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A tower crane mainly ensures the success or efficiency of building construction. Fatigue crack analysis is important for tower crane components to prevent any accidents to workers in construction sites caused by component failure and to ease the maintenance or replacement of failed components. This work aimed to characterise the damage of failed components, analyse the relationship between the metal magnetic memory (MMM) result and the damage of failed components, and to validate the relationship between MMM and finite element analysis (FEA).

MMM was used in this work to detect any irregularities or early failure on the basis of the high stress concentration zone of ferromagnetic steel using magnetic flux leakage. Magnetic flux leakage was used on the MMM device to achieve the first objective using the MMM system by detecting the irregularities. The results of MMM analysis were validated through comparison with FEA results by determining their relationship.

MMM results show that the position of defects on the tower crane pulley is within the stress area shown on FEA.

Hence, MMM method is a potential tool in monitoring failure mechanism in construction site.