CONSTRUCTION

MACHINERIES

By: ENGR. ALEXANDER B. TRILLANA 1

OSH CONSULTANT
 AGENDA
• Objectives
• Introduction
• Crane
– Types
– Operator’s Qualification & Certification
– Inspection & Testing
– Load Calculating & Rated Capacity
– Work near Electric Power lines
• Typical Construction Equipment

2
 AGENDA
• Hoist
– Types
– Inspection & Testing
– Rated Capacity
• Conveyor
– Types
– Inspection

3
 AGENDA
• Standard Operational Procedure
– Inspection & Testing Certificate / Sticker
– Preventive Maintenance
– Operating Procedure
– Lock Out & Tag Out System
• Permit to Install

4
 HOUSE RULES

o The facilitators may be interrupted at anytime for

questions and clarifications.
o Flexibility of time for each session.
o Cellular phones should be set to silent or vibra-mode
during the sessions.

5
 OBJECTIVES

• To learn the various mechanized

equipment and their requirements
• To learn the basic rigging
calculations

6
 INTRODUCTION

• Cranes, Hoists, and Conveyors are

usually utilized to transfer a certain
objects, such as raw materials,
products, etc., from one place to
another.

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 HI-PO ACCIDENT
This lift should have been stopped before it got this far
HI-PO ACCIDENT
HI-PO ACCIDENT
HI-PO ACCIDENT
HI-PO ACCIDENT
HI-PO ACCIDENT

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HI-PO ACCIDENT

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HI-PO ACCIDENT

Slewing Ring Failure 15

 HI-PO ACCIDENT

Pick and carry

operation!
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 HI-PO ACCIDENT

Broken Wind Shield

Hit by a bundle of rebars
during off-loading from
the delivery truck.

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HI-PO ACCIDENT
Crane Safety

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HI-PO ACCIDENT
Crane Safety
A good example of
sheer laziness and
putting others at risk
The operator was
told to move
materials and set up
correctly, this took
approximately 8
minutes.

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 HI-PO ACCIDENT
Crane Safety

• The result of this

accident/operator
crushed, died of injuries
sustained
• Out riggers not fully
extended.
• Lifting out of radius
• Poor supervision
Note lack of
outrigger extension
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HI-PO ACCIDENT
Crane Safety

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HI-PO ACCIDENT
Crane Safety
• A good example of
inexperience or unsafe
crane operation
• Possible reasons
• Load drifted out of
radius/Windy conditions
• Crane not level
• Weight gauge not working.
• Unknown weight
• Ground collapse
• Operator inexperience

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 HI-PO ACCIDENT
Crane Safety

Extra beams loaded on the outriggers for

added lifting capacity

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 HI-PO ACCIDENT
Crane & Rigging Failures

• How much time have you got to get out of the way?
• When the lifting attachments fails or the crane tips
over, there is no time to move out of the way.
• Usually it happen when your looking the other way.

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HI-PO ACCIDENT
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HI-PO ACCIDENT
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HI-PO ACCIDENT
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HI-PO ACCIDENT

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HI-PO Whole
ACCIDENT
Picture

Arrow shows pivot point on Portal crane legs. All lifting

should have been carried out using top beam.
 HI-PO ACCIDENT
Mast had moved sideway

Employee was
standing here
and was
Legs on portal crane
trapped by
moved in this
bottom beam
direction once lifted
from the bottom
beam.
HI-PO ACCIDENT
Sustained injuries

Workers legs
trapped in between
pipes and bottom
beam of crane. 60
ton assisting crane
hook and slinging
point opposite
injured worker
HI-PO ACCIDENT
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 CRANE TYPES

• Mobile Crane
• Tower Crane
• Barge Crane
• Overhead Traveling Crane
• Etc.

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MOBILE CRANE [CRAWLER-LATTICE BOOM]

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MOBILE CRANE [CRAWLER-LATTICE BOOM]

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MOBILE CRANE [TRUCK MOUNTED-LATTICE BOOM]

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 MOBILE CRANE
[TRUCK MOUNTED-TELESOPIC BOOM]

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 MOBILE CRANE
[ROUGH TERRAIN-TELESOPIC BOOM]

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TOWER CRANE
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TOWER CRANE
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BARGE CRANE

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BARGE CRANE 43
BARGE CRANE
BARGE CRANE 45
BARGE CRANE-CLAMP SHELL 46
Overhead Traveling

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Overhead Traveling

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Overhead Traveling

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Overhead Traveling

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 OPERATOR’S QUALIFICATION
AND CERTIFICATION

• Vision Test 20/30 in one eye & 20/50 in the

other (corrected & uncorrected), normal depth
perception, field of vision & color vision.
• Sufficient strength, endurance, agility,
coordination & responsiveness to meet the
demands of the equipment operation.
• Adequate Hearing

51
OPERATOR’S QUALIFICATION AND
CERTIFICATION

• No physical defects or emotional disorders.

• No evidence of seizures or loss of physical
control.
• LTO license & TESDA Certificate.

52
 INSPECTION & TESTING

• Third Party Inspection

– Accredited Agency by DOLE-BWC….TUV
BAYERN
– Yearly or After Modification, Alteration,
Repairs, Transfer or Re-install…
– Load Testing = 125% Above the max. load
• Internal Inspection
– Before using on site
– Monthly

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 INSPECTION & TESTING

• Internal Inspection
– Items:
• Hoisting & Lowering
• Trolley Travel
• Swing Motion
• Brakes & Clutches
• Limit-Locking & Safety Devices

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 INSPECTION & TESTING

• Internal Inspection
– Items:
• Assembly, Foundation & Erection
• Control Operations
• Running Gear & Drives
• All other Mechanism pertinent to the safe
operation of the equipment.

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Jib or Boom & Fly Jib

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Boom Stops
• Boom stops are telescoping,
shock absorbing, or hydraulic-
type safety devices designed
and installed in a manner to
stop or shut off power to the
boom controls. The purpose of
the boom stops is to prevent
the boom from being raised to
a point where the center of
gravity is shifted to the rear of
the crane causing the boom to
fall backwards over the crane

57
Jib Angle Indicator
• Jib Angle Indicators are
required to indicate the angle
of the boom tip from the base
section on a horizontal plane.
They may be either mechanical
(activated by gravity) or
electronic, with a display
readout in the cab. Accurate
readout of boom angle
determines load capacity and
working radius.

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Slew Ring

59
Winch Drum

60
Head Sheaves

61
Falls

62
Main Hook Block & Sheaves

63
Main Block & Spare Bond

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 Anti Two Block

When activated stops the cranes winch

drums immediately
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Crane Hook Ball

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Outrigger

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Counterweight

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Crane Condition

A well maintained machine.

69
 Crane Condition

A well maintained machine

70
 Crane Condition

An example of a poorly maintained crane.

Machines that look like this invite attention.
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Crane Condition

No kinks or broken
strands on winch
wire. Running true
onto the drum

72
 Crane Condition

Measuring internal Gape to establish distortion. All

information such as gape size will be found in the
Operators manual.Technical Specifications.
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Crane Condition

No broken strands
in the lay

Diameter of rope
indicates wear and
renewal

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Crane Condition

• Spare bond.
• Badly rusted
• Broken strands
• Worn diameter
• Kinks

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 Crane Condition

Hydraulic Leaks from jib rams

Broken tail lights

Trust your instincts they are usually right.

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Rope Sockets
Rope termination points

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Incorrect Use

This wedge and socket is

positioned incorrectly the
live wire should be on the
opposite side.

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Acceptable Method

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 LOAD CALCULATION

• Load Weight
– Check from name plate or tag.
– By weighing scale.
– By mathematical computation.
• CRANE CAPACITY
– Mobile Crane
• By radius & boom length
– Tower Crane
• By radius

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WORK NEAR ELECTRIC POWERLINES

• Minimum Safe Approach Clearance

• Up to 125,000 volts………….…..3m
• 126,000 to 250,000 volts………4.5m
• Over 250,000 volts………….……7.5m

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TYPICALCONSTRUCTION EQUIPMENT

WSO/LCM/BOR 82
LOADER
BACHOE-LOADER

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BACHOE-LOADER

85
BULLDOZER WITH RIPPER

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BULLDOZER

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BULLDOZER
BACKHOE CONVERTED ONTO BREAKER
BACKHOE CONVERTED ONTO BREAKER
BACKHOE
BACKHOE

BACKHOE
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NO MORE EQYUIPMENT REQUIRED 108
NO MORE EQYUIPMENT REQUIRED 109
NEW EXCAVATOR
NEW EXCAVATOR
 WORLD'S BIGGEST EXCAVATOR

Built by KRUPP of Germany 45,500 tons

95 meters high 215 meters long

NEW EXCAVATOR 112

FORKLIFT

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FORKLIFT Hydrogen Fuel

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TELEHANDLER 115
TELEHANDLER
TELEHANDLER DISCOVERY
 “NOBODY GETS HURT”

Tipper Truck Control

Trucks are only allowed to dump on flat, even

compacted ground.

CONSTRUCTION EQUIPMENT
“ EVERY ONE , EVERY DAY , EVERY TASK “
 CONSTRUCTION EQUIPMENT MANAGEMENT

8/9/2013 119
HI-PO ACCIDENT
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HI-PO ACCIDENT
121
HI-PO ACCIDENT
122
 DOZER REVERSING

HI-PO ACCIDENT 123

HI-PO ACCIDENT
124
 “NOBODY GETS HURT”

Case Studies: Barzan Early Site Works

HI-PO ACCIDENT
“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Barzan Early Site Works

HI-PO ACCIDENT
“ EVERY ONE , EVERY DAY , EVERY TASK “
HI-PO ACCIDENT
127
Accidents can happen at any time

HI-PO ACCIDENT
128
 “NOBODY GETS HURT”

Tipper Truck Control

NEVER CLIMB A
VEHICLE TO CLEAR
A STUCK LOAD

HI-PO ACCIDENT
“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Tipper Truck Control

NO OVERLOADING
TIPPER TRUCKS

HI-PO ACCIDENT
“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”
HI-PO ACCIDENT
Tipper Truck Control

TWO TRUCKS ARE NOT ALLOWED TO TIP TOGETHER

SIDE BY SIDE. THEY SHOULD BE AT LEAST 25 METERS
APART.

“ EVERY ONE , EVERY DAY , EVERY TASK “

 “NOBODY GETS HURT”

Safe work practices: Exclusion zones

RESPECT EXCLUSION ZONES

AND KEEP OTHERS AWAY

0
HI-PO ACCIDENT
“ EVERY ONE , EVERY DAY , EVERY TASK “
Discuss the Hazard
HI-PO ACCIDENT 133
HI-PO ACCIDENT

134
 “NOBODY GETS HURT”

This is the roller operator

The victim water bottle is here

HI-PO ACCIDENT
“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Safe work practices: Blind spots

DO NOT STAND IN BLIND SPOTS!

HI-PO ACCIDENT
“ EVERY ONE , EVERY DAY , EVERY TASK “
HI-PO ACCIDENT
HI-PO ACCIDENT 138
HI-PO ACCIDENT 139
HI-PO ACCIDENT 140
HI-PO ACCIDENT
 “NOBODY GETS HURT”

Safe Work Practices: Overhead hazards

Always
check for
overhead
hazards

HI-PO ACCIDENT
“ EVERY ONE , EVERY DAY , EVERY TASK “
HI-PO ACCIDENT
 “NOBODY GETS HURT”

Safe work practices: Line Of Fire

DO NOT PUT
YOURSELF IN
HARMS WAY!

0
HI-PO ACCIDENT
“ EVERY ONE , EVERY DAY , EVERY TASK “
 Previous Accident

HI-PO ACCIDENT 145

 Previous Accident

HI-PO ACCIDENT 146

 Previous Accident

HI-PO ACCIDENT 147

 Previous Accident

HI-PO ACCIDENT 148

 Previous Accident

HI-PO ACCIDENT 149

HI-PO ACCIDENT
Vehicle reversing accident!

HI-PO ACCIDENT
 HOIST TYPES

• Personnel Hoist

• Material Hoist

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 INSPECTION & TESTING

• Third Party Inspection

– Accredited Agency by DOLE-BWC….ACEL
– Every 6 mos. or After Modification, Alteration,
Repairs, Transfer or Re-install…

• Internal Inspection
– Before using on site
– Monthly

158
 INSPECTION & TESTING

• Internal Inspection
– Items:
• Design and Installation
• Warning Notice & Operating Rules
• Hoist way enclosure
• Tower Anchorage
• Cage Enclosure
• Door Interlocks
• Overhead Protection

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 INSPECTION & TESTING

• Internal Inspection
– Items:
• Over speed safety devices
• Emergency stop switch
• Controls
• Maximum speed
• Maximum safe working load
• Travel limit stops
• Hoist ropes
• Trained operator
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 CONVEYOR TYPES

• Guard Screw Conveyor

• Roller Conveyor

• Belt Conveyor

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 INSPECTION

• Stop Watch
• Stop Pull Cable
• Audible Warning Signal
• Suitable Guards, IE, Catch, Nets, Side,
Panels, Etc.
• Conveyor Motor Control
• Danger & Warning Signs

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 STANDARD OPERATIONAL
PROCEDURE

• Inspection & Testing

– Certificate & Sticker
– Color coding for lifting gears
• Preventive Maintenance
• Operating Procedure
• Lock Out & Tag Out Systems

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RED: January to March
GREEN: April to June
BLUE: July to September
YELLOW: October to December
Page 31 of 65 180
DO’S & D0NT’S ON CONVEYORS

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 Don’t
ignore the
“LOTO”

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183
 PERMIT TO INSTALL

• Obtain the permit to install from the

building official.

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 END OF MODULE:
CONSTRUCTION
MACHINERIES

THANK YOU

By: ENGR. ALEXANDER B. TRILLANA 185

OSH CONSULTANT