Title: Cranes%20and%20Derricks
1- Cranes and Derricks
- OSHA 1926.453
2Crane 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
3Crane 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.
4Crane and Hoist Safety
- OSHA programs
- Last standard update was in the 70s
- Many advancements have been made, but not
addressed
5GENERAL 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 !!!!!!
6General 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.
7General 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
8General 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.
9General 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.
10General Requirements
- The employer shall designate a competent person
who shall inspect all machinery and equipment
prior to each use as well as during use.
11General Requirements
Inspected ?? Yes or No
12General Requirements
13General Requirements
Rusted and Bent This needs to be replaced prior
to use.
14COMPETENT PERSON
- What constitutes a
Competent Person ????
15Competent 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.
16General 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.
17WIRE ROPE
18WIRE ROPE
- Wire rope shall be taken out of service for a
number of reasons and should be inspected daily.
19Wire 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.
20Wire 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.
21Wire 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
22Wire 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.
23PROPER SET-UP
- Level
- Stable
- Clearance
- Reach
24BASIC 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
25BASIC RIGGING
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.
26BASIC RIGGING
- Protecting the overall stability of the rig by
using throat latches. - Must be in place and functional
27BASIC RIGGING
Load blocks etc. must be rigged properly.
28Guarding
- 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
29Guarding
- 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.
30Guarding
A very dangerous situation unless protected.
31Guarding
- All exhaust pipes etc. shall be protected from
employee contact.
32Guarding
- ALL windows in cabs shall be of safety glass, or
equivalent that introduces no visible distortion
to the operator.
33Guarding
- 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.
34Fire Protection
- At least a 5BC rated fire extinguisher shall be
available at all operator stations or cabs of
equipment.
35ELECTRICAL 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.
36Electrical 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 !!!!
37Electrical Safety
- Things to consider when deciding on the
Clearance - 1. Clearance from What ??
- 2. Drift
- 3. Load swing (Tag Lines)
- 4. Boom and Jib
38Electrical 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.
39Electrical 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
40Electrical 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
41Electrical 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
42Electrical 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
43Electrical 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.
44Electrical Safety
- INDUCED ELECTRICAL CHARGES
- Combustible and flammable materials shall be
removed from the immediate area prior to
operations
45Suspended 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.
46ACCIDENTS
FAMOUS LAST WORDS ITLL NEVER HAPPEN HERE !!
47ACCIDENTS
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.
48ACCIDENTS
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.
49ACCIDENTS
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.
50ACCIDENTS
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.
51ACCIDENTS
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.
52ACCIDENTS
All cranes have limits.They will tip when those
limits are exceeded.
53ACCIDENTS
Inexperience usually results in the above
54ACCIDENTS
Inexperience usually results in the above
55Accidents 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.
56THE MOTHER OF ALL CRANE COLLAPSES
57THE 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.
58 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).
59SUSPENDED PERSONNEL PLATFORMS
60SUSPENDED 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.
61SUSPENDED 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.
62SUSPENDED 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.
63SUSPENDED 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.
64SUSPENDED 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.
65SUSPENDED 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
66SUSPENDED 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.
67SUSPENDED PERSONNEL PLATFORMS
- All operator controls, gauges etc. must be
visible and in working order when lifting
personnel.
68SUSPENDED 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).
69PLATFORM 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.
70PLATFORM 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.
71PLATFORM 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).
72PLATFORM 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.
73PLATFORM 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.
74PLATFORM 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.
75PLATFORM 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.
76PLATFORM 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.
77RIGGING 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.
78RIGGING 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.
79RIGGING THE PLATFORM
- All eyes in wire rope slings shall be fabricated
with thimbles.
80TRIAL 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.
81TRIAL 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.
82TRIAL 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
83TRIAL 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
84TRIAL 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
85WORK 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.
86WORK 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.
87WORK 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.
88WORK 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.
89PRE-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.