Part One Overview

Objectives:
Understand that cranes and hoists have a lot of regulation Know the hazards associated with cranes and hoists Become familiar with common types of industrial cranes and hoists Understand rigging basics, including the importance of sling angle. Be familiar with methods of controlling crane hazards and preventing accidents. Understand the basics of performing a lift. There is a lot to know and understand about hoists and cranes. These very help tools can save us a lot of time and effort in our work day and make some tasks possible that would not be so if we did not have a lift assist. However, these tools can also be extremely dangerous because they are lifting things that we cannot. Your safety and the safety of your coworkers depend on your ability to operate a hoist properly every time.

Michigan Regulations
General Industry Standards Part 18 - Overhead and Gantry Cranes Rules 1801-1875 Part 20 - Under hung Cranes and Monorail Systems Rules 2001-2045 Part 49 - Slings Rules 1901-1965

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Federal Regulations
General Industry (29 CFR 1910)

1910 Subpart N, Materials handling and storage 1910.179, Overhead and gantry cranes 1910.180, Crawler locomotive and truck cranes 1910.181, Derricks

Construction Industry (29 CFR 1926) 1926.1501, Cranes and derricks 1926.552, Material hoists, personnel hoists, and elevators 1926.554, Overhead hoists

Industry Consensus Standards

ANSI/ASME* - B-30 Series - Safety Requirements for Cranes, Derricks, Hoists, Jacks, and Slings CMAA** - Specifications No. 70 and 74 - Crane Operators Manual

*American National Standards Institute * American Society of Mechanical Engineers ** Crane Manufacturers Association of America

All Employers Must:

Maintain Crane Safeguards. Review Job Specific Hazards. Implement Corrective Actions. Conduct Hazard Assessments. Conduct Accident Investigations. Provide Training to All Required Employees. Control Workplace Hazards Using PPE as a Last Resort.

Crane Hazards
Over 250,000 cranes are in operation (does not include hoists) 125,000 in construction 80,000 in general & maritime 80 fatalities per year One death per 1000 crane operators in their working lifetime (45 years) Risk to citizens and other workers. Major cause of incidents are: Contact with energized power lines (45% of all incidents) Overturned cranes Dropped loads Boom Collapse Crushing by counter weight Improper outrigger use Falls
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Rigging Failure

Types of Cranes and Hoists Industrial Overhead Gantry Jib

Overhead Cranes Common in industrial facilities Supported by overhead rails Components Bridge Trolley Hoist Often pendant or remote operated Easy to use, little training required, no stability issues

Gantry Similar to overhead cranes but supported by a frame which travels on the ground.

Jib Crane/Hoist Pivot mounted boom with trolley and

Floor-mounted jib crane

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hoist.

Hoists Power hoist Usually electric or air operated Chain hoist (or chain fall) Hand operated Can put stress on the human body from pushing or pulling activities.

The Employees Role Considerations

1. 2. 3. 4. 5. Report All Accidents and Near-Misses Immediately. Contribute to Make Corrective Actions. Always Provide Complete and Accurate Information. Report All Crane Safety Problems or Deficiencies. Follow-up With Any Additional Information.

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 Operators Requirements (Rule 1851)

18 years old Must have corrected vision. Effective use of all 4 limbs Be tall enough to operate controls and see the life area. Have coordination between eyes, hands, & feet. Have no convulsive disorders or episodes of unconsciousness. Must be able to understand signs, labels, and instructions.

Training Requirements Training (Rule 1852 (1))

Equipment Capacities Purpose, use and limits of controls Estimating load weight Signals Operation (startup, General, shutdown, Emergency)

Must be refreshed every 3 years as a minimum. Retraining (Rule 1852 (2))

If observed to operate in an unsafe manner Has been involved in an incident or near-miss Evaluation of unsafe operation New or differ style of crane/hoist Changes in operating conditions effecting safe crane usage

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 Testing (Rule 1853)

Done via class room and practical demonstration. Conducted for all normal job functions Knowledge of Equipment Daily checks & inspection requirements MIOSHA Part 18 Must be available for review at all times during work hours Must indicate the type of crane/hoist is qualified on Must have adequate Identification information

Documentation
1. Identify items that were inspected. 2. Show the status of the inspected items. 3. Provide the signature of the inspector. 4. Show the date. 5. File it and maintain it! REVIEW THE MANUFACTURERS SPECIFIC INSPECTION REQUIREMENTS!

Permit to Operate

Inspection, Testing & Maintenance Start of Each Shift:

1. Visually Inspect all units for integrity, leaks etc. 2. Check the operation of the crane; controls & movement. 3. Operate empty hook till it actuates the upper limit switch. 4. Operate hoist and trolley brakes, ensure no excessive coasting. 5. Check for twisted, broken or kinked cables or chains. 6. Observe correct drum spooling as the hook is raised. 7. Inspect for deformed, cracked, or stretched hooks. 8. Inspect for serviceable safety latches. 9. Check for air or hydraulic fluid leakage. 10. Check for load capacity stenciling on both sides of unit. REVIEW THE MANUFACTURERS SPECIFIC INSPECTION REQUIREMENTS!

Monthly Inspections:
1. Visually Inspect all critical items. 2. Measure hooks for deformation or stretching. 3. Inspect hooks for cracks, missing or broken parts. 4. Measure lifting chains for excessive stretch, twisting etc. 5. Inspect for twisted, broken or kinked cables or chains. 6. Follow any additional recommendations of the manufacturer. REVIEW THE MANUFACTURERS SPECIFIC INSPECTION REQUIREMENTS!

Periodic Inspections (1 to 12 Month Intervals):

1. 2. 3. 4. Interval dependent on the type of activity performed. Interval dependent on the severity of service. Interval dependent on the environmental conditions. As a minimum the inspection should cover:
Reeving Hoist Drives Limit Switches Balance End Stops Hook Condition Travel Drives Couplings Controls Signage

Periodic CMAA Inspection Recommendations:

Class Description Typical Schedule
A Standby or infrequent service Annually B Light service - 2-5 lifts hr. Annually C Moderate service - 50% capacity, 5-10 lifts hr. Annually D Heavy service - 50% capacity, 10-20 lifts hr. Semiannually E Severe service - Near capacity, 20+ lifts hr. Quarterly F Continuous severe service - Near capacity and continuous service throughout day Bi-monthly

Chain or cable Electrification Brakes Rails Warning Devices

REVIEW THE MANUFACTURERS SPECIFIC INSPECTION REQUIREMENTS!

DIFFERENT CONDITIONS MAY SUGGEST DIFFERENT

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INTERVALS.0000

New Cranes:
Prior to initial use, cranes must be tested and inspected completely using the criteria applicable to periodic inspections. A report should be kept on file for future reference.

Idle Cranes:
Cranes that have been idle for a period that exceeds six months must be inspected and tested before being placed back in service using the criteria that applies to periodic inspection. Special attention should be given to the hook, lifting chain and wire rope.

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 Load Testing a New Crane:

New and rebuilt hoist are load tested by the manufacturer at the factory. Most manufacturers will furnish load test certificates for a nominal charge.

Load Testing a Used Crane:

When load testing a used crane, the test load cannot exceed 125 percent of the rated load unless otherwise recommended by the manufacturer. The hoist, trolley and crane should be operated a number of times at various positions. The test load should be transported by the trolley and bridge over the full length of the crane. A report should be issued by the testing organization giving the conditions under which the system was load tested. 1. Ensure all emergency disconnects are known before any test. 2. If youre not familiar with the cranes operation get help. 3. Ensure that the manufacturers recommendations are followed. 4. If you have a checklist - follow it! 5. Inspect all electrical controls for proper operation. 6. Check for obstructions in the travel path of the crane. 7. Test all controls to determine proper operation. 8. Observe for smooth operation of the components. 9. Never unwind the spool completely! 10. Check upper and lower limit switches.

Preventive Cover:

Maintenance

Should Preoperational Tests - General:

1. Cleaning and lubricating the wire rope (cable) and load chain. 2. Adjusting the brakes. 3. Checking and filling the gear cases to the proper levels. 4. Replacing any contaminated oils. 5. Lubricating the bearings, gears, pinions, linkages, shafts, etc. 6. Adjusting the operation of limit switches. 7. Cleaning or replacing pitted or burned electrical contacts. 8. Cleaning or replacing the air and fluid filters. 9. Inspecting the operation of all controls and warning systems. Preoperational Tests - Rope: 1. Reduction in rope diameter (replace if found). 2. Broken or worn outside wires. 3. Corroded or broken wires at end of connections. 4. Severe kinking, crushing, cutting or unstranding. 5. Corroded, cracked, bent, worn, or improperly applied end connections.

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Part 2 Safety
Crane Safety
Lifting operations are inherently dangerous. Even when proper training is conducted, Equipment is properly maintained, Employees conduct themselves in a safe manner, and other facets of the safety program are conscientiously attended to, accidents can still occur. The reason is that crane operations are primarily dependent on mechanical devices.

These devices can and do fail. When this happens during a lifting event the results can be catastrophic. You are the only controlling influence that can minimize the hazard. Your life literally is in your own hands!

Safe Practices for Operators:

Test all hoist controls and brakes at the beginning of each shift. Never attempt to operate a crane or hoist that is suspected to be unsafe. Always test brakes by a short lift to ensure control. Move loads only after being signaled by the designated, qualified signaler.

Safe Practices for Operators (continued)

Never carry loads over workers. Never carry loads past workers (they must yield right of way). Signalers must keep line-of-sight with the operator. Never allow riders on loads or hooks. Never allow unauthorized persons to operate cranes. Always lockout before maintenance or
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repairing cranes. Frequently inspect cranes exposed to adverse conditions.

Safe Practices for Operators (continued)

Always position the hook directly over the load before lifting the load off of the floor. Document and maintain inspection records. Check warning devices and signals before use. Signalers must watch the load. Operators must watch the signalers. Know your travel path in advance of the lift! Know where youre going to set the load down! Will the new location support the weight?

Leaving or Parking Hoists or Cranes

Raise all hooks to - but not through - limit switches. Place all controls in the off position. Place main power switch in the off position. Make a visual check for any dangerous condition. Report any defects immediately. Tag out defective equipment immediately. Report all cranes that are not in operation immediately. Follow the manufacturers recommendations.

Lifting Factors
Size, Weight, and Center of Gravity of the Load. The Number of Sling Legs. The Angle the Sling Makes With the Horizontal Line. The Rated Capacity of the Sling. The History of the Care and Usage of the Sling. Number of Legs and Angle with the Horizontal. As the angle formed by the sling leg and the horizontal line decreases, the rated capacity of the sling also decreases.

Lifting Factors Continued

Size, Weight, and Center of Gravity of the Load. To make a level lift, the crane hook must be directly above the center of gravity point. If the crane hook is too far to one side of the center of gravity, dangerous tilting and unequal stress to the sling leg will result.

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Consult with the sling manufacturer concerning how sling angles affect load capacities for different types of slings.

Rated Capacity of the Sling. The rated capacity varies depending upon the type of the sling, the size of the sling, and type of hitch. Consult with the manufacturer. Also, older slings must be used with additional caution. Sling charts are generally based on new sling usage.

Sling Angles:
The angle the sling is hung affects the sling load capacity. The greater the sling angle the greater the stress. Multiple sling usage drastically affects load capacity. The type of sling used is a factor. Consult with the sling manufacturer for proper usage.

See below for more examples:

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 Sling angle
Stress on sling legs varies with the angle

Divide the load by the number of sling legs, and divide by sin of the angle For a two-legged sling, 2000 lb load and 60 degree, stress = 1155 lbs on the sling leg

Sling Angles:
The use of two slings, each supporting the same amount of weight and having the same support angle results in equal distribution of the load weight.

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If slings are used as twin slings, the carrying capacity decreases as the spread between the slings increases. To determine the capacity of each sling in a bridle hitch: 1. Measure the distance along one sling for the same number of units as the capacity of the sling in tons (Distance A). 2. Measure the vertical distance from the point located in (1) to the load in tons. (Distance B). 3. The number of units in this vertical distance (B) is the working load for the sling.

A = 2 ft. (or any unit) (2 Ton Sling Capacity) B = 1.5 ft. Working Capacity of Each Sling = 1.5 Tons
Note: The individual sling capacity must be more than half of the total load weight! Consult with the manufacturer for specific types of rigging arrangements

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History of Care and Usage of Rigging

Mishandling and misuse of sling are the leading cause of sling-related accidents. Proper care is essential for maximum service and safety. Always protect slings with cover saddles, burlap padding or wood blocking to prevent sharp bends and cutting edges.

Estimating Weight of Load

Use a Dynamometer. Check shipping papers. Check nomenclature plates. Use industry standard tables or charts. Consult with the equipment manufacturer. Estimate weight using weights of similar loads. Never attempt a load lift based solely on a guess! Stay within 50% of the cranes rated capacity when estimating loads (or manufacturer recommendation).

Consult with the sling manufacturer concerning load capacities, usage methods, restrictions and other pertinent data for specific types of slings.

Rigging Types of Rigging and Slings

Chains. Wire Rope. Fiber Rope. Synthetic Web. Cargo Nets. EACH TYPE HAS ADVANTAGES AND DISADVANTAGES!

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Rigging

Cranes and hoists are always used with rigging or some other specific lifting aid. Always use rigging to connect the load to the hook.

General Practices
Slings must be free of twists, bolts, knots, kinks, and other listed damage. Damaged slings cannot be used. They must not be used for lifts over their rated capacity. Rigging must always be properly labeled with tag or badge that displays the specific load rating. Fingers must be kept clear of where the sling and the load will be tightened.

Materials
Wire Rope

Fabric

Chain

Metal Mesh

MIOSHA Rule 4912.

(1) A sling and all fastenings shall be inspected for damage and defects by a designated employee before each days use. (2) Where service conditions warrant, additional inspections shall be performed during sling use. re inherently dangerous. Even when proper training is part shall be immediately removed from service.

Wire Rope
Usually a core member is included to increase flexibility. Fiber Core (FC) Wire Strand Core (WSC) Independent Wire-rope Core (IWRC) Classified by strand and wire count 6x31 IWRC is common rope for overhead cranes. 6 strands of 31 wires each and a central core.

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Example of Wire Rope Construction

Rules for use Must always follow Manufacturers guidelines. Cannot be used at temperatures over 200 F Proper minimum length An eye in a wire rope must not be made by using a knot or rope clip. Damage to Wire Rope If any of the damaged shown to the left is present then the wire rope sling must be removed from service.

MIOSHA Rule 4932

(1) Cable laid and a 6 x 19 and 6 x 37 sling shall have a minimum clear length of wire rope 10 times the component rope diameter between splices, sleeves, or end fittings. (2) A braided sling shall have a minimum clear length of wire rope 40 times the component rope diameter between the loops or end fittings. (3) A cable laid grommet, strand laid grommet, and endless sling shall have a minimum circumferential length of 96 times their body diameter. A wire rope sling shall be removed from service if any of the following conditions are present: (a) Ten randomly distributed broken wires in 1 rope lay, or 5 broken wires in 1 strand in 1 rope lay. (b) Wear or scraping of 1/3 the original diameter of outside individual wires. (c) Kinking, crushing, bird caging, or any other damage resulting in distortion of the wire rope structure. (d) Evidence of heat damage. (e) End attachments that are cracked, deformed, or worn. (f) Hooks that have been opened more than 15% of the normal throat opening measured at the narrowest point, or twisted more than 10 degrees from the plane of the unbent hook. (g) Corrosion of the rope or end attachments.

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 Chain
Must have label Must be regularly inspected If damaged it must be immediately taken out of service. Any attachments must have at least the same rated strength as the chain.

Inspection Procedures for Alloy Steel Chain Slings Remove from service if you find:
1. 2. 3. 4. 5. 6. Defective or questionable welds. Bending or elongation of chain links. Cracked or deformed master and coupling links. Missing or removed identification tags. Any end attachments cracked, deformed or worn. Any other reason to suspect an unsafe condition.

Rule 4921
An alloy steel chain sling shall have a permanently affixed, durable identification, stating the size, grade, rated capacity, and reach.

Fabric
Must have label Splicing may only be done to MIOSHA specifications Knotting is not allowed Must not be used around material with sharp edges Must be regularly inspected If damaged it must be immediately taken out of service. Any attachments must have at least the same rated strength as the chain. Some types of Rope can not be used around specific hazardous materials.

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Inspection Procedures for Synthetic Web Slings Remove from service if you find:
1. Acid or caustic burns. 2. Age deterioration (drying out cracking etc.). 3. Melting or charring of the sling surface. 4. Snags, tears or cuts causing exposure of colored thread. 5. Missing or removed identification tags. 6. Any other reason to suspect an unsafe condition.

Rigging Hitches Sling Hitches

Straight (regular) Choker Basket Double,triple, etc.

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 Only the hitches illustrated in the previous slide are allowed by MIOSHA. Other styles of hitching are considered to be jury rigged and to increase the risk of rigging failure. MIOSHA Part 49 has tables with specific ratings for many types of rigging. If the rigging your using is not listed then you MUST follow the manufacturers recommendations.

Working Rules for Slings

Never load in excess of the rated capacity. Never use a sling that is damaged in any way. Never pull a sling from a suspended load under tension. Never shorten with knots, bolts or other makeshift devices. Always keep suspended loads clear of employees. Always keep suspended loads clear of all obstructions. Always keep hands and fingers clear of untensioned loads. Always pad or protect slings from sharp edges of the load. Always think before you affect a load.

Storage Rules for Slings:

In a dry environment out of direct sunlight. Off of the floor or ground to prevent corrosion. Hung from hooks to prevent tangling and easy access. Away from electrical sources. By type - i.e. dont mix steel chain slings with synthetics. In a controlled area.

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Signaling
Safe Practices for Signalers
Only one person is the designated signaler. Maintain line-of-sight with the operator. Ensure the operator acknowledges every signal. Stop the operation if comprehension is lost. Operators must watch the signalers. Plan in advance where the load is going! Know the new location will support the weight.

When to use Hand Signals

When distance, noise, or other audio limitations prevent adequate communication then hand signals must be used. Knowing the correct hand signals is required by MIOSHA Regs.

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Lift Follow up

After the Lift is Completed:

Clean the sling. Check for damage. Follow proper storage rules. Leave in proper condition for the next lift. Dont wait to report damaged or defective slings. Follow proper disposal or replacement procedures.
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Summary of Training Remember, You Control Your Facility or Area! Review Their Procedures With Them Before Starting the Job! Determine Their Safety Performance Record! Determine Who Is in Charge of Their People! Determine How They Will Affect Your Employees!
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