Cranes%20and%20Derricks

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• Cranes and Derricks
• OSHA 1926.453

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Crane and Hoist Safety

• 1999 will see approximately 125,000 cranes in
  operation with an additional 100,000 in general
  industry.
• Approximately 250,000 crane operators
• Averaging 1 death per thousand operators

3
Crane and Hoist Safety

• Many cranes are located in populated areas and
  the risk to civilians is increasing.
• Safe clearance on the site is essential although
  not always possible.

4
Crane and Hoist Safety

• OSHA programs
• Last standard update was in the 70s
• Many advancements have been made, but not
  addressed

5
GENERAL REQUIREMENTS

• The employer shall comply with the manufacturers
  specifications and limitations applicable to the
  operation of any and all cranes and derricks.
• There is a very large percentage of accidents
  caused by human error in exceeding the
  recommended limits !!!!!!

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General Requirements

• Modifications
• No modifications or additions which affect the
  capacity or safe operation of the equipment shall
  be made by the employer without the
  manufacturer's written approval and if changes
  are made, the capacity, operation, and
  maintenance instruction plates, tags, or decals,
  shall be changed accordingly. In no case shall
  the original safety factor of the equipment be
  reduced.

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General Requirements

• Modifications
• Many failures result from personnel adding to or
  modifying the crane in manners which it was not
  designed.
• Typical modifications
• Adding of a torque arm
• Adding a Jib
• Adding of a power pack

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General Requirements

• Rated load capacities, and recommended operating
  speeds, special hazard warnings etc. SHALL be
  conspicuously posted on all equipment. They
  shall be visible to the operator when at the
  controls.

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General Requirements

• Hand signals shall be those prescribed by the
  applicable ANSI for the type crane in use. An
  illustration of the signals shall be posted at
  the job site.

10
General Requirements

• The employer shall designate a competent person
  who shall inspect all machinery and equipment
  prior to each use as well as during use.

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General Requirements

• Daily Inspections

Inspected ?? Yes or No
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General Requirements

• Daily Inspections

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General Requirements

• Daily inspections

Rusted and Bent This needs to be replaced prior
to use.
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COMPETENT PERSON

• What constitutes a
  Competent Person ????

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Competent Person

• A Competent Person is one who is able to
  recognize and correct actual and/or potential
  hazards involved with crane operation knows
  how to safely operate the crane AND who has the
  Authority to ensure a safe operation.

16
General Requirements

• A thorough, annual inspection of the hoisting
  machinery shall be made by a competent person, or
  by a government or private agency recognized by
  the U.S. Department of Labor.

17
WIRE ROPE

• Terminology

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WIRE ROPE

• Wire rope shall be taken out of service for a
  number of reasons and should be inspected daily.

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Wire Rope

• Reasons for removal from service
• In Running Ropes, Six randomly distributed
  broken wires in one lay or three broken wires in
  one strand in one lay.

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Wire Rope

• Reasons for removal from service
• Wear of 1/3 the original diameter of outside
  individual wires, Kinking, crushing, bird
  caging, or any other damage resulting in
  distortion of the rope structure.
• Evidence of any heat damage from any cause.

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Wire Rope

• Reasons for removal from service
• Reductions from nominal diameter of

Only a competent person with the proper calipers
can make this determination
Rope Size Reduction Up to 5/16 lt 1/64 3/8
- 1/2 lt 1/32 9/16 - 3/4 lt3/64 7/8 -
1 1/8 lt 1/16 1 1/4 - 1 1/2 lt 3/32
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Wire Rope

• Reasons for removal from service
• Reductions from nominal diameter of rope
• WHO REMEMBERS ALL THE MEASUREMENTS OF THE LAST
  OVERHEAD ???

Cranes are the one piece of equipment that really
need the charts etc.
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PROPER SET-UP

• Level
• Stable
• Clearance
• Reach

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BASIC RIGGING

• No matter what size crane or hoist, it still is
  dependent on the rigging setup

Tension 8 TONS
Tension 15.5 TONS
300
150
8 TONS
8 TONS
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BASIC RIGGING

• Load charts

Chain size Single 600 gt 450gt 300gt 7/32 2,500
4,300 3,550 2,500 9/32 4,100 7,100 5,800 4,1
00 3//8 7,300 12,600 10,300 7,300 1/2 13,000
22,500 18,400 13,000 5//8 20,300 35,000 28,5
00 20,300
Load charts apply to all components of the
lift Master links, Grab hooks, Chains, Web
slings etc.
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BASIC RIGGING

• Protecting the overall stability of the rig by
  using throat latches.
• Must be in place and functional

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BASIC RIGGING

• Rigging it properly

Load blocks etc. must be rigged properly.
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Guarding

• All moving parts of the crane shall be properly
  guarded to prevent accidental contact with
  personnel
• Belts Sprockets
• Gears Drums
• Shafts Fly wheels
• Pulleys Chains
• Other moving parts

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Guarding

• Swing radius protection
• Accessible areas within the swing radius of the
  rear rotating part of the crane , either
  permanently or temporarily mounted, shall be
  barricaded to prevent employees being struck.
• OSHA has made an interpretation
  on this issue that strikes down
  a lot of current ideas.

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Guarding

• Swing radius protection

A very dangerous situation unless protected.
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Guarding

• All exhaust pipes etc. shall be protected from
  employee contact.

32
Guarding

• ALL windows in cabs shall be of safety glass, or
  equivalent that introduces no visible distortion
  to the operator.

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Guarding

• Where necessary for rigging or service, a ladder
  or steps shall be provided for access to the cab
  roof.
• Guardrails, handholds and steps shall be provided
  for easy access to the car and cab.
• Platforms etc. shall have anti-skid walking
  surfaces.

34
Fire Protection

• At least a 5BC rated fire extinguisher shall be
  available at all operator stations or cabs of
  equipment.

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ELECTRICAL SAFETY

• Your primary means of protection is to have all
  exposed overhead electrical lines
  de-energized when working in the
  area.
• Real life dictates that this
  is usually not the case.

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Electrical Safety

• When lines cannot be de-energized, proper
  clearance must be maintained

VOLTAGE MINIMUM CLEARANCE 50 kV or below 10
Feet lt 50 kV 10 Feet 0.4 for each 1kV
over 50 kV up to and including 345 kV gt 750
kV 16 Feet
These are MINIMUMS !!!!
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Electrical Safety

• Things to consider when deciding on the
  Clearance
• 1. Clearance from What ??
• 2. Drift
• 3. Load swing (Tag Lines)
• 4. Boom and Jib

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Electrical Safety

• A person SHALL be designated to observe clearance
  of the equipment and give timely warning for all
  operations where it is
  difficult for the
  operator to maintain
  the desired clearance
  by visual means.

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Electrical Safety

• Monitor Person MUST have absolute authority to
  stop the operations and can only be overridden by
  the operator on the side of safety.
• ie Monitor says OK, Operator says STOP

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Electrical Safety

• Overhead lines
• Any overhead wire shall be considered to be an
  energized line unless and until the person owning
  such line or the electrical utility authorities
  indicate that it is not an energized line and it
  has been visibly grounded

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Electrical Safety

• INDUCED ELECTRICAL CHARGES
• Prior to work near transmitter towers where an
  electrical charge can be induced in the equipment
  or materials being handled, the transmitter shall
  be de-energized or tests shall be made to
  determine if electrical charge is induced on the
  crane. The following precautions shall be taken
  when necessary to dissipate induced voltages

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Electrical Safety

• INDUCED ELECTRICAL CHARGES
• The following precautions shall be taken when
  necessary to dissipate induced voltages
• The equipment shall be provided with an
  electrical ground directly to the upper rotating
  structure supporting the boom

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Electrical Safety

• INDUCED ELECTRICAL CHARGES
• Ground jumper cables shall be attached to
  materials being handled by boom equipment when
  electrical charge is induced while working near
  energized transmitters. Crews shall be provided
  with nonconductive poles having large alligator
  clips or other similar protection to attach the
  ground cable to the load.

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Electrical Safety

• INDUCED ELECTRICAL CHARGES
• Combustible and flammable materials shall be
  removed from the immediate area prior to
  operations

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Suspended loads, picking the load

• All employees shall be kept clear of loads about
  to be lifted and of suspended loads.

This employee was killed because he was adjacent
to an improperly lifted load. The hoist line was
not vertical over the load causing it to swing
and fall on the employee.
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ACCIDENTS
FAMOUS LAST WORDS ITLL NEVER HAPPEN HERE !!
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ACCIDENTS
The operator was asked, by the project rigging
superintendent, to walk the above 4000 Manitowoc
with 300 feet of boom off of the mats it was
sitting on onto soft soil. The operator told the
super, "I'll do what you want, but if I do, the
crane will turn over." The rigging superintendent
replied, "That is not your problem, let me worry
about that. You are to operate the crane and
follow instructions from supervision." With that,
the operator got back in the seat, made sure the
area was clear of other workers, knuckled the
crane into travel, set the throttle at a slow
speed and climbed off of the crane. No,
fatalities, no injuries. Believe it or not,
neither man was fired.
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ACCIDENTS
The crane was left on a barge near the edge of a
river over a week-end. Rain upstream caused the
river to rise and wash the sand from under one
end of the barge. Out of four barges left on the
bank, two went into the river, one was lost and
never found. An expensive lesson for the
contractor.
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ACCIDENTS
The above hydraulic crane was turned over by a
young operator in Puerto Ordez, Venezuela in
1979. He picked a load up (precast concrete
stadium seats) near the crane with his boom up at
a high degree of angle. He proceeded to boom down
and before he realized that he had more load than
the crane could handle, at the radius the load
had reached, it was too late. He tried to get
down on the load, but since the crane was
hydraulic, he couldn't let it down fast enough.
Fortunately the operator jumped clear before it
crushed the cab.Isn't it amazing how we all
tend to learn faster after a "Been There - Done
That" experience.
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ACCIDENTS
The roll-over protection landed on my left knee
and pinned me down. It took an hour and
forty-five minutes to get another machine to the
site to lift it off of me. Diesel was running
under me, and I was losing blood fast. My left
arm was broken in five places and all but
mangled. I now have a steel plate in it holding
the five breaks together. I lost about fifty
percent use of the arm. Thank God, I can still
pull control levers with it.Am I now paranoid
about seat belts? You bet. When I mount a piece
of rubber tired equipment now, the first thing I
do is fasten the seat belt. I pulled a stupid
stunt, but I will not be fool enough to do it
again.
Been There, Done That It is very embarrassing to
publicize this, especially since that is me,
Doyle Peeks, trapped under that 580 Case
loader/backhoe. I have put this here in hopes it
may keep someone else from repeating what I did.
The accident happened on October 6, 1988 near
Dallas, Texas on Lake Ray Hubbard. I had well
over thirty-five years of operating experience. I
just got too confident. I thought I could go
running down a slopped embankment without rolling
the machine. I had always thought that if a
machine ever started to roll that I could hang on
to something and not be thrown off of the
machine. Boy, was I ever wrong. It happened so
fast, I was on the ground before I knew what was
happening. I grabbed at everything I could and
couldn't find a thing to hold on to.
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ACCIDENTS
This accident happened in St. Croix, U.S.V.I. in
1974. The crane was climbing a grade into a tank
farm and the operator decided he wanted to swing
around to see where they were going. Caution
Don't swing a machine when it is moving or in an
unstable position.
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ACCIDENTS
All cranes have limits.They will tip when those
limits are exceeded.
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ACCIDENTS
Inexperience usually results in the above
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ACCIDENTS
Inexperience usually results in the above
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Accidents Leave Victims My husband was killed in
Louisville, Kentucky, on December 18, 1998. He
was standing near an HTC-835 crane. The
counterweight came around and struck him in the
back. He was pinned between the counterweight and
the bed of the truck. He died at the hospital 1
hour later.There was no warning tape around the
crane.
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THE MOTHER OF ALL CRANE COLLAPSES
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THE MOTHER OF ALL CRANE COLLAPSES

• Civil Damages
• VERDICT AT A GLANCEThe 99.25 million jury award
  to the three widows of the ironworkers killed in
  the Miller Park crane collapse breaks down this
  way 94 million in punitive damages against
  Mitsubishi Heavy Industries of America 4.2
  million, or 1.4 million to each widow, for the
  pain and suffering of the ironworkers 1.05
  million, or 350,000 to each widow, for loss of
  companionship

The verdict went to appeal.
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Statistics US crane accidents claim 50 lives
every year.More than 500 US construction workers
died in crane accidents between 1984 and 1994,
according to a study of Occupational Health and
Safety Administration (OSHA).The International
Union of Operating Engineers revealed that 502
workers died in 480 separate accidents. Power
line contact was by far the most common cause of
accidents, accounting for 39 percent of all
fatalities.Other major causes included
assembly/dismantling (12 percent), boom buckling
(8 percent), rigging failure (7 percent) and
upset/overturn (7 percent).
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SUSPENDED PERSONNEL PLATFORMS

• STOP RIGHT HERE !!!!

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SUSPENDED PERSONNEL PLATFORMS

• The use of a crane or derrick to hoist employees
  on a personnel platform is prohibited, except
  when the erection, use, and dismantling of
  conventional means of reaching the worksite, such
  as a personnel hoist, ladder, stairway, aerial
  lift, elevating work platform or scaffold, would
  be more hazardous or is not possible because of
  structural design or worksite conditions.

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SUSPENDED PERSONNEL PLATFORMS

• Hoisting of the personnel platform shall be
  performed in a slow, controlled, cautious manner
  with no sudden movements of the crane or derrick,
  or the platform.

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SUSPENDED PERSONNEL PLATFORMS

• Load lines shall be capable of supporting,
  without failure, at least seven times the maximum
  intended load, except that where rotation
  resistant rope is used, the lines shall be
  capable of supporting without failure, at least
  ten times the maximum intended load.

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SUSPENDED PERSONNEL PLATFORMS

• Load and boom hoist drum brakes, swing brakes,
  and locking devices such as pawls or dogs shall
  be engaged when the occupied personnel platform
  is in a stationary position.

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SUSPENDED PERSONNEL PLATFORMS

• The crane shall be uniformly level within one
  percent of level grade and located on firm
  footing. Cranes equipped with outriggers shall
  have them all fully deployed following
  manufacturer's specifications, insofar as
  applicable, when hoisting employees.

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SUSPENDED PERSONNEL PLATFORMS

• The total weight of the loaded personnel platform
  and related rigging shall not exceed 50 percent
  of the rated capacity for the radius and
  configuration of the crane or derrick.
• BACK TO THE LOAD CHART

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SUSPENDED PERSONNEL PLATFORMS

• The use of machines having live booms (booms in
  which lowering is controlled by a brake without
  aid from other devices which slow the lowering
  speeds) is prohibited.
• The load line hoist drum shall have a system or
  device on the power train, other than the load
  hoist brake, which regulates the lowering rate of
  speed of the hoist mechanism (controlled load
  lowering.) Free fall is prohibited.

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SUSPENDED PERSONNEL PLATFORMS

• All operator controls, gauges etc. must be
  visible and in working order when lifting
  personnel.

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SUSPENDED PERSONNEL PLATFORMS

• A positive acting device shall be used which
  prevents contact between the load block or
  overhaul ball and the boom tip (anti-two-blocking
  device), or a system shall be used which
  deactivates the hoisting action before damage
  occurs in the event of a two-blocking situation
  (two-block damage prevention feature).

69
PLATFORM DESIGN FEATURES

• The personnel platform and suspension system
  shall be designed by a qualified engineer or a
  qualified person competent in
  structural design.
• The suspension system shall be designed
  to minimize tipping of the platform due
  to movement of employees occupying the
  platform.

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PLATFORM DESIGN FEATURES

• The personnel platform itself, except the
  guardrail system and personnel fall arrest system
  anchorages, shall be capable of supporting,
  without failure, its own weight and at least five
  times the maximum intended load.

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PLATFORM DESIGN FEATURES

• Each personnel platform shall be equipped with a
  guardrail system which meets the
  requirements of Subpart M, and shall be
  enclosed at least from the toeboard
  to mid-rail with either solid
  construction or expanded metal having openings no
  greater than 1/2 inch (1.27 cm).

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PLATFORM DESIGN FEATURES

• A grab rail shall be installed inside the entire
  perimeter of the personnel platform.
• Access gates, including sliding or folding gates,
  shall be equipped with a restraining device to
  prevent accidental opening and shall not swing
  outward.

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PLATFORM DESIGN FEATURES

• Headroom shall be provided which allows employees
  to stand upright in the platform.
• In addition to the use of hard hats, employees
  shall be protected by overhead protection on the
  personnel platform when employees are exposed to
  falling objects.

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PLATFORM DESIGN FEATURES

• The personnel platform shall be conspicuously
  posted with a plate or other permanent marking
  which indicates the weight of the platform, and
  its rated load capacity or maximum intended load.

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PLATFORM LOADING

• Personnel platforms shall be used only for
  employees, their tools and the materials
  necessary to do their work, and shall not be used
  to hoist only materials or tools when not
  hoisting personnel.
• Materials and tools for use during a personnel
  lift shall be secured to prevent displacement.

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PLATFORM LOADING

• Materials and tools for use during a personnel
  lift shall be evenly distributed within the
  confines of the platform while the platform is
  suspended.

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RIGGING THE PLATFORM

• When a wire rope bridle is used to connect the
  personnel platform to the load line, each bridle
  leg shall be connected to a master link or
  shackle in such a manner to ensure that the load
  is evenly divided among the bridle legs.

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RIGGING THE PLATFORM

• Hooks on overhaul ball assemblies, lower load
  blocks, or other attachment assemblies shall be
  of a type that can be closed and locked,
  eliminating the hook throat opening.

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RIGGING THE PLATFORM

• All eyes in wire rope slings shall be fabricated
  with thimbles.

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TRIAL LIFTS

• A trial lift with the unoccupied personnel
  platform loaded at least to the anticipated lift
  weight shall be made from all locations of entry,
  hoisting and positioning
• This trial lift shall be performed immediately
  prior to placing personnel on the platform.

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TRIAL LIFTS

• The operator shall determine that all systems,
  controls and safety devices are activated and
  functioning properly and that all configurations
  necessary to reach those work locations will
  allow the operator to remain under the 50 percent
  limit of the hoist's rated capacity.

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TRIAL LIFTS

• After the trial lift, and just prior to hoisting
  personnel, the platform shall be hoisted a few
  inches and inspected to ensure that it is secure
  and properly balanced. Employees shall not be
  hoisted unless the following conditions are
  determined to exist

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TRIAL LIFTS

• A visual inspection of the crane or derrick,
  rigging, personnel platform, and the crane or
  derrick base support or ground shall be conducted
  by a competent person immediately after the trial
  lift

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TRIAL LIFTS

• At each job site, prior to hoisting employees on
  the personnel platform, and after any repair or
  modification, the platform and rigging shall be
  proof tested to 125 percent of the platform's
  rated capacity by holding it in a suspended
  position for five minutes

85
WORK PRACTICES

• Except over water, employees occupying the
  personnel platform shall use a body belt/harness
  system with lanyard appropriately attached to the
  lower load block or overhaul ball, or to a
  structural member within the personnel platform
  capable of supporting a fall impact for employees
  using the anchorage.

86
WORK PRACTICES

• Employees shall keep all parts of the body inside
  the platform during raising lowering, and
  positioning
• Tag lines shall be used unless their use creates
  an unsafe condition.

87
WORK PRACTICES

• The crane or derrick operator shall remain at the
  controls at all times when the crane engine is
  running and the platform is occupied.
• Hoisting of employees shall be promptly
  discontinued upon indication of any dangerous
  weather conditions or other impending danger.

88
WORK PRACTICES

• Employees being hoisted shall remain in
  continuous sight of and in direct communication
  with the operator or signal person. In those
  situations where direct visual contact with the
  operator is not possible, and the use of a signal
  person would create a greater hazard for the
  person, direct communication alone such as by
  radio may be used.

89
PRE-LIFT MEETINGS

• A meeting attended by the crane or derrick
  operator, signal person(s) (if necessary for the
  lift), employee(s) to be lifted, and the person
  responsible for the task to be performed shall be
  held to review the appropriate requirements of
  paragraph (g) of this section and the procedures
  to be followed.