Training Program on

“Crane Safety”
Safety ”

Date :- 15-Nov-2016.
Type of Cranes & it’s
Applications.
 Type of Cranes

Crane

Stationary (Fix) Mobile

EOT Tower Tyre Crawler

Mounted Mounted

Lattice Telescopic
Mech. Hydraulic
Boom Boom

Rough All Truck

Terrain Terrain Mounted
 What is a Crane
A crane is described as a piece of equipment that is designed to
lift, move and land a load.
 CRANE BASIC OPERATIONS
 Hoisting / Lowering :
Hoisting or Lowering of Hook block.
 Swing :
Swing of Crane structure to either side along with his
own axis.
 Boom Hoisting / Lowering:
It is lowering or hoisting of boom to increase or decrease
radius.
 Marching ( Propelling):
In case of crawler cranes only travel of crawler crane
forward or reverse.
 Telescopic Boom Extension / Retraction:
Extending or Retracting of telescopic boom to increase
or decrease boom length.
LIFTING EQUIPMENT’S LIFTING TOOLS & TACKLE

 FORK LIFT
 MOBILE HYDRA  DEE SHACKLE
 HOIST  BOW SHACKLE
 ELECTRICAL STACKER  WIRE ROPE SLING
 MOBILE ELEVATED WORK PLATE FORM  CHAIN SLING
(MEWP)  CHAIN PULLEY BLOCK
 TYRE MOUNTED CRANE  POLYESTER WEBBING SLING
 TRUCK MOUNTED CRANE  VERTICAL PLATE LIFTING CLAMP
 CRAWLER CRANE  HORIZONTAL PLATE LIFTING CLAMP
 EOT CRANE
 GANTRY CRANE
 TOWER CRANE
Hydra Crane (Pick & Carry)

For the lifting and transferring

of

1. Raw Material.

2. Objects less than 6m length

and less than 12 Tons
weight.

3. HMV/HGV license is required

to operate Hydra.
Tyre-Mounted Crane
For the lifting and shifting 360°
around the axes of rotation of
crane.

1.Raw Material
2.Semi Finished Material
3.Channels

Never use in Tandem Lift

Caution – Marching &

Reverse with load isn’t
possible.
Truck Mounted Crane
For the Lifting and
Transferring

1.Loose Material.
2.Chemical Drums.
3. Pipes.
4. Diesel tank.
Crawler Crane
For the lifting and transferring

1.Raw Material like pipes,

I-beams, plates etc....

2.Semi Finished Products

3.Finished Products like frames,

skid, Vessels.

4.Tandem Lift.
Hazard involved in crane operation & Risk
Assessment.
 Hazards of Crane
 Over Loading
 Excessive Speeds

 No Standard hand signals.

 Inadequate Inspection and Maintenance.

 Unguarded Crane rotating parts.

 Crane Hazards
 Working near by electrical power line.

 Improper Ground condition.

 Adverse weather condition.

 Competency level of Crane Operator

 Swing area not barricaded.

Over Loading
Over loading
Use of defective Tools & Tackles
 Use of defective Tools & Tackles
Causes Consequences
(Hazard) (Risk)
 Not Known about Color  Property damage.
Codes for lifting tools &
tackles  Failure of Lifting Tools &
Tackles.
 Short Cut
 Injury to person
 Make Shift Arrangement
 Time Delay
 Doesn’t know about
checklists.  Breakdown of Machines.
 Time Lost/ Production Lost
 Failure of Lifting Tools &
Tackles.
Control Measure
 Workers must be aware
about the color codes &
Certification of tools &
tackles.
 Inspection of Lifting
machines & tools tackles
before taking into use.
 Follow the standard
Procedure.
 Checklists must be
available with the operator
& He has to inspect the
equipment on daily basis.
Work under Suspended Load
Line of FIRE
Pinch Points
Sudden Release of Load
 Sudden Release of load.
Causes Consequences Control Measure
(Hazard) (Risk)
 Release of lifting  Injury to person  Lifting assembly should
assembly while in remove when job is
tension. totally grounded.
 Failure of Lifting
Machines  Check the capacity
marking on tools &
 Production Lost tackles.
 Use of uncertified &
unsafe lifting tools &  Property damage  Check color coding &
tackles. Certification.
Contact with Overhead Electrical Lines
Maintain 10 feet or 3
meter safe distance
between electrical power
line and material handling
equipment's.
Identify Hazards
Crane Safety Devices
 Over Hoist Limit switch

Boom Hoist
Limit Switch Hook safety
Latch

Boom Angle
Indicator

Safe Load
Indicator (SLI)
Crane Hook Safety Latch

28
Boom Hoist Limit Switch

No Boom Hoist
Limit Switch

Boom Hoist
Limit Switch

29
Over Hoist Limit Switch

No Limit Switch Limit Switch

30
Load Chart and Safe Load Indicator (SLI)
 Load Chart.
Radius in Main Boom Length in Meters 7.6 m Ext. &
Meters 21.4 m
8.3 12.2 15.2 18.3 21.4 29.0
2.5 20.000 (63.5) 19.800 (72.5) 19.250 (76.5)
3 20.000 (59.5) 17.450 (70) 17.175 (74.5)
3.5 16.825 (55.5) 15.000 (67.5) 15.000 (72.5) 14.250 (76)
4 14.475 (50.5) 12.875 (65) 12.875 (70.5) 12.875 (74)
4.5 12.625 (46) 11.225 (62) 11.225 (68.5) 11.225 (72.5) 10.000 (78)
5 11.150 (40) 9.900 (59.5) 9.900 (66) 9.900 (71) 9.115 (75)
6 8.910 (25) 7.880 (53.5) 7.880 (67.5) 7.880 (67.5) 7.880 (72) 5.670 (78)
7 6.740 (46.5) 6.740 (64) 6.740 (64) 6.740 (69) 5.055 (75.5)
8 5.665 (39.5) 5.665 (52.5) 5.665 (60) 5.665 (66) 4.760 (73.5)
9 4.825 (30) 4.825 (47.5) 4.825 (56.5) 4.825 (63) 4.500 (71.5)
10 4.240 (41.5) 4.240 (52.5) 4.240 (60) 4.220 (69)
12 3.095 (27) 3.095 (43.5) 3.095 (52.5) 3.660 (64.5)
14 2.345 (32.5) 2.345 (49) 2.705 (60)

16 1.820 (36) 2.070 (55)

18 1.435 (24) 1.610 (49.5)
20 1.265 (44)
Load Chart.
Crane Boom Angle Indicator
Crane Swing Indicators
(Audio visuals Alarm)
Flickering Light , Rear View Mirrors ,
Cameras and Fire Extinguishers(DCP).
BASKET HITCH BRIDAL HITCH
SWL*2 Depends on Sling Angle
Double Capacity
37
Center of Gravity

 When the CG is not equally spaced

between the pick points.

 The sling connected to the pick point

closest to the CG will carry the
greatest share of the load.

 Sling 2 is closest to CG. It will have the

greatest share of load.

 Sling 2= 10,000 x 8 = 8,000 lbs.

 Sling 1= 10,000 x 2 = 2,000 lbs.

 Slings
Tension On Slings

T=WxL
HxN

T = TENSION

W = WEIGHT OF THE LOAD

L = LENGTH OF SLING

N = NO. OF SLING LEGS

 Slings

If L is greater than S then sling angle is OK

 Types of Hook
“C” Hook Ram shorn Hook
 Hook

Without Safety Latch

Unsafe

Safe
With Safety Latch

Unsafe

With Safety Latch but not

at Place
Do not Point Load
Hocks – Load should
bear on the bowl of
hook.
Effect of Eccentric Loads on Hook Capacity
 x
Side Load
x
Back Load
x
Tip Load
 x

Never Wrap a Rope Around a Hook

Whenever 2 or more ropes are to be placed
over a hook – Use a Shackle


 Unsafe xx Unsafe

Never replace a shackle

An ordinary bolt will bend under load.
pin with a bolt.
Effect of Knots and Severe Bends on Rope Strength

Reduce Strength by
up to 50%

x
Effective use of Corner Pads

Packing
Never Twist or Knot a Chain

``

Don’t Twist

Don’t
Knot
 Unsafe use of chain Sling

x
Connecting chain links with
bolts or wires to be avoided.
x
Wrapping the chain several times
around a hook to be avoided
Bull Dog Grip
 Bull Dog Grip

CORRECT: “U” Bolt of all

clips on dead end of rope.

x INCORRECT: Do not
stagger clips.

INCORRECT: U-Bolt of
all clips on live end of
x rope.
 Installing Bull Dog Grips
(As per IS 2361:2002)
Minimum Nos. of bull dogs to be fitted:
Up to dia. Of wire rope mm Min. No. of Grips
1). Up to and including 20 3
2). over 20 up to and including 32 4
3). Over 32 up to and including 38 5
4). For 41 6
The Distance between two Bull Dog Grips shall be Approximately
6 times then Wire Rope Dia.
6.Safe Operating Practices

56
 Crane Capacity
Mobile crane capacity defined as
Turning Moment = Main boom capacity X Radius
For example
Capacity of crane is 75Tons @ 03 Mtrs
= 75 Tons X 3 Mtrs.
= 225 Ton - Mtrs.

Now if you want to lift e.g. 50ton @ 10mtrs

the turning movement will be 500TMtrs
Which is more than the crane capacity so
Crane will topple. Radius

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 Equally Extension of Telescopic crane Boom Section.

Boom sections should be equally extended. If they are not done so, the larger
extended section may be overloaded. (Load chart for hydraulic boom cranes are
based on the boom sections being equally extended. )

58
Prevent Lifted Load Contacts with
Crane Boom.

59
Safe Distance with electrical power line

60
Jumping clear from Crane after
contact with electrical Line.

61
Snub load to Crane

62
Avoid Working on Slop Condition

The load moves in towards the

machine.
The decrease in load radius may
cause the machine ( or jib) to trip
over backwards.
Greatest danger of instability occurs
when load set down.

63
 Ensure Ground Condition

Ground
Level

Rupture of gas line Gas

results in leakage. Line

64
Placement of Crane out rigger pad.
Placement of Crane out rigger pad.
Barricading of Crane Swing Area.
No tandem lift

Also Ensure, no
Tandem Lifting is
carried out using tyre
mounted cranes.

Avoid loading beyond

85%of SWL

Follow procedure.
Hand signaling for mobile crane.
 Applicable Standard

 IS 13367 (Part 1) : 1992

 BS 7121
Hoist the Load

With forearm vertical,

forefinger pointing
up, move hand in
horizontal circles
Slowly Raise the Load

With forearm vertical,

forefinger pointing up,
move hand in horizontal
circles & place other
hand’s palm just over
the fore finger
Lower the Load

With arm extended

downward, forefinger
pointing down, move
arm in horizontal
circles
Slowly Lower the Load

With arm extended

downward, forefinger
pointing down, move
arm in horizontal circles
& place palm just below
the forefinger
Raise Boom

Arm extended,
fingers closed,
thumb pointing
upward
Lower Boom

Arm extended, fingers

closed, thumb pointing
downward
Extend Boom

Both fists in front of

body with thumbs
pointing outward
Retract Boom

Both fists in front of

body with thumbs
pointing toward each
other
Lower Boom & Raise Load

One arm extended,

fingers closed, thumb
pointing downward.
Other arm vertical
with forefinger
pointing up, move arm
in horizontal circles
Raise Boom & Lower Load

One arm extended,

fingers closed, thumb
pointing upward. Other
arm extended downward
with forefinger pointing
down, move arm in
horizontal circles
Swing

Move arm parallel to

ground facing palm
downward
Stop

Stretch one arm and move

up and down placing palm
downward
Stop Everything

Place one hand in another

8.Lifting Scheme / Plan.

84
Critical operations – Critical Lifts
• Critical operations shall require a Critical Lifting
Plan, accompanied by drawings and more detailed
planning and preparation.
• A crane operation shall be considered critical
when any one of the following conditions exists:
 The load exceeds 85 percent of the
manufacturer’s recommended crane
capacity, as shown on the load charts for the
configuration to be used.
 The load must be lifted by more than one
crane.
 Load is greater than 50 Metric Tones
 Heavy Lifting Procedure
What is Critical Lifting ?

 Tandem Lifting – Lifting by more than one crane.

 More then 50 Ton even if only one crane.
Documents required before a critical Lift

 Risk Assessment

 Lift Plan/ Scheme

 Work permit

 Toolbox Talk

 Safety Inspection checklist

9.Legal Requirements.
 THE FACTORIES ACT, 1948
(Section: 29)

 THE GUJARAT FACTORIES RULES, 1963

(Rule: 60)
 THE FACTORIES ACT 1948 , (Section : 29)
(a) all parts, including the working gear, whether fixed or
movable, of every lifting machine and every chain, rope
or lifting tackle shall be
(i) of good construction, sound materials and adequate
strength and free from defect;
(ii) properly maintained; and
(iii) thoroughly examined by a competent person at least
once in every period of twelve months, or at such intervals as
the Chief Inspector may specify in writing; and a register shall be
kept containing the prescribed particulars of every such
examination;
 GUJARAT FACTORIES RULES, 1963 (Rule: 60)
(Rules prescribed under sub-section (1) of Section 29)
(1) No lifting machine and no chain, rope or lifting tackle except
a fiber rope or fiber rope sling shall be taken in use in any
factory, for the first time therein unless it has been tested and
all parts have thoroughly examined by a competent person
and a certificate of such test and examination specifying
the same working load or loads and signed by the person
making the test and examination has been obtained and is
kept available for inspection.
(2) A register in Form 10 containing the particulars, there
specified shall be kept for every examination made under
sub-rule (1). The register shall be readily available for
inspection.
(3) Such lifting machines, chains and lifting tackle shall be thoroughly
examined by a competent person at least once in every twelve months
and particulars of such examination shall be entered in the register in
Form 10 .
(4) All lifting machines, chains, ropes and lifting tackle except a fiber
rope or fiber sling, which have been lengthened, altered or repaired by
welding or otherwise, shall, not be used again. Unless it is adequately
tested and examined by a competent person and certified in writing by
him to be in order.
(5) No person who has not completed eighteen years of age and no
adult who is not sufficiently trained in the working of lifting machines
and acquainted with the hazards of the machines shall be employed as
a driver of a lifting machine whether driven by mechanical power or
otherwise, or to give signals to a driver.
Form No. 10
 Periodical Color Code for Lifting Tools & Tackles
WHITE JAN – JUNE 2013, 2015, 2017….(Odd Year)

BLUE
JULY - DEC 2013, 2015, 2017…. (Odd Year)

ORANGE JAN – JUNE 2014, 2016…. (Even Year)

GREEN
JULY - DEC 2014, 2016….(Even Year)

Red Rejected
Documents required for crane.

96
1. R.C. Book (R.T.O. Registration) - Hydra and Tyre Mounted
Crane.

2. Valid Fitness Certificate from R.T.O. -Hydra and Tyre

Mounted Crane.

3. Valid Insurance Policy.

4. Driver’s valid license from R.T.O.
1. Hydra – HMV.
2. Tyre Mounted Crane – HGV.
3. Crawler Crane – HGV.

97
5. Valid P.U.C. Certificate.

6. Original Test certificate of crane by Manufacturer.

7. Crane Manufacturer Operating & Maintenance Manual.

8. Load Chart of the Crane in original by Manufacturer .

9. Valid test certificate of crane by Competent Person in

Form No. 10, as per the GFR.
10.Checklist & Preventive maintenance log book.

98
11. Selection criteria for crane operator.

99
The person should Be.

(1) Be more than 18 years of age.

(2) Have valid HMV license for Hydra / HGV license for crane.

(3) Be able to read and speak Hindi / English language.

(4) Be medically fit, with particular regard to eyesight, hearing

and reflexes.

100
(5) Have the stature to enable him to operate the crane safely.

(6) Have been adequately trained in the operation of the type of

crane he is driving and be able to judge distances, heights
and clearances.

(7) Have sufficient knowledge of the working of the crane to

enable him, as may be instructed, to carry out routine
checks.

101
(8) Understand fully the duties of the slinger and be familiar
with the signal code (hand signals) in order to implement
safely the instructions of the slinger or signaler.

(8) Authorized and trained by HSE department.

102
Responsibilities of
Operator, Rigger,
Supervisor & Engineers.
 Responsibilities of A Crane Operator
1. Operate the crane in a safe, controlled and smooth manner.
2. Maintain the crane log book.
3. Confirm the load and rigging weight.
4. Select the appropriate boom, jib and crane configuration to meet
lift requirements and determine the net lifting capacity of this
configuration.
5. Have a thorough understanding of the information in the Crane’s
operating manual and to understand the crane’s limitations.
6. Know, understand and properly use the crane’s load charts.
7. Inspect the crane daily and perform daily maintenance as
prescribed by the manufacturer and crane owner. Must confirm
operating aids and safety devices are operational (i.e. load
indicator, brakes, instruments, controls etc.).
8. Check that the site is adequately prepared for the crane.

104
 Responsibilities of A Crane Operator

9. Check that all hazards have been identified e.g. power lines, underground
facilities like gas mains, drains or water pipes etc.

10. Inform site supervision for any dangerous conditions / faults observed
before or during crane operations in order that they can be rectified.

11. When the ground conditions are crucial, he must take special measures to
spread the load from the out riggers (in case of a tyre mounted crane).

12.Assess weather conditions at time of lift to confirm lift can safely proceed.

13.Shut down and secure the machine properly when it is unattended.

14.Cease operations if an unsafe situation or condition is observed.

105
Operator Do's and Don'ts

 Do not eat or drink.

 Do not sleep.
 Never divert attention when there is a load.
 Practical jokes are forbidden.
 Do not use alcohol or other intoxicants.
 Do not operate if taking medication.
 Responsibilities of A Rigger
1. Must be qualified as a rigger / slinger
2. Rig loads and equipment to the manufacturer’s recommendations.
3. Interpret the sling charts and lift plans.
4. Identify appropriate rigging components for the load to be lifted.
5. Visually inspect rigging components on a regular basis and prior to
each lift to ensure compliance with appropriate standards, codes,
specifications and procedures.
6. Know and understand the operating parameters of cranes.
7. Be capable of identifying different rigging components and to be
knowledgeable in their proper application.
8. Be capable of performing inspections of applicable rigging
components to ensure they are in an adequate condition to perform
the lifting tasks.
 Responsibilities of A Rigger
9. Be capable of reading wire rope / synthetic sling capacity charts.
10. Be knowledgeable of the different sling configurations available and
know which to use on different load applications.
11. Be knowledgeable of the weight of the load to be lifted.
12. Give all signals in a slow, smooth and decisive manner.
13. Be aware of overhead hazards and obstructions.
14. Be aware that the swing path must be kept clear of vehicular and
pedestrian traffic.
15. Be aware that the load should never be brought over the top of
people.
16. Communicate with the crane operator throughout all stages of the
rigging process.
 Responsibilities of A Supervisor.
1. Explain Rigger foremen and his team about lifting plan and any
precautions etc. prior to start of erection activity.

2. Ensure crane, lifting tools & tackles is inspected and certified by

safety department before start of erection activity.

3.Ensure no loose materials are lying on the structure.

4. Ensure that lifting plan is strictly adhered to.

5. Clear and demarcate the area of crane marching.

6. If required area shall be barricaded.

 Responsibilities of A Engineers.
1.Prepaire lifting scheme / plan for critical lifting.
2.The crane utilization ratio shall not exceed 85%
3.Ensure safe operations
4.Ensuring the job or component to be lifted does not foul with
any structure/existing equipments etc.
6.Using of mandatory PPE’s
7.Give feedback to design dept. after erection is over.
8.Unwanted workmen are removed from site.
9.Wind speed is not exceeding the prescribed wind speed in
lifting plan.
General Guide lines for crane operation.

111
 Always,
 Ensure Operators/riggers are trained and competent.
 Select the correct appliance and tackles for the job.
 Use correct rigging methods.
 Protect sling from sharp edges.
 Ensure the sling is securely attached to the hook.
 Ensure load is lifted to correct height and moved
at an appropriate speed.
 Use standard hand signals.
 Ensure good ground condition and weather condition.
 Never,
 Drag load or allow sudden jerk, shock loading.

 Use defective equipment

 Exceed the safe working load.

 Increase sling angle.

 Lift a load over workers

 Use mobile phone.

 Crane Safety After Use
 Spot crane in the approved location.
 Lower the load to the ground.
 Disconnect the load and slings.
 Raise all the hooks to upper limit switch.
 Place all controls to off position.
 Visually check for dangerous conditions.
 Never leave a load unattended.
Thank
You.
L&T Hydrocarbon Engineering Modular Fabrication Facility – Hazira