle (button) to unbrake the mechanism when the engine is shut down may
be installed on the drive of a support drum. In such case unbraking shall be
possible after some continuous pressing of the treadle (button).
If electric protection actuates or voltage is fed to the grid, the brake shall be
automatically engaged even if the treadle (button) is pressed.
4.5.4. Load lifting and crane radius changing mechanisms shall be equipped with
brakes, which shall have unbreakable cinematic connection with drums.
A torque-limiting clutch may be installed in cinematic circuits of chain and rope
telpher lifting mechanisms.
4.5.5. The brake of load and boom lifting mechanisms, with the exception of cases
stated in clause 4.5.8, shall provide a breaking torque accounting for the
deceleration margin factor, which shall be taken from standard documentation,
but shall be at least 1.5.
To reduce dynamic loads at the boom lifting mechanism, two brakes may be
installed, with the deceleration margin factor of one brake being at least 1.1, and
that of the second being at least 1.25. The brakes shall be actuated automatically.
27
4.5.6. Mechanisms of load lifting and crane radius changing for hoisting units to
transport melted metal and slag, noxious substances and explosives shall be
equipped with two brakes acting independently.
Lifting mechanisms of specific metallurgical cranes (stripping, etc.) designed to
transport glowing metal shall be also equipped with two brakes.
4.5.7. If two brakes are installed, they shall be mounted so that one of them is easily
disengaged to check the efficiency of the other.
4.5.8. If two or more brakes are installed on a drive, the deceleration margin factor of
each of them shall be at least 1.25. If a lifting mechanism has two
simultaneously actuated drives, at least one brake with the same deceleration
margin shall be installed at each drive. If each drive has two brakes, and there
are two or more drives at the mechanism, the deceleration margin factor of each
brake shall be at least 1.1.
4.5.9. If a load winch is equipped with two drives, the latter shall have rigid cinematic
connection to prevent spontaneous lowering of the load if one of the drives fails.
4.5.10. A load thrust brake may be applied as the second one for telphers. In that case
deceleration margin factor of the electromagnetic brake shall be at least 1.25.
One of the brakes at lifting mechanisms with the classification (mode) group of
M1 may be replaced with self-braking transmission.
4.5.11. Brakes shall be installed at movement mechanisms of hoisting units in the
following cases:
a) If the equipment is designed to operate in the open air;
b) If the unit designed to operate indoors moves along a track laid on the floor;
c) If the unit (truck) designed to operate indoors on a rail track moves with the
speed above 32 m/min (0.53 m/sec.).
Brakes on turning mechanisms shall be installed on all the cranes operating
outdoors, as well as on cranes operating indoors (classification group M2 and
above).
4.5.12. Brakes on turning mechanisms shall be installed on hoisting equipment of
classification (mode) group M2 and above.
4.5.13. Breaks on movement and turning mechanisms of hoisting equipment shall be of
the normally closed type and automatically disengaging when the drive is
actuated. The exception will be movement mechanisms of truck and wheel-
mounted cranes, cranes on specific chassis and railway cranes, as well as turning
mechanisms of tower and frame cranes.
28
Hand brakes shall be installed on truck and wheel-mounted cranes, as well as on
cranes mounted on specific automobile chassis the movement mechanism of
which is equipped with a regulated brake of a normally open type.
Brakes on the movement mechanism of railway cranes shall comply with the
Republic of Kazakhstan Ministry of Transport and Communications standards.
Regulated brakes of the normally open type may be installed on the mechanisms
of tower, boom, with the tower and boom equipment, and frame cranes. In that
case the brake shall be provided with a device to fix it in the closed position.
Such device may be installed on brake regulating levers or treadles.
4.5.14. Brakes of movement and turning mechanisms may remain unlocked when the
power engine is OFF if the wiring diagram provides for the possibility of
braking with the help of the engine. In such case the diagram shall provide for
the brake engagement (disengagement) with an additional device (button) when
the controller is at the zero position.
An additional drive for gradual braking may be installed at movement and
turning mechanisms. In that case there may be no automatic locking of the
brake.
4.5.15. Brakes at movement and turning mechanisms of the equipment operating
outdoors shall ensure that the unit and the truck stop and remain motionless at
the maximum possible wind speed taken for the operational condition of the
crane from GOST 1451 accounting for the permissible gradient.
4.5.16. Worm gear cannot serve as the brake substitution of hoisting equipment
mechanisms.
4.5.17. The weight locking a brake shall be fastened on a lever so that the possibility of
its falling off or spontaneous shifting is eliminated. If springs are applied, the
break locking shall be produced with the force of a compressed spring.
4.5.18. The brake shall be protected from moisture or oil getting directly on the brake
pulley.
4.5.19. Cranes moving on rails outdoors shall be equipped with anticreep devices.
Overhead cranes operating outdoors may have no anticreep devices if the value
of movement mechanisms deceleration margin is at least 1.2 at the maximum
possible wind speed taken from GOST 1451 for stand-by conditions of the
crane.
4.5.20. If rail locks are applied as anticreep devices, their design shall allow securing of
the crane at the whole length of its track.
4.5.21. Anticreep devices with mechanical drives shall be equipped with appliances to
engage them by hand.
29

4.6. Running Wheels

4.6.1. Running wheels of hoisting equipment and trucks movement mechanisms may
be forged, rolled, pressed or cast. Forged wheels shall comply with GOST
28648. Wheels without ledges may be applied given there are devices preventing
the wheels from coming off the rails.
4.6.2. One-ledge running wheels may be applied in the following cases:
a) If the track for cranes is not wider than 4 m and both track lines are located
on the same level;
b) If cranes move with each side on two rails given the wheel ledges on one rail
are located opposite the ledges on the other rail;
c) On support and suspended trucks;
d) On suspended monorail trucks. If one-ledge wheels of support cranes are
applied, the width of the rim less the ledge shall exceed the width of the rail
top for at least 30 mm. The wheels of tower cranes on rails shall be of two
ledges regardless of the track width.

4.7. Supporting Parts, Limit Stops and Bumpers

4.7.1. Hoisting equipment moving on rails shall be provided with supporting parts for
the cases of wheels or axles failure.
Supporting parts of monorail trucks with a towing cab shall be installed on the
carriage of the cab. If the cab and lifting mechanism are suspended on a common
frame, supporting parts shall be installed on arch carriage.
Supporting parts shall be installed at the distance not exceeding 20 mm from the
rails the hoisting unit or truck moves on. They shall be designed for the largest
possible load.
4.7.2. Supports or other devices to prevent the boom from falling back shall be
installed on boom cranes with the alternating radius and flexible boom
suspension.
Such devices shall be installed on tower cranes if the angle between the
horizontal line and the boom exceeds 70 at the maximum radius.
4.7.3. The force applied to raise (pull out) extension supports or their parts by hand
shall not exceed 200 H.
In case of a greater force, such supports shall be supplied with hydraulic,
mechanical or other drives.
30
4.7.4. Boom self-propelled cranes with cushioned running gear and non-outrigger
characteristics shall be equipped with devices eliminating the action of elastic
suspension and transmitting the load received by the crane directly to the
carriage or extended supports. Such cranes shall be also equipped with a
stabiliser of elastic suspension to allow the load be evenly transmitted to all the
springs of one carriage axle and to provide their even sag. There may be no such
devices installed on the front axles of truck cranes with specific chassis.
4.7.5. Arresters shall be installed at the ends of rail tracks to prevent hoisting units
from going off the rails.
4.7.6. Hoisting units with mechanic drives moving along rails and their trucks shall be
equipped with elastic bumpers on appropriate heights to mitigate their possible
impacts against arresters or each other. If operation documents provide for
installation of shock-free dead-end arresters, bumpers are not installed.

4.8. Counterweight and Ballast

4.8.1. Components of crane counterweight and ballast shall be secured or enclosed in a
casing to protect them from falling and prevent the weight designed from
alteration. If small articles are used as a counterweight, it shall be placed in a
steel box. The box design shall eliminate precipitation penetrating into it, as well
as loss of the load. Sand, gravel and crushed stone shall not be applied as
counterweight. Inventory marked loads shall be provided as ballast at cranes of
the boom type. They shall be produced and placed in accordance with the crane
producer's drawings.
4.8.2. Movable counterweights shall be moved automatically with the change of the
crane radius, or be provided with an easily visible indicator of the counterweight
depending on the radius.

4.9. Safety Instruments and Devices

4.9.1. Cranes with mechanical drives shall be equipped with devices (limit switches) to
stop automatically the following:
a) The gripping device lifting mechanism in its extreme upper and lower
positions. The limit switch of the gripping device lowest position may not be
installed if operation conditions do not require lowering of the load below
the level established by the design (certificate);
b) The mechanism of the crane radius changing in the boom extreme positions;
c) The mechanism of crane and its truck movement along rails (with the
exception of railway ones) if the crane (truck) speed may exceed 0.5 m/sec at
the time of its approaching the extreme position (movement mechanisms of
tower and gantry cranes with the flight above 16 m and transhipment cranes
shall be equipped with limit switches irrespective of their movement speeds);
31
d) Movement mechanisms of gantry and cantilever cranes or their load trucks
operating at one track.
The above devices shall be also installed if the run of any other mechanism has
to be limited, e.g. turning mechanisms, mechanisms of a hoisting unit telescopic
part extension, mechanisms of the gripping device and cab lifting.
4.9.2. Limit switches installed on hoisting equipment shall be switched so that the
possibility to move in the reverse way is provided. Further movement in the
same direction may be admitted for the mechanism of an overhead crane
movement, when it approaches a landing site or dead-end arrester with the
lowest speed permitted by the wiring diagram of the crane control.
4.9.3. The limit switch of the lifting mechanism shall be installed so that after the
gripping device stops, the clearance between the gripping device and the limit
stop of the telpher is at least 50 mm during load lifting. For all the other hoisting
units it shall be at least 200 mm.
4.9.4. The diagram of the lifting limit switch at clam-shell cranes with separate two-
engine power drive for the clam-shell winch shall be designed in such a way that
simultaneous disengagement of the lifting mechanism engine and the clam-shell
locking engine is achieved, when the clam-shell reaches its utmost upper
position.
4.9.5. The movement mechanism limit switch shall be installed in such a way that
disengagement of its engine takes place at the distance from the stop of at least
half decelerating way of the mechanisms. For tower, frame and gantry cranes, as
well as transhipment cranes, it shall be at least one and a half-decelerating ways.
If stop blocks for mutual run restraining are installed at overhead and cantilever
mobile cranes operating at one track, the above distance may be reduced to 500
mm. The producer shall state the unit braking distance in the crane certificate.
4.9.6. Overhead cranes shall be equipped with a device to automatically cut off power
from the crane, when people go out to its gallery. Power may not be cut off at
trolley cables not exceeding 42 V if cranes operate indoors.
The door leading to the gallery of an overhead crane shall be equipped with such
interlink, if the entrance to the crane is provided through the gallery.
4.9.7. The door from the landing site to the cab of a crane control shall be equipped
with an electric interlink, which will not allow the crane to start moving with the
door open. If the cab is provided with an anteroom, such interlink shall be
installed on the anteroom door.
4.9.8. The wiring diagram of magnetic cranes shall be designed so that if power is cut
off from separate units by way of safety instruments and devices, it is not cut off
from the load magnet.
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4.9.9. To prevent people from being squeezed between the non-turning and turning
parts of tower cranes with a non-turning tower or frame cranes, where the cab is
located at the turning part, a device to automatically cut the power engine of the
turning mechanism off shall be installed. It shall be engaged till the personnel
pass from the non-turning part to the turning one and to the cab. It shall also
apply to metallurgical cranes with a turning cab.
4.9.10. Boom self-propelled, tower and frame cranes shall be equipped with a lifting
capacity limit (load factor limit) to prevent them from falling backwards. The
device shall automatically disengage load lifting and radius changing
mechanisms if a weight exceeding the one for that particular radius by above
10% is being lifted. For tower cranes with the load factor up to 20 tonnes
x
m
and frame cranes the weight excess shall be above15%.
Load lowering down or engagement of other mechanisms to reduce the load
momentum shall be possible after the lifting capacity limit actuation
Cranes with two or more load lifting features shall apply a lifting capacity limit
with a device to switch it over to operation in accordance with the feature
selected. Access of the crane operator to the switch shall be prohibited at tower
cranes. The protection board or relay (electronic) block of the lifting capacity
limit shall be sealed.
4.9.11. Overhead cranes shall be equipped with lifting capacity limits (for each load
winch) if the production process makes overloads possible. Cranes with lifting
capacity varying along the length of the gantry shall be also equipped with such
limits.
The limit of an overhead crane shall not allow any overload above 25%.
4.9.12. Gantry and transhipment cranes shall be designed for maximum possible tilt
forces occurring during movements, or equipped with automatic tilt limits.
4.9.13. Cranes with electric drives shall be provided with protection from load and
boom falling down if any of the three feeding grid phases breaks.
When the load or boom lifting power engine is disengaged, voltage shall be cut
off from the coils of the electric magnet or winding of the hydraulic pusher
engine.
4.9.14. Terminations of power crane safety devices and instruments (limit switches,
manhole and cab door interlock, emergency switches, etc.) shall operate
breaking the circuit.
4.9.15. Cranes with electric drives, lifting capacity of which changes with the radius,
shall be provided with a lifting capacity indicator corresponding to the radius
selected. The scale of the indicator shall be clearly seen from the operator's
place.
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While calibrating the scale of the lifting capacity indicator, the radius shall be
measured on a horizontal area with the load on the hook corresponding to that
particular radius, and scale marks shall be made after the load is taken off.
4.9.16. Indicators of the crane tilt angle (inclinometers and annunciators) shall be
installed in the cab and non-turning frame of boom self-propelled cranes.
4.9.17. Tower cranes with the height of above 15 m to the head top, gantry cranes with
the flight above 16 m, frame and cable cranes and transhipment cranes shall be
equipped with a device (anemometer) to automatically actuate a siren if wind
speed reaches the value stated in the crane certificate.
4.9.18. Boom self-propelled cranes (with the exception of caterpillar ones) shall be
equipped with protection from dangerous voltage during their operation close to
overhead power lines.
4.9.19. Frame cranes shall be provided with a drum to automatically wind the cable
feeding power to the end.
4.9.20. The wiring diagram of the hoisting unit power engines control shall eliminate
the following:
a) Self-starting of power engines after voltage supply resumes in the feeding
grid;
b) Power engines start with a wrong acceleration mode;
c) Power engines start with safety device terminations (limit switch and
interlink device contacts).
4.9.21. Voltage from the outer grid shall be supplied to the hoisting equipment through
an input device provided with a hand or distant drive to cut voltage off.
4.9.22. The input device (protection board) of overhead and cantilever cranes shall be
equipped with an individual contact lock with a key (mark-key). No voltage
supply to the crane shall be possible without it.
The input device and control board of tower cranes shall be equipped with a
device to lock them.
4.9.23. An easily accessible switch shall be installed to feed power to the main trolley
cables or flexible cable.
The switch feeding the main trolley cables or flexible cable shall have a device
to lock it in the disconnected position.
4.9.24. Lamps installed on tower cranes shall be switched on with an independent
switch installed on the gantry.
4.9.25. Hoisting equipment controlled from the cab or control panel (in case of distant
control) shall be equipped with a sound-signalling device. The sound shall be
34
clearly heard within the movement locations and its tone shall differ from that of
an automobile honk.
4.9.26. The control cabin and engine part shall be electrically lighted.
Lighting at hoisting equipment with power drives shall remain connected, when
power is cut off from electric equipment of the unit.
Lighting and alarm grids connected prior to the input device shall be supplied
with a separate switch.
4.9.27. Cranes shall be equipped with low voltage maintenance lighting system not
exceeding 42 V.
The maintenance lighting grid shall be fed from a transformer or battery
installed on the crane.
4.9.28. Crane steel structures shall not be used as an operating current conductor to feed
lighting, control and other grids with voltage above 42 V.
4.9.29. Electric heating appliances installed in the hoisting unit cab shall be fire safe,
and their current conducting parts shall be guarded. Electric heating appliances
shall be connected to the power grid after the input device. The body of the
heating appliance shall be grounded.
Installation of self-made heating appliances shall be prohibited.
4.9.30. Power engine starting resistors shall not be installed in the control cab of a
hoisting unit.
4.9.31. All steel structures and metal parts (power engine and device housings, metal
casing of conductors and cables, protection pipes, etc.) of cranes with electric
drives fed from the outer grid shall be grounded in accordance with the Power
Unit Design Regulations (PUE). The above parts are not included into the power
grid, but may occur under voltage due to insulation failure.
4.9.32. The housing of a push-button device to control a power hoisting unit regulated
from the floor shall be made of a dielectric material or grounded with at least
two conductors. The line holding the pushbutton device may serve as one of the
grounding conductors.
4.9.33. The gripping device of a rod removing crane and power equipment housing
being under voltage conditioned by operation requirements shall not be
grounded. In such case they shall be insulated from grounded parts of the unit
with at least three stages of insulation. Resistance of each insulation stage shall
be at least 10 MOhm after the assemblage of a newly produced crane or a crane
after major repairs. Power equipment and wiring insulation shall be designed for
the case of load tension being applied, when the stages of protection insulation
are damaged or blocked.
35
4.9.34. Safety valves shall be installed on the discharge line of each pump at cranes with
hydraulic drive. The valves shall be adjusted for pressure exceeding the
operating one by not more than 10%.
The lines of fluid supply and discharge shall be designed in such a way that fluid
leaks are eliminated during operation or stand-by periods.
Flexible hoses applied in the hydraulic drive shall be reliable and protected from
possible mechanical damage. The system of operation fluid supply shall provide
for devices to completely remove the fluid while repairing, the possibility of
main line purging and cleaning the fluid from contaminants.

4.10. Control Mechanisms and Devices

4.10.1. Control devices of a hoisting unit shall be manufactured and installed so that
control is easy and does not impede observation of the gripping device and load.
The direction of handles, levers and hand wheels operation shall be reasonable
and shall correspond to the direction the executive mechanisms and units move.
Conventional signs shall be installed on such mechanisms and devices to show
the directions of movements caused. Such signs shall be preserved during the
whole period of their operation.
Separate positions of control handles, levers and hand wheels shall be fixed and
be marked.
The fixation force in the zero position or in OFF position shall exceed that of the
intermediate position.
Buttons for each mechanism reverse starting shall be interlinked to prevent
simultaneous engagement of reverse contactors.
4.10.2. Manual control starting devices applied at hoisting equipment controlled from
the floor shall have devices for self-reset into the zero position. If contactors are
used in such cases, their retention in the ON position shall be possible by way of
continuously pressing the start button only.
Control devices shall be suspended on a steel line with such length that it shall
enable the person operating the mechanism remain at a safe distance from the
load lifted. The control device shall be located at the distance from 1000 mm to
1500 mm from the floor.
4.10.3. Engagement of the protection board contactor at hoisting units with power drives
shall be possible in case all the controllers are in zero position only.
Terminations of the zero interlink of magnetic controllers with the individual
zero protection may be excluded from the protection board (input device)
contactor circuit.
36
In such case, light signals shall be installed in the control cab to inform of the
magnetic controller engagement or disengagement.
4.10.4. If several control stations are arranged for a hoisting unit (with the exception of
manipulator cranes), an interlink preventing the unit from being controlled from
separate stations simultaneously shall be provided.

4.11. Control Cabins

4.11.1. The control cab or panel shall be located at such place, where the operator could
observe load gripping, as well as the load and gripping device during the whole
cycle of the crane operation.
An exception may be made for tower, boom, with tower and boom equipment,
and frame cranes.
4.11.2. The control cab of a boom crane shall be located so that the load cannot strike
the cabin during usual crane operation with the shortest radius. Crane
mechanisms shall not be located directly above the cab.
4.11.3. The cab of an overhead crane and movable cantilever crane shall be located
under the gantry (cantilever) gallery and be connected to it with a ladder.
Overhead cranes may have the cab suspended to the frame of the load truck. In
that case the exit from the cab to the gallery shall be arranged through the truck
deck or railed outer catwalk.
4.11.4. An overhead crane cab shall be suspended from the side opposite the one, where
the main trolley cables are located. Exclusions may be made in cases, when
trolley cables are not accessible for any accidental touch from the cab, landing
site or ladder.
4.11.5. The control cab shall have the following minimum size: 2000 mm high, 900 mm
wide and 1300 mm long, the minimum volume shall be 3 m . The height may be
reduced to 1600 mm in cabs with a non-vertical front part in the cross section
going through the centre of the operator's seat. The size of boom self-propelled
crane cabs shall be taken from GOST 22827. Equipment located in the cab shall
be easily accessible.
4.11.6. Cabs of hoisting equipment designed for operation outdoors shall have an
uninterrupted enclosure from all sides and uninterrupted upper cover to protect
the operator from adverse weather conditions. Fenestration in the cab shall be
covered with safety (shatterproof) glass.
Open cabs of double-beam overhead and movable cantilever cranes may be
enclosed for the height of at least 1000 mm from the floor.
Cabs in one-beam overhead cranes designed for seated work may be enclosed
for the height of 700 mm.
37
If the cab is enclosed with safety (shatterproof) glass for the height of 1000 mm,
an additional metal grid will be required.
There may be no upper cover at open cabs of cranes operating indoors.
4.11.7. Cabs of overhead and movable cantilever cranes, in cases, when the distance
between the back wall of the cab and the items it moves in relation to is below
400 m, shall be provided with an uninterrupted enclosure from the back and
lateral sides for the height of at least 1800 mm. The back wall enclosure shall
cover the whole width, and the sides shall have covers for the width of at least
400 mm from the side adjoining the back wall.
4.11.8. Glass shall be installed in the cab in the way that makes it easy to clean the glass
from both inside and outside, or a device to clean glass shall be provided.
Lower glasses, the operator may stand on, shall be provided with a grid to bear
his weight.
Sun protection screens shall be installed in cabs of cranes operating outdoors.
4.11.9. The door to enter the cab may be of a swinging or sliding type, and shall be
equipped with a lock from the inside.
A swinging door shall open to the inside of the cab, with the exception of boom
self-propelled cranes and if there is an anteroom or platform with appropriate
railing at the entrance to the cab. In those cases the door may open to the
outside. Cranes operating outdoors shall be provided with a device to lock the
door from the outside when the operator leaves the working place.
Entrance to the cab through a manhole in the floor shall be prohibited.
4.11.10. The floor in the cab of a hoisting unit with power drive shall be covered
with planking of non-metal materials to prevent sliding and covered with a
dielectric rubber rug. If a cab floor area is big, rubber rugs with the size of at
least 500 x 700 mm may be only laid at places, where the operator works with
power equipment.
4.11.11. Crane cabs shall be equipped with a stationary seat for the operator. It
shall be designed and located so that he may control crane devices and observe
the cargo seating. The seat shall be adjustable vertically and horizontally to
make work and control devices operation convenient.
In cases provided by standard documents, operator's seat at control boards or the
whole cab shall be rotating.
4.11.12. The crane cab shall be designed and equipped so as appropriate
temperature conditions and ventilation are provided in accordance with standard
documents. The producer shall install a heating device in the cab.
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4.11.13. Design and equipment of hoisting unit cabs operating in hot chemical or
other shops, where dust and hazardous gases are emitted shall comply with the
requirements of standard documents.

4.12. Guarding

4.12.1. Easily accessible movable parts of a hoisting unit, which may cause an accident,
shall be enclosed with securely fastened steel detachable guarding. The guarding
shall be easily examined and oiled. The following shall be provided with
guarding:
a) Tooth, chain and worm gear;
b) Couplings with prominent bolts and pins, as well as other couplings located
in the passageways;
c) Drums located close to the operator's working place or in the passageways.
At the same time guarding shall not impede the view of the rope winding on
the drum;
d) The shaft of overhead crane movement mechanisms, with the rotation speed
of 50 and above r/min (if the speed is below 50 r/min, the shaft shall be
guarded at the location of the manhole leading to the gallery).
Shafts of other mechanisms shall be also guarded if they are located at places
designed for the operating personnel passage.
4.12.2. Running wheels of cranes moving on rails (with the exception of railway cranes)
and their trucks shall be equipped with screens to prevent foreign objects from
getting under the wheels. The clearance between the screen and the rail shall not
exceed 10 mm.
4.12.3. All non-insulated conductors of a hoisting unit including switches, contactor
panels and resistor boxes shall be guarded if they are located in such places,
where people in the cab, on the gallery, on catwalks or close to the unit may
accidentally touch them. Non-insulated conducting parts of switches supplying
power to the main trolley cables or feeding cable shall be also guarded.
Contactor panels and resistor boxes may remain unguarded if power is
automatically cut off when people enter the places of their location, as well as if
they are installed in special appliance cabs locked for the period of the hoisting
unit operation.
4.12.4. The main trolley cables located along the crane track and their current collectors
shall not be accessible for an accidental touch from the crane gantry, stairs,
landing sites and other places, where people may turn up. The above shall be
ensured with the help of the cables and current collectors appropriate location or
guarding.
4.12.5. Trolley cables located on a hoisting unit and not cut off with the hatch interlink
device (cables of a load electric magnet, trolley cables with the voltage above 42
39
V at cranes with a movable cab) shall be guarded or located among the gantry
frames at the distance inaccessible for the operating personnel.
Trolley cables shall be guarded along their whole length and at the butts.
4.12.6. Adequate protection shall be installed at places, where load ropes may contact
main or ancillary trolley cables of an operating crane or other crane located a
layer below.
Trucks of overhead cranes installed on open sites shall be protected from
precipitation.

4.13. Galleries, Platforms and Ladders

4.13.1. Overhead and movable cantilever cranes, with the exception of those stated in
clause 4.13.4, shall be equipped with galleries or platforms with convenient
entrances and access to all the mechanisms of the crane and its power
equipment. The galleries and platforms are required for safe and easy servicing
of equipment and devices located outside the cab.
4.13.2. Tower, gantry and frame cranes shall be provided with easy entrances from the
ground to the crane and into the cab. Overhead cranes shall also have a safe exit
to the truck.
4.13.3. Frame cranes shall be equipped with a safe entrance from the gantry stairs to the
platform located around the gantry cap (head) at any position of the rotating part
of the crane. The height from the deck of the platform to the lowest prominent
elements of the turning part shall be at least 1800 mm. The turning part of the
crane shall be accessible from the gantry at any position it is in.
4.13.4. Platforms and galleries are not necessary at one-beam overhead cranes with a
hand or mechanic drive, as well as at double-beam suspended cranes, if
maintenance platforms are available.
4.13.5. The width of a free passageway along the gallery of overhead and movable
cantilever cranes designed for power equipment and mechanisms servicing shall
be as follows:
a) At least 500 mm on cranes with transmission drives;
b) At least 400 mm on cranes with non-transmission or hand drives.
The width of the passageway between the railing and devices supporting trolley
cables and current collectors on the same cranes if their galleries are used to
locate them shall be at least 400 mm.
4.13.6. Galleries shall be installed in bays of buildings with overhead cranes of
classification (mode) A6 and above in accordance with ISO 4301/1 in the bays
to provide passages along crane tracks at both sides of the bay.
40
Galleries arranged as passages along the crane track shall be provided with
railing from the bay side, and the opposite side if there is no wall there. A
gallery on an open trestle may be provided with railing from the outer side only
(opposite of the bay).
The width of the passageway (clear distance) along the gallery shall be at least
500 mm, and the height at least 1800 mm.
At column locations, a passage at least 400 mm wide and 1800 mm high shall be
arranged at the side of a column or through the column. Every gallery section
near columns shall be enclosed. If a passageway is arranged through a column,
the width of the passage in the gallery shall be reduced to that of the passage
through the column at the distance of 1000 mm from it.
Every gallery shall be provided with exits to stairs at least every 2000 m.
4.13.7. Maintenance platforms shall ensure safe and convenient access to mechanisms
and power equipment.
If the distance between the floor of the maintenance platform and the lowest
parts of the crane is below 1800 m, the door of the maintenance platform shall
be equipped with a lock and automatic interlink to cut off power from the main
trolley cables of the maintenance section.
Movable platforms may be arranged instead of stationary maintenance ones.
4.13.8. Overhead cranes controlled from the cab (except for one-beam ones) shall be
equipped with cabs (platforms) to service the main trolley cables and current
collectors if they are located below the deck of the crane gallery.
A manhole to enter the cab from the deck to service the main trolley cables shall
be provided with a lid and a device to lock it.
The cab to service the main trolley cables shall be enclosed with railing at least
1000 mm high covered completely at the top for the height of 100 mm.
4.13.9. If a manhole is arranged in the maintenance platform deck, its size shall be at
least 500 x 500 mm. The manhole shall be provided with an easily opening lid.
The angle between the manhole lid in the open position and the deck shall not
exceed 75.
4.13.10. A landing site (platform) with stationary stairs shall be arranged to enter
a control cabin of an overhead, movable cantilever crane or an electric truck
moving on rails on the ground.
The distance from the floor of the landing platform to the lowest parts of the
overhead cover or prominent parts of structures shall be at least 1800 mm. The
floor of the platform shall be located on the same level with the floor of the cab
or anteroom if any. The clearance between the landing platform and the door
41
(anteroom) threshold shall be at least 60 mm, but not exceed 150 mm, when the
crane stops at the landing platform.
A landing platform may be arranged below the cab floor level, but not exceeding
250 mm in cases, when the clearance of 1800 mm in height cannot be achieved
if the platform is at the same level with the cab floor. It may be also done in
cases when the landing platform is located at the butt of the building and the
established clearance between the cab threshold and the platform cannot be
achieved. If a landing platform is arranged at the end of the crane track below
the cabin floor level, an overlap of the cab and platform is acceptable, but not
exceeding 400 m when bumpers are fully compressed. In such case the clearance
between the platform and the lowest part of the cab (vertically) shall be within
100-250 mm, that between the cab and the platform railing shall be within 400-
450 mm, and from the side of the entrance to the cab - 700-750 mm.
4.13.11. An entrance to the control cab of an overhead crane may be arranged
through the gantry in cases, when direct getting into the cab is impossible due to
design or operation reasons. In such case the entrance to the crane shall be
arranged in a specially allocated place through a door in the gantry railing
equipped with an electric interlink in compliance with clause 4.9.7 hereof.
No entrance to the control cab of magnetic cranes through the gantry shall be
acceptable. The exception may be made for the cases, when trolley cables
feeding the load electric magnet are enclosed or located in a place inaccessible
for accidental touching and the power is cut off by the interlink of the crane
entrance door.
4.13.12. Galleries, platforms, passageways and stairs shall be designed in
accordance with the requirements hereof.
4.13.13. Decks of galleries, platforms and passageways shall be metal or made of
other solid materials if they comply with fire requirements. The deck shall be
laid along the whole length of the gallery or platform. A metal deck shall prevent
any sliding (steel grooved, punched sheets, etc.). if expanded or punched metal
is applied, no hole shall exceed 20 mm.
4.13.14. Galleries, platforms, passages and stairs arranged in places, where trolley
cables or non-insulated conductors under voltage are located shall be equipped
with guarding to prevent accidental touching of trolley cables or conductors
irrespective of entrance interlink existence.
4.13.15. Platforms and galleries located at hoisting units, end beams of overhead
cranes and platforms and galleries designed to service hoisting equipment shall
be enclosed with railing 1000 mm high, with complete cover at the bottom for
the height of 100 mm and an intermediate link at the height of 500 mm. Railing
and cover at the bottom shall be also installed at the butt ends of overhead crane
trucks, and if there is no gallery, along the crane gantry and at the lengthwise
sides of the truck.
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The height of railing may be reduced to 800 mm at the truck of an overhead or
movable cantilever crane and at the end beam of such cranes if the dimensions
of the building do not allow railing 1000 mm high.
Posts on a landing platform the railing or fastening structures of the platform are
secured to shall be located at least 400 mm away from the cab if they are at the
height of 1000 mm from the platform deck.
4.13.16. Stairs from the floor to the platform and galleries shall be at least 600
mm wide. The width of stairs located on the crane itself, with the exception of
those not exceeding 1500 mm in height, shall be at least 500 mm. Stairs lower
than 1500 mm located on the crane, as well as stairs leading from the cab to the
gallery of overhead or movable cantilever cranes may be at least 350 mm wide.
4.13.17. The distance between steps shall not exceed 300 mm for vertical stairs,
250 m for inclined stairs and 200 mm for inclined stairs of tower cranes. The
spacing of steps shall be the same for the whole staircase. Steps of vertical stairs
shall be at least 150 mm away from the crane steel structures.
4.13.18. Stairs leading from the floor to landing and maintenance platforms and
galleries to pass along the crane track shall be located so as squeezing of people
on them by the moving crane or its cab is prevented.
Such landing stairs shall be inclined, with the angle of the incline to the horizon
not exceeding 60.
4.13.19. Inclined stairs shall be railed from both sides to the height of at least
1000 mm from the steps and have flat steel steps at least 150 mm wide
eliminating the possibility of slipping.
4.13.20. Guarding in the shape of arcs shall be installed on vertical stairs starting
from 2500 mm from the staircase bottom. The arcs shall be located at the
distance not exceeding 800 mm from each other and connected with at least four
longitudinal bands. The distance from the staircase to an arc shall be at least 700
mm and shall not exceed 800 mm with the radius of 300-400 mm.
There is no need to install the arc guarding if a staircase is located inside a lattice
column with the cross section not exceeding 900 x 900 mm or a tubular tower
with the diameter not exceeding 1000 mm. Arrangement of vertical stairs above
manholes shall be unacceptable.
If a staircase is above 10 m high, platforms shall be provided on them every 6-8
m. If a staircase is located within a tubular tower, such platforms are not
required.





43
4.14. Installation of Hoisting Equipment

4.14.1. Overhead cranes in buildings, tower, frame and cable cranes on open sites, in
ports and other permanent operation locations shall be installed in accordance
with a design developed by a specialised company.
4.14.2. Hoisting equipment shall be installed in such a way that when a load is lifted, it
is not required to drag it with the load ropes being inclined, and there is an
opportunity to transport the load lifted for at least 500 mm above equipment,
cargo piles, vehicles, etc.
While cranes controlled from the floor or on the radio are being installed, an
easy passageway for the worker controlling the crane shall be provided.
Installation of hoisting units with an electric magnet as a gripping device above
industrial and other rooms shall be prohibited.
4.14.3. Installation of cranes, load trucks and movable tackle above industrial premises
to lift and lower loads through a hatch in the flooring may be allowed in the only
case if one room is located directly above the other.
The hatch in the flooring shall be provided with stationary guarding at least 1000
mm high with complete cover at the bottom for 100 mm and mandatory
arrangement of light signals (lit lettering) to warn people of both the load above
the hatch and lowering of the load. It shall be also provided with signs
prohibiting staying of people under the load moved.
Installation of stationary tackle or winches to lift loads through a hatch in the
flooring shall be prohibited.
4.14.4. Hoisting units moving along rails on the ground shall be installed in compliance
with the following requirements:
a) The distance from the hoisting unit upper point to the ceiling of the building,
the lowest belt of the roof truss or articles fastened to it, as well as to the
lowest point of another hoisting unit operating one level above, shall be at
least 100 mm;
b) The distance from the deck of platforms and galleries of an overhead crane,
with the exception of end beam and truck decks, to the roofing, the lowest
belt of the roof truss or articles fastened to it, as well as to the lowest point of
another hoisting unit operating one level above, shall be at least 1800 mm;
c) The distance from prominent parts in the crane butts to the building columns
and walls and railing of galleries shall be at least 60 mm. Such distance shall
be established at the symmetric position of the crane wheels relative to the
rail;
d) The distance between the lowest point of a hoisting unit (not including the
gripping device) to the floor of the shop or platforms, where people may be
working during the crane operation (with the exception of the crane
maintenance platforms) shall be at least 2000 mm. The distance between the
44
lowest point of the crane cab and the floor level shall be at least 2000 mm or
(in grounded cases) within the range from 500 mm to 1000 mm;
e) The distance between the lowest prominent parts of a hoisting unit (not
including the gripping device) to equipment located within the area of its
operation shall be at least 400 mm;
f) The distance between the lowest prominent parts of a control cab and trolley
cables servicing cab to a wall, equipment, pipelines, prominent parts of the
building, columns, roofs of ancillary facilities and other objects the cab
moves relatively to shall be at least 400 mm.
4.14.5. The horizontal distance from the prominent parts of a crane moving along rails
on the ground to buildings, cargo piles and other objects located at the height of
up to 2000 mm above the ground surface level or platforms shall be at least 700
mm, and at the height above 2000 mm - at least 400 mm. The vertical distance
from the counterweight cantilever or counterweight located under the cantilever
of a tower crane to platforms with possible location of people shall be at least
2000 mm.
4.14.6. Installation of cranes, suspended electric trucks and tackles with automatic or
semi-automatic control, when the operator does not accompany the hoisting unit
shall ensure that the load does not impact the building elements, equipment,
cargo piles, etc. Presence of people shall be eliminated along the way of such a
unit movement. Safety covering (mesh, etc.) capable of sustaining falling loads
shall be installed above the carriageways and passageways for people.
4.14.7. Cranes for construction and installation work shall be mounted in accordance
with the design of work to be carried out by cranes developed by a company
licensed by Gosgortechnadzor.
4.14.8. The line owners shall approve installation of cranes moving on rails within the
protection zone of overhead power lines. The permit of such installation for
construction purposes shall be kept together with the work design, and in other
cases with the crane certificate.
4.14.9. Boom self-propelled cranes shall be mounted on a levelled and prepared ground
accounting for its characteristics and category. Cranes shall not be mounted on
newly backfilled and non-compacted ground, as well as on a site with an incline
exceeding the value stated in the crane certificate.
4.14.10. A boom self-propelled crane shall be installed in such a way that during
its operation the distance between the rotating part of the crane and buildings,
cargo piles and other objects is at least 400 mm at any position of the crane.
4.14.11. If there is a requirement to install a boom self-propelled or railway crane
on extended supports, it shall be mounted on all the extended supports available.
Firm and stable pads shall be laid under supports. The pads under additional
crane supports shall be included in its inventory.
45
4.14.12. Boom self-propelled cranes may be mounted at the edge of a pit (trench)
batter on condition all the distances stated in Table 6 are complied with. Iv the
distances are not possible to comply with, the slope shall be stabilised in
accordance with the design.
Table 6
Minimum Distances (in mm) from the Pit (Trench) Batter to the Nearest Crane
Supports with Solid (not Backfilled) Ground
Pit (Trench)
Depth, m
Ground
Sand and Gravel Sandy Loam Loam Clay Dry Loess
1 1.5 1.25 1.0 1.0 1.0
2 3.0 2.4 2.0 1.5 2.0
3 4.0 3.6 3.25 1.75 2.5
4 5.0 4.4 4.0 3.0 3.0
5 6.0 5.3 4.75 3.5 3.5

4.15. Crane Track

4.15.1. Rail tracks for a hoisting unit (with the exception of railway crane tracks) shall
be constructed in accordance with a design developed by a specialised company
or crane producer.
Prior to crane installation on its rail track the latter shall be tested for the load.
The rail track of a railway crane shall be constructed and maintained in
accordance with the standards of the RoK Ministry of Transport and
Communications.
4.15.2. The following basic data shall be included into the design for a crane rail track:
a) The rail type;
b) The type and length of cross ties;
c) The distance between ties;
d) The technique of rails fastening to cross ties and to each other;
e) The requirement of pads between the rails and cross ties;
f) The clearance between the rails;
g) The material and size of the ballast layer;
h) The minimum permissible radius of the curve at the curved track section;
i) Maximum permissible values of the general longitudinal incline, subsidence
under the wheels and tolerances for the gauge width and the difference in the
railhead levels;
j) Dead-end arresters design;
k) Rail track grounding design.
46
4.15.3. Crane tracks (with the exception of those for tower and railway cranes) and
tracks of suspended load trucks equipped with points or turn-tables, as well as
crossings serving to move the hoisting unit or its truck from one track to another,
shall comply with the following requirements:
a) Uniform motion shall be ensured at places, where the hoisting unit or its
truck moves from one track to another;
b) To prevent two close rails of the crane track from splitting, locks with an
electric interlink shall be installed to lock the close rails securely and prevent
the hoisting unit or its truck from moving if the lock is not locked. It also
applies to the rail of the crane track and the rail of the point or turn-table.
Electrical interlink may be replaced by mechanical for mechanisms with a
hand drive;
c) Sections of the track to be disconnected, as well as the rails of points and
turn-tables shall be equipped with automatic locks to prevent the hoisting
unit or its load trucks from going off the rail track;
d) A point or turn-table shall be switched with the help of a special mechanism
controlled from the ground of control cab of the hoisting unit;
e) Power shall be fed to the hoisting unit trolley cables, point regulating devices
and power interlink devices with the help of one switch.
4.15.4. Crane rails and load truck rails shall be installed in such a way that their lateral
and longitudinal shift is avoided during the hoisting unit movement and
operation. If rails are secured with welding, the possibility of their thermal strain
shall be eliminated.
4.15.5. Vehicles and forklifts may cross the tracks of gantry and tower cranes in
exceptional cases only, if no by-pass is possible. The owner of the crane shall
develop safety measures accounting for the intensity of its operation and traffic.
4.15.6. Crossings of gantry, tower and frame crane tracks with rail tracks of the plant
traffic may be admitted in separate grounded cases on an approval of
Gosgortechnadzor bodies and after arrangements to prevent operating cranes
from crashing with the rolling stock are developed.
A crossing of a frame crane track with a railway track shall be constructed in
accordance with a design developed by a specialised company and approved by
both the owners of the crane and the owners of the railway.
4.15.7. Tolerances for the gauge size, linearity and horizontality of the track and
permissible values of rail elastic subsidence under the crane wheels shall be
taken from standard documents.
If such data are not available in standard documents, the values of tolerances
shall be identified in accordance with Appendix 7.
4.15.8. A section for the crane stand-by location shall be stated in the rail track design.
47
4.15.9. If there exist buried engineering lines laid previously without accounting for a
rail track construction above them, an estimation shall be carried out to eliminate
the possibility of causing damage to the lines and their cover designed if
required.
4.15.10. A rail track being ready for operation shall be certified with an
Acceptance Statement (in accordance with Appendix 8). The results of the track
transversal and longitudinal profiles survey and the gauge size testing shall be
attached to the Statement.
4.15.11. The rail track condition inspection and its grounding resistance testing
shall be carried out in accordance with the standard documentation.

5. CABLE TYPE CRANES

5.1. Requirement set forth by Chapters 1-4 and 7 with amendments and additions
provided for by this Chapter shall be applicable to cable cranes (with bearing
ropes).
5.2. The stability factor of movable solid crane supports (non-swing bearing) each
way accounting for all the basic and additional loads (inertia forces, wind load,
snow weight, etc.) shall be at least 1.3 at their worst combination.
The stability factor of swing bearings in the plane perpendicular to bearing ropes
shall be at least 1.3.
5.3. Cranes shall be equipped with a device to automatically stop support movement
mechanisms in case one of them moves farther than another one for a distance
exceeding the designed value, and an indicator of such difference value installed
in the operator's cab.
5.4. Cranes shall be equipped with lifting limits actuating at lifting capacity excess of
25%. Load lowering only shall be possible after the lifting limit actuation.
5.5. Cranes with movable supports shall be equipped with anemometers sending a
sound signal when wind speed exceeds the value stated in the crane certificate.
5.6. A movable crane shall be secured with hand grips when operating at one place.
If operation of a crane requires its frequent relocation, the crane may remain
ungripped, but they shall be secured with grips after the end of work.
5.7. Indicators of the gripping device position according to its height and along the
span, as well as an indicator of the clamshell open or closed position shall be
installed in the operator's cab.
Such indicators shall be adjustable to remove errors accumulated.
5.8. The lifting mechanism and clam-shell closing mechanism of clam-shell cranes
shall be equipped with devices (limit switches) to automatically stop them:
48
a) When lifting if the distance between the bumpers of the gripping device and
the load truck reaches 1 m;
b) When lowering if at least three rope wraps remain on the drum;
5.9. The load truck movement mechanism shall be equipped with a device (limit
switch) to automatically stop it at the distance of at least 5 m from the support
site or a polyspast truck. Further movement of the load truck may be allowed to
the support sites or polyspast truck with a lowered speed.
5.10. A load truck shall be designed so that its fall in case of failure or running wheels
going off the carrying rope (ropes) is impossible.
5.11. The load truck from the bottom and the gripping device (hook, clam-shell
blocks) from the top shall be equipped with wooden or other bumpers, which
will not allow the gripping device to rest against the truck equipment.
5.12. The load truck moving mechanism shall provide for inspection speed not
exceeding 0.5 m/sec to examine and oil ropes.
5.13. The movable load truck brake shall provide for the breaking torque accounting
for the deceleration margin factor of at least 1.25.
5.14. If the moving mechanism of a truck has a rope-driving sheave, the diameter of
the sheave shall be at least 60 rope diameters. The traction factor of the rope and
the sheave shall be at least 1.5 calculated for the static load, and at least 1.25
accounting for dynamic loads.
5.15. Maintenance personnel only may go by a load truck. Such work shall be carried
out on the basis of a work permit to be issued in accordance with the form given
in Appendix 9.
5.16. The engine department of a crane shall comply with the following requirements:
a) The height of the department shall be designed accounting for the location of
hoisting means (cranes and tackles) above the main equipment;
b) The distance from the department walls to winches and between the winches
shall be at least 800 mm. The distance between the wall and a winch may be
reduced to 200 m on condition a safe passage is provided to the winch parts
requiring servicing;
c) The size of the door to the department shall ensure movement of the largest
inseparable parts of the equipment. The height shall be at least 1800 mm.
5.17. The engine department, operator's cab and crane tower heads shall be equipped
with telephones allowing for a simultaneous conversation among all the
locations.
5.18. Plates with the crane lifting capacity, its number and the date of the next testing
shall be placed in the crane engine department, operator's cab and on supports.
49
5.19. Load trucks shall be supplied with platforms to examine bearing ropes and
supports in the crane span.
The platforms shall be at least 750 mm wide, with the railing 600 mm high, two
intermediate longitudinal connections (rods) and with an uninterrupted enclosure
at the bottom 100 mm high. Entrances to the platform shall be equipped with
rigid barriers and locks eliminating their arbitrary opening.
5.20. Crane supports shall be provided with platforms to tighten bearing ropes,
maintain the equipment and enter the load truck. The width of such platforms
shall be at least 1000 mm, and their railing shall comply with the requirements
hereof.
5.21. Cranes with swinging supports shall be equipped with special platforms and
installation blocks to set the counterweight of the swinging tower. The platforms
shall be designed for the weight of the support with bearing ropes detached.
5.22. Bearing ropes shall represent an enclosed structure and made of one piece.
Multistrand ropes with a steel core may be applied at cranes with hooks designed
for installation work.
5.23. Double-spin ropes with the core of a fibre material shall be applied for lifting
and haulage ropes.
Regular lay ropes shall be applied as lifting ones. Long lay ropes may be applied
if the rope untwisting or polyspast branches spinning are eliminated.
Application of long lay ropes is preferable for haulage ropes to move the truck
and supports.
5.24. The device to fasten a bearing rope on supports shall be a hinged one to regulate
the rope tension. If several bearing ropes are applied, their uniform tension shall
be ensured.
5.25. A bearing rope shall be fastened in a coupling with a cotter or cast moulded with
a metal alloy.
The rope may be fastened with clamps on cranes with a variable span. In such
case the hold shall be designed for a force equal to the breaking strength of the
whole rope
5.26. The diameter of the drum and guiding blocks for load, haulage and clam-shell
(both supporting and closing) ropes shall be estimated according to the following
equation:
, d h D >
where:
D is the diameter of the drum or block measured along the rope centre line, mm;
d is the diameter of the rope, mm;
h is the factor of the drum or block diameter selection to be identified from
Table 7.
50
Table 7.
Minimum Z
p
and h Factors

Rope Purpose h Z
p

Bearing - 3.0
Lifting:
Hook installation


Hook transshipment


Clam-shell transshipment

30
40
50
30
40
50
30
40
50

5.0
4.5
4.0
5.5
5.0
4.5
6.0
5.5
5.0
haulage:
load truck moving
driving support movement
crane (support) moving

30
30
30

4.0
4.0
4.0
Crane (support) retention from movement by wind in stand-by
conditions
30 2.5
For bearing ropes anchoring polyspasts
For cam supports suspension
For mast and support guying
For power cables suspension
Installation:
With a hand drive
With a mechanic drive
30
-
-
-

12
20
6.0
3.0
3.0
3.0

4.0
4.0

* It is assumed that the weight of the clamshell with material is evenly
distributed to all the ropes.
5.27. Lifting, haulage ropes and ropes to suspend cables shall be intact. Rope splicing
may be accepted in separate cases. The length of the sections spliced shall be at
least 1000 rope diameters.
5.28. Bearing ropes of an enclosed design, as well as double-spin ropes shall be
rejected in accordance with the criteria given in Appendix 10.
If a crane with a swing support is shut down due to bearing ropes wear-out, the
support shall be mounted on the installation foundation.
5.29. Static testing of a crane shall be carried out with a load exceeding its lifting
capacity by 25%. In that case the load truck shall be placed in the middle of the
span, the load shall be lifted to the height of 200-300 mm and kept there for 30
minutes. After that, the conditions of ropes in the couplings and the general
condition of the crane shall be inspected.
5.30. The following shall be carried out during the crane dynamic testing:
a) Rotating lifting and lowing of a load stopping at various heights;
b) Rotating movement of the load truck stopping at various points within the
span;
51
c) Rotating movement of the crane in different directions to different distances;
d) Rotating lifting and lowing of a load, with simultaneous movement of the
load truck.
5.31. The following shall be attached to the crane certificate in addition to documents
enumerated in clause 7.1.3 for its registration at Gosgortechnadzor:
a) Steel Structure Acceptance Statements (at the producer's or installation site).
b) The Steel Structure Testing Statement if such testing is provided by the
design;
c) The crane track design;
d) The Statement of Crane Track and Foundations Acceptance with survey
marks and adjustments;
e) The Statement of Ropes Fixation in Couplings;
f) The Statement of Bearing Ropes Sagging Measurements;
g) The Statement of Tension in Support Guys Measurements;
h) The Statement of the Swing Support Position Inspection.
The sag of the bearing rope shall be measured with the truck being in the middle
of the span and with the maximum operation load. The actual sag value shall not
differ from the designed one for more than the tolerance established. The check
of the swing support position compliance with the designed one shall be carried
out with the empty truck being at the non-swinging support.
When crane tracks are inspected, the angle of inclined crane tracks shall be
measured, the linearity and horizontality, the distance between the track of one
support and the tracks of opposite supports. Inspections of the track conditions,
rope fixation in couplings and support guys tension, as well as inspections of
rope sag compliance with the design and the swing support position in the course
of operation shall be carried out during each certification of a cable crane.

6. HOISTS AND WINCHES TO LIFT PEOPLE

6.1. Requirement set forth by Chapters 1-4 and 7 with amendments and additions
provided for by this Chapter shall be applicable to hoists on tower cranes and
winches to lift people.
6.2. Hoists at tower cranes and methods of their testing shall comply with the
standard documentation for tower cranes manufacturing developed by
companies specialised in crane production.
6.3. Winches with hand drives shall be equipped with safe handles, their design shall
provide for lifting or lowering by way of uninterrupted force application to the
handle. The speed of lowering shall not exceed 0.33 m/sec.
52
6.4. Winches with power drives shall be equipped with normally closed brakes,
which shall automatically close with the engine disengagement. The deceleration
margin factor shall be at least 2.
6.5. The shaft of the engine shall be connected to the shaft of the drum with the help
of tooth or worm gear. Belt and friction gear, friction and cam clutches shall not
be applied for the purpose.
6.6. Winches shall be secured on foundation or provided with ballast to ensure their
stability at double operational load.
6.7. The method of the cradle and platform for people suspension shall eliminate the
possibility of their falling over. Cradles and platforms shall be equipped with
railing at least 1200 mm high. Workers shall be fastened with safety belts when
lifted in cradles seated (without railing). Arrangement of doors in the railing is
prohibited. If cradles are suspended on a hook, the latter shall be equipped with a
safety clamp to eliminate falling of the cradle.
6.8. In cases, when a cradle or a platform may hit against prominent building parts,
structures, or when their speed exceeds 0.33 m/sec, rigid or flexible guides shall
be installed and arrangements made to protect people lifted from their possible
hitting prominent building or structure parts.
6.9. Measures shall be taken to provide smooth stopping of a cradle or platform if the
lifting or lowering speed of winches with power drives exceeds 0.33 m/sec.
6.10. Stationary winches with power drives shall be equipped with automatic switches
to disengage the engine when the cradle approaches the upper position.
6.11. Stationary power winches shall be controlled from cradles or platforms by way
of continuous pushing of the control button. The winch shall stop when pushing
is ceased.
6.12. Winches shall undergo complete examination before commissioning and every
12 months.
6.13. Static testing of winches shall be carried out with the help of a load 1.5 times
exceeding their tractive force when lifting, and dynamic testing - with the load
exceeding it 1.1 times.

7. OPERATION OF HOISTING EQUIPMENT

7.1. Registration

7.1.1. The following hoisting units shall be registered at Gosgortechnadzor bodies:
a) Cranes of all types, with the exception of those stated in clause 7.1.2;
b) Excavators designed to operate with a hook or electric magnet;
53
c) Load power trucks with a control cab moving along rail tracks on the
ground.
7.1.2. The following hoisting units do not require registration at Gosgortechnadzor
bodies:
a) Crane of all types with hand driven mechanisms and cranes that alongside
hand driven movement mechanisms a pneumatic or hydraulic cylinder is
applied as a lifting mechanism;
b) Overhead cranes and movable or rotating cantilever crane with the lifting
capacity up to 10 tonnes inclusive controlled from the floor with a push-
button device or from a stationary panel;
c) Boom cranes with the lifting capacity up to 1 tonne inclusive;
d) Boom cranes with the permanent radius or having no rotation or moving
mechanism;
e) Adjustable cranes to install masts, towers, pipes adjusted on the structure
being installed;
f) Overhead cranes and tower cranes mounted on training grounds for training
purposes;
g) Cranes mounted on excavators, crushing and loading, and other process
equipment to be applied for such equipment maintenance only;
h) Telphers and winches to lift loads and/or people.
7.1.3. Hoisting equipment shall be registered at Gosgortechnadzor bodies on a written
application of the owner and his submission of the equipment certificate.
The application shall state availability of engineers and technicians in the
company (whose knowledge hereof has been assessed) to supervise safe
operation of hoisting equipment, and availability of trained personnel to service
the crane. It shall also confirm that technical conditions of the crane allow its
safe operation. If the owners have no required experts available, they shall
submit an agreement with a specialised company for supervision and servicing.
If an overhead crane, tower or frame crane are registered, a statement certifying
that the crane has been mounted in accordance with the instructions and signed
by an authorised representative of the installation company.
If an overhead crane is registered, the drawing of its installation shall be attached
with the certificate indicating locations of the main trolley cables and the landing
platform to enter the crane. The drawing shall show actual dimensions regulated
in clauses 4.13.10 and 4.14.4.
When a hoisting unit moving along a rail track on the ground is registered, a
certificate confirming that the track has been designed for that particular unit
operation shall be submitted. The designing company or the owners of the crane
shall give the certificate stating that the track is in line with the loads of the
crane with reference to the design.
54
If the counterweight and ballast plates for tower and frame cranes have been
made by the owners of the cranes, the Plates Acceptance Statement shall be
submitted stating the actual weights of the plates.
If cranes are installed on wharfs, a certificate shall be submitted stating that
cranes on them are acceptable.
If a crane is registered after having operated the rated life-span through, a
resolution of a specialised company shall be submitted stating the possibility of
its further operation.
When imported cranes are registered, resolutions of the certification body shall
be attached.
If boom self-propelled cranes (with the exception of caterpillar ones) are
registered, Gosgortechnadzor shall make a note on the owners' application to
register it at the road police department (State Automobile Inspectorate).
7.1.4. In case a hoisting unit is not supplied with the producer's certificate, it may be
registered at Gosgortechnadzor on the basis of the certificate compiled by a
specialised company.
In addition, the certificate of a hoisting unit shall include the following data:
a) A conclusion made on the basis of the unit and its separate elements lifting
capacity correspondence to the effective lifting capacity (confirmation of the
effective lifting capacity may be also given on the basis of the unit basic
designed elements comparison with the same elements of another hoisting
unit of the same type);
b) A laboratory certificate of chemical analyses and mechanical properties of
the steel structure material, with the closest analogue of local steel identified;
c) The hook design and calculations if it does not correspond to the State
Standard or is not provided with the producer's stamp;
d) The Statement of steel structures and welded joints quality testing.
7.1.5. Hoisting units shall be re-registered after:
a) Reconstruction;
b) Maintenance if a new certificate was made for the unit;
c) Transfer to other owners;
d) Installation of an overhead crane at another location.
7.1.6. If a hoisting unit is registered after reconstruction, a new certificate compiled by
the company that carried out the reconstruction shall be submitted, or the old
one, with the following documents attached:
55
a) The certificate of the reconstruction character signed by the specialised
company, which had worked out the design of the reconstruction;
b) New crane characteristics and the drawings of its overall view with the basic
dimensions if they have changed;
c) The principle wiring and hydraulic diagrams if they have changed;
d) Cinematic diagrams of mechanisms and rope reeving diagrams if they have
changed;
e) Copies of certificates (extracts from certificates) for metal applied in the
hoisting unit reconstruction;
f) Specifications of the adding material (built-up metal testing results or
welding rods certificates copies);
g) Data of steel structures welding quality control.
7.1.7. If a hoisting unit registration is denied, the reasons of it shall be stated in writing
with reference to appropriate clauses hereof and standard documents.
7.1.8. If a crane is dispatched for operation to other regions for a period of above 3
months, the owners shall notify the Gosgortechnadzor body, where the crane is
registered, about it stating the registration number of the crane, the new location
and the period of operation. On the crane arrival to the place of destination, the
work supervisor shall register it temporarily in the local Gosgortechnadzor body
and obtain a permit for the crane operation. In that case documents regulating
the procedure of preventive inspection and maintenance, the design of
construction and installation work to be carried out and memorandums assigning
persons in charge and servicing personnel shall be submitted.
7.1.9. A hoisting unit shall be taken out of registration in the following cases:
a) When it is written off;
b) When transferred to other owners;
c) When transferred into the category of those not liable to registration, a
hoisting unit shall be taken out of registration by Gosgortechnadzor bodies
on a written application of the owners and with entering the reasons into the
certificate.
7.1.10. Hoisting units not liable to registration at Gosgortechnadzor bodies, as well as
detachable gripping devices shall be provided with individual numbers, such
shall be entered in the hoisting unit and gripping device record log.

7.2. Commissioning Permit

7.2.1. A Commissioning Permit for a hoisting unit subject to registration at
Gosgortechnadzor bodies shall be obtained from the above bodies in the
following cases:
56
a) Prior to commissioning of a newly registered hoisting unit;
b) After installation due to the hoisting unit relocation (except for boom self-
propelled cranes);
c) After a hoisting unit reconstruction provided for by clause 3.333;
d) After steel structure design elements or parts maintenance or replacement
with welding;
e) After a frame crane installation at a new location.
7.2.2. A Commissioning Permit for a hoisting unit subject to registration shall be
issued by a Gosgortechnadzor Inspector on the basis of an examination carried
out by the owners. The owners shall inspect the conditions of the hoisting unit
and the crane track. The system of units supervision and servicing arrangement
in the company shall be also checked.
The owners shall notify Gosgortechnadzor (Inspector) about the coming hoisting
unit commissioning within at least 5 days.
7.2.3. A commissioning permit for caterpillar and wheel-mounted cranes after their
relocation shall be issued by an engineer in charge of safe crane operation
assigned by the owner's memorandum. It shall be issued after the hoisting unit
conditions examination and when safe operation is ensured.
7.2.4. A commissioning permit for a newly manufactured boom crane supplied to the
owners assembled shall be issued by Gosgortechnadzor on the basis of the crane
mill test results and technical examination (without testing under load) carried
out by the owners. An appropriate entry shall be made in the certificate.
7.2.5. A commissioning permit for hoisting units not subject for registration at
Gosgortechnadzor shall be issued by an engineer in charge of safe crane
operation on the basis of the crane producer's documents and technical
examination.
7.2.6. A commissioning permit for a hoisting unit subject to registration at
Gosgortechnadzor shall be entered in its certificate by a Gosgortechnadzor
Inspector, and for other hoisting units - by an engineer in charge of safe crane
operation. A commissioning permit for detachable gripping devices and
containers shall be entered in the recording log by the person who issues the
permit.

7.3. Technical Examination

7.3.1. Hoisting units and detachable gripping devices shall undergo complete technical
examination prior to their commissioning.
Hoisting units liable to registration at Gosgortechnadzor shall be examined prior
to their registration.
57
Technical examination shall be carried out in accordance with the instructions on
the hoisting unit operation developed accounting for ISO 4310 (texts of basic
International Standards are given in Appendix 11). If the above Instructions give
no appropriate guidelines, the examination shall be carried out in accordance
herewith.
7.3.2. Hoisting units in operation shall be examined from time to time:
a) Partially - at least once every 12 months;
b) Completely - at least once every 3 years with the exception of rarely
operating units (cranes to serve motor halls of power plants and pumping
stations, compressor units and other hoisting equipment used during
equipment maintenance only).
Seldom operated hoisting units shall undergo complete examination at least once
every 5 years. The owners shall identify cranes as seldom operating ones on co-
ordination with Gosgortechnadzor.
7.3.3. An extraordinary complete examination of a hoisting unit shall be carried out
after the following:
a) Installation due to a hoisting unit relocation;
b) A hoisting unit reconstruction;
c) A hoisting unit steel structure repairs, with design elements or parts
replacement;
d) Installation of removable boom equipment or boom replacement;
e) The load (boom) winch major repairs or replacement;
f) The hook or hook suspension replacement (static testing only);
g) Bearing or guy ropes replacement at cable cranes;
h) A frame crane installation at a new location;
i) On a request of a Gosgortechnadzor Inspector or a person in charge of
supervision.
7.3.4. After the replacement of worn out load or other ropes and in all the cases of rope
re-reeving, their new reeving and rope end fastening, as well as rope stretching
with operating load shall be checked. An engineer in charge of the hoisting unit
operating conditions shall enter the results in the crane certificate.
7.3.5. The owners shall carry out technical examinations of hoisting equipment, with
the exception of cases set forth in clause 7.3.6. An engineer in charge of
supervision and safe hoisting equipment operation shall carry out technical
examinations, with participation of an engineer in charge of crane operating
conditions.
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Testing after a hook or hook suspension replacement at night may be assigned
by a shop memorandum to shift engineering personnel at metallurgical and other
plants with a continuous process.
7.3.6. Hoisting units manufactured at a producing or specialised maintenance plant and
transported to the site assembled shall be completely examined at the plant prior
to their shipment to the owner. The date of such examination and its results shall
be entered into the crane certificate. Prior to the start-up, the owner shall
partially examine the crane and enter the results into the crane certificate.
7.3.7. Technical examinations have the objective to identify that:
a) The hoisting unit and its installation comply with the requirements hereof,
the certificate and the documents submitted for registration;
b) The hoisting unit is in good working condition ensuring its safe operation;
c) The arrangement of the hoisting unit supervision and maintenance comply
with the requirements hereof.
7.3.8. In case of a complete technical examination a hoisting unit shall undergo the
following:
a) Visual inspection;
b) Static testing;
c) Dynamic testing.
In case of partial technical examination, neither static nor dynamic testing is
carried out.
7.3.9. Technical examination of a hoisting unit shall include visual inspection and test-
running of its mechanisms and power equipment, safety devices, brakes, running
wheels and control appliances, as well as checking of lighting and overall
dimensions regulated hereby.
While checking the operation of the hatch leading to the crane gantry interlink
contact, it is required to make sure that power is not supplied to trolley cables
located on the crane.
In addition, the following shall be checked during the examination:
a) The condition of the hoisting unit steel structures and its welded (riveted)
joints (absence of cracks, displacements, wall thickening due to corrosion,
loosening of riveted joints and other deficiencies), as well as the cab, stairs,
platforms and railing;
b) The condition of the hook, running wheels, blocks, drums, braking elements.
In case of hoisting units transporting melted metal and liquid slag, forged
and pressed hooks and their suspension parts shall be tested by the plant
laboratory in accordance with the instructions on NDT application. The
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conclusion of the laboratory shall be kept together with the crane certificate.
Non-destructive testing shall include checking for cracks in the threaded part
of the forged (pressed) hook, cracks in the threaded part of the plate-type
hook and in the axle of the plate-type hook connection to the fork or spreader
bar. Such examination shall be carried out at least once every 12 months.
The owner shall establish the requirement to inspect suspension parts and the
frequency of such inspections.
c) The actual distance between the hook suspension and the stop at the lifting
mechanism limit switch actuation;
d) The condition of cables and grounding insulation at a power crane, and
assessment of their resistance;
e) Compliance of the counterweight and ballast weights with the values stated
in the crane certificate for a boom crane;
f) The condition of the crane track and its compliance with the requirements
hereof, design and operation instructions;
g) The condition of ropes and their fastening.
The limits to reject elements of a hoisting unit shall be given in operation
instructions. If the instructions do not contain them, elements shall be rejected
on the basis of recommendations given in Appendixes 10 and 12.
Work provided by clauses "a", "b" and "d" of this Article may be carried out
before the technical examination. In such case the results of visual inspections
and tests shall be recorded in a statement signed by the inspecting and testing
person.
7.3.10. Static testing of a hoisting unit shall be carried out with a load exceeding its
lifting capacity by 25% in accordance with methods provided by the crane
operation instructions. Such testing is targeted at checking the durability of the
unit.
7.3.11. Static testing of an overhead crane and movable cantilever crane shall be carried
out as follows further. The crane shall be installed above the supports of the
crane track, and its truck (trucks) shall be installed in the position corresponding
to the greatest sag. The hook or device substituting it shall grip the load and lift
it to the height of 100-200 mm, where it shall be kept for 10 minutes.
The load shall be lowered in 10 minutes and the crane gantry checked for
residual deformation.
Static testing of a gantry crane and transshipment crane shall be carried out in
the same way as that of an overhead crane. Each cantilever of a cantilever crane
shall be tested separately. In case of residual deformation resulting from the
crane test, such crane shall not be accepted for operation till a specialised
company identifies the causes of the deformation and estimates the possibility of
the crane further operation.
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7.3.12. Recurrent or extraordinary testing of a boom crane with one or several lifting
characteristics shall be carried out in the position corresponding to the highest
lifting capacity of the crane.
Cranes with removable boom equipment may be tested with the equipment
installed on them for operation.
After removable boom equipment has been installed on a crane, the test shall be
carried out in the position corresponding to the crane highest load capacity with
the equipment installed.
Boom cranes without any mechanism to change the radius (the boom is
supported with a guy line) shall be tested with the radius established for the
crane. Further operation of the crane shall be permitted with that very radius
given the results of testing are satisfactory.
7.3.13. When boom cranes are statically tested, the boom shall be installed in the
position corresponding to the crane lowest designed stability relative to the
running platform. The load shall be lifted to the height of 100-200 mm.
7.3.14. The crane shall be considered having passed the static test satisfactorily if the
load lifted does not lower down to the ground within 10 minutes, and no cracks,
residual deformation or other damage to steel structures and mechanisms are
found.
7.3.15. Dynamic testing of a hoisting unit shall be carried out with a load exceeding its
lifting capacity by 10%. Such testing is targeted at checking the functioning of
mechanisms and brakes.
Dynamic testing shall include numerous lifting and lowering of the load, as well
as checks of other mechanisms in combinations of movements provided by the
operation instructions.
7.3.16. If a hoisting unit is equipped with two or more lifting mechanisms, each of them
shall be tested.
7.3.17. If a hoisting unit is applied to lift and lower loads only (lifting of water gates at a
hydraulic power plant), its dynamic testing may be carried out without moving
the unit itself or its truck.
7.3.18. Static and dynamic testing of overhead cranes operating at hydraulic and thermal
power plants and sub-stations may be carried out with the help of specific
devices allowing creation of the testing force without load application.
The device shall allow for dynamic testing of a mechanism under load within at
least one revolution of the drum. Testing of the movement mechanism under
load is not necessary.
The crane owners or specialised company shall develop additional instructions
to test cranes with specific devices.
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7.3.19. Testing of a crane with several removable gripping devices may be carried out
with the device installed on the crane at the time of testing. Testing of magnetic
and clamshell cranes may be carried out with a magnet or clam-shell
accordingly.
7.3.20. If operation conditions do not require a crane application (with the exception of
a boom self-propelled one) with its rated capacity, complete examination of such
crane may be based on its reduces lifting capacity. In that case an entry shall be
made in the crane certificate that the capacity is reduced. Appropriate changes
shall be made in the nameplate on the crane and operator's instructions.
7.3.21. Technical examination of cranes that have operated through their rated life span
shall be carried out after their inspection made by a specialised company in
accordance with methodological guidelines developed by specialised companies
and approved by the RoK Gosgortechnadzor.
7.3.22. The owners shall ensure availability of a set of testing loads with their weights
marked for crane resting purposes.
7.3.23. The technical examination results shall be entered into the crane certificate by
the person, who has carried out the examination. The time of the next testing
shall be also stated.
When a newly mounted crane is examined, the entry in its certificate shall
confirm that the crane has been assembled and installed in accordance with the
Regulations and operation instructions, and that it has passed tests satisfactorily.
The entry of an operating crane undergoing a recurrent examination shall certify
that the crane complies with the requirements hereof, is in good condition and
has passed tests satisfactorily. The permit for further operation of the crane shall
be issued in that case by the safe crane operation supervising engineer.
7.3.24. Recurrent visual inspections and maintenance of hoisting units, as well as repairs
and alignment of crane tracks shall be carried out in accordance with the
producer's instructions and within the terms provided by the preventive
maintenance schedule. The schedule shall be developed accounting for the crane
actual operating time and its condition.
The owners of hoisting equipment shall ensure compliance of the above work
with the schedule and timely elimination of deficiencies found.
Crane operation after the time rated for inspection and maintenance is
prohibited.
7.3.25. The results of visual inspections and maintenance, information of hoisting
equipment repairs shall be entered into a log. Information of a hoisting unit
repairs requiring its extraordinary technical examination shall be entered into its
certificate.
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7.3.26. The results of removable gripping devices and containers visual inspections shall
be entered into a log.
7.3.27. After having operated the rated life span through a hoisting unit shall be
inspected by a specialised company licensed by Gosgortechnadzor bodies.
The procedure of a permit (license) for crane inspection issuing is set forth by
the standard documentation of the RoK Gosgortechnadzor.
7.3.28. Owners shall inspect removable gripping devices and containers from time to
time in the course of their operation. The frequency shall be as follows:
Spreader bars of tongs, other grips and containers - every month;
Slings (except for those applied seldom) - every 10 days;
Seldom applied removable gripping devices - before application.
Slings and containers shall be inspected in accordance with the instructions
developed by a specialised company. The instructions shall identify the
procedure and methods of inspection, rejection criteria and methods to eliminate
damage found. If the instructions are not available, slings shall be rejected on the
basis of recommendations given in Appendixes 10 and 13.
Damaged removable gripping devices identified in the course of inspection shall
be immobilised.

7.4. Supervision and Servicing

7.4.1. Company managers and private owners of hoisting units, containers, removable
gripping devices and crane tracks, as well as managers of companies operating
cranes shall provide their good working conditions and safe operation conditions
by way of proper inspection, examination, maintenance, supervision and
servicing arrangement. The following shall be done for the purpose:
a) An engineer to supervise safe operation of hoisting equipment, removable
gripping devices and containers, an engineer in charge of keeping hoisting
equipment in good working conditions and a person in charge of safe crane
operation shall be assigned;
b) Maintenance service and the procedure of recurrent inspections, maintenance
and repairs shall be established to provide good working conditions of
hoisting units, crane tracks, removable gripping devices and containers;
c) Personnel training and knowledge assessment procedures shall be
established as required hereby for people servicing hoisting units, as well as
the procedure of engineering personnel knowledge hereof assessment;
d) Instructions for persons in charge and service personnel, work diagrams,
flow charts, specifications for handling, load slinging and piling patterns, and
other regulations of hoisting unit safe operation shall be developed;
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e) Distribution of hoisting unit safe operation regulations, job descriptions and
guidelines among engineers, and operation instructions among the personnel
shall be ensured;
f) Compliance of engineers herewith and servicing personnel with the
instructions shall be provided.
7.4.2. The owners shall assign engineers to supervise hoisting equipment safe
operation after their knowledge hereof assessment by a Committee, with a
Gosgortechnadzor Inspector participation, and issue of appropriate certifications
in accordance with the form given in Appendix 14.
Knowledge of engineers supervising hoisting equipment safe operation shall be
assessed every 3 years. The numbers of the supervision service and its structure
shall be established by the hoisting equipment owners accounting for the number
of units and their operation conditions, and shall be approved by
Gosgortechnadzor.
7.4.3. The engineer supervising hoisting equipment safe operation shall:
a) Supervise the conditions and safe operation of hoisting units, removable
gripping devices, containers and crane tracks, and make arrangements to
prevent breaches of safety regulations;
b) Inspect hoisting equipment and issue permits for its operation in cases
provided hereby, as well as keep records of and inspect hoisting units and
removable gripping devices not subject to registration at Gosgortechnadzor if
no one else is made responsible for that;
c) Control implementation of improvement notices issued by
Gosgortechnadzor, compliance with the schedules of hoisting equipment and
crane tracks recurrent inspection and maintenance and terms of removable
gripping devices and containers visual inspections;
d) Check compliance with the work permit procedure established herein for
workers operating and servicing hoisting equipment, participate in
committees attesting servicing and maintenance personnel and assessing
their knowledge, committees assessing knowledge of engineers in charge of
keeping of hoisting equipment in good working conditions and persons in
charge of crane safe operation;
e) Control availability of operation instructions and compliance of servicing
personnel, engineers (experts) in charge of keeping of hoisting equipment in
good working conditions and persons in charge of crane safe operation with
the above instructions;
f) Check implementation of safety regulations, work charts and process
schedules during hoisting equipment operation. Special attention shall be
paid to correct application of load slinging methods, compliance with load
piling overall sizes established, accuracy of boom self-propelled cranes
installation, application of proper working and personal protection
techniques. He shall also check compliance with the system of work permits
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when operating close to overhead power lines and on crane tracks of
overhead and movable cantilever cranes;
g) Control compliance with the procedure of boom self-propelled cranes
allocation and dispatch to the sites procedure established by the owners.
7.4.4. If faults or breaches hereof are revealed in the course of hoisting equipment
operation and maintenance, the engineer supervising hoisting equipment safe
operation shall take measures to eliminate them, and shut down the unit if
required.
The engineer supervising hoisting equipment safe operation shall prohibit a unit
operation if:
a) Faults of brakes, blocks, ropes and their fastening, chains, hooks, winches,
running wheels, interlink devices and safety devices, as well as incompliance
of the crane wiring with the design are found;
b) There are cracks and displacements in bearing steel structures;
c) Faults in the crane track are revealed (Appendix 15);
d) The term of technical inspection or rated life span of the unit have expired;
e) It is serviced by non-attested operators and slingers, engineers in charge of
keeping of hoisting equipment in good working conditions and persons in
charge of crane safe operation have not been assigned;
f) The crane certificate or information of its registration at Gosgortechnadzor
are not available;
g) Removable gripping devices and containers appropriate for the weight and
character of loads are not available or faulty;
h) Improvement notices issued by him or Gosgortechnadzor are not
implemented;
i) Grounding or power equipment are faulty.
7.4.5. The responsibility for keeping of hoisting equipment in good working conditions
shall be imposed on an adequately qualified engineer after his knowledge hereof
assessment by a committee including a Gosgortechnadzor inspector, and on his
reception of an appropriate certificate and job description. The personnel (except
for slingers) servicing the crane shall report to him.
Such engineer's knowledge shall be assessed every 3 years.
The number and date of the memorandum of the person in charge assignment,
his position, name, identity card number and signature shall be included in the
hoisting unit certificate.
Such information shall be entered in the certificate prior to the unit registration
at Gosgortechnadzor, and also every time a new person in charge is assigned.
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For the period of such person's annual holidays, business trip, sick leave or in
other cases of his absence, his responsibilities shall be imposed on the person
substituting him in his position. The latter shall be of appropriate qualification
and after his knowledge hereof are assessed (without entering of his name into
the unit certificate).
The owner shall create conditions for the person in charge to carry out his
obligations.
7.4.6. The engineer in charge of keeping hoisting equipment in good working
conditions shall provide the following:
a) Keeping of hoisting units, removable gripping devices, containers and crane
tracks in good working conditions (if working condition of the latter is not
the duty of another service) by way of recurrent inspections, maintenance
and repairs within the time set forth by schedules. Regular control of
accurate inspection log maintenance and timely elimination of deficiencies
found, as well as personal inspection of hoisting units, crane tracks,
removable gripping devices and containers within the time scheduled.
b) Maintenance of hoisting equipment by trained and attested personnel with
adequate knowledge and skills to carry out their duties. He shall also ensure
recurrent assessment of the servicing personnel knowledge;
c) Compliance of the operators and maintenance personnel with operation and
maintenance instructions;
d) Timely preparation of hoisting equipment for technical examination, as well
as preparation of cranes, which life-span has expired;
e) Shut down of hoisting equipment for scheduled maintenance;
f) Compliance with the mark-key system in overhead cranes operation;
g) Compliance with the established procedure of servicing and other workers
access to crane tracks of overhead and movable cantilever cranes for
maintenance and other work;
h) Proper keeping of certificates and specifications for hoisting units and
removable gripping devices, containers and crane tracks, as well as
maintenance of personnel recurrent knowledge assessment logs;
i) Implementation of improvement notices issued by Gosgortechnadzor and the
engineer in charge of safe hoisting equipment operation.
Good working conditions of removable gripping devices, containers and crane
tracks may be imposed on another expert of appropriate qualification.
7.4.7. A person responsible for crane safe operation shall be assigned in every shift at
every shop, construction site or other site, where hoisting equipment operates.
Such person is a foreman, crew leader or section foreman.
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Storekeepers may be assigned as persons in charge of crane safe operation at
warehouses on Gosgortechnadzor approval.
Such persons shall be appointed after their knowledge of appropriate sections
hereof, job descriptions and those for crane operators and slingers is assessed. A
committee including a Gosgortechnadzor inspector shall carry out such
assessment and issue certificate and instructions to those who pass the
assessment satisfactorily.
The knowledge of such persons shall be assessed at least every 12 months.
7.4.8. The person in charge of crane safe operation shall:
a) Arrange crane operation in accordance with the safety regulations, work
design, specifications and process schedules;
b) Instruct crane operators and slingers about safe work methods paying
attention to hazardous factors, specific conditions at the site, non-admission
of the crane overload, accuracy of slinging and gripping, accuracy of boom
self-propelled cranes installation, safety requirements while unloading
railway cars, platforms and trucks and personal safety of slingers;
c) Eliminate access of untrained and non-attested personnel to crane operation,
estimate the number of slingers required and the requirement of signalmen
during operation;
d) Eliminate application of removable gripping devices and containers if they
are unmarked, faulty or inappropriate according to their lifting capacity;
e) Show crane operators and slingers the place, order and overall sizes of load
piling;
f) Directly supervise operations of railway cars loading and unloading, load
handling with several cranes, close no overhead power lines, above overhead
coverings with industrial or ancillary rooms under them, where people may
be present, cases when loads without slinging patterns are handled and in all
other cases provided for by designs or process schedules;
g) Show crane operators the locations to install boom self-propelled cranes
when close to power lines and issue work permits entering it into a shift log;
h) Control compliance with the mark-key system in overhead cranes operation;
i) Eliminate operations without work permits in cases provided by these
Regulations;
j) Provide workers with required implements and means for safe work;
k) Look after the operator and slingers' compliance with instructions, work
designs and process schedules.
7.4.9. At companies with a small number of hoisting units (up to three registered
cranes), where all the persons in charge provided hereby can not be appointed,
the duties of the engineer in charge of hoisting equipment working conditions
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and the person in charge of safe crane operation may be imposed on one
engineer or (under a contract) an expert of a specialised company.
Gosgortechnadzor shall approve it.
7.4.10. If the owner of a hoisting unit has no opportunity to assign persons in charge
provided hereby, their duties may be imposed on employees of a specialised
company under a contract and on an approval by Gosgortechnadzor.
7.4.11. The owners shall assign crane operators and mechanics to control and maintain
hoisting equipment and electricians in addition to them for units with power
drives.
7.4.12. An assistant of a crane operator shall be assigned in cases provided for by the
crane operation instructions if required by local conditions.
7.4.13. A driver may be assigned to control a crane truck after his training for a crane
operator and assessment by a qualification committee.
7.4.14. Slingers shall be appointed to sling loads to the crane hook, with the exceptions
of cases stated in clause 7.4.15. Other workers (riggers, etc.) may be accepted as
slingers if they are trained for a position requiring slinging operations.
An entry shall be made in the certificates of such workers about their assignment
as slingers.
7.4.15. Workers of basic positions trained additionally as slingers according to a
shortened programme may be permitted to hang loads on a hoisting unit hook
without its preliminary slinging (loads with eyes, frames, trunnions or those
being in various containers). They may also do it in cases when the load is
gripped with a semi-automatic gripping device. The same requirements hereof as
those for slingers shall be applicable to such workers.
7.4.16. In cases, when the area served by a hoisting unit is not entirely seen from the
operator's cab and there is neither radio nor telephone communication between
the operator and slingers, one of the slingers shall be appointed a signalman.
7.4.17. Workers at least 18 years old may be assigned as crane operators, operator
assistants, mechanics, electricians and slingers.
7.4.18. Crane operators, their assistants and maintenance personnel shall pass medical
examination prior to their assignment to estimate if their health complies with
the requirements for the positions.
7.4.19. Crane operators, their assistants, slingers, mechanics, electricians and safety
device setters shall be trained and attested at vocational schools and at courses
and technical schools for workers. Technical schools and courses may be
established at companies and construction sites possessing an adequate base for
theoretical and practical training and a permit (license) of Gosgortechnadzor.
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Training of workers for the above positions shall be carried out in accordance
with programs developed at training centres and approved by the RoK
Gosgortechnadzor.
7.4.20. Crane operators and their assistants, when transferred from cranes of one type to
cranes of other types (e.g. from a tower crane to an overhead one), shall be
trained and attested in the order established hereby. Training in such cases may
be carried out on the basis of a shortened program approved by
Gosgortechnadzor.
If crane operators and their assistants are transferred to a crane of the same type,
but another model, index or with another drive, they shall be familiarised with
the peculiarities of such crane operation and maintenance and pass a probation.
Such workers may be admitted to independent work after their knowledge and
skills assessment.
The owner of the crane shall establish the procedure of training, probation and
skills assessment.
7.4.21. Crane operators and their assistants shall be assessed by a committee appointed
by the crane owner after a break in their work for more than a year. If the
assessment results are satisfactory, they may be admitted for probation to restore
the skills required.
7.4.22. The qualification committee shall assess recurrently knowledge of the servicing
personnel (crane operators, their assistants, mechanics, electricians, safety
device setters and slingers) as follows:
a) Recurrently at least every 12 months;
b) When workers are transferred to another working place;
c) On a request of the engineer supervising crane safe operation or
Gosgortechnadzor Inspector.
Recurrent knowledge assessments shall be carried out within the scope of
instructions. Inspector's participation in such assessments is not required.
7.4.23. The results of attestation and servicing personnel recurrent knowledge
assessment shall be stated in Minutes and entered into certificates.
7.4.24. Gosgortechnadzor representative's participation in the work of the crane
operators qualification committee is mandatory.
Gosgortechnadzor (inspector) shall be notified of the examination date within at
least 10 days.
The qualification committee of the company or training company may attest
other workers serving hoisting equipment without Gosgortechnadzor inspector's
participation.
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In separate cases, Gosgortechnadzor may require its representative's
participation in attestation of slingers.
7.4.25. On passing their exams workers shall be given certificates in accordance with
the form established (Appendix 16) signed by the Committee Chairman, and in
case of crane operators and their assistants they shall be signed by the Chairman
and Gosgortechnadzor representative.
Types and indices of cranes the crane operator is permitted to work at shall be
stated in his certificate.
Certificates of crane operators and slingers shall bear their photos. They shall
have their certificates with them at work.
7.4.26. Work permits for crane operators, their assistants, mechanics, electricians, safety
device setters and slingers shall be issued as a memorandum (order) of the crane
owners.
7.4.27. Workers of basic professions (machine operators, riggers, etc.) may operate a
hoisting unit from the floor or stationary panel and hook loads on such units
after an appropriate induction and operation and slinging skills assessment
according to a procedure developed by the crane owners. Workers qualified for
crane operators and having appropriate certificates may control cranes by radio.
7.4.28. Attested slingers only may work as signalmen. The person in charge of crane
safe operation shall appoint signalmen.
7.4.29. Workers of basic professions servicing cranes controlled from the floor or with a
stationary panel and hooking loads shall have recurrent inductions every 3
months.
7.4.30. For cranes to be served properly, the owners shall provide crane operators, their
assistants, mechanics, electricians and slingers with instructions identifying their
rights, duties, safe work procedures and responsibilities.
The instructions shall be distributed among the above workers (against receipt)
before their work permit.
7.4.31. The owners of hoisting equipment, removable gripping devices and containers
shall establish procedures for the persons in charge of the equipment servicing
(crane operators, their assistants, electricians and mechanics) to look after it by
way of visual inspections and test running, and maintain it in good working
conditions.
Crane operators shall inspect hoisting units before commencing work, and the
owners shall allocate a certain time period for it.
The results of the operators' visual inspections and checking shall be entered into
the shift logbook (the form is given in Appendix 1).
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Slingers shall visually inspect removable gripping devices and containers before
their application.

7.5. Operation

7.5.1. Hoisting units may be permitted to lift and handle only such loads, which weight
does not exceed the lifting capacity of the unit. In case of boom self-propelled
and railway cranes, the position of extended supports, and in case of cranes with
travelling counterweights, the position of the counterweight shall be accounted
for. Requirements stated in the certificate of a hoisting unit and in its operation
instructions shall not be infringed during its operation.
7.5.2. Hoisting units equipped with a clamshell or magnet may only be admitted to
operation given specific directions for the purpose stated in producer's
instructions are implemented.
7.5.3. A hoisting unit equipped with a magnet may handle a one-piece load (slabs,
ingots) solely if its transloading is eliminated.
7.5.4. Hoisting units with lifting mechanisms equipped with friction clutches or cam
clutches can not be applied to lift and handle melted metal, noxious substances
and explosives, and pressure vessels.
7.5.5. Load handling above overhead coverings with industrial or ancillary rooms
under them, where people may be present shall be unacceptable. In separate
cases, on an approval of Gosgortechnadzor, loads may be handled above
overhead coverings with industrial or ancillary rooms under them, where people
are present after special arrangements are developed to provide safe operation.
7.5.6. Load handling by several cranes may be permitted in separate cases. Such work
shall be carried out in accordance with the design or process chart, where load
slinging and handling patterns shall be stated, operational sequence and positions
of load ropes noted. They shall also include the requirements for the track
conditions and other instructions on safe operations. If several cranes handle
loads, the load proportion for each crane shall not exceed its capacity.
The person in charge of safe crane operations shall directly supervise the work
of load handling by several cranes.
7.5.7. Operating hoisting units shall be provided with nameplates, with the registration
number, lifting capacity and the date of the next partial or complete inspection
clearly marked.
7.5.8. Hoisting units, removable gripping devices and containers, which have not
undergone technical examination shall not be admitted to operation.
Faulty removable gripping devices and devices without nameplates (stamps)
shall not be kept at operation sites. Unmarked and damaged containers shall be
also removed from such locations.
71
7.5.9. A mark system shall be employed in operation of overhead cranes controlled
from the cab. Such system means that solely the crane operator, who receives the
mark-key completing the electric circuit of the crane control may control the
crane.
7.5.10. An easy access shall be provided for the person controlling the unit if it is
controlled from the floor.
7.5.11. Exits to the tracks and galleries of overhead and movable cantilever cranes shall
be locked if the cranes ate in operation.
Access of crane servicing personnel and other workers to the track and passage
galleries of operating overhead and movable cantilever cranes for maintenance
or any other work shall be arranged on the basis of a work permit stating the
conditions of safe operation.
The crane owners shall develop the procedure of work permit issue and
induction of workers.
Crane operators of all the shifts in the workshop span, where work is to be
carried out, and if necessary operators of adjoining spans shall be notified about
it with the help of an entry in the shift log.
7.5.12. The procedure of the crane operator's safe descending from the cab shall be
developed in every workshop (span) with overhead or movable cantilever cranes
not equipped with passage galleries along the crane track. It shall be done for the
case of the crane emergency halt away from the landing platform. The
descending procedure shall be stated in the operator's instructions.
7.5.13. At the owner's discretion, overhead cranes may be applied for painting and other
work from platforms on the crane. Such work shall be carried out on the basis of
work permits identifying safety arrangements to prevent falling off the crane,
electric shocks, clashes of cranes, movement of the crane and its truck. Load
handling with people carrying out work on the gantry shall be unacceptable.
7.5.14. The owners of hoisting units shall develop the methods of accurate load slinging
and hooking to be taught to slingers. Graphic presentation of the slinging and
hooking methods shall be distributed among the slingers and operators, or placed
at work locations.
The owners shall also develop the methods of slinging for machine parts and
units handled during installation, dismantling and repairs. Appliances and
methods of safe load canting shall be also mentioned if such operation is carried
out with a crane.
Graphic presentation of the slinging and canting methods, as well as the list of
gripping devices applied shall be given in process schedules.
Handling of loads without slinging patterns shall be carried out under the
supervision of the person in charge of safe crane operation.
72
The management of sea and river ports shall ensure that load handling
operations with hoisting equipment are carried out in accordance to process
charts approved.
7.5.15. The owners of hoisting units, together with operating companies, shall:
a) Develop and dispatch to crane operation sites construction and installation
work designs, process charts for load storage, handling loads from the rolling
stock and other process schedules;
b) Familiarise (against receipt) persons in charge of safe crane operation,
operators and slingers with the designs and process schedules;
c) Provide slingers with distinction signs, tested and marked removable
gripping devices and containers corresponding to load weight and character;
d) Place the list of basic handled loads and their weights at the work location.
The same list shall be handed to crane operators and slingers servicing boom
self-propelled cranes during construction and installation;
e) Provide for recurrent testing of the lifting limit of the crane with the help of a
precisely weighed load within the terms stated in the operation instructions
or device certificate;
f) Establish the order of boom self-propelled cranes allocation to sites on the
basis of applications, and provide compliance with it;
g) Establish the procedure of tower crane protection board sealing and locking,
as well as lifting limit relay block on boom self-propelled cranes sealing;
h) Identify the areas for load storage, equip them with attachments and
accessories required (racks, pyramids, shelving, ladders, stands, supports,
pads, spacers, etc.) and instruct operators and slingers about piling
procedures and overall sizes;
i) Ensure implementation of work designs and other process schedules during
hoisting equipment operation;
j) Ensure good working conditions of tower cranes being at the site as stand-by
equipment. Disconnect the crane from the power source and make
arrangements to eliminate movement of the crane by wind after the client's
notification about work completion (prior to dismantling commencement).
k) Ensure good conditions of crane tracks.
7.5.16. The owner of a hoisting unit shall establish the pattern of signals exchanged by
the operator and slingers. The system recommended is given in Appendix 18.
When buildings and structures above 36 m are constructed, a two-way radio
communication system shall be applied. The signalling system and signals
applied in radio communication shall be recorded in the instructions for the
operator and slingers.
7.5.17. The site of crane operation shall be lighted in accordance with the design or
standard documents.
73
7.5.18. Crane operation shall be halted if wind speed exceeds the limit of that particular
crane, in case of a snow fall, rain or fog, as well as in other cases, when the
operator scarcely distinguishes the signals of slingers of the load being handled.
7.5.19. If boom self-propelled cranes operate at the distance below 30 m from their
lifted (expanded) part at any position, or from the load to the vertical plane
formed by the projection to the ground of the closest overhead power conductor
under the voltage of 42 V and above, the work shall be carried out on the basis
of a work permit. The latter shall specify the conditions of safe operation (the
form is given in Appendix 19).
The procedure of work arrangement close to overhead power lines, a work
permit issue and induction of workers shall be established by the orders of the
crane owner and superintendent of work.
Safe conditions specified in the work permit shall comply with GOST 12.1.013.
The issuing company shall establish the period of the permit validity.
The work permit shall be handed to the crane operator prior to work
commencement.
The operator shall not install the crane near an overhead power line himself, the
prohibition shall be entered into his way ticket. Crane operation close to a power
line shall be carried out under direct supervision of the person in charge of safe
crane operation. Such person shall show the operator the location to install the
crane at, provide compliance with the conditions stipulated in the work permit
and make an entry in the shift log of the crane about his permission to work.
If work is to be carried out within the protection zone of a power line, or within
openings provided by the High Voltage Power Line Protection Regulations, the
work permit may be issued if there is a permit of the line operating company
only.
If boom self-propelled cranes operate at existing power plants, substations and
power lines, and if hoisting work is carried out by the personnel operating the
power units while the crane operators are in the staff of the power company, the
work permit for operations close to conductors and equipment under voltage
shall be issued in accordance with the requirements of the industry.
Self-propelled cranes may operate under urban transport contact wires if the
distance between the boom and the wire is at least 1000 mm. A stop (arrester)
shall be installed to prevent the above distance from being reduced when the
boom is lifted.
The line owners shall establish the procedure of a crane operation close to a
power line utilising flexible cable. Work permits are not required in that case.
7.5.20. The owners of cranes and the company that carries out work shall ensure
compliance with the following requirements to provide safe load handling:
74
a) Persons without direct relation to the operations shall be denied access to the
load handling site and the crane;
b) People shall enter and descend overhead and movable cantilever cranes
through a landing site (platform), or in separate cases through passage
galleries;
c) The knife-switch of the input device shall be disconnected if there is a need
to examine or repair crane mechanisms, power equipment, or examine and
repair steel structures. The same requirement shall be complied with if there
is a necessity to go out to the gantry of an overhead crane;
d) If rails of a load truck are located at the level of an overhead crane gallery
deck, the truck shall be placed in immediate proximity to the exit from the
cab on to the deck before the servicing personnel goes out to the gallery;
e) Construction and installation work shall be carried out in accordance with
the work design, which shall provide for the following:
- conformity of cranes with the construction and installation work as
related to their lifting capacity, lifting height and radius (crane lifting
characteristics);
- provision of safe distances from power grids and overhead lines, urban
transport and pedestrian routes, as well as safe distances from cranes to
buildings and parts and materials storage grounds;
- crane installation and operation close to slopes and pits safe conditions;
- safety conditions for several cranes operating on the same track or
parallel tracks;
- the list of gripping devices applied and graphic presentation of load
slinging;
- load storage locations and overall sizes, access roads, etc.;
- arrangements of safe operations accounting for particular conditions at
the crane site (fencing of the construction site, installation area, etc.);
The person in charge of safe crane operation, operators and slingers shall be
familiarised with the design (against receipt) prior to the work commencement;
f) Load handling and piling with cranes at bases, warehouses and sites shall be
carried out in accordance with process charts worked out accounting for the
requirements of GOST 12.3.009 and approved in the established order;
g) Loads shall not be lowered on a truck or lifted if there are people in the cab
or body. Stationary racks or suspended platforms for slingers shall be
arranged at the locations, where trucks or railway cars are loaded/unloaded.
Railway cars shall be loaded/unloaded with hook cranes in accordance with
the technology approved by the crane owners. It shall specify the locations of
slingers during loads handling and their ways to racks and suspended
platforms. Presence of people in cars when they are loaded/unloaded is
unacceptable;
75
h) Loads shall not be handled with people beneath. A slinger may stay close to
the load during its lifting or lowering if the load is lifted to the height not
exceeding 1000 mm from the platform level;
i) Loads shall be slinged in accordance with slinging patterns. Slings shall
conform with the weight and character of the load lifted. The number of
strings and their incline angles shall be accounted for. General purpose slings
shall be selected so that the angle between their strings does not exceed 90;
j) Small-piece loads shall be handled in specially designed containers. Pieces
falling out of such containers shall be eliminated. Bricks may be lifted on
pallets without enclosure when loaded on or unloaded (on the ground) from
hauling units;
k) Loads of unknown weights shall be handled after their actual weights are
identified only;
l) A load or gripping device shall be lifted 500 mm above objects in the way to
move them horizontally;
m) When a boom self-propelled crane moves with a load, the boom position and
the loads on the crane shall be assumed in accordance with the crane
operation instructions;
n) A load handled may be lowered on the place assigned for the purpose only.
Such location shall eliminate falling, overturn or sliding of the load.
Appropriate spacers shall be placed at the location for the slings to be easily
and without damage drawn from under the load. Loads shall not be placed at
locations not designed for it. Loads shall be stacked up and unstacked
evenly, not disturbing overall sizes established and jamming passageways.
Loads shall be stowed in railway card and on platforms in accordance with
the RoK Transportation and Communication Ministry standards and on the
consignee's approval. Loads shall be placed on trucks and other haulers so
that its easy and safe slinging is ensured when unloading.
Railway cars, platforms, trucks and other hauling units shall be loaded and
unloaded without disturbing their equilibrium.
o) Presence of people and any work shall be prohibited within the range of
cranes with clamshells or magnets operation.
Shiftmen servicing such cranes may be admitted to carry out their duties
solely during breaks in the crane operation and after the clamshell or magnet
is lowered to the ground. Locations of such cranes operation shall be fenced
and marked with warning signs.
p) A clamshell shall not be used to lift people or carry out ant work it is not
designed for.
q) On work completion, or during a break, no load shall be left suspended, the
knife-switch in the operator's cabin or gantry shall be put in the OFF position
and locked. On completion of a tower, frame, overhead, gantry and
transhipment crane operation, the control cabin shall be locked, and the crane
shall be secured with all available means against unauthorised movement.
76
r) Loads may be canted with cranes at canting areas or specially provided
places. Such work may only be carried out in accordance with a process
developed in advance. It shall describe the sequence of operations, slinging
methods and safe work instructions;
s) If cranes operate being installed on several layers, the upper layer cranes
shall be able to move above the lower ones without loads and with the hook
lifted to the upper working position only;
t) When a load is lifted, it shall first be lifted to the height not exceeding 200-
300 mm to check the accuracy of slinging and reliability of brakes;
u) When a load is lifted close to a wall, column, stack, railway car, machine or
other equipment, people (including those hooking the load) shall not remain
between the load lifted and the above parts of the building or equipment. The
same requirement shall be strictly complied with when lowering loads.
7.5.21. The following shall be unacceptable during a hoisting unit operation:
a) Admission into the hoisting unit cab during its movement;
b) Presence of people close to an operating boom self-propelled or tower crane
to eliminate their jamming between the turning and non-turning parts;
c) Handling of a load being in unstable position or hooked with one arm of a
double hook;
d) Movement of people or a load with people on it. People may be lifted with
cranes in exceptional cases only, in a specially designed cage and after
specific safety arrangements are worked out. Such work shall be carried out
in accordance with specific instructions approved by Gosgortechnadzor.
e) Lifting of loads covered with soil or frozen to the ground, covered with other
loads, fastened with bolts or concrete, as well as lifting of metal or slag
hardened in the furnace or stuck after being poured out;
f) Load dragging on the ground, floor or rails with the crane hook, load ropes
being tilt without guiding blocks application to provide the vertical position
of load ropes;
g) Crane application to release slings, ropes or chains pinched with a load;
h) Pulling a load aside during its lifting, movement or lowering;
Hooks or guys of appropriate lengths shall be applied to turn long and bulky
loads when handling them;
i) Aligning of the load being dandled by hand and correction of slings when
hanging;
j) Feeding of loads through windows or on balconies without special receiving
platforms or appliances;
k) Application of limit switches as tools to stop mechanisms automatically,
with the exception of the case, when an overhead crane approaches the
landing site arranged in the butt wall of the building;
77
l) Operation with disengaged or faulty safety devices and brakes;
m) Starting of crane mechanisms when people are on the crane outside the cab
(in the engine department, on the gallery, boom, tower, counterweight, etc.).
an exception can be made for people examining and adjusting mechanisms
and power equipment. In such case the mechanisms shall be started on a
signal of the examining person;
n) Load lifting immediately from its location (ground, stack, etc.) with the
boom winch;
7.5.22. The engineer in charge of hoisting equipment good working conditions shall be
the person to shut down a crane for maintenance in accordance with the schedule
approved by the owners.
A work permit shall be issued in accordance with the established order for the
maintenance of overhead and movable cantilever cranes.
The work permit shall describe measures to be taken to create safe maintenance
conditions. In particular, arrangements shall be made to prevent electric shocks,
falls of people down from height, operating cranes colliding with the repaired
one and access of the maintenance personnel to the tracks of operating cranes.
The date and time of a crane shut down for maintenance, as well as the name of
the person in charge of it shall be entered into the work permit and the shift log
of the operator.
Preventive examination, servicing of the crane and elimination of defaults on the
operator's request may be carried out without a work permit.
If several crews carry out repairs at an overhead crane, a work-permit shall be
issued for each of them.
Crane operation during its repairs is prohibited.
7.5.23. The engineer in charge of the hoisting equipment good working conditions shall
issue the permit for a crane to operate after repairs, with the exception of cases
set fort by clause 7.2.1. Such permit shall be recorded in the shift log.

8. RESPONSIBILITY FOR BREACHES OF THE
CRANES DESIGN AND SAFE OPERATION REGULATIONS

8.1. These Regulations shall be binding for all the managers and professionals of
companies engaged in hoisting equipment design, production, maintenance,
reconstruction, installation, operation and diagnosing irrespective of their
ownership and the industry they refer to, and also for physical persons owing
cranes.
8.2. Managers, professionals and physical persons responsible for breaches hereof
shall be held responsible for the infringements committed in accordance with
78
current legislation regardless weather it results in an emergency or accident.
Such persons shall be also held responsible for infringements hereof committed
by their subordinates.
8.3. If officers issue orders forcing their subordinate employees to infringe these
Regulations and instructions, without authorisation resume operations suspended
by Gosgortechnadzor representatives, and also in case such officers fail to make
arrangements aimed at elimination of infringements of the Regulations and
instructions, such officers shall be held responsible in accordance with current
legislation.
8.4. Workers (crane operators, slingers, mechanics and electricians) trained and
attested in the established order, and supplied with operation instructions shall
be responsible for infringements of directions provided by them.
8.5. Depending on the character and consequences of infringements, persons
indicated in clauses 8.2, 8.3 and 8.4 may be held administratively, disciplinarily
or criminally responsible in accordance with the legally established procedure.

9. EMERGENCY AND ACCIDENT INVESTIGATION PROCEDURES

9.1. Investigation of incidents occurring during hoisting equipment operation and
liable to registration at Gosgortechnadzor shall be carried out in accordance with
the procedures established by the RoK Gosgortechnadzor.
9.2. In case of an incident, the owner of the unit subject to registration shall notify
Gosgortechnadzor within 1 day and provide preservation of the incident set-up
until a representative of Gosgortechnadzor arrives if it does not present risk for
the health and lives of people.
Notifications about incidents shall be sent to organisations concerned in
accordance with the current provisions of industrial accidents investigation.

10. FINAL PROVISIONS

10.1. Due to these Regulations coming into force, the requirement and deadlines for
existing hoisting equipment reconstruction shall be established by the equipment
producers and owners on an approval of Gosgortechnadzor.
10.2. Managers and experts of companies, as well as physical persons engaged in
hoisting equipment design, production, maintenance, reconstruction, installation,
operation and diagnosing shall pass their knowledge hereof assessment within
the time periods approved by Gosgortechnadzor.
79
APPENDIX 1
(to Section 1.4)

TERMINOLOGY AND DEFINITIONS

Ref. # Terms Definitions Diagrams






1.0






1.1




1.1.1



1.1.2




1.1.3





1.1.4




1.2



Load Lifting
(Hoisting) Unit




Crane






Overhead
travelling type
crane


Overhead
travelling
crane

Gantry crane




Semi-gantry
crane




Berth
transhipment
crane


Cable type
crane


A cyclic-operation hoisting device,
with a reciprocating motion of the
load gripping part.

1. TYPES OF CRANES

A cyclic-operation hoisting device
designed to lift and spatially move
loads suspended with a hook or held
with other load gripping device.

Design Based Crane Classification

A crane that has a load gripping part
suspended on a load trolley, chain
block or boom crane that travels along
a bridge.

A crane that has bearing structural
components rested directly upon the
crane track.

A crane that has bearing structural
components rested upon the crane
track with the help of two supporting
stanchions.

A crane that has bearing structural
components rested upon the crane
track directly on one side, and with
the help of a supporting stanchion on
the other.

A crane with one or two cantilevers
that has bearing structural components
rested upon the crane track with the
help of a portal.

A crane that has a load gripping part
suspended on a load trolley that
travels along bearing lines fastened on
two supports.
-




80
1.2.1



1.2.2




1.3



1.3.1



1.3.2



1.3.3





1.3.3.1






1.3.4


1.3.5


1.3.6



1.3.7



Cable crane



Overhead
travelling
cable crane


Boom type
crane


Portal crane



Semi-portal
crane


Boom crane





Self-propelled
boom crane





Tower crane


Railway crane


Floating crane



Marine boom
crane


A crane, with cable lines as bearing
components that are fastened at the
tops of supporting masts (towers).

A crane, with cable lines as bearing
components that are fastened at the
ends of a bridge installed on
supporting stanchions.

A crane that has a load gripping part
suspended on a boom or trolley
travelling along a boom.

A travelling crane rotating on a portal
that is designed to let railway cars or
trucks through.

A travelling crane swinging on a half-
portal that is designed to let railway
cars or trucks through.

A rotary crane that has a boom or
tower and boom equipment fastened
on a turning platform, which is
located directly upon the running
gear.

A boom type crane that may be
equipped with tower and boom
equipment and may travel both loaded
and unloaded on a motor vehicle
chassis maintaining balance and
stability due to gravity force.

A rotary crane, with a boom installed
in the upper part of a vertical tower.

A crane installed on a platform
travelling along a railway track.

A crane on a self-propelled, or non-
self-propelled pontoon designed for
crane installation and movement.

A rotary crane installed on a deck of a
watercraft and designed to load and
unload the craft.

81
1.3.8



1.3.8.1



1.3.8.2



1.3.9





1.3.9.1





1.3.9.2




1.3.9.3



1.3.10

Derrick pole



Guyed derrick
pole


Stiff-leg
derrick pole


Cantilever
crane




Cantilever
crane on a
column



Wall-track jib
crane



Wheeled
column crane


Crane-
manipulator

A rotary crane, with the boom
fastened with a hinge on a derrick that
has lower and upper supports.

A derrick pole, with the top of the
derrick fastened with the help of guy
lines.

A derrick pole, with the top of the
derrick fastened by way of stiff
tension bars.

A boom-type crane, with a load
gripping part suspended on a rigidly
fastened cantilever (boom), or a
trolley travelling along a cantilever
(boom).

A cantilever crane, with a potential to
swing on a pillar that has its base
fastened to a foundation, or fastened
to a pillar that may rotate in a bearing
installed in the foundation.

A stationary crane attached to a wall,
or travelling along a ground crane
track fastened to a wall or bearing
structure.

A cantilever crane that travels along
the ground rail track held with a guide
at the top.

A boom crane installed on a truck
chassis and serving for its loading and
unloading.

Crane Classification on the Basis of the Load Gripping Part
1.4


1.5


1.6


Hook crane


Clamshell
crane

Magnetic
crane

A crane equipped with a hook as a
load-gripping device.

A crane equipped with a clamshell as
a load-gripping device.

A crane equipped with an electric
magnet as a load-gripping device.


82
1.7




1.8




1.9



1.10



1.11



1.12



1.13





1.14



1.15



1.16

Charging box-
magnet crane



Charging box-
clamshell
crane


Turnaround
charging crane


Rod removing
crane


Stacker (piler)
crane


Pouring crane



Block
transport crane




Forging crane



Ingot-stripping
crane


Pit crane


An overhead travelling type crane
equipped with an electric magnet as a
load-gripping device, and with a
device to transfer moulds.

An overhead travelling type crane
equipped with a clamshell as a load-
gripping device, and with a device to
transfer moulds.

An overhead travelling type crane
equipped with an overarm to grip
moulds.

An overhead travelling type crane
equipped with a gripping device to
remove rods from electrolytic baths.

An overhead travelling type crane
equipped with a vertical pillar and a
device to stack (pile) load.

An overhead travelling type crane
equipped with tools to lift and tilt a
foundry ladle.

An overhead travelling type crane
equipped with a turnaround pillar that
has horizontal tongs in its lower part
to grip metal blocks and feed them
into a furnace.

An overhead travelling type crane
equipped with a device to lift,
transport and turn forged pieces.

An overhead travelling type crane
equipped with a device to push ingots
out of moulds.

An overhead travelling type crane
equipped with a tong grapple and
designed to serve pit furnaces

Crane Classification on the Basis of Travelling Capacities
1.17

Stationary
crane
A crane that is fixed on its foundation
or other immobile base.

83

1.18




1.19




1.20



1.21


1.21.1



1.21.2


Self-elevating
(climbing)
crane


Adjustable jib




Radial crane



Mobile crane
(jenny)

Trailed crane



Self-propelled
crane


A crane installed structures of a
building under construction, and
climbing with the help of its own
devices as the building grows.

A crane, which is installed on a base,
and may be moved from one location
to another manually or utilising other
hoisting equipment.

A crane that may move while
operating in relation to one stationary
support.

A crane that may be moved during
operation.

A mobile crane that has no self-
propelling equipment and is towed
with a tractor (hauler).

A mobile crane that has self-
propelling equipment to move during
operation and/or transportation.

Crane Classification on the Basis of Running Gear (Chassis)
1.22



1.23


1.23.1



1.23.2


1.23.3


1.23.4


Crawler
(caterpillar)
crane

Crane on
wheels

Truck-
mounted crane
(picker truck)

Specific
chassis crane

Pneumatic
wheel crane

Short-base
crane

A self-propelled crane equipped with
caterpillar tracks for re-location.


A self-propelled crane equipped with
wheels for re-location.

A crane mounted on a serial
production truck chassis.


A crane mounted on a specific truck-
type chassis.

A crane mounted on a pneumatic
wheel chassis.

A crane mounted on a short-base
chassis.


84
1.24

Track-riding
crane

A crane travelling on a rail track.

Crane Classification on the Basis of the Drive Type
1.25

1.26


1.27


1.28

Manual crane

Electric crane


Mechanical
crane

Hydraulic
crane

A crane, with a hand drive for its gear.

A crane, with a power drive for its
gear.

A crane, with a mechanical drive for
its gear.

A crane, with a hydraulic drive for its
gear.


Crane Classification on the Basis of the Rotation Degree
1.29



1.29.1




1.29.2




1.30

Rotary crane



Partially
rotating crane



Full-rotating
crane



Non-rotating
crane

A crane that may swing (horizontally)
its rotating part with a load against the
supporting part.

A rotary crane that may swing its
rotating part from one limit position to
another at an angle below 360
degrees.

A rotary crane that may swing its
rotating part from one limit position to
another at an angle of 360 degrees and
above.

A crane that cannot swing a load
(horizontally against the supporting
part.



Crane Classification on the Basis of the Manner of Support
1.31


1.32

Supporting
crane

Suspended
crane

An overhead travelling crane that is
rested upon the ground crane track.

An overhead travelling crane that is
suspended on the lower flanges of the
crane track.




85
2. PARAMETERS
Loads
2.1



Effective
lifting capacity


A load, with the weight of m
PL
, lifted
by the crane and suspended with the
help of removable load gripping
devices, or in the absence of such,
suspended directly on stationary load
gripping devices. If cranes are
applied to lift gates at hydraulic power
plants or lift loads from the water
surface, effective lifting capacity may
include efforts caused by water
suction or cohesion due to suction.







2.2








2.3









2.4







Removable
load gripping
device






Net load-
lifting capacity








Stationary
load-gripping
device





Any equipment (with the weight of
m
NA
) connecting a load that conforms
to the effective load-lifting capacity
with the crane, and being neither a
part of the crane nor the load. The
removable load-gripping device is
easily removed from the hoisting unit,
and disconnected from the load.

A load, with the weight of m
NL
lifted
by a crane and suspended by way of
stationary load-gripping devices. The
weight of m
NL
is a summarised value
of the load weight corresponding to
the effective load-lifting capacity
(m
PL
), and removable load-gripping
devices (m
NA
): m
NL
= m
PL
+ m
NA


Any equipment (with the weight of
m
FA
) to suspend a load that
corresponds to the net load-lifting
capacity, and which is permanently
fastened to the lower end of the
hoisting unit. Stationary load-
gripping device form an integral part
of the hoisting unit.
Refer to the Diagram in
Section 2.1







Refer to the Diagram in
Section 2.1








Refer to the Diagram in
Section 2.1






86

2.5.











2.6








2.7












2.8



2.9




2.10



Interim load-
lifting capacity
(on ropes)









Lifting device








Gross lifting
capacity











Load
momentum:
M = L x Q


Tilting load
momentum:
M
A
= A x Q

Design weight
(G
k
)


A load with the weight of m
HL
, which
is lifted by a crane and is suspended to
the lower end of the hoisting unit.
The m
HL
weight is a summarised
value of the load weight
corresponding to the effective load-
lifting capacity (m
PL
), removable
load-gripping devices (m
NA
), and
stationary load-gripping devices
(m
FA
): m
NL
= m
PL
+ m
NA
+ m
FA


Ropes, chains or any other equipment,
with the weight of m
NM
that hangs
from the crane, load trolley or boom
tip and is driven with a winch to lift or
lower down a load suspended to the
lower end of the lifting device.
Lifting devices form a part of the
hoisting unit.

A load with the weight of m
GL
, which
is suspended directly on the crane,
load trolley or boom tip. The weight
is a summarised value of the load
weight corresponding to the effective
load-lifting capacity (m
PL
),
removable and stationary load-
gripping devices (m
NA
and m
FA
), and
the lifting device (m
NM
):
m
GL
= m
PL
+ m
NA
+ m
FA
+ m
NM



The product of the crane radius value
(L), multiplied by the corresponding
lifting capacity (Q).

The product of the radius from the tilt
edge value (A), multiplied by the
corresponding lifting capacity (Q).


The crane weight without ballast and
counterweight in non-serviced state,
i.e. without fuel, oil, lubricants and

Refer to the Diagram in
Section 2.1










Refer to the Diagram in
Section 2.1








Refer to the Diagram in
Section 2.1


87





2.11



2.12








Total weight
(G)


Load on a
wheel (P)


water. For boom cranes, the value is
assumed as an assembly with the main
boom and counterweight in a non-
serviced state.

A complete weight of a crane in the
serviced state, with the ballast and
counterweight.

The value of the maximum vertical
load transmitted by one running wheel
onto the crane track or axel.

Crane Linear Parameters
2.13





2.14





2.15





2.16



2.17



2.18






Crane radius
(L)




Radius from
the tilt edge
(A)



Cantilever
radius (l)




Clearance (C)



Rear clearance
limit ()


Lifting height
(H)





A horizontal distance from the
rotation axis of the rotating part to the
vertical axis of the load-gripping part,
without any load, while the crane is
installed on a horizontal area.

A horizontal distance from the tilt
edge to the vertical axis of the load-
gripping part, without any load, while
the crane is installed on a horizontal
area.

The largest horizontal distance from
the axis of the closest to the cantilever
crane support to the axis of the load-
gripping part located on the
cantilever.

The minimum horizontal distance
from the crane rail axis to the vertical
axis of the load-gripping part.

The maximum radius of the crane
rotary unit from the side opposite to
the boom.

A vertical distance from the level of
the crane location site to the load-
gripping part located in its uppermost
position:
- for hooks and forks, up to their
seating surfaces;
- for other load-gripping

88








2.19














2.20




2.21










Lowering
depth (h)













Lifting range
(D)



Crane track
height (H
Q
)


devices, up to their lowest
point (in the closed position).
The lifting height of an overhead
crane shall be measured from the floor
surface. The lifting height shall be
measured without a load, while the
crane is installed on a horizontal area.

A vertical distance from the level of
the crane location site to the load-
gripping part located in its lowest
position:
- for hooks and forks, down to
their seating surfaces;
- for other load-gripping
devices, down to their lowest
point (in the closed position).
The lowering depth of an overhead
crane shall be measured from the rail
level. The lowering depth shall be
measured without a load, while the
crane is installed on a horizontal area.

A vertical distance between the upper
and lower operating positions of the
load-gripping part (see Sections 2.18
and 2.19).

Vertical distance from the floor
(ground) level to the level of the crane
track railheads.

Operation Movement Speeds
2.22



2.23




2.24




Load lifting
(lowering)
speed (V
n
)

Landing speed
(V
m
)



Rotation
frequency
(angle speed
(w))

The speed of vertical load relocation
under steady movement conditions.


The minimum lowering speed of the
maximum operating load during
installation or laying down under
steady movement conditions.

The angle speed of the crane rotary
part rotation under steady movement
conditions. It is estimated at the
largest radius with the operating load,
while the crane is installed on a

89




2.25






2.26









2.27









2.28









2.29




2.30





Crane
travelling
speed (V
k
)




Trolley
travelling
speed (V
t
)







Radius
alteration
speed (V
r
)







Time of radius
alteration








Inspection
speed



Transportation
speed (V
o
)
horizontal area, and the wind speed
does not exceed 3 m/sec at the height
of 10 m.

Crane travelling speed under steady
movement conditions. It is estimated
while the crane is travelling with the
operating load along the horizontal
track, with the wind speed not
exceeding 3 m/sec at the height of 10
m.

The travelling speed of the load
trolley under steady movement
conditions. It is estimated while the
trolley is travelling with the maximum
operating load along the horizontal
track, with the wind speed not
exceeding 3 m/sec at the height of 10
m.

The average speed of operational load
horizontal relocations under steady
movement conditions. It is estimated,
when the radius is changed from the
largest to the smallest value, while the
crane is installed on a horizontal track,
with the wind speed not exceeding 3
m/sec at the height of 10 m.


The time required when changing the
radius from the largest to the smallest
value. It is estimated while the radius
is changed under load equalling to the
load-lifting capacity for the largest
radius, and while the crane is installed
on a horizontal track, with the wind
speed not exceeding 3 m/sec at the
height of 10 m.

A low speed of the cable-type crane
load trolley travelling under steady
movement conditions used to inspect
track cables and units of the crane.

The highest speed of a crane
movement in transportation position
90


2.31




Operating
cycle time

that is ensured by its own drive.

The time required to carry out one
established operating cycle.

Parameters Related to the Crane Track
2.32








2.33



2.34





2.35



2.36




2.37



2.38








Crane location
level







Span (S)



Track (K)





Base (B)



Outrigger base
(B
o
)



Distance
between
outriggers (K
c
)

Track gradient








The horizontal surface of the
foundation or the surface of railheads,
upon which the non-rotary part of the
crane is supported. For cranes that
have supports located at different
heights, the location level is assessed
on the basis of the lower crane support
location.

The horizontal distance between the
crane track rail axes for overhead
travelling cranes.

The horizontal distance between the
track rail axes or running gear wheels
for boom-type cranes.
For load trolleys, the distance between
rail axes the trolley travels along.

The distance between the crane
support axes measured along its
longitudinal centreline.

The distance between the outrigger
vertical axes measured along the
longitudinal centreline of the crane.


The distance between the outrigger
vertical axes measured across the
longitudinal centreline of the crane

The gradient, on which crane
operation is acceptable. The gradient
is estimated utilising the ratio of i=h/B
that corresponds to the difference of
levels of two points located from each
other at the distance of B, which
equals to the crane base. The value of
level difference is measured, when
there is no load on that particular

91


2.39



2.40




2.41



2.42





Climbable
gradient


Supporting
contour



Curve radius
(R
k
)


The smallest
radius of the
turn


section of the track.

A gradient (i=h/B) that a crane may
overcome with its constant
transportation speed.

The contour formed by horizontal
projections of the lines connecting
vertical axes of the crane supporting
components (wheels or outriggers).

The smallest radius of the inner rail
axis curve at a curved section of the
track.

The radius of a circumference
circumscribed by the crane outer front
wheel when changing the movement
direction.

General Parameters
2.43




2.44







2.45











2.46
Classification
group
(operating
conditions)

Clearance to
obstructions






Braking
margin factor










Characteristics
Crane characteristics that account for
its application on the basis of load-
lifting capacity and time, as well as
operation cycles.

The area determined by safety
requirements during the crane
operation close to structures. The
load gripping part only may go
outside the clearance area during
operations.


The ratio of the momentum created by
the brake to the maximum momentum
at the brake shaft due to static loads
applied:
- the maximum operating load
(for the lifting gear)
- boom weight, counterweight,
the maximum operating load,
wind in the operating
conditions (for the radius
alteration unit)

Load lifting characteristics of a self-

92



without
outriggers

propelled crane, when operating
without outriggers installed.

3. BASIC NOTIONS
Movements
3.1


3.2



3.3


3.4




3.4.1




3.5


3.6



3.7


Load lifting
(lowering)

Smooth
landing of the
load

Boom lifting
(lowering)

Radius
alteration



Load
horizontal
movement


Travelling of
the crane

Travelling of
the load trolley


Turn


Vertical relocation of the load.


Lowering of the load with the
minimum speed while its installation
or laying.

Angle boom movement in the vertical
plane.

Movement of the load-gripping part
by way of boom lifting, lowering or
relocation, or by way of load trolley
relocation.

Alteration of the radius performed by
lifting of the boom, when the load
automatically moves along the curve,
which is close to a horizontal line.

Movement of the whole crane in the
operating position.

Movement of the load trolley along
the overhead bridge, cable, boom or
cantilever.

An angle movement of the overhead
travelling or boom-type crane rotary
part in the horizontal plane.


Crane Stability
3.8


3.9





Crane stability


Load stability





Capacity of the crane to withstand
tilting forces.

Capacity of the crane to withstand
tilting forces, which are formed by
load weight, inertia forces, wind load
in the operating conditions, and other
factors.


93
3.10

Inherent
stability

Capacity of the crane to withstand
tilting forces in both operating
(including without a load) and stand-
by conditions.

Testing
3.11




3.12


Static testing




Dynamic
testing

Crane testing by way of static load
application to the load-gripping unit.
The load shall exceed the crane load-
lifting capacity by X%.

Crane testing by way of conducting
routine operations under load. The
load shall exceed the crane load-
lifting capacity by Y%.


4. UNITS
4.1

4.2


4.3



4.4



4.5


4.6


4.7








4.8
Lifting gear

Crane
travelling gear

Trolley or
chain block
travelling gear

Radius
alteration gear


Rotation gear


Boom
extension gear

Winch








Chain block
A drive unit to lift and lower loads.

A drive unit to move the crane.


A drive unit to move the trolley or
chain block.


A drive unit to change the radius by
way of changing the angle of the
boom and/or gooseneck incline.

A drive unit to swing the rotary part
of the crane in the horizontal plane.

A drive unit to change the length of
the crane boom.

Gear, which traction force is
transmitted by way of a flexible
component (cable, rope) from the
drive drum.
Winch types:
- drum-type
- with cable driving pulleys
- capstan winch.

A load lifting gear assembled in one

94


4.9



4.10




4.11




4.12





4.13


4.14







4.15


4.16




4.17




4.18



Running gear



Portal




Equalising
trolley



Bridge





Load trolley
(carrier)

Support-
turning table
(unit)





Turning
platform

Tower




Column




Boom

housing with the drive.

The crane base to install the rotary
platform or tower that includes a drive
unit to move the crane.

A structure that has an elevated
running frame supported with the help
of posts, or resting directly on the
crane track.

A supporting structure equipped with
wheels or rollers, and provided with a
hinged joint to equalise load
transmission to wheels or rollers.

A bearing structure of overhead
travelling cranes designed to provide
travelling of a load trolley, or a
structure between supports of a gantry
or semi-gantry crane.

A structure designed to move
suspended loads.

A unit to transmit loads (load
momentum, vertical and horizontal
forces) from the rotary part of the
crane to the non-rotating one, and to
rotate the rotary part. The unit may
also include the gear to rotate the
table.

A turning crane structure to locate
gear units.

A vertical crane structure that
supports the boom and/or turning
platform and provides the required
elevation to locate the boom support.

A vertical structure that supports the
turning boom with the operating load
and provides the required elevation
for load lifting.

A crane structure that provides the
required radius and/or elevation to lift
95


4.19




4.20



4.21



4.22





4.23


4.24



4.25


4.26


4.27





4.28



4.29


4.30


Tower and
boom
equipment


Swinging
mounting


Stable
mounting


Counterweight





Ballast


Brake



Block (cable)


Equalising
block

Cable guiding
sheave




Polyspast
(block and
tackle)

Duplex
polyspast

Hook
the load-gripping device.

Removable equipment of a boom self-
propelled crane that consists of a
tower, boom with or without a
gooseneck, and required devices.

A cable crane support that can change
the angle to the horizontal line as
forces change in bearing cables.

A cable crane support that cannot
change the angle to the horizontal line
as forces change in bearing cables.

Loads adjusted to the counterweight
cantilever or turning platform to
balance weights of operating loads
and/or separate crane parts during
operations.

A load adjusted to the frame or portal
to provide stability of the crane.

A device designed to lower the speed
of movement or to stop and/or keep
the gear motionless.

A rotating component with one or
several grooves to guide cables.

A block that serves to equalise loads
in two cable branches.

A rotating cable sheave with grooves
(a groove) that serves to drive one or
several cable branches by way of
friction forces occurring between the
sheave and cable.

A block and cable system that serves
to change the force and speed of cable
movements.

A polyspast, with both cable ends
fixed on one or two drums.

A system of blocks located on a
96


4.31



4.32











4.33



4.34


4.34.1



4.34.2



4.34.3


4.34.4





4.35



4.36

suspension

Load-gripping
part


Cinematically
non-releasing
link









Outrigger



Ladder


Boarding
ladder


Inclined ladder



Vertical ladder


Rigging ladder





Gallery



Catwalk

frame, which is equipped with a hook.

A unit (hook, clamshell, electric
magnet, fork, etc.) to grip and move
loads.

A mechanical link between the engine
and the drum that is implemented by
way of:
direct connection of the engine with
the reducer, and the reducer with the
drum utilising non-releasing
couplings, with the help of the gear
shift mechanism (in the case, when no
spontaneous starting or declutching of
the mechanism is possible, or unless
no normally closed brake is engaged).

A device designed to enlarge the
crane support contour in the operating
conditions.

A structure including a row of steps to
climb up.

A ladder providing access to the
crane, with the gradient to the
horizontal plane up to 60 inclusive.

A ladder, with the gradient to the
horizontal plane being from 60 to 75
inclusive.

A ladder, with the gradient to the
horizontal plane above 75.

A simplified structure, without railing,
designed for workers admitted to
work at elevated locations
(steeplejacks), or to be used in case of
emergency.

A long narrow structure with
horizontal flooring, which is designed
to provide free passage.

A structure in the form of a bridge,
with horizontal or inclined flooring,
97




4.37





Platform

whish is designed to provide passage
during crane servicing or
maintenance.

A horizontal surface designed to
locate a person during crane servicing
or maintenance.

5. LIMITERS AND INDICATORS
Load and Movement Limiters and Indicators
5.1






5.2


5.3

5.3.1



5.3.2



5.3.3


5.4

5.4.1



5.4.2



5.4.3



Limiter






Crane function
limiter

Load limiter

Load-lifting
capacity
limiter

Load
momentum
limiter

Bumper


Limit stops

Operating
movement
limiter

Lifting
elevation
limiter

Lowering
elevation
limiter

A device that shall cause a stop, limit
movements or functions of the crane.
The majority of such devices actuate
automatically, when the appropriate
movement or function reach their
threshold conditions.

A limiter that causes a stop to or
limits operational functions of a crane.

-

-



-



A device to mitigate impacts.


-

a limiter that causes a stop to and/or
limits specified movements of the
crane.

-



-




98
5.4.4


5.4.5


5.4.6



5.4.7


5.5



5.6



5.7

5.7.1



5.7.2



5.8


5.8.1


5.8.2

Rotation
limiter

Travelling
limiter

Trolley
travelling
limiter

Boom pitch
limiter

Indicator



Operating
parameter
indicator

Load indicator

Lifting
capacity
indicator

Load
momentum
indicator

Movement
indicator

Radius
indicator

Boom pitch
indicator

-


-


-



-


A device that provides visual and/or
sound information to the crane
operator for proper crane operation.

A device that provides visual and/or
sound information about operating
parameter values to the crane operator

-

-



-



-


-


-


Function Limiters and Indicators
5.9


5.9.1


Function
limiter

Bridge tilt
distortion
limiter
-






99

5.9.2


5.9.3



5.9.4



5.9.5



5.9.6


5.9.7



5.9.8



5.9.9




5.10


5.10.1



5.10.2


5.10.3


5.10.4



Cable winding
limiter

Cable
unwinding
limiter

Rotation
frequency
limiter

Lifting
(lowering)
speed limiter

Travelling
speed limiter

Trolley
travelling
speed limiter

Safety valve
(in hydraulic
systems)

Anticreep
grapple



Function
indicator

Bridge tilt
distortion
indicator

Crane tilt angle
indicator

Drum rotation
indicator

Cable slack
indicator


-


-



-



-



-


-



-



A device to prevent the crane from
travelling along the rail track, when
impacted by wind in stand-by
conditions.



100
6. TYPES OF WORK, ORGANISATIONS AND PERSONS RELATED TO CRANES
6.1









6.2




6.3








6.4






6.5














Regulatory
documentation
(standards,
specifications)






Maintenance
(overhaul)




Reconstruction







Compliance
certification
(certification)




Specialised
organisation
(company) for
cranes











Documents containing safety
requirements (approved by the
Republic of Kazakhstan
Gosgortechnadzor), regulations,
general principles, and characteristics
related to particular types of
operations or their results, and
available to a wide range of customers
(users).

Restoration of damaged, worn out or
becoming worthless for any other
reason crane units, and bringing the
crane to serviceable conditions.

Changing of the crane design, which
leads to the requirement of entering
changes into its certificate (e.g.,
changing of the drive type, boom
length, tower height, lifting capacity,
and stability), crane alteration and
other modifications that cause
redistribution and alteration of loads.

Confirmation of hoisting equipment
or production compliance with the
requirements of domestic and/or
international regulatory documents,
which is conducted by an independent
organisation.

An organisation (company) that has a
permit (license) issued by the
Republic of Kazakhstan
Gosgortechnadzor (GGTN) (on the
basis of a resolution by a Head
Organisation as related to design
work) to carry out the following:
- full-scale or partial designing in
relation to crane fabrication, overhaul
and/or reconstruction;
- crane fabrication, assemblage,
overhaul, reconstruction, and/or
adjustment of safety devices;
- crane operation;
- inspection of cranes with overdue

101


6.6




















6.7








6.8





6.9


6.10



6.11



Head Crane
Fabrication
Organisation


















Engineering
Centre for
Safety
(Engineering
Centre)




Certification
Body




Crane
Operator

Operating
personnel


Crane owner

service period.

An organisation authorised by the
Republic of Kazakhstan GGTN to:
- carry out research on safe hoisting
equipment operation;
- implement full-scale functions of a
specialised organisation;
- develop regulatory documents in
relation to hoisting equipment;
- perform expert analyses of newly
developed and upgraded cranes (prior
to acceptance testing);
- participate in acceptance testing of
hoisting equipment;
- participate in certification of hoisting
equipment and producing companies;
- perform expert analyses of hoisting
equipment, including imported units;
- inspect hoisting equipment,
including units with expired service
life periods.

An organisation authorised by the
Republic of Kazakhstan GGTN to
carry out work related to practical
assistance to organisations,
companies, and individuals in the
field of safety provision during
hoisting equipment operation,
maintenance and overhaul.

A company authorised by the
Republic of Kazakhstan GGTN to
arrange and carry out certification of
hoisting equipment and its production,
and issue compliance certificates.

A person permitted to operate a crane
and performing his/her duties.

Persons operating a crane that is
controlled from the floor, or operating
a crane with automatic control system.

A company, association, partnership,
or other organisations, irrespective of
their ownership, that have the hoisting
102
equipment on their balance sheets, or
co-operators, farmers, or other
individuals having hoisting equipment
as their property, as well as lessees
that undertake functions of crane
owners on in accordance with a
contract.


103

APPENDIX 2
(to Section 1.4)

LIST
of Regulatory Documents to be Applicable for Hoisting Equipment Designing,
Fabrication, Maintenance and Operation

GOST 2.601-68 ESKD. Operation Documents.
GOST 12.1.013-78 SSBT. Construction. Electrical Safety. General
Requirements.
GOST 12.27058-81 Safety. Cranes. Colour Indication of Hazardous Parts.
GOST 12.3.009-76 SSBT. Load Handling Work. General Safety
Requirements.
GOST 12.4.026-76 SSBT. Colour Signals and Safety Signs.
GOST 15.001-73 Product Development and to Putting in Production.
GOST 15.001-88 Product Development and to Putting in Production
System. Industrial Purpose Products.
GOST 191-82 Lifting Leaf Chain. Specification.
GOST 228-79 Chain Cable, with Spacers. General Specification.
GOST 483-75 Hemp Ropes. Specification.
GOST 1088-71 Sisal Ropes. Specification.
GOST 1412-85 Cast Iron, with Lamellate Graphite for Moulding.
GOST 1451-77 Cranes. Wind Loads. Standards and Determination
Methods.
GOST 1575-87 Cranes. Series of Basic Parameters.
GOST 2105-75 Forged and Extruded Hooks. Specification.
GOST 2688-80 Double Spin Rope, of the LK-R Type, Design 6x19
(1+6+6/6)+1. Assortment.
GOST 3241-80 Steel Cables. Specification.
GOST 6619-75 Leaf Hooks, Single- and Double-Armed. Specification.
GOST 6627-74 Single-Armed Hooks. Rough Workpieces. Types.
Design and Sizes.
GOST 6628-73 Double-Armed Hooks. Rough Workpieces. Types.
Design and Sizes.
GOST 7512-82 Non-Destructive Testing. Welded Joints. Radiographic
Method.
GOST 7665-80 Double Spin Rope, of the LK-3 Type, Design 6x25 (1+6;
6+12)+1. Assortment.
GOST 7667-80 Double Spin Rope, of the LK-3 Type, Design 6x25 (1+6;
6+12)+7x7(1+6). Assortment.
GOST 7668-80 Double Spin Rope, of the LK-RO Type, Design 6x36
(1+7+7/7+14)+1. Assortment.
GOST 7669-80 Double Spin Rope, of the LK-RO Type, Design 6x36
(1+7+7/7+14)+7x7(1+6). Assortment.
GOST 12840-80 Safety Locks for Single-Armed Hooks. Types and Sizes.
GOST13556-91 Tower Cranes for Construction. General Specification.
GOST 14782-86 Non-Destructive Testing. Welded Joints. Ultrasonic
Methods.
104
GOST 15150-69 Machines, Instruments and other Industrial Purpose
Products. Design for Various Climatic Regions.
Categories, Storage and Transportation Conditions in
Relation to Impacts of Ambient Weather Conditions.
GOST 16765-87 Boom Self-Propelled Cranes, General Purpose.
Acceptance and Testing Methods.
GOST 18899-73 Steel Cables. Enclosed Bearing Cables. Specification.
GOST 22045-89 Overhead Travelling Cranes, Electric, Single Support
Beam. Specification.
GOST 22827-85 Boom Self-Propelled Cranes, General Purpose.
Specification.
GOST 22584-88 Electric Cable Block and Tackle. Specification.
GOST 24599-87 Cable Clamshells for Bulk Loads. General Specification.
GOST 25546-82 Cranes. Operating Conditions.
GOST 25573-82 Cable Load Slings for Construction.
GOST 25835-83 Cranes. Unit Classification on the Basis of Operating
Conditions.
GOST 27584-88 Electric Overhead Travelling and Gantry Cranes. General
Specification.
GOST 27913-88 ISO 7752/1. Cranes. Control Units. Locations and
Characteristics. Part 1. General Principles.
GOST 27914-88 ISO 8087-85. Self-Propelled Cranes. Dimensions of
Drums and Blocks.
GOST 27555-87 ISO 4306/1-85. Cranes. Terminology and Definitions.
GOST 27551-87 ISO 7752/2-85. Self-Propelled Boom Cranes. Control
Units. General Requirements.
GOST 27552-87 ISO 4306/1-85. Self-Propelled Boom Cranes.
Terminology and Definitions.
GOST 27553-87 ISO 4301/2-85. Self-Propelled Boom Cranes.
Classification on the Basis of Operating Conditions.
GOST 28609-90 Cranes. Basic Provisions for Modelling.
GOST 28648-90 Crane Wheels. Specification.
GOST 29266-92 ISO 9373-89. Cranes. Requirements for Accuracy of
Parameter Measurements while Testing.
ISO 2408 Steel Wire Ropes of General Purpose. Characteristics.
ISO 4301/1 Cranes. Classification.
ISO 4306/1 Hoisting Equipment. Glossary.
ISO 4308/1 Load Lifting Cranes. Wire Rope Selection.
ISO 4308/2 Load Lifting Cranes. Steel Cable Selection. Part 2. Self-
Propelled Boom Cranes. Usage Ratio.
ISO 4309 Cranes. Wire Ropes. Standards and Regulations for
Inspection and Discarding.
ISO 4310 Cranes. Testing Regulations and Methods.
ISO 7363-86 Cranes and Hoisting Devices. Specifications and
Acceptance Documents. Power Unit Design Regulations.
Consumer Power Unit Operation Regulations. Safety
Regulations for Consumer Power Unit Operation. Traffic
Rules.
105
SNiP 2.01.01-82 Construction Climatology and Geophysics.
SNiP II7-81 Design Standards. Construction in Seismic Regions.
SNiP III-4-80 Safety in Construction.
SNiP 3.08.01 Mechanisation in Construction Industry. Rail Tracks of
Tower Cranes.
OST 34-62-81 Load Lifting Equipment. General Requirements.
OST 22-115-70 Blocks for Steel Cables.
OST 24.090.63-87 Load Lifting and Transportation Equipment.
Requirements for Fabrication of Welded Steel Structures.
OST 24.090.85-88 Electric Drives of Load Lifting Cranes. Calculation
Standards.
RD 22-25-79 Self-Propelled Boom Cranes of General Purpose.
Guidelines for Certificate Preparation.
RD 22-145-85 Self-Propelled Boom Cranes. Standards for Calculation
of Stability against Tilting.
RD 22-166-86 Tower Cranes for Construction. Calculation Standards.
RD 22-205-88 Ultrasonic Flaw Detection of Welded Joints in Cranes.
RD 22-207-88 Load-Lifting Equipment. General Requirements and
Standards for Production.
RD 22-317-91 Temporary Regulatory Documents for Polyamide
Application to Fabricate Blocks.
RD 22-318-91 Tower Cranes. Methodological Directives for Inspection
of Cranes with Expired Service Life Period.
RD 22-319-92 Self-Propelled Boom Cranes of General Purpose.
Methodological Directives for Inspection of Cranes with
Expired Service Life Period Conditions.
RD 24.090.52-90 Load Lifting and Transportation Equipment. Materials
for Welded Steel Structures.
RD 24.090.90-89 Hoisting Equipment. Basic Requirements for Technical
Documents for Reconstruction.
RD 24.090.91-89 Hoisting Equipment. Basic Requirements for
Reconstruction for Further Application in Fire Hazardous
Areas.
TP RD 24.090.95-89 Hoisting Equipment for Explosive Areas. Basic
Requirements for Designing.
TP RD 24.090.96-89 Hoisting Equipment for Fire Hazardous Areas. Basic
Requirements for Designing.
RD 24.225.03-90 Self-Propelled Boom Cranes. Steel Structures.
Calculation Standards.
MU 34.22.2002-92 Methodological Directives for Inspection of Cranes with
Expired Service Life Period to Assess the Potential of
their Further Operation. Methodological Directives for
Inspection of Cranes, with the Purpose to Assess the
Potential of their Further Operation. The Fourth Issue,
Revised and Supplemented. Guidelines for Incoming
Control of Metal Quality for Crane Overhaul, Fabrication
and Reconstruction.
106

APPENDIX 3
(to Section 2.1)

LIST
of Head Organisations in Crane Production

Organisation
Description
Equipment Assortment Organisation Address
Kazsteelconstruction Cranes of overhead travelling and
cable types, portal, cantilever, railway
cranes, telphers. Specific installation
cranes. Tower cranes, timber loading
cranes, movable and derrick pole
cranes, , boom cranes on rail tracks.
(illegiblein the
original) Dzhandosov
St., 480070 Almaty.

107

APPENDIX 4
(to Section 2.24)

ESTIMATION OF TENSION IN A SLING STRING

A load with the weight of Q is suspended on a hook by way of a sling rope or chain with
n strings that are inclined to the vertical line at the angle of o.

When the load weight (Q t) is known, the tension of S (kN) occurring in each string
shall be calculated in accordance with the following equation:

S = 10Q__ = M 10Q__
ncoso n

where the M factor at o = 0, 30 and 45 will be equal to 1, 1.15 and 1.42 accordingly.


108

APPENDIX 5
(to Section 3.22)

CRANE CERTIFICATE FORM

A Certificate shall be issued with a hard cover on sheets of the 210x297 mm format. A
certificate published at a printing-house shall have the format of 218x290 mm.

Certificate Cover

______________________________________________________________________
(Crane Description)
______________________________________________________________________
(Crane Index)

CERTIFICATE*

______________________________________________________________________
(Certificate Description)

* This Certificate is a specimen to serve as the basis for producers to develop their own
Certificates accounting for the types of cranes they produce in accordance with the
regulatory documents of the Head Organisation, and to select from the list contained in
the specimen only the data that refer to the particular type of crane to be included in
their Certificates. If required, a Certificate may include additional data, which will
characterise the specific character of a produced crane. The Certificate shall be
prepared in Russian.

Front Page

The crane is liable to registration with Gosgortechnadzor Bodies prior to its putting into
operation (the caption shall be included for cranes liable for registration only).

The place for the producers trademark (logotype).

______________________________________________________________________
______________________________________________________________________
(Company Name)
______________________________________________________________________
(Crane Type and Description)
______________________________________________________________________
(Crane Index)

CERTIFICATE

______________________________________________________________________
(Certificate Description)
______________________________________________________________________
(Registration Number)
109
If the crane is transferred to another owner or leased with transference of the owners
functions, this Certificate shall be handed over together with the crane.

Front Page Reverse Side

1. The owner of the crane or organisation (a company, co-operative, joint stock
company, partnership or individual) that rents the crane with the owners
functions shall permanently keep this Certificate.
2. A permit for crane operation shall be obtained in accordance with the
procedure provided by the Crane Design and Safe Operation Regulations.
3. A list of permits issued by Gosgortechnadzor for deviations from the
Regulations (copies) shall be attached to the Certificate.
4. _____________________________________________________________
(other details for the crane owner
______________________________________________________________
to pay special attention to)
______________________________________________________________


Page 1

Page for the drawing of the crane general view in the operating position, and with
the basic sizes identified.

Format 210x297 (218x290) mm.


Page 2

Permit (License) for production
No. __________ of _______________ (Date)


______________________________________________________________________
(The title and address of the Gosgortechnadzor Body
______________________________________________________________________
that has issued the permit
______________________________________________________________________
for the crane production)
______________________________________________________________________

1. General Information

1.1 The Crane producers title and address ________________________________
1.2 The crane type ___________________________________________________
1.3 The crane index __________________________________________________
1.4 Serial number ____________________________________________________
1.5 Year of production ________________________________________________
110
1.6 The purpose of the crane ____________________________________________
1.7 Crane classification (conditions) group _________________________________
1.7.1 Unit classification (conditions) groups _________________________________
Main lifting ______________________________________________________
Auxiliary lifting ___________________________________________________
Radius alteration __________________________________________________
Crane travelling ___________________________________________________
Trolley travelling __________________________________________________
Turning __________________________________________________________
1.8 Drive type _______________________________________________________
(for self-propelled boom cranes, the type of locomotion gear drive, and the
drive type of the gear located on the turning platform shall be identified)
1.9 Ambient conditions of the environment, in which the crane may be operated:
The highest above 0
Temperature ___________________________ C _______________________
The lowest below 0
Relative air humidity _______________________________________________
Explosion hazard __________________________________________________
Fire hazard _______________________________________________________
Other features of the environment as required ____________________________
________________________________________________________________
1.10 Permissible wind speed, m/sec.:
For operating conditions (accounting for wind gusts) corresponding to the action
threshold of the wind indicator (anemometer) installed on the crane __________
For operating conditions of a crane, which is not equipped with a wind indicator
(anemometer), at the height of 10 metres _______________________________
For stand-by conditions of the crane, at the height of 10 metres ______________
________________________________________________________________
(For modular cranes, data for particular combinations
________________________________________________________________
shall be indicated)
1.11 A permissible gradient of the area, on which a self-propelled boom crane may be
installed, % (degrees):
When operating with outriggers ______________________________________
When operating without outriggers ____________________________________
1.12 Requirements for the site, where crane relocation with a load may be permitted:
Ground pressure (specific), Pa (kg-force/cm
2
) ___________________________
Gradient, % (degrees) ______________________________________________
1.13 Limitation of simultaneous performance of operations _____________________
1.14 Type of electric current, voltage, and the number of phases
Power circuit _____________________________________________________
Operational lighting circuit __________________________________________
Maintenance lighting circuit _________________________________________
1.15 Basic engineering requirements, regulations and guidelines of
Gosgortechnadzor, International and National standards, in accordance with
which the crane has been manufactured (code and description) ______________
________________________________________________________________
________________________________________________________________
________________________________________________________________
111
2. Basic Specifications of the Crane

2.1 Basic crane specifications
-
:
Maximum lifting capacity for the main lifting, t (tonnes) ___________________
Maximum lifting capacity for the auxiliary lifting, t _______________________
Load lifting capacity at the maximum radius, t ___________________________
Maximum load momentum, t x m _____________________________________
Maximum lifting height, m __________________________________________
Lifting height at the maximum radius, m _______________________________
Lowering elevation, maximum, m ____________________________________
Maximum radius, m _______________________________________________
Radius at the maximum load lifting capacity ____________________________
Minimum radius, m ________________________________________________
Crane span, m ____________________________________________________
Cantilever radius, m ________________________________________________
2.2 Load-lifting and height characteristics (to be compiled for any operating
condition combinations and crane designs, at which its operation is envisaged).
Load-lifting characteristics:

Tables, diagrams and graphs of the crane load-lifting characteristics.

Height characteristics:

Tables, diagrams and graphs of load-lifting elevations.

2.2.1 The maximum weight of a load, for which a boom section may be extended,
tonnes (the boom design shall be indicated telescopic, telescopic with an
extension, with mechanical extension; and also operation with or without
outriggers shall be noted) ____________________________________________
________________________________________________________________
2.2.2 The maximum weight of a load, for which relocation of a self-propelled boom
crane may be admitted, tonnes (the site condition, speed of movement, and the
boom position versus the relocation axis shall be indicated) _________________
________________________________________________________________
2.3 Crane geometrical parameters:
Base, m __________________________________________________________
Outrigger base, m __________________________________________________
Track, m _________________________________________________________
Rear dimensions, m ________________________________________________
(to be indicated with advanced and retracted counterweight)
Turning radius, m __________________________________________________
The smallest radius of the inner rail axis curve at a curved section of the track, m
________________________________________________________________




-
Data for particular combinations shall be indicated for modular cranes, data for the main boom shall be
given for self-propelled boom cranes.
112
Crane diagram and tables showing values of the basic crane dimensions and parameters
of its manoeuvring
-


2.4 Speed ___________________________________________________________
(For units with several speeds, all the values or the range of their changes shall be
indicated)

Load Lifting, Lowering and Landing Speeds, m/sec. (m/min)
Polyspast
Multiplicity
Main Lifting Speed Auxiliary Lifting Speed
Rated Increased
--
Landing Rated Increased** Landing



Locomotion speed, m/sec (m/min or km/hr):
Of the crane with a load on its hook ___________________________________
Of the crane without load (operating) __________________________________
(The whole range of speeds shall be indicated from the minimum to the maximum)
Of the crane transportation (trailed by a tractor) __________________________
Of the boom section extension/retraction _______________________________
Radius alteration (average) __________________________________________
Rotation frequency, rad./sec. (rev/min) _________________________________
(To be indicated for any design of operating equipment)
2.5 Time for complete radius change (for the main boom):
From the maximum to the minimum, sec. (min) _________________________
From the minimum to the maximum, sec. (min) _________________________
2.6 Turning angle, rad (degrees) _________________________________________
2.7 Climbable road gradient, rad (degrees) _________________________________
(Values for any transportation options or their range shall be indicated)
2.8 Control location:
During operation __________________________________________________
During assemblage and testing _______________________________________
During a self-propelled boom crane locomotion __________________________
In operating conditions _____________________________________________
In transportation conditions __________________________________________
For outriggers _____________________________________________________
2.9 Control method (methods of control shall be indicated):
Mechanical, electric, hydraulic, pneumatic, etc. as related to a particular unit
(gear) or a group of units ____________________________________________
2.10 Power supply to the crane and units ___________________________________
2.11 Stability characteristics _____________________________________________






-
Shall be mandatory for self-propelled boom cranes.
--
Conditions, at which operation with increased speed is permitted (or provided), shall be indicated.
113
Load Momentum, kN x M (t x m) Stability with
Load
Inherent
Stability
Holding Momentum, M
h
---
(with the radius of), m
Tilting Momentum, M
t
*** (with the radius of), m


2.12 Weight of the crane and its main parts, tonnes:
The design weight (to be indicated together with the main boom for a self-
propelled boom crane) ______________________________________________
________________________________________________________________
The total weight of the crane (to be indicated together with the main boom and
in a fully serviced state for a self-propelled boom crane) ___________________
Counterweight ____________________________________________________
Ballast weight ____________________________________________________
Weight of the main assembly parts of the crane that are transported separately
________________________________________________________________
Weight of the crane in the transported condition __________________________
2.13 Design load of the running wheel on the rail, kN (t/sec) ____________________
2.14 Load of the chassis axels on the base in transported conditions

Crane Design Load, kN (t/sec)
Total \ Front axel Rear axel


2.15 Average specific ground pressure, Pa (for caterpillar cranes) ________________
2.16 Other data as required (e.g., data related to metal, ballast drawings, etc.) ______
________________________________________________________________
________________________________________________________________

Specifications and Characteristics of Assemblies and Parts

3.1 Engines of power units and gear ______________________________________
3.1.1 Internal combustion engines (parameter values at the sea level): _____________
________________________________________________________________
Purpose __________________________________________________________
Type and symbolic notation __________________________________________
Rated capacity, kW (HP) ____________________________________________
Rotation frequency, rad/sec (rev/min) __________________________________
Maximum torque, N x m (kg-force x m) ________________________________
Rotation frequency, rad/sec (rev/min) __________________________________
Specific fuel consumption, g/kW/hr ___________________________________
Start-up device, type and symbolic notation _____________________________
Capacity, kW (HP) _________________________________________________
Air filter, type ____________________________________________________
Capacity of the fuel tank, litres _______________________________________

---
Momentum values shall be indicated, which characterize inherent stability and that under load for
operating equipment and at the boom position (radius) of M, when the ratio of momentums is closest to
one.
114
Batteries:
Type and symbolic notation __________________________________________
Voltage, V _________________________________________________
Rated capacity, u ____________________________________________
Quantity ___________________________________________________
Specific power consumption for an hour of the crane operation, kW-hr/hr _____
Type of engine connection to transmission:
Type ______________________________________________________
Notation ___________________________________________________
Service meter, notation _____________________________________________

3.1.2 Generators and power engines

Parameters
Electric
Engine of a
Power Unit
Generators
Electric
Engine of a
Gear Drive
Purpose (the gear, the engine is installed for)
Type and symbolic notation
Type of current
Voltage, V
Rated current, A
Frequency, Hz
Rated power, kW
Rotation frequency, rad/sec (rev/min), % per
10 minutes

Protection level in accordance with GOST
17494

Type of engine connection to transmission
the type description and notation.



3.1.3 Cumulative rated power of the electric engine, kW _______________________
3.1.4 Hydraulic pumps and hydraulic monitors

Parameters Hydraulic
Pumps
Hydraulic
Monitors
Purpose
Quantity
Type and symbolic notation
Limit momentum (for hydraulic monitors)
Rated consumed power, kW (for hydraulic
pumps)

Rated pressure of the operating medium
discharge pressure, Pa (kg-force/cm
2
)

Rated capacity (flow rate), litre/min
Rotation frequency, rad/sec (rev/min)
Direction of rotation
115

3.1.5 Hydraulic cylinders:
Purpose __________________________________________________________
Quantity _________________________________________________________
Type and symbolic notation __________________________________________
Cylinder diameter, mm _____________________________________________
Piston stroke, m ___________________________________________________
Rated pressure of the operating medium discharge pressure, Pa (kg-force/cm
2
)
________________________________________________________________
Liquid type _______________________________________________________
3.2 Diagrams ________________________________________________________
3.2.1 Wiring schematic diagram ___________________________________________

Room for the diagram

3.2.1.1 List of power equipment components

Legend Description and Brief
Specification
Type Qty. Notes


3.2.1.2 Wiring drawings

Room for the wiring drawing

3.2.2 Schematic diagram for hydraulics

Room for the schematic diagram

3.2.3 Schematic diagram for pneumatics

Room for the schematic diagram

3.2.4 Cinematic diagram (the cinematic diagram shall include the diagram of bearing
installation, and their list shall be attached as a specification to the diagram).

Room for the diagram

3.2.4.1 Characteristics of tooth gear

Position on
the Diagram
No.
Notation on
the Drawing
Part
Description
Module,
mm
Number of
Teeth
Material,
Type
Thermal
Treatment (teeth
hardness)


3.2.4.2 Characteristics of Chain Gear Sprockets


116

Position on
the Diagram
No.
Standard
No., or
Notation on
the Drawing
Description Spacing,
mm
Number of
Teeth
Material Thermal
Treatment (teeth
hardness)


3.2.4.3 Reducer characteristics

Position on the
Diagram No.
Description, Type Notation on the
Drawing
Transmission Ratio


3.2.4.4 Brake characteristics:
The unit, where the brake is installed ________________________________________
Number of brakes ________________________________________________________
The type and system (automatic, controlled, normally open or closed, block brake, disk
brake, etc.) _____________________________________________________________
Brake pulley of the disk diameter, mm _______________________________________
Braking margin factor of:
The load winch __________________________________________________________
The boom winch ________________________________________________________
Brake drive:
Type __________________________________________________________________
Effort, N _______________________________________________________________
Effector stroke, mm ______________________________________________________
Unit braking distance _____________________________________________________
3.2.5 Reeving diagrams and characteristics of ropes and chains (reeving diagrams for
load polyspasts of the main and auxiliary lifting, boom, gooseneck, etc. lifting
polyspasts; the diagrams shall indicate sizes of drums and blocks, and also
methods of cables and chains fastening)

Room for diagrams

3.2.5.1 Cable characteristics (to be filled in on the basis of certificates provided by the
cable producers):
Cable purpose (main or auxiliary lifting, boom, etc.) ______________________
Cable design and standard notation ____________________________________
Diameter, mm ____________________________________________________
Length, m ________________________________________________________
Temporary resistance of wires to break-up, N/mm
2
_______________________
General strength of the cable, N ______________________________________
Design tension of the cable, N ________________________________________
Utilization factor (strength margin factor):
Designed ________________________________________________________
Standard _________________________________________________________
Wire surface coating (in accordance with GOST) _________________________
________________________________________________________________
117
3.2.5.2 Chain characteristics (to be filled in on the basis of certificates provided by the
chain producers):
Chain purpose and notation on the diagram _____________________________
Chain design and standard notation ____________________________________
Link diameter (calibre), or roller diameter, mm __________________________
Chain spacing, mm ________________________________________________
Chain length, m ___________________________________________________
Strength of the chain, kN ____________________________________________
Design tension, kN _________________________________________________
Strength margin factor:
Designed ________________________________________________________
Standard _________________________________________________________
3.3 Load-gripping devices (to be filled in on the basis of the certificate provided by
the load-gripping device producer)
3.3.1 Hooks:
Design __________________________________________________________
Type (single-armed, double-armed, forged, leaf, etc.)
________________________________________________________________
Rough workpiece of the hook according to the Standard and Standard notation
________________________________________________________________
Rated load-lifting capacity, t _________________________________________
Serial No. (Certificate, year of production) ______________________________
Crane producers QC Department stamp ________________________________
________________________________________________________________

3.3.2 Clamshells:
Type ____________________________________________________________
Bucket capacity, m
3
________________________________________________
Type of materials to be handled with the clamshell, and their maximum bulk
weight, kN/ m
3
____________________________________________________
Clamshell weight, t ________________________________________________
Weight of material scooped by the clamshell, t ___________________________
Serial No. ________________________________________________________
Producers QC Department stamp _____________________________________
3.3.3 Electric magnets:
Type ____________________________________________________________
Power, kW _______________________________________________________
Feed current:
Type of current ____________________________________________________
Voltage, V _______________________________________________________
Weight of the electric magnet, t _______________________________________
Lifting force, kN __________________________________________________
When lifting the following materials:
Shavings ________________________________________________________
Scrap metal ______________________________________________________
Cast iron ingots ___________________________________________________
Maximum temperature of handled load, C ______________________________
Serial No. ________________________________________________________
118
Producers QC Department stamp _____________________________________
3.3.4 Other load-gripping devices (spreaders, automatic grapples, etc.).
3.4 Instruments, safety devices and alarm systems. Protection devices.
3.4.1 Limit switches
-


Type lever,
spindle, etc.
switch
(wiring
diagram)
Gear, the
limit switch
is
functionally
related to
(installation
location)
Distance
from the
crane
gripping
devices, and
the trolley to
the limit at
the time the
engine is shut
down (m,
degrees,
revolutions,
etc.)
Interlink Quantity
Position No.
on the
schematic
wiring
diagram


3.4.2 Load lifting limiter:
Gear shut down with the limiter ______________________________________
Notation (type, modification, and the serial No.) _________________________
________________________________________________________________
System __________________________________________________________
Maximum overload, at which the limiter actuates, % ______________________
Availability of sound and light warning signals __________________________
Overload, at which warning signals actuate______________________________
3.4.3 Safety contacts

Installation location (the
cabin, remote control
panel, etc.)
Type Purpose Position No. on the
schematic wiring diagram


3.4.4 Arresters and bumpers:
Units ____________________________________________________________
Design (rigid, spring, hydraulic, etc.) __________________________________
Maximum stroke, mm (for spring, hydraulic, etc. bumpers) _________________
3.4.5 Other safety devices

Description Type, type of drive Purpose
Anemometer (wind indicator)
Anticreep devices
Parking brake
Arresters of caterpillar trolleys

-
For self-propelled boom cranes, the table shall be compiled accounting for all types and designs of
operating equipment supplied with the crane.
119
Tilting limiter of a gantry crane
Other safety devices

3.4.6 Indicators

Description Type Purpose
Load-lifting capacity and radius indicator
Crane tilt indicator
Load on the crane gripping device indicator
Other information purpose indicators

3.4.7 Signalling and communication devices

Description Type, notation, and
system of the device
Purpose, actuation
conditions
Radio station
Alarm signal of hazardous overhead power
line (under voltage) approach

Sound signal
Overall size light signals
Other devices

3.5 Cabins

Location _________________________________________________________
Purpose __________________________________________________________
Type, design solution
________________________________________________________________
(open, enclosed, etc.)
Number of seats ___________________________________________________
Type and characteristics of glass ______________________________________
Insulation characteristics (thermal, acoustic, etc.) _________________________
Characteristics of systems applied to establish micro-climate in the cabin
(ventilation, hating, air conditioning, etc.) _______________________________
Other equipment (screen wipers, fire extinguishes, etc.) ____________________
________________________________________________________________
3.6 Data related to the metal utilised in the main structures of the crane (to be filled
in on the basis of certificates provided by material vendors)

Unit and
component
descriptions
and notations
Type and
thickness of
rolled metal,
standard
Material type,
category,
group, and
strength class
Standard for
the material
type
Certificate No.





120
4. Acceptance Statement (Certificate)

The crane ______________________________________________________________
(description, type, index, design)
Serial No. ______________________________________________________________
has been fabricated in compliance with engineering standards _____________________
______________________________________________________________________

The crane has passed testing in accordance with the programme __________________,
and has been accepted as fit for operation with the parameters stated in the Crane
Certificate
-
_____________________________________________________________
Warranted service life is ________________________________ months
Service life at 1.5-shift operation in the Certificate specified conditions shall be ______
years.
Resources till the first overhaul shall make up ________ motor-hours.


____________________________
Signature
Chief Engineer
Stamp of the Company

_______________________ ____________________________
Date Signature
Head of the
QA/QC Department



5. Documentation to be Supplied by the Producer

5.1 Documents to be included into the Crane Certificate:
a) A diagram of ballast and counterweight installation, with weight
allowance and plate gravity centres disconnection, warning painting and
lettering on plates to be stated therein;
b) Ballast and counterweight drawings.
5.2 Documents to be supplied with the Crane Certificate:
a) A Certificate (guidelines) of the load lifting (load momentum) limiter,
and a diagram of its operation;
b) A Certificate of the automobile chassis;
c) A Certificate of the internal combustion engine;
d) A Certificate (guidelines) of safety instruments and devices.
e) A crane operation manual;
f) Guidelines for rail track construction;
g) A set of drawings for wearing out parts;
h) A bill of spare parts, tools and appliances;

-
To be filled in for the cases, when the producer ships a crane in an assembled state, or if the plant
performs a complete assemblage of the crane.
121
i) A set of wiring diagrams (as required);
j) Other documents (as required)

Information of the crane location*

Name of the company (organisation)
owning the crane, or the name and
initials of an individual owner
Crane location
(owners address)
Date of installation
(delivery)


___________________________
* At least 2 pages

Information about assignment of engineering and technical staff to be responsible for
crane safe and serviceable conditions*

No. and Date of the
Assignment
Memorandum, or a
Contract with the
Company
Persons
Name
Position Certificate No.
and Validity
Period
Signature


___________________________
* At least 5 pages

Information about steel structure overhauls and replacements of units, and load-gripping
device cables*

Date Details of the Overhaul
and Crane Component
Replacement Character
Details of the Crane
Acceptance after the
Overhaul (date,
document No.)
Signature of the
Engineer Responsible
for the Crane Safe and
Serviceable Conditions


___________________________
* At least 5 pages

Note: Documents certifying quality of newly installed units, cables and other crane
components, as well as applied materials (rolled metal, welding rods and wire, etc.), and
also the conclusion of welding quality shall be kept with the Crane Certificate.

Records of technical inspection results*

Inspection Date Inspection Results Time of the Next Inspection
(complete and partial)


___________________________
* At least 32 pages
122
Note: Results of a specific crane inspection, when it has operated through its designed
service life period (technological lifespan), shall be also included herein.

Registration
(a separate page)

The crane has been registered with the No. of __________________________________
______________________________________________________________________
(State the registering body)

The Certificate contains ____ numbered pages and totally ______ stringed sheets,
including drawings on ______ sheets.

Stamp ________________________
(Signature and position)
_____________________ _________________________
Date (Name and initials of the registering
person)

123

APPENDIX 6
(to Section 3.22)

CHAIN BLOCK CERTIFICATE FORM

Producers Trade Mark (Logotype) A Certificate shall be issued with a
hard cover on sheets of the
210x297 mm format. A certificate
published at a printing-house may
have the format of 145x218 mm.

Certificate Cover


CERTIFICATE*

______________________________________________________________________
(Chain Block Description)
______________________________________________________________________
(Chain Block Notation)

Registration No. ______________

If the chain block is transferred to another owner, this Certificate shall be handed over
together with the chain block.

______________________________________________________________________
(Place Name of the Chain Block Production)


Page 1

Permit (License) for production
No. __________ of _______________ (Date)
________________________________________
(The title and address of the Gosgortechnadzor Body
________________________________________
that has issued the permit for the chain block production)

1. General Information

1.1 The chain block producers title and address _____________________________
________________________________________________________________
1.2 The chain block type _______________________________________________
1.3 Serial number _____________________________________________________
1.4 Year of production _________________________________________________
1.5 Classification group ________________________________________________
1.6 Drive type _______________________________________________________
124
1.7 Ambient conditions of the environment, in which the chain block may be
operated:
The highest above 0
Temperature ___________________________ C _______________________
The lowest below 0
Relative air humidity _______________________________________________
Explosion hazard __________________________________________________
Fire hazard _______________________________________________________
Other features of the environment as required ____________________________
1.8 Basic engineering standards, in accordance with which the chain block has been
manufactured

2. Basic Specifications and Characteristics

2.1 General data:
Load-lifting capacity, t ______________________________________________
Lifting height, m __________________________________________________
Rated lifting speed, m/sec ___________________________________________
Type of current in the power circuit:
Voltage, V _______________________________________________________
Frequency, Hz ____________________________________________________
Type of current in the control circuit:
Voltage, V _______________________________________________________
Frequency, Hz ____________________________________________________
Method of power supply to the chain block _____________________________
Type and profile of the track _________________________________________
Minimum radius of a track curve, m ___________________________________
Load on a wheel, N ________________________________________________
Dead weight, kg ___________________________________________________
2.2 Steel cables:
Cable design and standard notation ____________________________________
Diameter, mm ____________________________________________________
Length, m ________________________________________________________
Temporary resistance of wires to break-up, N/mm
2
_______________________
________________________________________________________________
General strength of the cable, N ______________________________________
Strength margin factor ______________________________________________
Wire surface coating _______________________________________________
2.3 Hook:
Standard notation _________________________________________________
Hook No. according to Standard ______________________________________
Load-lifting capacity, t ______________________________________________

2.4 Power engines:

Parameters Lifting Gear Travelling Gear
Type and symbolic notation
Voltage, V

125
Rated current, A
Frequency, Hz
Power, kW
Rotation frequency, rev/min
Starting time, % per 10 minutes
Number of start-ups per 1 hour
Design
Level of protection

2.5 Brakes

Parameters Lifting Gear Travelling Gear
Type
Number of brakes
Deceleration (braking) margin factor
Brake drive:
Type
Effort, N
Effector stroke, mm


2.6 Safety devices
2.6.1 Limit switches

Type Gear the Switch is
Designed to Stop
Distance from the Chain Block
Hook Suspension to the Stop
after the Gear id Stopped
Quantity

2.6.2 Other safety devices ________________________________________________
________________________________________________________________
2.7 Control devices

Description Type Purpose


3. Acceptance Statement (Certificate)

The chain block ______________________________ Serial No. __________________
has been fabricated in compliance with the requirements of GOST __________ (or TU
_________________) and the Crane Design and Safe Operation Regulations.

The chain block has passed testing in accordance with __________________________,
______________________________________________________________________
(Description of the Regulatory Document)
and has been accepted as fit for operation with the parameters stated in the Certificate.
Warranted service life is ________________________________ months



126
____________________________
Signature
Chief Engineer
Stamp of the Company

_______________________ ____________________________
Date Signature
Head of the
QA/QC Department

4. Documentation to be Supplied by the Chain Block Producer with the Certificate

A Certificate (guidelines) of the load lifting limiter (if available), and a diagram of
its operation;
A chain block operation manual;
Guidelines for the chain block installation;
Guidelines for rail track construction;
A list of chain block parts and assembly units, with noted related to their routine
maintenance (if required)
A bill of spare parts, tools and appliances;
Other documents (as required)

Information of the chain block location*

Name of the chain block owner Chain block location Date of installation


___________________________
* 1 page

6. Information about assignment of engineering and technical staff to be
responsible for the chain block safe and serviceable conditions*

No. and Date of the
Assignment Memorandum
Persons Name and
Position
Signature


___________________________
* 1 page
Note: Documents certifying quality of newly installed units, cables and other crane
components, as well as materials applied in the overhaul, shall be kept in a separate file.

7. Records of technical inspection results*

Inspection Date Inspection Results Time of the Next Inspection
(complete and partial)


___________________________
* At least 8 pages
127
APPENDIXES TO THE CERTIFICATE

Appendix A

General View (1 page)

A drawing with the general view shall be attached stating overall and installation
dimensions.

Appendix B

Schematic Wiring Diagram (1 page)

A drawing with the schematic wiring diagram shall be attached including a table to
interpret notations.

Appendix C

Cinematic Schematic Diagram (1 page)

A drawing with the cinematic schematic diagrams of the chain block lifting and
travelling gear, as well as the diagram of cable reeving and fastening shall be attached.

128

APPENDIX 7
(to Section 4.15)

Maximum Permissible Deviations of Rail Tracks (Plane and Profile Views) from
the Designed Position

Deviation
Graphical
Representation of the
Deviation
Cranes
Overhead
Travelling
Tower Gantry Portal Trans
ship
ment
Difference in elevations
of railheads in the cross
section (P
1
), mm (S is
the size of the track, m)

Difference in rail
elevations at
neighbouring columns
(P
2
), mm

Narrowing or widening
of the rail track (rail
horizontal deviation
from the design
position), (P
3
), mm

Mutual displacement of
joined rail butts both
horizontally and
vertically (P
4
), mm

Gaps in rail butt joints
(at the temperature of
0C, and the rail length
of 12.5 m) (P
5
), mm

Difference in railhead
elevations at the rail
track section of 10 m
(total) (P
6
), mm
40




10




15





2




6




-

45-60
(for
S=4.5-
6 m)

-




10





3




6




40

40




-




15





2




6




30

40




-




15





2




6




20

50




-




20





2




6




30


Notes:
1. Maximum permissible values of deviations shall be complied with in operation.
Construction allowances shall be identified in design documents for the rail
track.
2. P
1
and P
3
deviations shall be measured at the whole length of the crane potential
travelling area, at the intervals of at least 5 m.
3. If the ambient temperature changes by 10C, allowance for P
5
gap shall be
amended by 1.5 mm. E.g., the gap allowance shall be reduced by 3 mm at the
temperature of 20C.
4. Deviation allowances for rail tracks of gantry cranes with the span above 30 m
shall be taken as those for transhipment cranes.
129

APPENDIX 8
(to Section 4.15.10)

STATEMENT FORM
for a Crane Rail Track Acceptance at Commissioning

______________________________________________________________________
(Company)

Date: ______________________

Facility address: _________________________________________________________
Crane type, serial and registration numbers ____________________________________
______________________________________________________________________

Rail Track

Length of the rail track ____________________________________________________
Availability of design documentation ________________________________________
______________________________________________________________________
(Design Developers)

Compliance of constructed rail track with design documents ______________________
______________________________________________________________________

Availability of the ground bed for the upper rail track structure Acceptance Statement _
______________________________________________________________________

Rolling smooth of the rail track has been carried out with the crane runs:
Without load _____________________________________________________
With the maximum operating load ____________________________________

Measurement Results:

Track width, mm ________________________________________________________
Straightness, mm ________________________________________________________
Longitudinal gradient _____________________________________________________
Cross slope _____________________________________________________________
Resilient trim, mm _______________________________________________________
Availability and serviceability of stop blocks __________________________________
Availability and serviceability of bumping posts _______________________________

Track Grounding

Grounding design ________________________________________________________
Grounding location and length _____________________________________________
______________________________________________________________________

130
Description, type and No. of the instrument applied to measure grounding resistance. __
______________________________________________________________________

Measurement location ____________________________________________________

Weather during the last three days and at the day of measurement __________________
______________________________________________________________________

Grounding resistance, Ohm _______________________________________________


Track Grounding:

Complies with the requirements ___________________________________________
Does not comply with the requirements _____________________________________

Rail track grounding has been installed by ___________________________________
(Company,
_____________________________________________________________________
name, position, signature)

Rail track grounding resistance has been measured by ___________________________
(Company,
_____________________________________________________________________
name, position, signature)

Work on crane rail track construction has been
carried out and handed over by _______________
(Company,
________________________________________
name, position, signature)


Crane rail track has been accepted for operation by
________________________________________
(Company,
________________________________________
name, position, signature)

131

APPENDIX 9
(to Section 5.15)

WORK PERMIT FORM

for the right of access to crane track and passage galleries of overhead travelling and
mobile cantilever cranes to carry out maintenance and other types of work.

1. Issued on ________________ (Date) at _____ hours ________ minutes
2. The responsible person ________________________________________________,
(Name)
with a crew consisting of ________ persons, is charged to carry out the following work:
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________

3. Work location (workshop, span) __________________________________________
______________________________________________________________________

4. To ensure safety during preparation to and carrying out of the work you shall
implement the following precautions:
a) to prevent electric shocks _________________________________________
________________________________________________________________
b) to prevent falls from elevated locations _______________________________
________________________________________________________________
c) to prevent injuries by operating cranes _______________________________
________________________________________________________________
d) to prevent access to crane tracks of operating cranes and cranes of adjoining
spans ___________________________________________________________
________________________________________________________________
e) crane operators of all shifts within the span (shop) and crane operators of
adjoining spans have been notified, and appropriate entries have been made in
the shift logbook __________________________________________________
________________________________________________________________

The Crew includes:
Members of the Crew (full
name, position)
Signatures of Crew members after
being familiarised with work
conditions and safety measures


________________________________________
(Signature of the Workshop Superintendent or Foreman that
supervises the work of the maintenance crew)

6. Work shall commence at ____ hours ____ minutes on ___________________ (Date)

132
7. The Work-Permit is issued by: ___________________________________________
(Signature of the Workshop Superintendent or his Deputy for Equipment)

8. Briefed on the work conditions and received the Work-Permit __________________
(Signature of the Responsible Person)

Note: A Work-Permit for the right of access to crane track and passage galleries of
overhead travelling cranes to carry out maintenance and other types of work
shall be issued on the basis of a Memorandum to the Work Supervisor
(Workshop or Area Superintendent, or Foreman that supervises the work of the
maintenance crew).
133

APPENDIX 10
(to Section 5.28)

STANDARDS TO REJECT ROPES OF HOISTING EQUIPMENT

1. Rejection (discarding) of ropes applied in operating hoisting equipment shall be
performed in accordance with the Guidelines on the hoisting unit operation
(Operation Manual), which shall be developed on the basis of ISO 4309
requirements.

If there is no appropriate section in the Operation Manual, rejection of ropes of a
hoisting unit shall be carried out in accordance with this Appendix.

The following criteria shall be applied to assess safety of the rope application:

a) The nature and number of wire breaks (Figures from 1 to 3), including
presence of wire at rope terminations, presence of wire break accumulations,
the intensity of the wire break number increase;



Figure 1. Breaks and displacements of
wires in a rope of a regular lay.





Figure 2. Combination of wire breaks
with wear-out:
a) in a regular lay rope;
b) in a long lay rope




Figure 3 Wire breaks within the area of
an equalising block:
a) in several rope strands;
b) in two strands in combination
with local wear-out.


b) A brake of a strand;
c) Surface and internal wear-out;
d) Surface and internal corrosion;
e) Reduction of the rope diameter, including a break of the core;
134
f) Reduction of the rope wires cross section area (loss of internal cross section);
g) Displacement in the form of corrugation, wage shape, extrusion of wires and
strands, squashing of strands, breaks, bends, etc.;
h) Damage resulting from temperature impacts or electric arc discharges.



Figure 4. Wear out of external wires in a
regular lay rope:
a) small flat spots on wires;
b) increased length of flat spots on
separate wires;
c) lengthening of flat spots on
separate wires, with a visible
reduction of the wire diameters;
d) flat spots on all the wires,
reduction of the rope diameter;
e) intensive wear-out of all external
wires of the rope (wire diameters
decrease by 40%)






Figure 5. Surface corrosion of wires in a
regular lay rope:
a) initial oxidation of the surface;
b) general oxidation of the surface;
c) visible oxidation;
d) high oxidation;
e) intensive corrosion.



Table 1
Number of Wire Breaks, with the Presence of Which Double Lay Ropes Operating
with Steel and Cast Iron Blocks shall be Rejected

Number of
bearing wires
in external
strands, n
Typical examples of rope
designs
Group of the unit classification (conditions)
M1, M2, M3 and M4 M5, M6, M7 and M8
Regular lay Long lay Regular lay Long lay
At a section with the length of
6d 30d 6d 30d 6d 30d 6d 30d
n s 50


51 s n s 75
6x7(1+6)+1x7(1+6)
6x7+1
8x6(0+6)+9

6x19(1+9+9)+1
2



3
4



6
1



2
2



3
4



6
8



12
2



3
4



6
135
76 s n s 100
101 s n s 120


121 s n s 140

141 s n s 160
161 s n s 180


181 s n s 200
201 s n s 220
221 s n s 240
241 s n s 260
261 s n s 280
281 s n s 300
300 < n

6x19(1+9+9)+7x7(1+6)
6x25(1+6; 6+12)+1
6x25(1+6; 6+12)+ 7x7(1+6)
6x19(1+6+6/6)+ 7x7(1+6)*
6x19(1+6+6/6)+1
6x16(0+5+11)+9
18x7(1+6)+1
8x19(1+6+6/6)+1
6x30(0+15+15_+7
6x30(6+12+12)+1
6x31(1+6+6/6+12)+1
6x31(1+6+6/6+12)+ 7x7(1+6)
6x36(1+7+7/7+14)+1
6x36(1+7/7+14)+ 7x7(1+6)
6x37(1+6+15+15)+1
18x19(1+6+6/6)+1*


4

5


6
6
6
7

8

8

10
10
11
12
0.04n
8

10


11
13
13
14

16

18

19
21
22
24
0.08n
2

2


3
3
3
7

4

4

5
5
6
6
0.02n
4

5


6
6
6
7

8

9

10
10
11
12
0.04n
8

10


11
13
13
14

16

18

19
21
22
24
0.08n
16

19


22
26
26
29

32

38

38
42
45
48
0.16n
4

5


6
6
6
7

8

9

10
10
11
12
0.04n
8

10


11
13
13
14

16

18

19
21
22
24
0.08n

Notes:
1. n is the number of bearing wires on external strands of a rope; d is the rope diameter, in
millimetres.
2. Filling wires are not considered bearing ones, thus are not liable to accounting. In ropes with
several layers of strands, wires of the visible external layer are accounted only. In ropes with a
steel core, the latter is considered as an internal strand, and hence is not accounted.
3. The number of visible breaks in strand design ropes shall be calculated in accordance with
established equations. The obtained value shall be rounded to a whole number towards the
larger one.
4. For ropes with different diameters of outer wires in external strands, the design class has been
reduced in the Table and marked with an apteryx. If a rope operates only or partially with blocks
of synthetic materials or metal blocks with synthetic lining, a considerable number of wire
brakes inside the rope prior to occurrence of visible break indications or intensive wear out of the
external surface is more characteristic [further text is illegible].

2. Ropes that operate with steel and cast iron blocks shall be rejected on the basis
of the number of wire breaks in accordance with Table 1.

Ropes of hoisting equipment designed to lift people, as well as those applied to
transport melted or glowing metal, flammable and toxic substances, shall be
rejected if the number of wire breaks is twice less.

3. If the rope diameter decreases due to surface wear-out (Figure 4) or corrosion
(Figure5) by 7% and more as compared with the rated diameter, the rope shall be
rejected even if there are no visible wire breaks.

If the rope diameter decreases due to damage caused to the core, e.g., internal
wear-out, squashing, break, etc. (by 3% of the rated diameter for non-whirling
ropes, and by 10% for other ropes), the rope shall be rejected even if there are no
visible wire breaks (Figure 6).



136



Figure 6. Local rope diameter decrease at the location of the organic core damage.

If a rope reveals surface wear-out or corrosion of wires, the number of brakes
serving as an indication for rejection shall be reduced in accordance with data of
Table 2

Table 2
Standards for Rejection on the Basis of Surface Wear-out or Corrosion

Wire Diameter Decrease Due to Surface
Wear-out or Corrosion, %
Number of Wire Breaks at a Lay Pitch,
% of those stated in Table 1
10
15
20
25
30 and more
85
75
70
60
50

If the original diameter of external wires decreases by 40% and more as a result
of wear-out (Figure 4) or corrosion (Figure5), the rope shall be rejected.

Wear-out and corrosion of wires on the basis of their diameter shall be identified
utilising a micrometer or other instrument, which provides analogous accuracy.

If the number of wire breaks is below the values specified in Table 1, as well as
if the wire surfaces are worn out without breaks, a rope may be accepted for
operation provided that its condition is thoroughly monitored and periodically
inspected, and the results are recorded in the inspection logbook. The rope shall
be replaced as the wear-out level specified in Table 2 is achieved.

If loads are suspended on two ropes, each of them shall be inspected and rejected
separately, and replacement of only one rope, the mostly worn-out one, may be
accepted.

4. To assess conditions of internal wires, i.e., to control the loss of the metal part of
the rope cross section (loss of internal cross section), which may be caused by
breaks, mechanical wear-out and corrosion of wires in internal layers of strands
(Figure 7), the rope shall undergo flaw detection along its whole length. If a
flaw detector identifies a loss of wire metal cross section, which reaches 17.5%
and above, the rope shall be rejected.




Figure 7. Decrease of the wire cross
section area (intensive internal corrosion)
137

5. If one or several broken strands are identified in a rope, the rope shall not be
accepted for further operation.







Figure 8. Corrugation of a rope (see the text for description).

6. Rope corrugation is characterised by the pitch and direction of its coil (Figure 8).
If the direction of the corrugation coil and that of the rope lay coincide, and the
pitch of the corrugation coil (H

) and that of the rope lay (H

k
) are equal, the rope
shall be rejected at d

>1.08d
k
, where d

is the diameter of the corrugation coil,

and d
k
is the rated diameter of the rope.

If the directions of the corrugation coil and rope lay do not coincide, and the
pitch of the corrugation coil and that of the rope lay are unequal, the rope shall
be rejected at d

>4/3d
k
. The length of the rope section under inspection shall not
exceed 25 d
k
.

7. Ropes shall not be accepted for further operation if the following is found:

- basket-shaped displacement (Figure 9);
- core extrusion (Figure 10);
- strand extrusion or separation (Figure 11);
- local increase of the rope diameter (Figure 12);
- local decrease of the rope diameter (Figure 6);
- squashed areas (Figure 13);
- kinks (Figure 14);
- breaks (Figure 15);
- bends (Figure 16);
- damage resulting from temperature impacts or electric arc discharges.


Figure 9. Basket-Shaped Displacement


Figure 10. Core Extrusion




Figure 11. Strand Wires Extrusion
a) in one strand;
b) in several strands
138



Figure 12. Local Increase of the Rope
Diameter



Figure 13. Rope Squashing.



Figure 14. Kink



Figure 15. Rope Break



Figure 16. Rope Bend


139

APPENDIX 11
(Reference)

INTERNATIONAL STANDARDS ISO 4301/1, 4302, 4308/1, 4308/2, 4310 and
8087

INTERNATIONAL STANDARD ISO 4301/1 (CRANES AND LIFTING UNITS.
CLASSIFICATION. PART 1. GENERAL PROVISIONS).

Introduction

Load-lifting cranes (hereinafter cranes) are applied to lift and relocate loads, weights
of which do not exceed their rated load-lifting capacities. Cranes of one type (e.g.,
overhead travelling ones) and cranes of different types (e.g., a tower crane for
construction and a port crane with a considerable lifting capacity) may have different
operating conditions. Crane designing shall account for conditions of operation to
ensure the required level of safety and durability that will comply with the requirements
of the customer. Classification is a system that is used as a tool to establish an effective
basis to design structures and machines, and as a basis to develop relations between the
Customer and Producer. The Classification will assist in selecting a particular crane for
the envisaged type of work.

The Classification reviews such operating conditions only that are not dependent on the
crane type and the ways of its control. Further International Standards will establish the
portions of the classification line that will be applicable to various crane types (i.e.,
overhead travelling, self-propelled, tower, etc.).

This International Standard establishes crane classification and forms a part of ISO 4301
International Standard.

A complete list of ISO 4301 parts is as follows:

Part 1. General Provisions.
Part 2. Self-Propelled Boom Cranes.
Part 3. Tower Cranes.
Part 4. Portal and Pedestal Cranes.
Part 5. Overhead Travelling and Gantry Cranes.

1. Purpose and Scope of Application

This International Standard establishes crane classification on the basis of operating
cycles performed during an expected period of the crane service, and the load
distribution factor, which represents rated loading conditions.

This Standard does not assume that the same method of load modelling or testing
method will be applicable to all types of devices included into ISO/TK 96 assortment.

140
2. Application of the Classification

In practice, the Classification may have two ways of application that may be considered
separately.

2.1. General Classification of a Lifting Unit

The first application of the Classification will allow the crane Purchaser and
Producer to achieve an agreement about operating conditions of that particular
crane. Hence, it is a contractual and technical reference matter, and is used for
designing. The classification method is represented in Section 3.

2.2. Classification for Designing Purposes

The second application of the Classification will allow the Designer to analyse
the project on its basis, and prove that the crane under his design is able to
operate during a certain service period in certain operating conditions
established for that particular type of application.

The Designer will receive the data of load distribution submitted by the
Customer or provided by the Producer (in case of serial equipment designing),
include them into initial data, on which his analysis will be based, and considers
the factors that govern sizes of the crane parts.

The form of load distribution requisition, on the basis of which the required data
may be identified, is to be developed in one of future International Standards.

3. Crane Classification Groups in General

To identify a group the crane refers to, it is required to consider the class of application
and loading conditions.

3.1. Application Class.

The Customer expects that during the service period the crane will perform a
certain number of operating cycles, which is one of the main parameters for
classification. In specific types of work (e.g., in bulk unloading by way of a
gripping device), the number of cycles may be obtained if the summarised
number of operating hours and the number of operating cycles per hour are
known. In other cases, e.g., when self-propelled cranes are considered, the total
number of operating cycles is more difficult to obtain, as such cranes are used in
various conditions; in this case appropriate values shall be obtained by
experiment. The total number of operating cycles is a sum of all operating
cycles per a certain period of the crane service.

Economic and engineering factors, influence of the environment and
obsolescence shall be taken into account when identifying a crane service life.

141
The total number of operating cycles depends on the frequency of the crane
usage. For the sake of classification, the whole range of potential operating
cycle numbers has been divided into ten application classes (Table 1). The
operating cycle commences, when a load is ready for lifting, and completes,
when the crane is ready to lift the next load.

Table 1.
Class of Crane Application

Application Class Maximum Number
of Operating Cycles
Notes
U
0

U
1

U
2

U
3

U
4

U
5

U
6

U
7

U
8

U
9

1.6x10
4

3.2x10
4

6.3x10
4

1.25x10
5

2.5x10
5

5x10
5

1x10
6

2x10
6

4x10
6

above 4x10
6

Irregular usage



Regular usage in easy conditions
Regular usage with intervals
Regular intensive usage
Intensive usage

3.2 Loading Conditions.

Another basic parameter of classification is that of loading conditions. Loading
conditions are related to the number of load lifts, while the load is of a particular
weight expressed in parts of the crane load lifting capacity. Table 2 shows the
rated values of load distribution factors for a crane (K
p
), and each of them
characterises a corresponding loading condition.

Table 2
Nominal Factors of Load Distribution for Cranes

Loading Condition Rated Factor of
Load Distribution
Notes
Q1 easy

Q2 moderate


Q3 heavy

Q4 rather heavy
0.125

0.25


0.50

1.00
Cranes that systematically lift light
loads, and rarely nominal loads.
Cranes that systematically lift
average loads, and rather often
nominal loads.
Cranes that systematically lift heavy
loads, and often nominal loads.
Cranes that systematically lift loads
close to nominal.

If numbers and weights of loads that are lifted during the crane service life are
not available, selection of the appropriate loading class shall be agreed between
the Producer and Customer.
142

If exact information about the numbers and weights of loads that are lifted
during the crane service life is known, the ratio of load distribution for the crane
may be modelled in the following way:

The load distribution factor for the K
p
crane shall be obtained utilising the
following equation:

where C
i
is the average number of operating cycles, with particular levels of the
load weight, = C
1
, C
2
, C
3
, , C
n
;
C
T
, is the total number of operating cycles with all the loads:
= E C
T
, = C
1
, + C
2
, + C
3
, + , + C
n
;
P
i
are values of separate load weights (load levels) for a typical application of
the particular crane:
P
i
= P
1
, P
2
, P
3
, , P
n
;
P
max
is the weight of the largest load (nominal, rated load) that is acceptable for
the crane to lift;
m = 3

Detailed, equation (1) shall look as follows:



The rated value of the load distribution factor for a crane shall be established on
the basis of Table 2 (the closest larger value shall be assumed).

3.3 Identification of the Crane Classification Group in General

After identification of the application class in accordance with Table 1 and the
loading conditions on the basis of Table 2, the Classification Group of the
particular crane may be established utilising Table 3.

Table 3
Crane Classification Groups in General

Loading
Conditions
Load
Distribution
Factor
Application Class and Maximum Number of Operating Cycles for the
Particular Unit
U
0
U
1
U
2
U
3
U
4
U
5
U
6
U
7
U
8
U
9

Q1 easy 0.125 A1 A2 A3 A4 A5 A6 A7 A8
Q2 moderate 0.25 A1 A2 A3 A4 A5 A6 A7 A8
143
Q3 heavy 0.5 A1 A2 A3 A4 A5 A6 A7 A8
Q4 rather
heavy
1 A2 A3 A4 A5 A6 A7 A8

Application of classification groups to model separate types of cranes will be developed
in future International Standards.

4. Gear Classification Groups in General

4.1. Class of Gear Application

A class of gear application is characterised by envisaged total duration of their
operation in hours, and rated classes shown in Table 4.

Table 4
Class of Gear Application

Application Class Total Duration of
Testing, hrs
Notes
T
0
T
1
T
2
T
3
T
4
T
5
T
6
T
7
T
8
T
9

200
400
800
1600
3200
6300
12500
25000
50000
100000
Irregular usage



Regular usage in easy conditions
Regular usage with intervals
Regular intensive usage
Intensive usage

The maximum total duration of operation may be obtained on the basis of
envisaged daily time of application in hours, the number of working days per
year, and the expected service life in years.

In this Classification, it was assumed that the time of gear operation is
understood as the time, during which the gear is moving.

The values of total duration of application shall be only viewed as theoretical,
conventionally assumed, and serving as initial data to design gear parts, for
which application time is the criteria for selection (e.g., ball bearings, toothed
gear wheels, and shafts). They cannot be considered as guaranteed values.

4.2. Loading Conditions

Loading conditions determine relative duration, with which gear will be exposed
to maximum or lowered loads. Table 5 gives rated loading conditions.

Table 5
144
Nominal Factors of Load Distribution for Gear (K
m
)

Loading Condition Rated Factor of
Load Distribution
Notes
L1 easy


L2 moderate


L3 heavy


L4 rather heavy
0.125


0.25


0.50


1.00
Gear that is systematically exposed
to light loads, and rarely to the
highest loads.
Gear that is systematically exposed
to moderate loads, and rather often
to the highest loads.
Gear that is systematically exposed
to heavy loads, and often to the
highest loads.
Gear that is systematically exposed
to the highest loads.

The load distribution factor for K
m
gear shall be calculated on the basis of the
following equation:

where t
i
is the average duration of the gear application, with particular levels of
the load, = t
1
, t
2
, t
3
, , t
n
;
t
T
is the total duration with all the particular levels of the load:
= E t
T
, = t
1
, + t
2
, + t
3
, + , + t
n
;
P
i
are values of separate loads (load levels) typical for that particular gear
application:
P
i
= P
1
, P
2
, P
3
, , P
n
;
P
max
is the largest load that may be applied to the gear;
m = 3

Detailed, equation (3) shall look as follows:


Rated values of the load factor for gear shall be established on the basis of Table
5 (the closest larger value shall be assumed).

4.3. Identification of the Gear Classification Group in General

145
The Classification Group of the particular gear shall be established on the basis
of Table 6 after identification of the application class and the loading conditions.

Table 3
Gear Classification Groups in General

Loading
Conditions
Rated Load
Distribution
Factor, m
Gear Application Class
T
0
T
1
T
2
T
3
T
4
T
5
T
6
T
7
T
8
T
9

L1 easy 0.125 M1 M2 M3 M4 M5 M6 M7 M8
L2 moderate 0.25 M1 M2 M3 M4 M5 M6 M7 M8
L3 heavy 0.5 M1 M2 M3 M4 M5 M6 M7 M8
L4 rather
heavy
1 M2 M3 M4 M5 M6 M7 M8

Application of classification groups to model separate types of gear will be
developed in future International Standards.


INTERNATIONAL STANDARD ISO 4301/2 (LIFTING UNITS.
CLASSIFICATION. PART 2. SELF-PROPELLED BOOM CRANES).

Introduction

This International Standard establishes crane classification and forms a part of ISO 4301
International Standard.

A complete list of ISO 4301 parts is as follows:

Part 1. General Provisions.
Note: Part 1 is to be developed on the basis of current ISO 4301.
Part 2. Self-Propelled Boom Cranes.
Part 3. Tower Cranes.
Part 4. Portal and Pedestal Cranes.
Part 5. Overhead Travelling and Gantry Cranes.

1. Purpose and Scope of Application

This International Standard establishes classification of self-propelled boom cranes and
appropriate crane gear on the basis of the number of operating cycles performed during
an expected period of a self-propelled boom crane or gear service, and the load
distribution factor, which characterises rated loading conditions.

The Standard shall be applicable to the basic types of self-propelled boom cranes and
gear in accordance with ISO 4306/2.

2. References

ISO 4301. Lifting Units. Classification
146
ISO 4306/2. Lifting Units. Glossary. Part 2. Self-Propelled Boom Cranes.
ISO 4308. Cranes. Wire Cable Selection.

3. Classification.

Classification of self-propelled boom cranes and their gear into groups on the basis of
operation conditions is represented in Table 1.

Table 1
Classification of Self-Propelled Boom Cranes into Groups*

Crane Operating Conditions Groups
Cranes for general load-lifting operations, with a hook, not
applied for continuous operation.
Cranes equipped with a clamshell, grapple or magnet.
Heavy conditions, e.g., container loading/unloading and
general operations in docks.
A1

A3
A4
* Corresponding lines of Q factors (loading conditions) and U (application class)
are given in ISO 4301.

4. Classification of Gear into Groups

Classification of self-propelled boom crane gear into groups is represented in Table 2.

Table 2
Classification of Gear into Groups (Refer to the Note)

Gear Purpose Crane Operating Conditions
A1 A3 A4
Load lifting
Crane rotation
Boom lifting and lowering
Telescoping
Crane locomotion (within the site only):
wheel-mounted crane
caterpillar crane
M3
M2
M2
M1

M1
M1
M4
M3
M3
M2

M1
M2
M6
M4
M3
M1*

M1
M2
* The function of telescoping is not performed with suspended loads.

Notes.
1. Refer to Table 6, ISO 4301
2. Appropriate lines of L factors (loading conditions) and T (application class) stated in
Table 6, ISO 4301 are applicable for M1, M2, M3, M4, and M5.
3. The above Classification shall not refer to values of Z
p
for cables and values of h for
the ratio of drum and block diameters (see ISO 4308).




147
INTERNATIONAL STANDARD ISO 4308/1 (CRANES AND LIFTING UNITS.
WIRE CABLE SELECTION. PART 1. GENERAL PROVISIONS).

Introduction

This International Standard is a part of ISO 4308 International Standard related to the
issue of steel wire cable selection for cranes and lifting equipment.

A complete list of ISO 4308 parts is as follows:

Part 1. General Provisions.
Part 2. Self-Propelled Boom Cranes.
Part 3. Tower Cranes.
Part 4. Portal and Pedestal Cranes.
Part 5. Overhead Travelling and Gantry Cranes.

1. Purpose and Scope of Application

This International Standard establishes two methods of wire cable selection for hoisting
units, types of which are set forth in ISO 4306/1 and listed in Appendix A.

This Standard establishes minimum requirements for wire ropes that shall have an
acceptable margin of stress and operational features accounting for their design,
application and maintenance.

The Standard gives the potential to select a wire cable utilising one of the two methods;
one of them is based on accounting for the value of the cable selection factor (C), and
the other accounts for the value of the utilisation factor (Z
p
). Table 1 shows the values
of the above factors.

Table 1
Values of Z
P
and C Factors (for R
0
=1570 N/mm
2
, and K=0.2948)

Gear Classification Group Z
p
C, mm/N
M1
M2
M3
M4
M5
M6
M7
M8
3.15
3.35
3.35
4.0
4.5
5.6
7.1
9.0
0.085
0.087
0.090
0.095
0.100
0.112
0.125
0.140

Note: Equation (1) gives exact ratio between the C and Z
p
factors. The values of C and
Z
p
are adjusted and correspond to numbers of the Renards series.

148
For a particular crane type (self-propelled boom, overhead travelling, gantry, etc.),
classification groups shall be selected in accordance with ISO 4301/1. Cable selection
shall account for values of C and Z
p
factor s (or their design equivalents) only.

2. References

ISO 2408. Steel Wire Cables of General Purpose. Specifications.
ISO 4301/1. Cranes and Lifting Units. Classification. Part 1. General Provisions.
ISO 4306/1. Lifting Units. Glossary. Part 1. General Terminology.
ISO 4309. Wire Cables for Lifting Units. Methods of Inspection and Discarding.

3. Cable Type

A wire cable to be used shall comply with the requirements of ISO 2408.

A steel cable that is not specified in ISO 2408 may be applied; in such cases the Vendor
shall confirm to the Customer that the cable complies with the minimum requirements
provided by the appropriate section of ISO 4308 Standard.

4. Operating Conditions

Classification of lifting unit gear shall be made accounting for operating conditions
specified in ISO 4301/1.

5. Cable Selection Procedure

5.1. Calculation of the cable selection factor (C).

The value of C is a function of Z
p
, and shall be calculated I accordance with the
following equation:


where C is the cable selection factor (minimum);
K is an empirically determined factor of the minimum breaking load of a
particular design cable (see Table 2 of ISO 2408);
R
0
is the minimum ultimate tensile strength limit of the cable wires, N/mm
2-
;
Z
p
is the minimum actual utilisation factor.

5.2. Values of the utilisation factor (Z
p
). Table 1 shows values of the Z
p
factor that
shall be applied for each gear classification group to comply with the minimum
requirements of the appropriate ISO 4308 Section, and design values of the C

-
1 N/mm
2
= 10
6
N/m
2
= 1 MPa.
149
factor, which correspond to, e.g., a cable with a particular tensile strength (R
0
=
157o N/mm), and empirical factor (K = 0.2948).

For cables with other than stated above ultimate tensile strength limit (R
0
) and
empirical factor (K), values of the C factor may be calculated utilising
equations (1) and (2).

5.3. Calculations of the minimum cable diameter.

The minimum cable diameter (d) in millimetres shall be identified in accordance
with the following equation:


where C is the cable selection factor, and S is the maximum cable tension in
Newtons, accounting for the following:

a) the rated operating load of the unit;
b) the weight of the tacking and/or other lifting device;
c) multiplicity of reeving (the polyspast transmission ratio);
d) the polyspast efficiency;
e) the weight of the hanging portion of the load rope (if the lifted load is
more than 5 metres below the turning gear of the lifting device).

5.4. Estimation of the minimum breaking tension.

The minimum breaking tension shall be identified in accordance with the
following equation:

F
0
= S x Z
p
(3)

Examples of a cable selection are given in Appendix B

6. Drum and Block Diameters

The minimum diameter of drums, blocks, and equalising blocks measured along the
centreline of a wound cable shall be calculated on the basis of the cable minimum
diameter, which is provided by Section 5.3, utilising appropriate values of h
1
, h
2
, and h
3

factors that depend on the gear classification group (Table 2):

D
1
> h
1
d (4), or D
2
> h
2
d (5), or D
3
> h
3
d (6)

where D
1
is the diameter of the drum on the centre line of the wound cable;
D
2
is the diameter of the block on the centre line of the wound cable;
D
3
is the diameter of the equalising block on the centre line of the wound cable;
D is the minimum diameter of the cable (Section 5.3);
150
h
1
is the drum diameter selection factor (the ratio of the drum diameter along the centre
line of the wound cable to the design cable diameter);
h
2
is the block diameter selection factor (the ratio of the block diameter along the centre
line of the wound cable to the design cable diameter);
h
3
is the equalising block diameter selection factor (the ratio of the equalising block
diameter along the centre line of the wound cable to the design cable diameter).

Table 2
Factors of h
1
, h
2
, and h
3
Selection

Gear Classification
Group
Diameter Selection Factors
Drum (h
1
) Block (h
2
) Equalising Block (h
3
)
M1 11.2 12.5 11.2
M2 12.5 14.0 12.5
M3 14.0 16.0 12.5
M4 16.0 18.0 14.0
M5 18.0 20.0 14.0
M6 20.0 22.4 16.0
M7 22.4 25.0 16.0
M8 25.0 28.0 18.0

For particular cases of hoisting equipment applications, e.g., self-propelled boom
cranes, it is recommended that a single line of h factor values should be selected
irrespective of the gear classification group.

7. Stationary Cables

Stationary cables are fastened at both ends, and are not used for winding on drums.
Such cables are selected in accordance with the requirements of Section 5.4, utilising
adjusted values of Z
p
factor specified in Table 3. The maximum tension of the cable (S)
shall be specified by the gear producer, and it shall account for both static forces, and
wind and dynamic loads.

Table 3
Z
p
Factor Value for Stationary Cables

Gear Classification Group Z
p
Factor Value
M1
M2
M3
M4
M5
M6
M7
M8
2.5
2.5
3.0
3.5
4.0
4.5
5.0
5.0

8. Hazardous Conditions

In case of operation in hazardous conditions (operations with liquid metal):
151

a) No classification group below M5 shall be applied;
b) When the cable is selected, the value for 25% Z
p
shall be considered up to
the maximum 9.0, or the value of C shall be taken for a higher classification
group.


9. Steel Wire Cable Inspection, Maintenance and Rejection

Wire cable inspection, maintenance and rejection standards in accordance with ISO
4309 are recommended for application.








INTERNATIONAL STANDARD ISO 4308/2 (CRANES AND LIFTING UNITS.
WIRE CABLE SELECTION. PART 2. SELF-PROPELLED BOOM CRANES.
UTILISATION FACTOR).

Introduction

This International Standard is a part of ISO 4308 International Standard related to the
issue of steel wire cable selection for cranes and lifting equipment.

A complete list of ISO 4308 parts is as follows:

Part 1. General Provisions.
Part 2. Self-Propelled Boom Cranes. Utilisation Factor.
Part 3. Tower Cranes.
Part 4. Portal and Pedestal Cranes.
Part 5. Overhead Travelling and Gantry Cranes.

1. Purpose and Scope of Application

This International Standard establishes minimum values of taken from practice
utilisation factor (Z
p
), which is specified in ISO 4308/1 for usual and non-spinning
cables applied at self-propelled boom cranes.

This Standard shall be applicable for all self-propelled cranes (see ISO 4306/2).

2. References

ISO 4301/1. Cranes and Lifting Units. Classification. Part 2. Self-Propelled Boom
Cranes.
152
ISO 4308/1. Cranes and Lifting Units. Wire Cable Selection. Part 1. General Provisions.
ISO 4306/2. Lifting Units. Glossary. Part 2. Self-Propelled Boom Cranes.

3. Utilisation Factor

3.1. General-purpose cables.

Minimum values of the utilisation factor (Z
p
) for general-purpose cables are
shown in Table 1 in accordance with the classification of cranes and lifting gear
specified in ISO 4301/2.








Table 1
General-Purpose Cables

Crane
Operating
Conditions
Crane
Classification
Moving Cables Stationary
Cables
Load Lifting Boom Lifting/Lowering,
Telescoping
In Ope
ration
During
Insta
llation Gear
Clas
sifica
tion
Z
p
Gear
Clas
sifica
tion
Z
p
in
Ope
ration
Z
p

during
Insta
llation
General A1 M3 3.55 M2 3.55 3.05 3 2.73
Continuous A3 M4 4 M3 3.55 3.05 3 2.73
Heavy A4 M5 4.5 M3 3.55 3.05 3 2.73

Note. It is assumed that cable safety during operation is based on selection of cable
inspection and rejection criteria.

3.2. A non-spinning cable is a cable that has eight or more strands in the external
layer laid along a spiral in the direction opposite to the direction of the
underlying layer.

Minimum values of the utilisation factor (Z
p
) for non-spinning cables are shown
in Table 2 in accordance with the classification specified in ISO 4301/2.

Table 1
General-Purpose Cables

Crane Operating Conditions Crane Classification Moving Cables for Load
Lifting, Z
p

General A1 4.5
153
Continuous A3 5.6
Heavy A4 5.6

Note. The Table shows conventional types of non-spinning cables. As new types of
non-spinning cables appear resulting from future researches, other values of utilisation
factors will be obtained.



INTERNATIONAL STANDARD ISO 4310 (CRANES, REGULATIONS AND
METHODS OF TESTING)

1. Purpose and Scope of Application

This International Standard establishes contents and methods of testing that are required
to check whether cranes comply with their specified characteristics, as well as to check
their capacity to lift rated loads. If stability determines the value of a rated load, then a
testing method and a testing load shall be established, which will allow the stability
margin to be easily tested.

This Standard shall be applicable for the following types of cranes:

a) overhead travelling;
b) gantry;
c) portal;
d) self-propelled boom and excavator cranes;
e) tower;
f) railway;
g) cable cranes;
h) other types of cranes that may be included into the list additionally.


2. Methods and Scope of Testing

2.1. Three types of testing shall be applied to achieve objectives specified in this
International Standard:

a) Testing for a crane compliance with the data specified in its certificate
(Section 3.1);
b) External inspection of the crane (Section 3.2); and
c) Testing to check if the crane is adequate for operations (Sections 3.4, 3.5,
and 3.6);

2.2. Each crane shall pass the tests, methods of which are stated above. In case of
large-scale production, the number of cranes to be tested (Section 2.1) shall be
established on a mutual agreement between the Seller and the Buyer
-


-
Legal Parties that have executed a contract: the Seller is the Party to supply the crane, and the Buyer is
the Party receiving the crane.
154

2.3 Cranes supplied from producing plants ready for operation shall have been tested
at the plant prior to their shipment. Cranes that are installed or finally assembled
at their operation locations shall be tested at such locations unless otherwise has
been provided by agreements between the Seller and the Buyer.

3. Content and Methods of Testing

3.1. Testing for a crane compliance with the data specified in its certificate.

Testing for a crane compliance with the certificate data shall be carried out in
accordance with their load characteristics to check the following parameters:

- Weight of the crane (if practical);
- Distance from the rotation axis to the stability edge;
- Height of the load lifting;
- Speed of the load lifting;
- Speed of landing;
- Speed of the crane locomotion;
- Speed of the trolley travelling;
- Rotation speed;
- Time for radius modification;
- Time for telescoping;
- Time for one cycle (if required);
- Operation of limiting devices;
- Operating characteristics of the power drive parameters, e.g., current
intensity in electric engines under conditions of testing loads application.

3.2. Visual inspection.

A visual inspection shall include a check for the crane compliance with the
certificate data and/or a check for conditions of all the critical elements, such as:

- gear, electric equipment, safety devices, brakes, control devices, lighting
and signalling systems;

- steel structures and their joints, ladders passage ways, cabins and
platforms;

- railing;

- the hook or other load gripping device and their suspension parts;

- cables and their fastening locations;

- blocks, axels and details of their fastening, as well as components of the
boom suspension system.

155
No disassembling of any assembled parts shall be included into the visual
inspection. Visual inspection includes a check of leads for their normal opening
in the course of standard operation, e.g., lids of limit switches.

The objective of the visual inspection is to examine and check compliance with
all the specified requirements for cranes.

3.3. Testing during operations with loads.

Tests for the crane adequacy for operation include the following:

- Static testing;
- Dynamic testing;
- Testing for stability (if required).

3.3.1 Static testing.

3.3.1.1. Static tests shall be carried out with the purpose to check the design
adequacy of the crane and its assembly units.

Tests shall be considered successful if during their performance no
cracks, residual deformation, paint peeling or damage that may influence
the crane operability and safety are identified, and no joint retention loss
or damage occurs.

3.3.1.2. Static tests shall be also carried out for each load-lifting unit, if it is
provided by the crane certificate, at simultaneous operation of load lifting
units in positions and design options that shall be selected so that
tensions in cables, as well as mending momentums and/or axial forces in
the basic crane components were the highest. A testing load shall be
gradually increased, lifted to the height of 100-200 mm from the ground
surface and held in that position during the time, which is required to
carry out the test, but at least 10 minutes.

3.3.1.3. The testing load (P) for all cranes shall be at least 1.25, unless a higher
value is required in accordance with National Standards or cable
positions.

Components of the P value are as follows:

a) Load on the lifting gear, including the weight of the effective
load, as well as the weight of the hook unit and rigging devices
(for self-propelled cranes);
b) The rated load-lifting capacity for the equipment established by
the producer. The rated load-lifting capacity shall not include any
lifting devices being a permanent part of the crane in operating
position (for other cranes).

156
3.3.2. Dynamic testing.

3.3.2.1. Dynamic tests shall be carried out with the purpose to inspect operation
of the crane gear and brakes.

The crane shall be considered as having successfully passed the test if it
is established that the above mentioned components perform their
functions, and if further visual inspection reveals no damage to the gear
or structural elements, and no joint retention loss occurs.

The crane shall be controlled during the tests in accordance with
requirements specified in the crane documentation. Attention shall be
paid in the course of the described tests to prevent accelerations and
speeds from exceeding the values specified for the crane operation.

3.3.2.2. Dynamic tests shall be carried out for each gear or, if it is provided by
the crane certificate, at simultaneous operation of the gear in positions
and design options that correspond to the maximum loading of the gear.

Testing shall include a re-start and a stop at each movement within the
whole range of such movement, and shall continue for at least 1 hour,
while complying with that particular operation cycle.

Testing shall include gear start-up from the intermediate position, with
suspended test load. In such case no reverse movement with the test load
shall occur.

3.3.2.3. The testing load (P) shall be at least 1.1.

3.3.3. Testing for stability.

3.3.3.1. Tests for stability under load shall be carried out with the purpose to
check the crane stability. The crane shall be considered as having
successfully passed the test if no tilt of the crane occurs, when a static
load is applied to the hook.

3.3.3.2. In case of self-propelled boom cranes, the testing load for stability tests
shall be established utilising the following equation:

1.25P +0.1F
i
(1)

where F
i
(F
1
or F
2
) is the weight of the crane boom (G), or the weight of
the gooseneck (g) adjusted to the head of the boom or gooseneck.

If the weight of the boom (G) is small, and the gooseneck is designed for
relatively small loads, testing for stability shall not be carried out in
accordance with equation (1), with the test load lifted on the gooseneck
head.
157

In such case requirements to stability shall be checked by way of
calculations.

Note: The value of 1.25P may vary in cases, when higher values are
required.

A drawing below shows a side view of a typical crane, with the described
parameters identified:

L and l are lengths of the boom and gooseneck (for telescopic booms it is
the length of the boom under discussion); X, Y and x, y are coordinates
of the boom and gooseneck gravity centres; j and k are radii of the boom
and gooseneck; m and n are gravity centre radii for the boom and
gooseneck;

Fi shall be calculated in accordance with the following equation:




Designation of Parameters to Estimate Loads for Stability Testing



158
For cranes equipped with a boom only, k=n=g=0, and


For cranes equipped with both a boom and a gooseneck, if the load is
lifted on the boom head, k=0, and
if the load is lifted on the gooseneck head,
Note: Values of P, G, g and the centre of gravity coordinates X, Y and x,
y shall be established in the crane documents for each value of L and l.

3.3.3.3. No special tests for stability shall be carried out for all cranes, with the
exception of self-propelled ones.

3.3.3.4. Tests shall be carried out at such positions and design options within a
specified operating area, at which the crane stability is minimum.

If different loads are established for different positions or operating
areas, stability testing shall be carried out to select such conditions.

3.4. A Testing Statement.

On completion of testing in accordance with Section 2.1, a Statement shall be
drawn out, which shall include conclusions and testing results. The Statement
shall state the serial No. of the tested crane, the date and testing location, and the
name of Testing Supervisor. Exact loads, positions, design options, methods and
testing results shall be also specified for each separate case.

With reference to cranes that comply with the requirements of Clause 2.1 b only,
the Statement may be drawn in a shortened form. Such Statement shall contain
the crane No., the date and location of testing, the Supervisors name and testing
results for each parameter.



159
4. Testing Conditions

4.1. To carry out testing, the crane shall be equipped with operating equipment for
the rated load in accordance with the crane documentation.

4.2. Cranes travelling along a rail track shall be tested on the track, which shall be
constructed and laid in accordance with specifications stated in the crane
certificate.

4.3. Air-tyred or caterpillar cranes shall be tested on a horizontal site with hard
cover, which will have a deviation from the horizontal line of 0.5%.

4.4. Wind speed during the testing period shall not exceed 8.3 m/sec (30 km/hr). The
crane position shall correspond to the mostly favourable conditions (wind speed)
unless it is provided by the Contract.

4.5. When air-tyred cranes are tested without outrigger application, pressure in the
tyres shall not differ from the pressure set by the producer for more than 3%, and
all the wheels shall be oriented along the crane centre line.

Note: Conditions of the overhead travelling crane bridge support shall be agreed
with the requirements of the producer.

4.6. If a crane is tested with outriggers, it shall be located with the deviation from the
horizontal line not exceeding 0.5%.

4.6.1. If an air-tyred crane is tested with outriggers, it shall be located so that its wheels
are not in contact with the ground, and are relieved from the crane weight, unless
there are other instructions of the Seller.

4.6.2. If a caterpillar crane is tested with outriggers, it shall be located so that reliable
support of outriggers on the bearing surface is ensured.

4.6.3. Cranes of other types shall be located as specified in National Regulations or
contracts.

4.7. The fuel tank shall be filled for one or two thirds of its capacity. Cooling liquid,
oil and hydraulic mixtures shall be filled up to the level specified by the Seller.



INTERNATIONAL STANDARD ISO 88087 (SELF-PROPELLED CRANES.
SIZES OF DRUMS AND BLOCKS

1. Purpose and Scope of Application

This International Standard establishes the minimum ratio of the drum and block
diameter to the rated diameter of the cable used for lifting and lowering.
160

The rated diameter of a cable is an initial value, which utilisation provides for
universality of application, as it is not limited by the crane gear, while self-propelled
cranes are designed for various purposes, such as load lifting with a hook, clamshell or
electric magnet.

This International Standard shall be applicable to the main types of self-propelled cranes
in accordance with ISO 4306/2.

2. References

ISO 4301/1. Cranes and Lifting Units. Classification.
ISO 4306/2. Lifting Units. Glossary. Part 2. Self-Propelled Boom Cranes.
ISO 4308. Cranes and Lifting Units. Wire Cable Selection.
ISO 4309. Wire Cables for Lifting Units. Standards and Regulations for Inspection and
Rejection.

3. Sizes of Drums and Blocks

The minimum ratio of the drum and block diameter to the rated diameter of a cable is
shown in the table below.

Taking into account that self-propelled cranes are often designed for versatile
application, only one group of ratios is given.

Thus, the values represented have no dependence on the classification of crane gear.

The Minimum Ratio of the Diameter* to the Rated Diameter of a Cable

Component Minimum Ratio
The Drum of a Load-Lifting Winch
A Load Block (in Movable Tacking)
An Equalising Block:
Lifting
Lowering
A Boom-Lifting Drum
A Boom Lifting Block
16.0:1
18.0:1

14.0:1
12.5:1
14.0:1
16.0:1

* The diameter shall be measured on the centre line of the wound cable.

161

APPENDIX 12
(to Section 7.3.9)

THRESHOLD STANDARDS OF LOAD-LIFTING EQUIPMENT COMPONENT
REJECTION

Component Description Defects that Serve as Criteria for the Component
Rejection
Running Wheels of Cranes
and Trolleys






Blocks


Drums



Hooks



Brake Sheaves




Brake Lining
1. Cracks of any sizes.
2. Wear-out of the flange surface for up to 50% of the
original thickness.
3. Wear-out of the roll surface that reduces the original
wheel diameter by 2%.
4. A difference in the diameters of wheels that are related
cinematically, by above 0.5%.

1. Wear-out of the block groove for above 40% of the
original groove radius.

1. Cracks of any sizes.
2. Wear-out of the drum groove along the cross section
for above 2 mm.

1. Cracks and tears on the surface.
2. Wear-out of the hook opening for above 10% of the
original height of the hook vertical cross section.

1. Cracks and breaks that penetrate operating and
mounting surfaces.
2. Wear-out of the rim working surface for above 25% of
the original thickness.

1. Cracks and breaks that penetrate to openings under
rivets.
2. Wear-out of the brake lining along its thickness up to
appearance of rivet heads, or for above 50% of the
original thickness.


* For gear with the central drive.

162

APPENDIX 13
(to Section 7.3.28)

STANDARDS FOR REJECTION OF DETACHABLE LOAD-GRIPPING
DEVICES

Rejection of operating removable load-gripping devices shall be carried out in
accordance with regulatory documentation, which identifies the rejection procedure,
methods and rejection criteria.

If the owner has no regulatory documents available, rope or chain slings shall be
rejected in accordance with recommendations specified in this Appendix.

A rope sling is liable for rejection if the number of visible breaks in the rope outer wires
exceeds the values shown in the Table below.

Double Lay Rope
Slings
Number of Visible Wire Breaks within A Section of a Rope
Sling, with the Length of:
3d
4
6d
6
30d
16

Note: d is the rope diameter in millimetres.


A chain sling is liable for rejection if a chain link is extended for above 3% of its
original size (Figure 1), and if the chain link cross section diameter is reduced by above
10% due to its wear out (Figure 2).




Figure 1. Elongation of the Chain Link:
L
0
is the original length of the link, in
mm.;
L
1
is the increased length of the link, in
mm.
Figure 2. Reduction of the Chain Link
Cross Section Diameter:
d
0
is the original diameter, mm;
d
1
, d
2
are actual link cross section
diameters measured in mutually
perpendicular orientations, mm.

163

APPENDIX 14
(to Section 7.4.2)

Knowledge Assessment Certificate Form for engineering and technical personnel
responsible for supervision of load-lifting equipment safe operation, engineering and
technical personnel responsible for load-lifting equipment maintenance in good
serviceable conditions, and persons responsible for safe performance of work by cranes.

______________________________________________________________________
(Description of the Company, Organisation, Facility)


Issued to: ______________________________________________________________
(Full Name)
Position: _______________________________________________________________
Place of Work: __________________________________________________________
To certify that he/she has passes Knowledge of ________________________________
______________________________________________________________________
____________________________________________________________ Assessment.
(State the Safety Regulations)
Basis: Minutes No. ____________ of __________________________________ (Date)
Chairman of the Examination Board ________________________________________
Board Members ____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Stamp

Information about Recurrent Examinations

Position: _______________________________________________________________
Place of Work: __________________________________________________________
To certify that he/she has passes Knowledge of ________________________________
______________________________________________________________________
____________________________________________________________ Assessment.
(State the Safety Regulations)
Basis: Minutes No. ____________ of __________________________________ (Date)
Chairman of the Examination Board ________________________________________
Board Members ____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Stamp

Position: _______________________________________________________________
Place of Work: __________________________________________________________
164
To certify that he/she has passes Knowledge of ________________________________
______________________________________________________________________
____________________________________________________________ Assessment.
(State the Safety Regulations)
Basis: Minutes No. ____________ of __________________________________ (Date)
Chairman of the Examination Board ________________________________________
Board Members ____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Stamp

Position: _______________________________________________________________
Place of Work: __________________________________________________________
To certify that he/she has passes Knowledge of ________________________________
______________________________________________________________________
____________________________________________________________ Assessment.
(State the Safety Regulations)
Basis: Minutes No. ____________ of __________________________________ (Date)
Chairman of the Examination Board ________________________________________
Board Members ____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Stamp

Position: _______________________________________________________________
Place of Work: __________________________________________________________
To certify that he/she has passes Knowledge of ________________________________
______________________________________________________________________
____________________________________________________________ Assessment.
(State the Safety Regulations)
Basis: Minutes No. ____________ of __________________________________ (Date)
Chairman of the Examination Board ________________________________________
Board Members ____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Stamp

Note: The Certificate shall be issued with a hard cover on sheets of the 110x80 mm
format.

165

APPENDIX 15
(to Section 7.4.4)

THRESHOLD STANDARDS TO REJECT BASIC COMPONENTS OF RAIL
TRACKS

Track Description Rail Defects
A rail track of seating load-lifting equipment









A rail track of suspended load-lifting
equipment
1. Cracks of any sizes.
2. Indents in a railhead or rail base.
3. Vertical, horizontal or adjusted (vertical
plus half of horizontal) wear out of the
railhead for above 15% of the value of the
appropriate non-worn out profile size.
4. Rail track deviations horizontally and
vertically above the values specified in
Appendix 7.

1. Cracks and dents of any sizes.
2. Reduction of the rail belt width due to wear
out:
AB > 0.05B
3. Reduction of the rail seat thickness due to
wear out:
Ao > 0.2o,
with a simultaneous seat bend:
f
1
s 0.15o
4. A bend of the rail seat (f
1
> 0.25o), with its
simultaneous wear out:
Ao s 0.1o (ref. to the Drawing)



Locations of the rail track profile basic
defects in case of suspended load-lifting
equipment:
B is the initial belt width;
t is the wall thickness;
f
1
is the seat bend;
o is the original thickness of the seat at the
distance of (B-t)/4 from the edge;
Ao is the reduction of the seat thickness
due to wear out.


166

APPENDIX 16
(to Section 7.4.25)

Knowledge Assessment Certificate Form for operating personnel (crane operators, their
assistants, mechanics, electricians, safety device adjusters, and slingers)


Photograph

__________________________________
(Personal Signature)
Issued on _____________________ (Date)

Stamp of the Training Institution


CERTIFICATE No. ____________

Page 2
Issued to: ______________________________________________________________
(Full Name)
to certify that he/she completed _____________________________________________
(Description, No. and location of the
______________________________________________________________________
(Training Institution)
______________________________________________________________________
on __________________________ (Date)

specialising in __________________________________________________________
______________________________________________________________________

Page 3
By the Examination Board Resolution
______________________________________________________________________
(Full Name)
is qualified as __________________________________________________________
______________________________________________________________________

and is permitted to operate _________________________________________________
______________________________________________________________________
(the Crane Type)

Page 4

The basis - the Examination Board Minutes
No. ___________________ of _________________________________ (Date)
Gosgortechnadzor Inspector ______________________________________________
(Inspectors stamp and signature)
Director of the Training Institution _________________________________________
(Signature)
Note: The Certificate shall be issued with a hard cover on sheets of the 110x80 mm
format.
167
Page 5
(Insert)
TO CERTIFICATE No. ___________
Recurrent Knowledge Assessment was carried out

Minutes No. __________
of _____________________ (Date)
Examination Board Chairman
___________________________
(Signature)

Page 6

The reason of a withdrawal
COUPON No. 1
__________________________________
__________________________________
__________________________________
__________________________________
__________________________________
__________________________________
(Position of the person
__________________________________
who withdraws the Coupon)

___________________________ (Date)
_________________________________
(Signature)
To be recorded and kept by the Safety and
Labour Protection Service
COUPON No. 1
To Certificate No. __________________
The Holder: _______________________
__________________________________
who has infringed safety standards and
regulations (operational guidelines) at ___
__________________________________
__________________________________
__________________________________
__________________________________
__________________________________


Page 7

The Coupon shall be withdrawn in case
the Certificate Holder infringes safety
standards and regulations.
__________________________________
__________________________________
__________________________________
__________________________________
(Position of the person
__________________________________
who withdraws the Coupon)

___________________________ (Date)
_________________________________
(Signature)







168
Page 8

The reason of a withdrawal
COUPON No. 2
__________________________________
__________________________________
__________________________________
__________________________________
__________________________________
__________________________________
(Position of the person
__________________________________
who withdraws the Coupon)

___________________________ (Date)
_________________________________
(Signature)
To be recorded and kept by the Safety and
Labour Protection Service
COUPON No. 2
To Certificate No. __________________
The Holder: _______________________
__________________________________
who has infringed safety standards and
regulations (operational guidelines) at ___
__________________________________
__________________________________
__________________________________
__________________________________
__________________________________


Page 9

The Coupon shall be withdrawn in case
the Certificate Holder infringes safety
standards and regulations. After the third
infringement the Holder shall be deprived
of the Certificate and suspended from
equipment operation. He/she has the right
to pass his/her Safety Knowledge
Assessment within 3 months.
__________________________________
__________________________________
__________________________________
__________________________________
(Position of the person
__________________________________
who withdraws the Coupon)

___________________________ (Date)
_________________________________
(Signature)

169

APPENDIX 17
(to Section 7.4.31)

Shift Logbook of a Crane Operator Form

Date _______________________________ Shift ______________________________
Crane Operator __________________________________________________________

Crane Inspection Results
Ref. # Unit, Geer and Part Description Inspection Findings Last Name and
Initials of the
Person, who
Eliminates the
Deficiency
1

1







3






4

5





6

7

8

9

10

11
Steel structure

Brakes of:
The load lifting winch
The boom lifting winch
Travelling gear
Trolley
Rotation
Crane locomotion gear

Safety devices:
Load lifting limiter
Limit switches
Interlink contacts
Indicators
Signalling devices

Power equipment

Ropes
Load lifting
Boom lifting
Boom guys
Trolley

Hook suspension

Lighting, heating

Crane track

Counterweight, ballast

Grounding

Other deficiencies revealed in the
course of operation

170
Shift received by: ________________________________________________________
(Last name, initials and signature of the crane operator)
Shift handed over by: _____________________________________________________
(State the crane condition)
______________________________________________________________________
(Last name, initials and signature of the crane operator)

Results of the crane inspection by:
Mechanic ______________________________________________________________
Electrician _____________________________________________________________
Engineer or Technician responsible for maintenance of load lifting equipment in good
serviceable conditions ____________________________________________________

171

APPENDIX 18
(to Section 7.5.16)

RECOMMENDED SIGNALS WHEN MOVING LOADS BY CRANES
-


Operation Picture Signal
Lift the load or hook








Lower the load or hook









Relocate the crane (bridge)







Relocate the trolley








Swing the boom





An abrupt movement of the
arm upwards at the waist
level, the palm is pointing up,
the arm is bent in the elbow.





An abrupt movement of the
arm downwards in front of the
chest, the palm is pointing
down, the arm is bent in the
elbow.





A movement with a stretched
arm, the palm points to the
direction of the required
movement.




A movement with an arm bent
in the elbow, the palm points
to the direction of the required
trolley movement.




A movement with an arm bent
in the elbow, the palm points
to the direction of the required
boom movement.




-
The recommended closes of a slinger: the vest and hardhat yellow, the shirt light blue, and the armband
red.
172
Lift the boom









Lower the boom








Stop (stop lifting or
locomotion).







Caution (to be applied prior to
one of the above listed signals
if there is a necessity of a
small relocation)






A movement upwards with a
stretched arm, which has been
previously lowered to the
vertical position, the palm is
open.





A movement downwards with
a stretched arm, which has
been previously lifted to the
vertical position, the palm is
open.





An abrupt movement of the
arm right and left, the palm
points down.





Hands are positioned with
palms facing each other an a
small distance apart, arms ate
lifted.







173

APPENDIX 19
(to Section 7.5.19)

FORM OF A WORK PERMIT
for a Crane Operation Close to an Overhead Power Line

______________________________________
(Description of the Company
______________________________________
and Ministry)

Work Permit No. ___________

The Work Permit shall be issued for operations to be carried out at the distance below
30 m from the outermost conductor of an overhead power line, with the voltage above
42V.

1. To the Crane Operator _________________________________________________
(Full Name)
of ____________________________________________________________________
(Crane Type, Registration No.)

2. Assigned for work _____________________________________________________
(The Company Allocating the Crane)

3. At the site of __________________________________________________________
(The Company the Crane is Allocated to,
______________________________________________________________________
Work Location, Construction Site, Warehouse, Workshop, etc.)

4. Voltage of the overhead line _____________________________________________

5. Work conditions _______________________________________________________
(Any requirement to cut off voltage
______________________________________________________________________
from the overhead power line, the minimum horizontal
______________________________________________________________________
distance permitted for the crane operation
______________________________________________________________________
from the outermost conductor to the closest crane parts,
______________________________________________________________________
load movement methods, and other safety precautions)

6. Crane relocation conditions ______________________________________________
(Boom positions and other
______________________________________________________________________
safety precautions)

7. Work commencement at ______ hours ______ minutes on _______________ (Date)
8. Work completion at ______ hours ______ minutes on ___________________ (Date)
174
9. The Person Responsible for Safe Operations ________________________________
______________________________________________________________________
(Position, Full Name, the Date and No.
______________________________________________________________________
of the Assignment Memorandum)

10. Slinger _____________________________________________________________
(Full Name)
______________________________________________________________________
(Certificate No., and the Date of the Last Safety Knowledge Assessment)

11. Permit for the crane to operate in the power line protection zone ________________
(The Company
______________________________________________________________________
that Issues the Permit, Permit No. and Date)

12. The Work Permit is issued by the Chief Engineer (Electrician) _________________
______________________________________________________________________
(Company, Signature)

13. Required safety actions specified by Section 5 have been taken ________________
______________________________________________________________________
The Person Responsible for Safe Operations __________________________________
______________________________________________________________________
_____________________________ _____________________________ (Date)
(Signature)
14. The instructions have been received by the Crane Operator ____________________
(Signature)

_______________________ (Date)

Notes:
1. The Work Permit shall be issued in two copies: the first one shall be given to the
Crane Operator, and the second shall be kept by the company performing the
work.
2. Section 11 hereof shall be filled in if the crane is to operate within the power line
protection zone.
3. Branch lines shall also refer to overhead power lines.
4. Work close to overhead power lines shall be carried out in the presence and
under supervision of the Person Responsible for Load Handling by Cranes.

175

List of Regulatory Documents Applicable to Facilities Supervised by the Regional
State Mining and Technical Supervision Inspectorates (GGTN) of the Republic of
Kazakhstan State Emergency Committee. (The Documents are Available at
Craneenergo Research and Development Association)

1. Labour Protection and Safety Manual for Gosgortechnadzor Inspectors.
2. Standard Safety Regulations for Blasting.
3. Methodological Directions for Servicing and Maintenance of Steel Structures
and Electric Equipment of Cranes (Suspended, Overhead Travelling, Gantry,
etc.). RD-01-93
4. Regulations for Welder Certification.
5. Welding, Thermal Treatment and Testing of Boiler Piping Systems and
Pipelines. RD-04-07-94.
6. Safety Regulations for Gas Systems.
7. Regulations for Lift Design and Safe Operation.
8. Provisions for the Procedure of the Vessel Service Life Extension in the
Republic of Kazakhstan. RD-03-94.
9. Standard Safety Regulations for Mineral Crushing, Sorting, and Concentration.
10. Standard Safety Regulations for Mineral Resources Development by Open Pit
Mining.
11. Regulations for Crane Design and Safe Operation.
12. Regulations for Pressure Vessel Design and Safe Operation.
13. Regulations for Steam and Water Boiler Design and Safe Operation.
14. Regulations for Steam and Hot Water Pipeline Design and Safe Operation.
15. Methods of Vessels and Equipment with Overdue Service Life Conditions
Diagnostics within the Republic of Kazakhstan. RD-04-94.
16. Methodological Directions for Inspection and Certification of Kotlonadzor
(Boiler Supervision) Supervised Facilities.
17. Typical Provisions for Engineering and Technical Staff Responsible for
Supervision of Load-Lifting Equipment, Removable Gripping Devices and
Containers Safe Operation.
18. Typical Provisions for Engineering and Technical Staff Responsible for
Maintenance of Load-Lifting Equipment in Good Serviceable Conditions.
19. Typical Provisions for a Person Responsible for Safe Performance of Work by
Cranes.
20. Typical Guidelines on Safe Work Methods for Tower Crane Operators.
21. Typical Guidelines on Safe Work Methods for Self-Propelled Boom Crane
Operators.
22. Typical Guidelines on Safe Work Methods for Overhead Travelling Crane
Operators.
23. Typical Guidelines for Slingers Servicing Cranes.
24. List of Regulatory Documents for Cranes and Load-Lifting Structures (GOST,
OST, TU, RD) current in the Republic of Kazakhstan (as of 01/02/96).
25. Methodological Directions for Inspection and Certification of Vessels, Tanks,
Drums and Cylinders Operating Under Pressure.
26. Typical Provisions for Engineering and Technical Staff Responsible for
Supervision of Pressure Vessel Conditions and Operation.
176
27. Typical Provisions for Engineering and Technical Staff Responsible for Pressure
Vessel Good Serviceable Conditions and Safe Operation.
28. Provisions for the Procedure of Expert Analyses and Inspections of Companies
(Organizations), Irrespective of their Ownership and Industrial Reference, to
Issue a Resolution of the Republic of Kazakhstan Gosgortechnadzor (GGTN) to
Permit such Companies to Carry out Work at Boiler and Gas Facilities, Load-
Lifting Equipment and in the Bread Producing Industry.
29. Provisions for the Procedure of Knowledge of Safety Regulations, Standards and
Guidelines Assessment and Examination of Managerial Staff and Experts of
Companies, Organisations and Facilities Supervised by the Republic of
Kazakhstan Gosgortechnadzor.
30. Regulations for Stationary Compressor Unit Design and Safe Operation.
31. Regulations for Operation of Stationary, Container and Mobile Filling Stations.
32. Regulations for Electrode Boilers and Power Boiler Houses Design and Safe
Operation.
33. Regulations for Steam Boilers, with the Steam Pressure of 0.07 MPa (0.7 kg-
force/cm
2
), Water Heating Boilers and Water Heaters, with the Heating
Temperature not Exceeding 388 C (115C), Design and Safe Operation.
34. Regulations for Hoist (Rig) Design and Safe Operation.
35. Regulations for Municipal Heating Boiler House Operation.
36. Amendment No. 1 to RD-04-07-94, Methodological Directions for Welding,
Thermal Treatment and Testing of Boiler Piping Systems and Pipelines in Cases
of Power Plant Equipment Installation and Maintenance.
37. Provisions for the System of Steam and Water Heating Boiler Diagnostics in
Industrial Power Generation.
38. Typical Provisions for Engineering and Technical Staff Responsible for Steam
and Water Heating Boilers Good Serviceable Conditions and Safe Operation.
39. Load-Lifting Slings, General Purpose. Requirements for Design and Safe
Operation.
40. Regulations of Non-Destructive Testing Expert Certification.
41. Specification, TU 640 RK 02495141-002-96, Cranes. Requirements for Welded
Steel Structure Fabrication and Maintenance.
42. Methodological Directions for Inspection and Certification of Stationary
Compressor Units Operating under Pressure of Compressed Air or Inert Gas.
43. Methodological Directions for Inspection of Boiler Houses and Certification of
Steam and Water Heating Boilers.
44. Typical Guidelines for Boiler House Personnel.
45. Guidelines for Supervision of Facilities Supervised by Kotlonadzor (Boiler
Supervision) Fabrication, Installation and Maintenance.
46. Provisions for Preliminary Supervision of Gas Supply System Construction and
Reconstruction.
47. Guidelines for Supervision of Lifting Structure Fabrication, Installation and
Maintenance.
48. Guidelines for Supervision of Gas Supply System Facilities Fabrication,
Construction, Installation, Commissioning and Maintenance.
49. Operation Regulations and Safety Requirements for Gas Supply Systems.
50. Typical Provisions for Engineering and Technical Staff Responsible for Steam
and Hot Water Pipelines Good Serviceable Conditions and Safe Operation.
177
51. Methodological Directions for Inspection of Cranes with Expired Service Life
(Tower Cranes) with the Purpose to Identify the Potential of their Further Safe
Operation.
52. Methodological Directions for Inspection of Cranes with Expired Service Life
(Self-Propelled Boom Cranes) with the Purpose to Identify the Potential of their
Further Safe Operation.
53. Methodological Directions for Inspection of Cranes with Expired Service Life
(Overhead Travelling Type Cranes, Cable Cranes, Railway Cranes, Column
Cranes, Cantilever Cranes, Portal Cranes, and Transhipment Cranes) with the
Purpose to Identify the Potential of their Further Safe Operation.
54. Regulations of Overhead Travelling Crane Tracks Design and Safe Operation.
55. Rail Tracks of Gantry Cranes. General Specification and Standards of Design
and Safe Operation.
56. Typical Guidelines for Persons Responsible for Maintenance of Hoists (Rigs) in
Good Serviceable Conditions.
57. Methodological Directions for Inspection of Hoists (Rigs) with Expired Service
Life.
58. Guidelines for Inspection and Certification of Buried Tanks for Liquefied Gas
Storage.

178
CRANEENERGO RESEARCH AND DEVELOPMENT ASSOCIATION

To everyone, who wishes to cooperate with Cranenergo R&D Association and receive
the latest regulatory documents related to operation, installation, maintenance and
diagnostics of Gosgortechnadzor supervised equipment and facilities.

Specialisation and basic types of activities:

- Scientific research and introduction of its results, laboratory analyses, designing,
fabrication, upgrading, overhaul, reconstruction, servicing, inspection,
maintenance and testing of cranes and lifting structures, process boilers, and
vessels of various types and designs;
- Expert analyses of design and cost estimate documentation, expert conclusions
on designed work related to designing, maintenance, reconstruction, overhaul
and fabrication of crane structures, boilers and other supervised by
Gosgortechnadzor equipment and facilities;
- Development of standards, regulations, guidelines, methodological directions
and other regulatory documents, information services;
- Personnel training and professional skills improvement training;
- Certification of lifting equipment and structures, steam and water heating
boilers, pressure vessels and pipelines for steam and hot water.

We invite you to mutually beneficial cooperation!