Accident Prevention Manual

1

• Accident Prevention Manual
• for Business Industry
• Engineering Technology
• 13th edition
• National Safety Council

Compiled by Dr. S.D. Allen Iske, Associate
Professor University of Central Missouri
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CHAPTER 16

• HOISTING AND CONVEYING EQUIPMENT

3
Hoisting Apparatus

• Definition A hoisting apparatus is a device used
  to raise and lower materials.
• Basic types
• electric
• air
• hand-operated chain

4
Hoisting Apparatus (Cont.)

• General information
• The safe load capacity of the hoist should be
  attached to the body of the machine. The label
  for safe operation should be able to be read from
  ground level.
• Loads should only be raised or lowered if the
  load is directly under the hoist (centered).
• Personnel should NOT be allowed to enter the area
  directly under the load.

5
Cranes

• Definition A crane is a mechanical device
  designed to raise, lower, and shift heavy objects
  through the use of a long movable arm.

6
Cranes (Cont.)

• General information
• A competent person must inspect all machinery and
  equipment prior to use to ensure safe operating
  condition any deficiencies repaired.
• All parts of every crane should be of adequate
  strength for its rated service.
• Do NOT use a hoist or crane to transport people.
• All equipment must be inspected and maintained to
  prevent incidents.
• Workers must be properly trained in the use of
  the hoist and all safety policies/procedures must
  be followed at all times.

7
Cranes (Cont.)

• Overhead and gantry cranes constructed and
  installed after Aug. 31, 1971, must be in
  compliance with ANSI/ASME B30.2.
• Open hooks should not be used if there is a
  danger of the tension decreasing during use.
• Each independent hoisting unit shall have brakes
  compliant with the standard.
• The load rating should be clearly marked on each
  side of the crane each hoisting unit should have
  its rated load marked.
• An audible alarm and wind indicator should be
  utilized and in visible sight of the crane
  operator.

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Cranes (Cont.)

• Design and construction
• Arrange the cab and locate control and protective
  equipment so that all operating handles are
  within convenient reach of the operator.
• Each control lever should be marked with its
  action and direction of control.
• The controls should be self-closing to a neutral
  position.
• Limiting devices to prevent overrunning safe
  limits
• Provide for safe footing and accessways
• Access to cab and/or bridge walkway by convenient
  fixed ladders, stairways or platforms
• Cab fitted with dry chemical or equivalent fire
  extinguisher
• Accessible areas within swing radius barricaded
  to protect employees from injury.

9
Cranes (Cont.)

• Guards and limit devices
• Gears and moving parts should be covered, or out
  of reach, during operation of the crane.
• Traveling cranes must be equipped with an audible
  warning device and a strobe light.
• Large hooks should have handles affixed to them
  to allow the load operator to manipulate the hook
  without danger to their hand/fingers.
• The hoisting motion must have an over-travel
  limit switch
• No guard, safety, or other device shall be made
  inoperable except for repairs or adjustments.
• All guards and safety devices must be immediately
  activated after completion of repairs or
  adjustments.

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Cranes (Cont.)

• General guidelines
• Use hoisting ropes of recommended construction
  for crane or hoist service.
• Inspection, testing, and maintenance should be
  performed by a qualified person only.
• Crane movement must be governed by a standard of
  code signals between the crane signaler and crane
  operator.
• Only one person should be authorized to signal
  the operator at any given point in time.
• Hand signals are preferred.

11
Overhead Gantry Crane
12
CraneSignals
13
Crane

Signals
14
Cranes (Cont.)

• Selection and training of operators
• Age 18
• Language Understand spoken and written
  words/instructions.
• Physical Physical fitness, visual acuity, depth
  perception, manual dexterity, etc.
• Knowledge Basic knowledge of the equipment, its
  usage, inspection, maintenance, etc.
• Skills Demonstrated proficiency in classroom and
  onsite. Maintain a file that clearly documents
  the operators KSA.
• Note Smoothness is a sign of a good crane
  operator.

15
Inspection

• Overhead and gantry cranes must be inspected
  according to ANSI/ASME B30.2.
• New laws for operators of cranes are being
  enacted by state laws and pending OSHA changes.
• Certification of cranes by state laws are
  required at least annually by certified crane
  inspector.
• Repairs of cranes should be performed by
  qualified individuals.
• Do performance testing of hoisting equipment
  prior to placing it in service.
• Perform regular pre-shift and on-shift
  inspections to ensure safe to operate.

16
Crane Operating Rules

• Review the list of Crane Manufacturer Association
  of America, Inc. operating rules for crane
  operators.
• Review the maintenance safety rules from
  ANSI/ASME B30.2 for Overhead and Gantry Cranes.

17
Overhead Cranes

• An overhead crane may be operated either from a
  cab or from the floor.
• All control handles must be clearly identified by
  signs and by shape or position so that an
  operator, while keeping contact with the
  signaler, can identify each control by touch.
• Keep controls in identical positions if multiple
  cranes are used in one location.

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Overhead Cranes (Cont.)
19
Overhead Cranes (Cont.)

• General information
• It is important that the operator have a safe
  route to and from the cab.
• In the event of an emergency, the operator must
  have a safe egress regardless of the position of
  the crane on the runway.
• A fire extinguisher should be located inside the
  cab.

20
Storage Bridge and Gantry Crane

• Storage bridge cranes and gantry cranes travel
  on rails that are on ground level.
• Gantry cranes typically have short spans, whereas
  storage bridge cranes typically have large spans
  and may be used to move large amounts of coal or
  ore.
• Access to the cab is by ladder on one of the
  crane legs.
• Keep track repaired and cleaned.
• Provide warning devices to indicate crane travel.

21
Gantry crane
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Storage Bridge and Gantry Crane (Cont.)

• Guidelines
• An audible alert should sound each time the
  travel controller handle is moved from the off
  position.
• The operator should apply the rail clamps at any
  point in time when the operator is not in the
  cab.
• Cranes of this nature are typically exposed to
  the elements therefore they require additional
  inspection and maintenance procedures.

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Monorail

• Definition A monorail is a system consisting of
  one or more independent trolleys, supported from
  or within an overhead track, from which the
  hoists are suspended.
• Three types
• Hand-operated material raised with hand-powered
  hoist and trolley propelled by hand
• Semi-hand-operated power hoist and is moved
  horizontally by hand
• Power-operated electrically actuated for both
  vertical and horizontal movements

24
Monorail (Cont.)
25
Jib Crane

• Definition A jib crane is capable of lifting,
  lowering, and rotating a load within a circular
  arc by a rotating arm or jib. The jib and
  trolley are typically supported or mounted from a
  building wall, column or pillar.
• The hoist, which is used to lift the loads, is
  suspended from the trolley that travels on the
  jib boom.
• Note A qualified engineer should determine if
  the structure is sufficient to support the crane.

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Jib Crane (Cont.)
27
Derricks

• Main types of derricks
• a-frame derrick
• stiff-leg derrick
• guy derrick
• All derricks must have every part firmly
  anchored.

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Derricks (Cont.)
29
Tower Cranes

• Tower cranes contribute to a large number of
  incidents.
• Common causes of incidents
• Improper erection or dismantling of crane
• Exceeding load capacity
• Improper bracing
• Operator error
• Use during high winds
• Tampering with safety devices or limit switches
• Operators not knowing limitations of cranes or
  inadequate training

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Tower Cranes(Cont.)
31
Tower Cranes (Cont.)

• Safety guidelines
• Appropriate steel or alloy for fabrication of
  crane structure
• Secure attachment of counterweights and safety
  ropes, rods or chains.
• Only qualified, proficient personnel, familiar
  with the work environment, may operate the crane.
• All moving parts should be guarded.
• Do not exceed lifting capacity.
• Account for weather conditions (wind forces,
  lightning, water weight added to load, etc.).
• Management plays a key role in the safe use of
  tower cranes.

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Tower Cranes (Cont.)

• Operation
• Only personnel of recognized ability should
  operate a tower crane (training and experience).
• Operator should have knowledge of crane
  construction and performance specifications.
• Operators should never stand or climb outside of
  the cab if the crane is in operation.
• Crane inspections prior to and during the
  loading.
• Know the load limits.
• Develop a plan for the lift as well as all
  aspects of crane use.
• Clear communication between all personnel during
  lifts.

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Mobile Cranes

• Engineering marvel to accomplish many tasks in
  construction with up to 1,000 ton capacity and
  length of 600 feet plus boom and jib.
• Mobile cranes may be powered by electricity,
  gasoline, diesel fuel or steam. Each requires
  specific safety guidelines.
• Outriggers must be utilized when required.
• Operators must exercise extreme caution when the
  crane boom is at an extreme angle, as the load
  may contact the boom.

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Mobile Cranes (Cont.)
35
Mobile Cranes (Cont.)

• When the boom is fully extended, the load must
  not be lowered to the side or at an angle to the
  crane body.
• If a crane is used to unload a truck, the truck
  must remain in place while the load is lifted in
  case the load is too heavy for the crane and the
  load must be lowered back into the truck.

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Mobile Cranes (Cont.)

• Safety data
• 20 of construction fatalities are crane related.
  (Canadian data and www.osha.gov)
• 90 of mobile crane injuries are linked to
  operator error.
• Other contributing factors
• support failure 30
• failure to use outrigger 20
• crane failure 10-20
• Rigging 415

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Mobile Cranes (Cont.)

• All injuries to employees at least 25 involved
  with the load and 1015 involved with
  maintenance, refueling, and so forth around the
  crane.
• Mobile cranes include locomotive cranes, crawler
  cranes, wheel-mounted cranes, and industrial
  truck cranes.
• All mobile cranes have booms with load hoists and
  boom hoists. Most cranes swing or rotate on a
  turntable. Power is electric motor, steam,
  gasoline, or diesel engine.

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Mobile Cranes (Cont.)

• Load Chartsevery crane has a capacity plate or
  sign noting the safe-load capacity at various
  radii from the center pin of the turntable.
• Signs must be clearly legible to operator,
  signaler, and rigger. Mount a boom angle
  indicator with freely suspended pointer.
• Pick must be within the limits prescribed in the
  chart.
• Capacity chart for operator must indicate boom
  length, boom angle, and capacity.
• Safe access, good lighting, and warning devices

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Mobile Cranes (Cont.)

• Operation
• Extended riggers are considered part of
  counterweight on load charts.
• Boom must never be swung too rapidly.
• Operating on soft or sloping ground or close to
  sides of trenches or excavations is dangerous.
• Outriggers provide stability only on solid
  ground.
• Use caution when operating the boom at a high
  angle with a suspended load. Do not let the load
  swing and strike the boom or steel lattice.
• Use care in lowering an extended boom to ground.
• Center the hook over the load.
• Never use the crane for jerk piling and, when
  unloading from a truck, dont allow the truck to
  drive off from under the load.
• Consult manufacturer prior to any modifications
  of equipment.

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Mobile Cranes (Cont.)

• Travel of cranes
• Cranes should not travel with a load suspended
  from the boom.
• If travel on public roads is necessary, the boom
  should point forward and a flagman should be
  ahead of the unit.
• Electric wires
• Any overhead wires should be considered
  energized. Use a signal person as well as warning
  devices.
• Inspection
• Routine inspections are important to determine
  deficiencies or deterioration in components.

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Aerial Baskets

• Aerial lift equipment is commonly used for
  working above ground.
• These boom-mounted buckets, baskets, or platforms
  are used in constructing and maintaining electric
  and telephone lines.
• Increased use in harbor and port work, aircraft
  industry, highway work, and maintenance
  workpainting, sandblasting, and firefighting.

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Aerial Baskets (Cont.)
43
Aerial Baskets (Cont.)

• Hazards
• improper precautions concerning electrical
  hazards
• improper positioning of vehicle or outriggers
• overreaching
• not using PPE including safety belts
• moving vehicle with boom raised or insufficient
  clearance for boom
• swinging the boom or basket against overhead
  obstruction or energized equipment
• moving boom into positions that interfere with
  traffic
• inadequately trained personnel

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Aerial Baskets (Cont.)

• Operation
• The lift, basket, and controls should be tested
  daily, prior to use to determine controls are in
  safe working condition.
• Inspect for any defects.
• Mechanical equipment inspected daily for safe
  operation.
• Load limits of the boom and basket posted and not
  exceeded.
• Warm-up period and hydraulic system tested.
• Truck not moved unless boom is lowered and basket
  or ladder cradled.
• Riding in basket while the truck is traveling
  shall not be permitted.
• Protect workers from unsafe positions during
  work.
• The operator must be cognizant of vehicular and
  pedestrian traffic.

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Aerial Baskets (Cont.)

• Inspection
• All components of the basket, boom, cables,
  sheaves, leveling devices, locking devices,
  controls, hydraulic system, and fluid levels for
  any wear or defect. If defects are found, report
  them immediately and perform appropriate repairs
  or corrections.
• Safeguards
• An aerial basket must be equipped with safety
  belts/lanyards and a means for attaching the
  lanyard to the equipment.
• Lanyards should be long enough to allow movement
  only inside the basket and prevent climbing onto
  the rim.
• Thoroughly train workers in the use of equipment
  before use.
• Proper footing for the wheels and outriggers
  should be provided.

46
Aerial Baskets (Cont.)

• What potential hazards are you able to identify
  in this picture?

47
Crabs and Winches

• Safety concerns
• Install some form of brake or safety lowering
  device.
• Anchor portable units securely against the pull
  of the hoisting rope or chain.
• The operator should be positioned away from the
  direct line of pull.
• Gears should be fully guarded.
• Barricade guards should be used to protect
  workers from flying strands of wire.
• A small lever should be welded to the locking
  pawl to help prevent hand/finger injuries.

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Block and Tackle

• Safety factor of 10 is recommended for
  determining the safe working load of Manila rope
  (falls) in a block-and-tackle assembly.
• Allows for (1) error in estimating the weight of
  the load, (2) vibration or shock in handling the
  load on the tackle, (3) loss of strength at knots
  and bends, and (4) deterioration of the rope due
  to wear or other causes.
• Governing factor is usually the safe working load
  of the blocks rather than the falls (rope).
• Protect personnel from injuries during use of the
  pulley and rope.
• Caution when using wire instead of fiber ropes.

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Block and Tackle (Cont.)

• To find the required breaking strength for new
  rope
• For each sheave 3 in. in diameter or larger, add
  10 to the weight of the load to compensate for
  friction loss.
• Divide this figure by the number of ropes or
  parts running from the movable block.
• Multiply the resultant figure by a safety factor
  of 10.
•  
• EXAMPLE
• A load weighs 2,000 lb, and the tackle consists
  of two double blocksfour sheaves, four rope
  parts at the moveable block.
• Friction loss (10 per sheave) 40 or 800 lb
• 2,000 800 2,800 lb., divided by 4 700 lb.
• Applying the safety factor of 10 (10 ? 700) gives
  7,000 lb., the required breaking strength of the
  rope.
• Look up on the manufacturers rope tables the
  proper size rope for the breaking strength that
  you have calculated.

50
Tiering Hoists and Stackers

• Tiering hoists (called stacking elevators,
  portable elevator, tiering machine, or platform
  hoist) are designed to raise material in a
  vertical line on a moving platform.
• Used in warehouses for piling and storing
  materials.
• Operated electrically or manually.
• Should have a braking device permitting safe
  lowering of the platform. Workers do not ride
  platforms.
• Protect the tiering machine from tipping over.

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Conveyors
52
Conveyors (Cont.)

• Definition A horizontal, inclined, or vertical
  device for moving or transporting bulk material,
  packages, or objects, in a path predetermined by
  the design of the device and having points of
  loading and discharge.

53
Conveyors (Cont.)

• General precautions
• Signed for loading points and safe load limit.
• Moving parts must be protected by guards.
• Underpasses should have sheetmetal ceilings.
• Special fire protection devices must be utilized
  at any point in which a conveyor passes through a
  fire wall.
• Guard conveyors for handrails and toeboards.
• Protect workers from falling materials.
• Provide crossovers or underpasses with proper
  safeguards for passage over or under all
  conveyors.
• All conveyors within 6 8 of a walkway that is
  meant to serve as an exit route must be in
  compliance with NFPA 101, Life Safety Codes.

54
Conveyors (Cont.)

• Operation precautions
• The start button should be located in an area
  where the operator has the greatest field of view
  of the corresponding conveyor.
• Start-stop devices must be clearly labeled.
• If conveyor passes through a wall or floor, equip
  each side with starting and stopping devices.
• Emergency stopping devices must not be located
  more than 75 ft apart along walkways.
• Provide anti-run-away and backstop devices.
• Workers must wear properly fitting clothes and
  PPE.
• Control dust levels with exhaust hoods and good
  ventilation.
• Use proper electrical rated fixtures.

55
Conveyors (Cont.)

• Maintenance
• The conveyor must be locked out, prior to any
  maintenance work being performed. The worker
  should carry the only key to the lock.
• If two or more gangs will perform the work, they
  should follow OSHA standard 1910.147 for lock
  out/tag out.
• Maintenance personnel should have access to
  change positions of pulleys, sprockets, or
  sheaves to compensate for normal working
  conditions.
• Provide guards for the on-running belt.
• Use fixed scrapers and revolving brushes to clean
  drums or pulleys instead of workers attempts by
  hand.
• Use guards in front of pinch points.
• Guard sides to prevent contact.

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Conveyors (Cont.)

• Frequent causes of injuries
• attempting repairs on moving conveyors
• attempting to cross over moving belts
• attempting to ride moving belts

57
Conveyors (Cont.)

• Unique hazards
• Dust explosions are a major concern in conveyor
  systems used for transporting grain or similar
  products. (silo)
• Portable conveyors must be equipped with locking
  devices to keep the belt and conveyor stable.

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Types of Conveyors

• belt conveyors
• slat and apron conveyors
• chain conveyors
• shackle conveyors
• screw conveyors
• bucket conveyors
• pneumatic conveyors
• aerial conveyors
• portable conveyors
• gravity conveyors
• roll or wheel conveyors
• live roll conveyors
• vertical conveyors

59
Power Elevators

• New elevators or alterations or modifications
  require compliance with code ANSI/ASME A17.1
  Safety Code for Elevators and Escalators.

60
Power Elevators (Cont.)

• Two types of drives
• Electric drive
• traction drive (preferred method)
• winding-drum drive
• Hydraulic drive
• Energy is applied by means of a liquid under
  pressure in a cylinder equipped with a plunger or
  piston.

61
New Elevators

• compliance with code ansi/asme a17.1
• safe and convenient access to the machine room
  and the pit
• adequate lighting in the machine room and
  overhead spaces
• convenient electric outlets on the crosshead and
  in the pit
• an inspection station with slow-speed up and down
  operating buttons and emergency stop switch on
  the top of the car for maintenance personnel and
  inspectors to use
• normal- and final-limit stops, interlocks on all
  hoistway doors, contact on car door and emergency
  exits for the car

62
Power Elevators

• Maintenance and hazard prevention
• Winding drive
• Check stop functionality. (Motor does not stop
  and cable is wound beyond stop, breaking the
  cable.)
• Check cables. (Cables are weakened as they are
  wound and subjected to friction and bending
  forces.)
• Hoistways should be cleaned on a regular basis to
  minimize fire hazards.
• Pits must have a minimum 2-ft clearance between
  the bottom of the car and the pit.

63
Power Elevators (Cont.)

• Maintenance and hazard prevention (cont.)
• Enclose counterweight runways from a point not
  more than 1 ft above the pit floor to a point at
  least 7 ft above the pit floor and adjacent pit
  floors to protect workers from crushing hazards.
• Never use elevator pit for storage or to sweep
  debris into.
• Special precautions must be taken to prevent
  tripping incidents. (passenger and freight)
• Provide lighting of at least 5 fc at the pits
  floor level.
• Emergency Stop switch shall be installed in every
  pit and shall be reachable from the pits access
  door.

64
Power Elevators (Cont.)

• Maintenance and hazard prevention (cont.)
• Only qualified personnel should have access to
  door keys.
• Sides and tops of cars should be made out of
  metal or a fire-resistant material.
• The car should be equipped with a maximum load
  capacity sign.
• Every elevator must have an emergency stop switch
  (red, clearly identified) in the car.

65
ElevatorsEmergency and Disabled

• Emergency procedure for safely removing persons
  in elevator.
• Incorporate the requirements for handicapped
  standard for all new elevators.

66
Sidewalk Elevator

• Definition a freight elevator for carrying
  material, exclusive of automobiles, between a
  landing, a sidewalk, or other area outside a
  building, and the floors below the sidewalk or
  grade level.
• Presents hazards that are not easy to eliminate.
• Best to locate inside the building line or in an
  area not open to the public.
• Conform to the Elevator Code.
• Except by permission of authorities, maximum
  dimensions of openings should be 5 ft at right
  angles to, and 7 ft parallel with building line.
  Side of opening nearest building should be not
  more than 4 in. from building wall.

67
Dumbwaiters

• Definition a hoisting and lowering mechanism
  equipped with a car that
• (1) moves in guides and has a floor area not
  exceeding 9 ft2
• (2) has a compartment height not exceeding 4 ft
• (3) has a rated capacity not greater than 500 lb
• (4) is used exclusively for carrying materials.
• Can be hand or power operated.

68
Escalators

• Definition a power-driven, inclined, continuous
  stairway for raising or lowering passengers.

69
Escalator Safety Devices

• Emergency Stop buttons or other hand-operated
  switches having red buttons or handles,
  accessibly located at top and bottom landings.
• Key-operated button to start and stop unit.
• Each escalator equipped with a speed governor
  that will interrupt the power.
• If tread chain breaks, sensing device should cut
  the power.
• Electrically released and mechanically applied
  brake able to stop the fully loaded escalator.
• Fire protection of escalator floor openings
  against spread of fire and smoke is required by
  local building codes.

70
Man-Lifts

• Principal hazards
• Rider may be carried over the top.
• Rider unable to make emergency stop.
• Rider jumps off early/late.
• Rider strikes head on surface if not conical
  hood.
• Rider unable to reach destination due to power
  failure or belt stoppage.
• Parts of man-lift fail or operate unsafely.

71
Man-Lifts (Cont.)

• Incident prevention
• Construct, maintain and operate man-lift in
  accordance with ANSI/ASME A90.1 Belt man-lifts.
• Use a safety factor of 6 on each step.
• Emergency landings should be provided every 25 ft
  or less.
• Guardrails should be used at floor openings.
• Maximum speed should not exceed 80 fpm.
• Conduct inspections by competent person every 30
  days.