Crane Safety PDF

EHS Training for OPGC
Environment, Health and Safety Supervisor Safety Training
Managing Risks Profitably

Chola MS Risk Services

April 2, 2016
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Topics in this Course
 Crane Hazards
 Crane types
• Industrial cranes
• Construction cranes
• Rigging (and “sling angle”)
 Controlling hazards
• Inspections and training
• Power lines
• Equipment failure and crane stability
• Other
EHS Training for OPGC April 2, 2016
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Crane and Hoist Safety

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Crane Hazards
 Over 250,000 cranes in operation
– 125,000 in construction
– 80,000 general and maritime
 80 fatalities per year
 One death per thousand crane operators in their working lifetime (45 years)
 Risk to citizens and other workers

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Causes of Crane Fatalities
Electrocution 39%
Crane assembly/disassembly 12%
Crane upset/overturn 7%
Rigging failure 7%
Overloading 4%
Struck by moving load 4%
Man lifts 4%
Struck by counterweight 2%
Two-blocking 2%
Hoist limitations 2%
Other 6%

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What is a Crane?
 Crane is a machine meant for lifting or lowering a load and moving it horizontally or slewing it
to left or right and in which hoisting is an integral part of machine. It may be driven manually
or by power and may be a fixed or mobile.

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EHS Training for OPGC Counterweights
Basic Principle of a Crane
A Crane, basically, is designed on the Principle of load
moment.
force X force Y
‘O’ Fulcrum
Crane Weight Total Load
x y
X Y
Xx > Yy
Some Definitions
Radius :-
 Radius is the Horizontal distance at ground
level, from the crane centerline of rotation
to a vertical line through the centre of
gravity of the suspended load on hook
Boom Length :-
 Boom Length of main boom measured from
Boom Pivot to the Top Boom Point
Boom Angle :-
 Boom Angle is the angle of Boom to the
horizontal

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Crane- Basic Operations
Boom Point Height :-
It is the vertical distance between Boom Point and Ground, measured perpendicular to the ground.
It is also referred as Boom Point Elevation.
Load Chart :-
It is a chart representing rated capacities as per the design of crane at various radius with respect to
various boom lengths, boom angle and configuration.
Rated Capacity :-
Rated capacity of a given radius is the maximum load permitted to be lifted by the crane at the
particular radius. These are calculated on basis of various design factors such as crane stability
structural limitations etc. This also is called as Safe Working Load or SWL.

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Maximum capacity of Crane :-
 This is the maximum capacity of a Crane and is obtained at minimum radius with basic minimum
boom length of a crane. A crane is basically defined by the maximum capacity only.
 For example :- A 20 MT capacity crane can lift 20 MT load only at its minimum radius and that
too, with it’s minimum or basic boom length only. Similarly a 500 MT crane can lift 500MT load at
its minimum radius with minimum or basic boom length only.
Propel :-
 The term ‘Propel’ refers to marching /traveling of crawler Cranes

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Hoisting/Lowering :-
 Hoisting or lowering of hook block with or with out Load.
Swing (or slewing) :-

 Slew of crane superstructure to either side along with its center line of rotation.
Boom Hoisting/Lowering :-
 It is hoisting or lowering of boom with respect to its pivot essentially to increase or decrease
Radius and Height (Boom point-elevation).

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 Marching (or Propelling) – (in case of crawler cranes only)Travel of a Crawler Crane forward or
reverse with or without Load .
 Telescopic boom extension/Retraction :- Extending or Retracting of Telescopic Boom to increase

or decrease Boom Length

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General Safety Features Of Crane
A2B (Anti Two Block) OR Over Hoist Limit Switch :-
It is installed at Boom tip and it gives alarm in case of Hook Over Hoisting and also trips off the
function of further hoisting.
Boom Hoist Limit Switch (Crawler Cranes) :-

Generally a ‘Shut Off’ valve which gives alarm in operator’s cabin (and cuts off further hoisting),
when the boom has reached to a pre-set (maximum) angle during hoisting.
Overload Limit Switch (Hydra) :-

Gives a only audible warning (alarm), in case the Hydra approaches Overload condition.

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General Safety Features Of Crane
Safe Load Indicator (SLI) :-
SLI, confirmed on selected configuration of Crane, measures and displays following data –
 Radius of Hook
 Boom Length
 Boom Angle
 Actual Load Lifted by Crane
 Rated Capacity (SWL)
SLI is also equipped to provide :-
 A2B condition, indication & Tripping in case of Over Hoisting
 Analog indication of Load Moment, in terms of Green (Safe Zone), Yellow (Alert Zone) and Red (Danger & Cut
Off zone)
 Indication, Alarm and Motion Cut Off, when an overload condition has reached.

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Crane Types
 "Industrial cranes“
• Overhead
• Gantry
• Jib
 "Construction cranes“
• Mobile
• Tower
• Derricks

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Industrial Cranes
 Gantry cranes
Similar to overhead cranes, but
supported by a mobile frame which
travels on the ground
• 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 problems
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Industrial Cranes
Small (1000 – 10,000 pound capacity) gantry crane

Large (600 ton capacity) gantry crane

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Tower Crane
Industrial Cranes
Tower Crane Truck Crane

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Industrial Cranes
• Tower cranes
• Variable height “climbing cranes” Hydraulic Cranes
• Used for building construction

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Load Chart
Load charts inside the cab include
Structural capacity and tipping
limits for the crane
Capacity is highest for short
radius “over front” loads with
outriggers extended.

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Load Chart

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Mobile Cranes Importance of Outriggers
a) Tipping load when outriggers are in full extension
Weight of crane =35MT. Weight of boom = 2 MT.
B = Boom CG - 7.5mts.
C = 2mts. - crane CG to tipping fulcrum
L = 4mts. distance from load to tipping fulcrum
Stability relationship of above:

a)Load x L + Boom weight x B = Crane weight x C
Tipping load= (35 x2-2 x 7.5) / 4 = 13.75 MT
b)Tipping load when outriggers are 0.5mts. short
of their full extension
C = 1.5 = 2.0 - 1.5;B = 8.0 = 7.5 + 0.5
L = 4.5 = 4.0 + 0.5
Tip. load = (35 x 1.5 - 2 x 8) / 4.5 = 8.1 MT
41% reduction of tipping load

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Controlling Crane Hazards
 Inspection • Operators
Frequent – Physical exam
• Daily, monthly – Knowledge (training)
• Hooks, rope, crane operation • Estimating load weight
Periodic
• At least annually • Signals
• Complete inspection - wear, damage, • Operation
deterioration, operation – Skill (demonstration)
• slings
 Testing
 Records

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Warning label

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Preventing Crane Accidents
Contact with energized power lines (45% of accidents)
• De-energize overhead lines

• Maintain minimum distance
• 10 feet distance for 50 kv
• Over 50 kv, add 4 inches per 10 kv
• Use proximity alarms
• Warn when energized line is near
• “No fatalities” in 25 years, according to mfg.
• Warning signs
• I-15 construction was a good example

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 Under hook lifting device problems
• Inspect, proper use, etc.
 Overturned cranes
• Assure a level and stable base for the crane
• Comply with load charts
• Weight
• Boom angle and extension
• Only vertical loads
• Wind can cause a significant side load

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 Dropped loads
Operating anti-two block device (upper limit switch)
Proper rigging
Inspection
 Boom collapse
Inspection
Stable base
No overloading
No horizontal loading
 Crushing by the counter weight

Stay away from the rear of the crane

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 Proper outrigger use
Level
Fully extended
Stable base
 Use cribbing to distribute the load

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Multi-Crane Lifts
 Two cranes- horizontal load
 Two cranes- vertical load
 Tailing a vertical load
 More than two cranes- horizontal loads
May be preferred when:
 Handling long pieces

 When obstructions may restrict a single crane
 Utilization of equipment on site
 The extra capacity works well with the nature of the load
 Loads must be placed at an angle
 When dictated by center of gravity issues
 To offload from double-bolstered railcars or hauling equipment
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Multi-Crane Lifts
Two Cranes – Horizontal Loads Two Cranes – Horizontal Loads

The two cranes used on this concrete beam
• Here two matched cranes lift an asymmetrical load
allowed the beam to be landed first on one end
The two cranes were probably on the jobsite, • Careful CG calculation and load distribution is very
resulting in cost savings important

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SAFE USAGE OF CRANES
 Check slings and hooks for any defects
 Enclose moving parts and guide the hook/handle
 Ensure minimum 3 windings of rope on drum
 Ensure no man movement under suspended load
 Do not use brakes while parking
 Attend to all suspended load

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Let us Summarize

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EHS Training for OPGC

Environment, Health and Safety Supervisor Safety Training

Managing Risks Profitably

Chola MS Risk Services

EHS Training for OPGC

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Swing (or slewing) :-

Chola MS Risk Services

 Telescopic boom extension/Retraction :- Extending or Retracting of Telescopic Boom to increase

Chola MS Risk Services

Boom Hoist Limit Switch (Crawler Cranes) :-

Overload Limit Switch (Hydra) :-

Chola MS Risk Services

Chola MS Risk Services

Chola MS Risk Services

Small (1000 – 10,000 pound capacity) gantry crane

Chola MS Risk Services

Tower Crane Truck Crane

EHS Training for OPGC

EHS Training for OPGC

Chola MS Risk Services

Chola MS Risk Services

Stability relationship of above:

41% reduction of tipping load

EHS Training for OPGC

Chola MS Risk Services

Chola MS Risk Services

• De-energize overhead lines

Chola MS Risk Services

Chola MS Risk Services

 Crushing by the counter weight

Chola MS Risk Services

Chola MS Risk Services

May be preferred when:

 Handling long pieces

Two Cranes – Horizontal Loads Two Cranes – Horizontal Loads

Chola MS Risk Services

 Enclose moving parts and guide the hook/handle

 Ensure minimum 3 windings of rope on drum

 Ensure no man movement under suspended load

 Do not use brakes while parking

 Attend to all suspended load

Chola MS Risk Services

Chola MS Risk Services

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