SS 497 : 2011

(ICS 53.020)

SINGAPORE STANDARD
Code of practice for design, safe use and
maintenance of gantry cranes, overhead
travelling cranes and monorail hoists

Published by
SS 497 : 2011
(ICS 53.020)

SINGAPORE STANDARD
Code of practice for design, safe use and
maintenance of gantry cranes, overhead travelling
cranes and monorail hoists

ISBN 978-981-4353-15-1
SS 497 : 2011

This Singapore Standard was approved by the General Engineering and Safety Standards Committee
on behalf of the Standards Council of Singapore on 24 November 2011.

First published, 2002

First revision, 2011

The General Engineering and Safety Standards Committee appointed by the Standards Council
consists of the following members:

Name Capacity

Chairman : Mr Chan Yew Kwong Member, Standards Council

Deputy
Chairman : Mr Seet Choh San Singapore Institution of Safety Officers
Secretary : Ms Kong Wai Yee Singapore Manufacturers’ Federation – Standards
Development Organisation
Members : Dr Kenneth Choy Ministry of Manpower
Assoc Prof Foo Swee Cheng National University of Singapore
Er. Goh Keng Cheong Housing & Development Board
Assoc Prof Hoon Kay Hiang Nanyang Technological University
Mr Albert Lim Packaging Council of Singapore
Mr Kenneth Lim SPRING Singapore
Mr Lim Meng Ann Workplace Safety and Health Council
Mr Liu Png Hock Land Transport Authority
Mr Ng Yek Meng Singapore Contractors Association Limited
Mr P K Raveendran Association of Singapore Marine Industries
Mr Tan Chong Lin Building and Construction Authority
Mr Tan Kai Hong Institution of Engineers, Singapore
Mr Tay Cheng Pheng Society of Loss Prevention in the Process
Industries
Mr Wong Choon Kin Singapore Manufacturers’ Federation
Mr Victor Yeow Association of Small and Medium Enterprises
Assoc Prof Zhou Wei Singapore Welding Society

The Technical Committee on Safety and Health Involving the Use of Equipment appointed by the
General Engineering and Safety Standards Committee and responsible for the preparation of this
standard consists of representatives from the following organisations:

Name Capacity

Chairman : Assoc Prof Hoon Kay Hiang Member, General Engineering and Safety
Standards Committee
Secretary : Mr Chen Lian Sze Singapore Manufacturers’ Federation – Standards
Development Organisation
Members : Mr Choo Choong Huat Singapore Institution of Safety Officers
Mr Goh Chin Keong Ministry of Manpower
Mr Idilfitri Bin Mohammed Singapore Manufacturers’ Federation
Yatim

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Members : Mr Lau Huat Poh Singapore Contractors Association Limited

Mr Patrick Phoa Land Transport Authority
Er. Manivel Rudrapathi Institution of Engineers, Singapore
Mr Seah Chong An TUV SÜD PSB Pte Ltd
Mr Tan Liong Kiat Singapore Polytechnic
Mr Alex Teo Association for Singapore Marine Industries
Mr Paul Yap Yong Peng Building and Construction Authority
Co-opted
Members : Mr S Damodaran Individual Capacity
Mr Jonathan Wan Individual Capacity

The Working Group appointed by Technical Committee to assist in the preparation of this standard
comprises the following experts who contributed in their individual capacity:

Name

Convenor : Er. Manivel Rudrapathi

Members : Mr Foong Kah Choong
Mr Goh Chin Keong
Mr Goh Kim Teo
Mr Han Kin Sew
Mr Kiang Siang Jack
Assoc Prof Ong Lin Seng
Mr Mark Ong
Mr Bernard Soh
Er. Alvin Yeo Kheng Hock

The organisations in which the experts of the Working Group are involved are:

AY Safety Consultancy and Inspection Services

Jenmon International Pte Ltd
MHE-Demag (S) Pte Ltd
Ministry of Manpower
Nanyang Technological University
PSA Corporation Ltd
R@dians Consultancy Services
Singapore Institution of Safety Officers
W Richards Pte Ltd
Workplace Safety and Health Council

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Contents
Page

Foreword 7

CLAUSES

Section One – General

1 Scope 9
2 Normative references 9
3 Definitions 11
4 Legislation relevant to this standard 14
5 Responsibilities 14

Section Two – Design considerations

6 Group classification of cranes 15
7 Loads and load combinations 18
8 Design of crane structures 32
9 Crane mechanisms 35
10 Electrical equipment and controls 44
11 Hydraulic equipment and controls 50
12 Pneumatic equipment and controls 53
13 Documentation and marking 56
14 Manufacture and construction 58

Section Three – Operation and maintenance

15 Safe use and operation of cranes 61
16 Inspection and testing 64

ANNEXES

A Application of the allowable stress method of design 67

B Application of the limit state method of design 69
C Information to be considered when installing an overhead travelling or gantry crane 71
D Selection of wire ropes 73
E Sample checklist for inspection of crane by owner 75

TABLES

1 Group classification of cranes according to utilisation 16

2 Classes of utilisation of cranes 16
3 Nominal load spectrum factor and state of loading for cranes 17
4 Categories of loads and load combination table 21

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Page

5 Application table for dynamic multiplier (I1) 22

6 Hoisting classes of cranes 22
7 Factors E2, I2 min and I2 max 24
8 Lateral loads due to acceleration from traverse (cross-travel) drives 26
9 Lateral loads due to acceleration from travel (long-travel) drives 27
10 In-service wind data 28
11 Recommended minimum values for the natural frequency of vertical vibration at different
bridge spans 34
12 Classes of utilisation of mechanisms 35
13 Nominal load spectrum factor and state of loading for crane mechanisms 36
14 Group classification of crane mechanisms 36
15 Permissible stress (Pc) for mechanism components 39
16 Mechanism duty factor, G 40
17 Minimum drum-to-rope and sheave-to-rope diameter ratios 44
18 Duty type factors 48

19 Values of coefficients Jf , Jm and Jp 69

20 Zp values 73
21 Minimum breaking load factor, K’ 74

FIGURES

1 Illustration of typical lifting attachments in relation to safe working load 13

2 Typical load spectra 17
3 Acceleration loads due to traverse (cross-travel) drives 26
4 Acceleration loads due to travel (long-travel) drives 27
5 Distribution of horizontal forces 27
6 Skew load coefficients 29

7 Dynamic multiplier (I5 ) for buffers 31

8 Headroom above platforms and walkways on crane 59
9 Clearances for access landings – Shearing and crushing conditions 59
10 Typical flow chart of the allowable stress method of design 68
11 Typical flow chart of the limit state method of design 70
12 Single girder overhead travelling crane 71
13 Double girder overhead travelling crane 71
14 Gantry crane 72

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Foreword

This Singapore Standard was prepared by the Technical Committee on Safety and Health involving
the Use of Equipment under the purview of the General Engineering and Safety Standards Committee.

It is a revision of SS 497 : 2002 which was for overhead travelling cranes only. This revised standard
is based on AS 1418.1:2002 – “Cranes, hoists and winches, Part 1 : General requirements” and is
reproduced with permission from SAI Global under Licence 1108-c146. Australian Standards can be
purchased online at: http://www.saiglobal.com.

This standard is expanded to include overhead travelling, gantry, jib cranes and hoists on monorails.
It is aligned with current industrial practices and legal requirements on the safe use, design,
maintenance and testing of such cranes. The salient points are as follows:

(a) The responsibilities of the relevant parties who are involved in the design, use, maintenance,
testing and inspection of cranes are delineated.

(b) The requirements under each clause are elaborated to provide a common understanding
amongst the various interested parties.

(c) The in-service wind speeds in Table 10 are based on the updated data obtained from the
Singapore Meteorological Service and SS EN 1991-1-4: 2009 ‘Eurocode 1 – Actions on
structures – Part 1-4: General actions – Wind actions’.

(d) Section Two covers the basic design considerations for the crane. Where the design and
calculations are based on an overseas / established crane standard, there shall be no mix-
and-match of the data quoted in this Singapore Standard and the aforesaid crane standard
(e.g. the load factors, coefficients, etc).

(e) Various safety limiters and indicating devices are introduced as part of the crane mechanism
to ensure safe operation. These include anti-collision devices, overload limiters, etc. Work
space limiters are also introduced to prevent operation of cranes in prohibited areas where
there is danger of collision of crane structure or load with a permanent object or structure.

(f) When tested with the SWL, the maximum deflection at the centre of the bridge shall not
exceed 1/750 of the span. The deflection at end of cantilevered bridge shall not exceed 1/300
of the span of the cantilevered portion of the bridge.

(g) The markings on cranes have been provided to ensure proper identification and SWL limits,
particularly for cranes fitted with at least 2 lifting devices.

(h) Manufacturer or supplier of cranes is required to provide complete documentation for the
crane installed. It includes operations manual, maintenance manual, parts book and log book.

In preparing this standard, references were made to the following publications:

1. AS 1418 Cranes, hoists and winches

Part 3 : 1997 Bridge, gantry and portal cranes (including container
cranes)
2. BS 2573 Rules for the design of cranes
Part 1 : 1983 Classification, stress calculations and design criteria
for structures
Part 2 : 1980 Classification, stress calculations and design criteria
of mechanisms

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3. DIN 15018 Cranes – Steel structures

Part 1 : 1994 Verification and analyses
4. IEC 60204 Safety of machinery – Electrical equipment of machines
Part 32 : 1998 Requirements for hoisting machines
5. ISO 2408 : 1985 Steel wire ropes for general purposes – Characteristics
6. ISO 4301 Cranes – Classification
Part 1 : 1986 General
Part 5 : 1991 Overhead travelling and portal bridge cranes
7. ISO 4308 Cranes and lifting appliances – Selection of wire ropes
Part 1 : 1986 General
8. ISO 4310 : 2009 Cranes – Test code and procedures
9. ISO 8686 Cranes – Design principles for loads and load combinations
Part 1 : 1989 General
Part 5 : 1992 Overhead travelling and portal bridge cranes
10. ISO 9927 Cranes – Inspections
Part 1 : 1994 General
11. ISO 10245 Cranes – Limiting and indicating devices
Part 1 : 1994 General
Part 5 : 1995 Overhead travelling and portal bridge cranes
12. ISO 10972 Cranes – Requirements for mechanisms
Part 1 : 1998 General
13. ISO 11660 Cranes – Access, guards and restraints
Part 5 : 2001 Bridge and gantry cranes
14. SS 536 : 2008 Code of practice for the safe use of mobile cranes
15. SS 559 : 2010 Code of practice for safe use of tower cranes
16. SS 567 : 2011 Code of practice for factory layout – Safety, health and welfare
considerations

Acknowledgement is made for the use of information from the above publications.

Attention is drawn to the possibility that some of the elements of this Singapore Standard may be the
subject of patent rights. Enterprise Singapore shall not be held responsible for identifying any or all of
such patent rights.

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Code of practice for design, safe use and maintenance of gantry

cranes, overhead travelling cranes and monorail hoists

Section One – General

1 Scope
This standard applies to the following types of powered cranes (hereinafter called “cranes”):

1.1 Gantry cranes

1.2 Overhead travelling cranes

1.3 Jib cranes; and

1.4 Monorail hoists.

It specifies the basic requirements of cranes and lays down the responsibilities of the various parties
involved.

NOTE 1 – This does not include mobile cranes and tower cranes (covered in their respective individual
Singapore Standards).

NOTE 2 – Annex C is informative and could be used as a reference when installing a crane.

2 Normative references
The following referenced documents are indispensable for the application of this standard. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.

AS 1418.1 : 2002 Cranes hoists and winches

Part 1 : 2002 General requirements
ANSI/AWS D14.1 : 2005 Specification for welding industrial and mill cranes and other material
handling equipment
BS EN 60470 : 2001 High-voltage alternating current contactors and contactor-based motor
starters
BS EN 60947-4-1 : 2001 Low-voltage switchgear and control gear. Contactors and motor-starters.
Electromechanical contactors and motor-starters
BS EN 13001- Crane safety. General design. Load effects
2:2004+A3:2009
BS EN 13001-1 : Cranes. General design. General principles and requirements
2004+A1:2009
BS EN 60309 Plugs, socket-outlets and couplers for industrial purposes
Part 2 : 1999 Dimensional interchangeability requirements for pin and
contact-tube accessories
DIN 1055-4 (2005-03) Action on structures – Part 4: Wind loads

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DIN 15018-1 (1984-11) Cranes - Principles for steel structures, stress analysis
Part 1 : 1994 Verification and analyses
Euro Code 3 Design of steel structures
Part 1-1 : 1992 General rules and rules for buildings
Part 1-2 : 1997 General rules – Structural fire designs
Part 1-3 : 1996 General rules – Supplementary rules for cold thin gauge
members and sheeting
IEC 60034 Ed.12 Rotating electrical machines
Part 1 : 2010 Rating and performance
IEC 60204 Ed.2.0 Safety of machinery – Electrical equipment of machines
Part 32 : 2008 Requirements for hoisting machines
IEC 60947 Low-voltage switchgear and control gear
Part 4 : Contactors and motor-starters
Section 1 : 2009 Electrotechnical contactors and motor-starters
Section 2 : 2007 AC semiconductor motor controllers and starters
Section 3 : 2007 AC semiconductor controllers and contactors for non-motor
loads
ISO 2394 : 1998 General principles on reliability for structures
ISO 3077 : 2001 Short link chain for lifting purposes – Grade T, (types T, DAT, and DT), find-
tolerance hoist chains
ISO 4306 Cranes – Vocabulary
Part 1 : 2007 General
ISO 12488 Cranes – Tolerances for wheels and travel and traversing tracks
Part 1 : 2005 General
ISO 8686 Cranes – Design principles for loads and load combinations
Part 1 : 1989 General
ISO 9374 Cranes – Information to be provided
Part 5 : 1991 Overhead travelling cranes and portal bridge cranes
ISO 11660 Cranes – Access, guards and restraints
Part 1 : 2008 General
Part 5 : 2001 Bridge and gantry cranes
ISO 13200 : 1995 Cranes – Safety signs and hazard pictorials – General principles
JIS B 8821 : 2004 Calculation of standards for steel structures of cranes
CP 5 : 1998 Code of practice for electrical installations
CP 35 : 1996 Code of practice for the selection, care and maintenance of steel wire ropes
for hoisting

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SS 145 13A plugs and socket outlets

Part 1 : 1997 Rewirable and non-rewirable 13A fused plug
Part 2 : 1997 13A switched and unswitched socket outlets
SS 472 : 1999 15A plugs and switched socket-outlets for domestic and similar purposes

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