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Working Safely With Bridge and Gantry Cranes PDF
Working Safely With Bridge and Gantry Cranes PDF
for workplaces
WorkSafe Victoria
Advisory Service
222 Exhibition Street
Melbourne 3000
Phone
Toll-free
Email
03 9641 1444
1800 136 089
info@worksafe.vic.gov.au
Head Office
Working safely
with bridge and
gantry cranes
03 9641 1555
1800 136 089
worksafe.vic.gov.au
Local Offices
Ballarat
Bendigo
Dandenong
Geelong
Melbourne
(628 Bourke Street)
Mildura
Mulgrave
Preston
Shepparton
Traralgon
Wangaratta
Warrnambool
VWA 1140/01/05.08
03 5338 4444
03 5443 8866
03 8792 9000
03 5226 1200
03 9941 0558
03 5021 4001
03 9565 9444
03 9485 4555
03 5831 8260
03 5174 8900
03 5721 8588
03 5564 3200
June 2008
Edition No. 1
Contents
Introduction
1. Equipment
10
17
2. Environment
19
Plant layout
20
Workplace traffic
20
Noise
21
Housekeeping
21
Lighting
21
3. Work procedures
22
23
25
Operating plant
26
Parking plant
28
Maintaining plant
29
31
5. Credits
32
Appendices
33
33
35
36
37
39
Introduction
Operating a bridge or gantry crane is skilled work. When the safe work principles
in this guide are not followed, there is potential to cause fatalities, injury or
property damage.
The guide covers the powered operation of bridge and gantry cranes in all
configurations. Powered operations include traversing, travelling, hoisting
(raise and lower are considered to be one operation) and rotation.
It is expected that employers, health and safety representatives (HSRs), health
and safety committees, employees and WorkSafe inspectors will use this guide
to form an opinion about suitable health and safety risk controls, under the test
of reasonably practicable.
This guide is not a substitute for training. This guide does not cover the specifics
that a bridge and gantry crane operator, dogging or rigging person would need
to know to perform their job competently and safely.
A general overview of guidance material can be found in Appendix A.
Occupational health and safety legislation in all states requires employers to:
ensure risks associated with plant and their operations are eliminated
or reduced so far as is reasonably practicable
ensure supervisors and employees, including independent contractors,
are trained and provided with information on:
the nature of hazards associated with the plant, and
the safe operation of plant.
Operating cranes safely is a critical function. Costs associated with crane incidents
have been significant due to a combination of reasons:
WorkSafe Victoria
fatalities
serious injuries
property damage
fines
increased premiums
lost time, and
training.
Introduction
Slinging
Crushed by plant
Damaged load
Under load
Structure failed
Altered plant
Inappropriate use
Prosecution type
Number
Total fines
Average fines
Employer
(OHS Act 2004)
21
$1,153,000 approx
$55,000 approx
Employer
(Dangerous Goods
Act 1985)
$19,700 approx
$9,900 approx
Individual, including
managers
$22,850 approx
$5,700 approx
It should be noted that eight of the prosecutions relate to plant failure. This guidance
primarily deals with inspection, maintenance and disposal of plant to make quality
requirements clear.
There were three prosecutions relating to inappropriate use of plant. Using plant
for its intended purpose is a fundamental safety requirement.
It should be noted that the potential for prosecution exists when there is failure
to comply with the law and not just when an incident occurs.
WorkSafe Victoria
1.
Equipment
WorkSafe Victoria
1.
Equipment
Bridge and gantry cranes may be operated from within a cabin mounted on the crane
bridge or remotely from the ground, either through a hard-wired pendant control or
radio control.
The major components of bridge and gantry cranes are:
A gantry crane.
the runways
the bridge
the hoist unit
the crab or hoist trolley used to transverse the load
the winch drum and hoist rope
the rope termination points, the hook and hook block, which may contain
one or more sheaves
the braking systems
the crane operating area
the electrical supply and its isolation points
the provision of access for service and maintenance/repairs, and
the load limiting devices, which prevent the rated capacity being exceeded.
Crane controls
Its advisable they:
Cabins may be cramped in design. Ensure controls are protected so that the operator
getting in and out of the cabin seat will not cause accidental operation. Dead mans
brake pedal or mechanical protection of joy stick control levers can prevent this.
WorkSafe Victoria
1.
Equipment
be energised by extra-low voltage (i.e. not greater than 50V AC or 12V DC), and
have the support cable and catenary insulated from the crane structure.
limit the reception range to within a distance that provides good visual interface
with the operator
be able to be automatically de-energised when unable to receive a signal within
550 metres
be able to be de-energised when interfered with by other signals
be able to be de-energised when the stop or emergency buttons are activated.
Where there are high risk areas it is critical that the bridge and gantry crew are
operating from a safe area. This can be done by operating the bridge and gantry
crane from a viewing platform or ensuring the controls will only work in a
predetermined safe area.
Lockouts
To operate bridge and gantry cranes safely, it is crucial there is an ability to lock
them out. The following are examples of when a bridge or gantry crane may
need to be locked out:
WorkSafe Victoria
1.
Equipment
Safety devices
There are a number of devices which can be fitted to bridge and gantry cranes
to improve their safety:
Anti-collision devices
Anti-collision devices prevent two or more bridge and gantry cranes operating
on the same runway from colliding with each other.
Deceleration devices
Deceleration devices, such as limit switches and two-stage decelerators, slow
the bridge or gantry crane down regardless of what control is being pressed when
a travelling crane is approaching the end of the runway, to prevent end stop collision
or over run.
Load-limiting devices
All bridge and gantry cranes should be fitted with load-limiting devices. Load-limiting
devices assess the load and prevent lifting should the rating capacity of the plant
be exceeded.
Anti-fall devices
Anti-fall devices, such as anti-drop plates, should be fitted to bridge and gantry
cranes to prevent falls of plant in the event of failure.
Minimum working height
The minimum clearance above working mezzanines is 1.8 metres.
Access to ladders and platforms
Service platforms should be provided for all bridge and gantry components that
require servicing. Where a permanent structure is not provided, a mobile device,
such as a cherry picker, can be provided so long as it remains available at all times.
Work platforms should have fall protection incorporated.
The work platform should be designed so that tools and parts can be accessed
without needing to be carried up ladders (three points of contact).
Service areas should be isolated from power sources. For further information, see
AS 1418.3 1997, Cranes, hoists and winches Bridge, gantry, portal and jib cranes.
Signage
The crane classification and working load limit of the crane must be displayed on
each bridge and gantry crane.
WorkSafe Victoria
1.
Equipment
A formalised job safety analysis and a risk assessment should also be completed.
This consultation, job safety analysis and the risk assessment should form the basis
of discussions with the supplier of the bridge and gantry crane.
Example:
It is determined that the crane needed must have: 5 tonne capacity, 15 metre span and
a two speed all motion capacity. The crane will operate 24 hours a day, 7 days a week.
In this case, see the table below for two options:
Costs
A: Standard crane
B: Production crane
Purchase
$30,000
$45,000
Service
$600pa
$1,800pa
Repair
$6,000pa
$2,000pa
In this example, crane choice A is not designed for that frequency of use, whereas
crane choice B is more suited to the work and represents a safer choice.
Crane A is designed to do less operating cycles than crane B is. The example
shows that due to overuse, the repair costs of crane A are running much higher
than would be expected.
Source: Engineering Buying Advisory Service.
WorkSafe Victoria
1.
Equipment
Inspection
Inspections should be carried out by competent person(s) at intervals to keep the
bridge and gantry cranes in a safe condition. This is to be determined by the designer,
manufacturer and/or the supplier of the plants recommendations in relation to
its frequency of use. The following inspections should occur as a minimum unless
otherwise stated by the designer, manufacturer and/or the supplier of the plant:
pre-operational inspections prior to the use of the bridge and gantry crane
on each shift
periodic inspection based on the duty cycle, but should not exceed 12 months
between inspections
major inspections to determine the bridge and gantry cranes suitability
for continued use this should occur at intervals not exceeding 10 years for
mechanical and 25 years for structural, or more frequently where recommended
by the designer, manufacturer and/or the supplier of the plant or when deemed
necessary by a competent person, and
third-party inspections it is recommended that third party inspections are
conducted at a frequency in accordance with the inspection table below:
Inspection table
C1
C2
C3
C4
C5
C6
C7
C8
M1
M2
M3
M4
M5
M6
M7
M8
0.5
>0.5 1
>1 2
>24
>4 8
>8 16
>16 20
>20
12
12
12
12
Source table 7.2.1 Australian Standard AS 2550.3 2005, Cranes, hoists and winches Safe Use Bridge, gantry, portal, jib and monorail cranes.
WorkSafe Victoria
1.
Equipment
Records
A bridge and gantry crane service record book should be kept for each crane.
The book should contain the following as a minimum:
WorkSafe Victoria
1.
Equipment
There are many accessories that are designed to be used with bridge and
gantry cranes. This section provides a basic overview of good safety principles
for lifting accessories.
From the hook to the load, the lifting gear can be made up of many parts. The weight
of the load must not exceed the Working Load Limit (WLL). The weight of all the
lifting gear must be calculated as part of the load for this purpose.
The working load limit of lifting gear is only as great as the part with the lowest
working load limit.
To keep it simple, its good working principle to ensure safety by configuring the
arrangement where the sling is the accessory with the lowest rating and has a rating
appropriate for the load to be lifted.
10
WorkSafe Victoria
Equipment
1.
General
Unacceptable Work Practice
WorkSafe Victoria
11
1.
Equipment
General (continued)
Unacceptable Work Practice
Synthetic slings
Synthetic slings
12
WorkSafe Victoria
Equipment
1.
General (continued)
Unacceptable Work Practice
Chain slings
Chain slings
Chain slings are not tagged with their working load limit
and identifying markings.
Selection
Unacceptable Work Practice
WorkSafe Victoria
13
Equipment
1.
Inspection
Unacceptable Work Practice
Synthetic slings
Synthetic slings
Chain slings
14
WorkSafe Victoria
Equipment
1.
Inspection (continued)
Unacceptable Work Practice
Disposal
Unacceptable Work Practice
WorkSafe Victoria
15
Equipment
1.
Storage
Unacceptable Work Practice
Synthetic slings
Chain slings
16
WorkSafe Victoria
Equipment
1.
General
General
Selection
Inspection
Inspection
WorkSafe Victoria
17
Equipment
1.
General
General
18
WorkSafe Victoria
2.
Environment
Plant layout
Workplace traffic
Noise
Housekeeping
Lighting
WorkSafe Victoria
19
2.
Environment
Bridge and gantry crane operation can be affected by the environment of the
workplace. This in turn can affect the overall health and safety of all employees.
Plant layout and other physical situations need to be considered and addressed
to ensure workers are not placed at risk.
Plant layout
The layout of plant should always be considered from a health and safety perspective,
as well as from a production perspective. Bridge and gantry cranes run on runways,
which gives the employer complete control of the crane operating area. The workplace
should be set up so that a crane operator has the load in full view at all times.
The following matters should always be considered:
the crane operating area of the bridge and gantry crane
the location of slings and other crane accessories
the location of designated raw material and delivery areas
raw materials are stored in an easily accessible area close to the
start of the production area
linear workflow through the production line
clear areas of work
elimination of blind spots
traffic management and identified segregation
the location of workstations, and
manual handling of loads and lifting equipment.
Workplace traffic
A documented traffic management plan is crucial for resolving many hazards and
risks. The plan should include bridge and gantry crane hazards and risks. The plan
needs to address hazards and risks where bridge and gantry crane work interacts
with worker, pedestrian, vehicle or other plant movements. This includes where
multiple cranes operate on the same runway.
Traffic hazards that should be addressed include:
pedestrian exclusion zones
designated traffic zones
loading and unloading zones
right of way
incident reporting and investigation
blind spots
site layout
signage
workstations in the crane operating area, and
trapping spaces.
The involvement of HSRs and other employees particularly a dogging or rigging
person and/or bridge and gantry crane operator is an essential part of this process.
This involvement should result in many ideas and possible solutions.
The Traffic Management Plan should be regularly reviewed and updated when
workplace changes or equipment upgrades occur.
Refer to WorkSafe Victorias guidance booklet Forklift safety. Reducing the Risk.
20
WorkSafe Victoria
2.
Environment
Noise
Bridge and gantry cranes can be located in a variety of workplaces. The noise
from surrounding areas can impact on the safe operation of this plant. The noise
regulations are to protect people from noise-induced hearing loss. There may be
other noise-related hazards that impact on safe bridge and gantry crane operation.
These hazards should be identified, assessed and controlled.
Where there is background or nuisance noise, an assessment should be conducted.
Any identified hazards and/or risks should be controlled.
Background or nuisance noise can cause a hazard or risk as it can become
a distraction or cause problems with communication. Background noise becomes
an issue where it impacts on the effective communication of the bridge and gantry
crane crew. Noise can also be a hazard when a worker is working within the crane
operating area and cannot hear that the crane has commenced work in the area.
Housekeeping
By implementing a good housekeeping plan, workplaces are kept clean and free
of waste. Risk of injuries occurring due to slip, trips and falls, together with injuries
resulting from hitting stationary objects, is also reduced. A tidy well laid out workplace
can also increase work efficiency. Working zones in the crane operating area
particularly need to be kept clean and free of waste.
Items should be stored correctly with no parts protruding onto walkways. Electrical
leads should not be on the floor; tools should have designated areas for storage; and
bins for waste should be readily available and be easy to empty.
Structured programs that focus on organisation, cleanliness and standardisation can
be introduced to the workplace to assist with this. Cleanliness can be maintained in
a clean as you go manner. Good housekeeping sets a clear environment that helps
identify hazards and risks more effectively.
Lighting
The quality of lighting in a workplace has a significant effect on safety and
productivity. Lighting should be sufficient so all areas of travel are lit for the crane
operator to clearly observe the load and hazards at all times. Lighting also needs
to be sufficient so that the bridge and gantry crane crew can perform tasks such
as slinging correctly and safely.
The following actions can improve the lighting within the workplace:
WorkSafe Victoria
21
3.
Work procedures
Operating plant
Pre-operation
Operating the bridge and gantry crane
Parking plant
Maintaining plant
Reporting faults
General maintenance
Preventative maintenance
Recommissioning
22
WorkSafe Victoria
3.
Work procedures
A licence is not required for bridge or gantry crane operation, providing that:
it is remotely controlled by way of pendant or radio, and
the crane does not have any more than three powered operations.
A dogging licence or rigging licence is required when:
the operator exercises judgment in the selection of slings, the weight
of the load or its centre of gravity, or
where there is a need to direct the bridge and gantry crane operator
in the movement of the load.
Note: It is recommended that for bridge and gantry crane operation, the crane operator
maintains line of sight with the load at all times.
Site specific training is required when employing a bridge and gantry crane
operator or a person with a dogging or rigging licence. This training will need to
cover (as a minimum) the specific equipment to be used and the site procedures.
Supervision
Safety supervision (supervision) is different from production supervision.
The employer must supervise to ensure that employees do what is required
for their own health, safety and welfare, including that of others.
Employees may fail to understand and follow instructions because:
the instructions may not have been clearly expressed
the system of work may not be sufficiently and clearly defined
the system of work may not be practicable
the relevance or importance of elements of systems of work may
not be appreciated
employees may not appreciate the dangers of not using or following safeguards, or
work pressures, environmental conditions or other distractions may lead
to inattention.
An employer may be in a position to personally supervise. The employer should
ensure proper supervision is being undertaken where this task has been delegated.
This can be done by reports from the person delegated. Supervisors must be
competent, know how to best use specific risk controls and be supported in this role.
Where a person is being trained to acquire competencies and/or licences they must
be provided with direct supervision. The supervisor of a trainee must be authorised
by the employer and be a suitably competent person. Where the trainee is being
trained in relation to licensed work, the supervisor must hold the relevant licence.
WorkSafe Victoria
23
Work procedures
3.
The plant
Unacceptable Work Practice
The workplace
Unacceptable Work Practice
24
WorkSafe Victoria
Work procedures
3.
Production
Unacceptable Work Practice
WorkSafe Victoria
25
Work procedures
3.
Maintenance
Unacceptable Work Practice
Operating plant
The task of operating bridge and gantry cranes is hazardous work. This work needs to be carefully planned and conducted by
competent and trained personnel in accordance with specifically developed standard operating procedures to ensure safety.
Pre-operation
Unacceptable Work Practice
26
WorkSafe Victoria
Work procedures
3.
WorkSafe Victoria
27
Work procedures
3.
Parking plant
When not in use, bridge and gantry cranes need to be parked. Parking bridge and gantry cranes in designated areas can prevent
accidental damage. The bridge and gantry crane also needs to be secured to prevent unauthorised use.
28
WorkSafe Victoria
Work procedures
3.
Maintaining plant
In the introduction to this guide, we covered the effects of poor maintenance in relation to prosecutions. This is a critical
area and planning these tasks goes a long way to reducing the associated risks. Supervision is another area that is critical
in achieving safety in relation to maintenance tasks.
Reporting faults
Unacceptable Work Practice
General maintenance
Unacceptable Work Practice
WorkSafe Victoria
29
Work procedures
3.
Preventative maintenance
Unacceptable Work Practice
Recommissioning
Unacceptable Work Practice
30
WorkSafe Victoria
4.
General
Information
and guidance
Legislation
Other publications
WorkSafe Victoria
31
5.
Credits
32
WorkSafe Victoria
Appendices
WorkSafe Victoria
33
Appendices
Issue Resolution
When a health, safety and/or welfare issue arises in relation to bridge or gantry
crane operation, the employer and employees affected must attempt to resolve
it. The employees are entitled to be represented by their HSR in this process.
Section 73 of the OHS Act details how health and safety issues are to be resolved
at the workplace. The employer or their representative (i.e. manager, supervisor) and
employees affected by an issue must try to resolve health and safety issues using
agreed workplace procedures. The employer or representative attempting to resolve
health and safety issues must be sufficiently senior and competent to act and make
decisions. If the issue cant be resolved, a WorkSafe Victoria inspector can be called
in to assist in this process.
For more information on the duty to consult, please refer to the WorkSafe Victorias
publications Guides Talking Safety Together and Consultation A Users Guide.
Contractors
Employers legal duty to provide and maintain a safe work environment applies
to employees, contractors and labour hire workers.
Young workers
Young Victorian workers aged between 15 and 24 are more likely to be injured
at work than any other age group. Young workers must be properly trained,
supervised and provided with sufficient information so that they can
work safely. Supervision especially needs to be tailored for young peoples
needs. See worksafe.vic.gov.au/youngworkers.
Reasonably practicable
When determining reasonably practicable controls, Section 20 of the Occupational
Health and Safety Act 2004 outlines what you must take into account when deciding
if something is reasonably practicable. Specifically, the factors to be taken into
account are:
Its important to understand that all the factors listed above have to be taken
into account when deciding if something is reasonably practicable.
For further information, refer to the WorkSafe Position How WorkSafe applies the law
in relation to Reasonably Practicable.
34
WorkSafe Victoria
Appendices
WorkSafe Victoria
35
Appendices
Flat slings
Endless
Reversed eye
Flat eye
Folded eye
All slings are labelled with the WLL. Slings that do not have a label must not be used.
36
WorkSafe Victoria
Appendices
WorkSafe Victoria
37
Appendices
38
WorkSafe Victoria
Appendices
SERIAL#:
DATE:
W.L.L.:
DEPT USED:
CERT#:
96413
TESTED BY:
Cert Lifters Pty Ltd
COMPONENT
Battery lifter
DESCRIPTION
WEIGHT
10 KG
DESCRIPTION OF LIFTING EQUIPMENT:
Box tube assembly with
Eyelet
Two bars with hooks
APPLICATION OF LIFTING EQUIPMENT
Used for lifting truck batteries into truck engine-bay on assembly line.
WorkSafe Victoria
VWA023
15 MAY 08
30 KG
Engine dress up
39
Appendices
40
WorkSafe Victoria
Contents
Introduction
1. Equipment
10
17
2. Environment
19
Plant layout
20
Workplace traffic
20
Noise
21
Housekeeping
21
Lighting
21
3. Work procedures
22
23
25
Operating plant
26
Parking plant
28
Maintaining plant
29
31
5. Credits
32
Appendices
33
33
35
36
37
39
A handbook
for workplaces
WorkSafe Victoria
Advisory Service
222 Exhibition Street
Melbourne 3000
Phone
Toll-free
Email
03 9641 1444
1800 136 089
info@worksafe.vic.gov.au
Head Office
Working safely
with bridge and
gantry cranes
03 9641 1555
1800 136 089
worksafe.vic.gov.au
Local Offices
Ballarat
Bendigo
Dandenong
Geelong
Melbourne
(628 Bourke Street)
Mildura
Mulgrave
Preston
Shepparton
Traralgon
Wangaratta
Warrnambool
VWA 1140/01/05.08
03 5338 4444
03 5443 8866
03 8792 9000
03 5226 1200
03 9941 0558
03 5021 4001
03 9565 9444
03 9485 4555
03 5831 8260
03 5174 8900
03 5721 8588
03 5564 3200
June 2008
Edition No. 1