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Accident Prevention Manual For Business & Industry:: Engineering & Technology 13th Edition
Accident Prevention Manual For Business & Industry:: Engineering & Technology 13th Edition
Compiled by
Dr. S.D. Allen Iske, Associate Professor
University of Central Missouri
CHAPTER 16
HOISTING AND CONVEYING EQUIPMENT
Hoisting Apparatus
• Basic types:
• electric
• air
• hand-operated chain
Hoisting Apparatus (Cont.)
• General information:
• The safe load capacity of the hoist should be attached to the body
of the machine. The label for safe operation should be able to be
read from ground level.
• Loads should only be raised or lowered if the load is directly under
the hoist (centered).
• Personnel should NOT be allowed to enter the area directly under
the load.
Cranes
• Definition: A crane is a mechanical device designed to
raise, lower, and shift heavy objects through the use of a
long movable arm.
Cranes (Cont.)
• General information:
• A competent person must inspect all machinery and equipment
prior to use to ensure safe operating condition; any deficiencies
repaired.
• All parts of every crane should be of adequate strength for its rated
service.
• Do NOT use a hoist or crane to transport people.
• All equipment must be inspected and maintained to prevent
incidents.
• Workers must be properly trained in the use of the hoist and all
safety policies/procedures must be followed at all times.
Cranes (Cont.)
• Overhead and gantry cranes constructed and installed
after Aug. 31, 1971, must be in compliance with
ANSI/ASME B30.2.
• Open hooks should not be used if there is a danger of the
tension decreasing during use.
• Each independent hoisting unit shall have brakes
compliant with the standard.
• The load rating should be clearly marked on each side of
the crane; each hoisting unit should have its rated load
marked.
• An audible alarm and wind indicator should be utilized
and in visible sight of the crane operator.
Cranes (Cont.)
Design and construction:
• Arrange the cab and locate control and protective equipment so
that all operating handles are within convenient reach of the
operator.
• Each control lever should be marked with its action and direction of
control.
• The controls should be self-closing to a neutral position.
• Limiting devices to prevent overrunning safe limits
• Provide for safe footing and accessways
• Access to cab and/or bridge walkway by convenient fixed ladders,
stairways or platforms
• Cab fitted with dry chemical or equivalent fire extinguisher
• Accessible areas within swing radius barricaded to protect
employees from injury.
Cranes (Cont.)
Guards and limit devices:
• Gears and moving parts should be covered, or out of reach, during
operation of the crane.
• Traveling cranes must be equipped with an audible warning device
and a strobe light.
• Large hooks should have handles affixed to them to allow the load
operator to manipulate the hook without danger to their
hand/fingers.
• The hoisting motion must have an over-travel limit switch
• No guard, safety, or other device shall be made inoperable except
for repairs or adjustments.
• All guards and safety devices must be immediately activated after
completion of repairs or adjustments.
Cranes (Cont.)
General guidelines:
• Use hoisting ropes of recommended construction for crane or hoist
service.
• Inspection, testing, and maintenance should be performed by a
qualified person only.
• Crane movement must be governed by a standard of code signals
between the crane signaler and crane operator.
• Only one person should be authorized to signal the operator at any
given point in time.
• Hand signals are preferred.
Overhead
Gantry Crane
Crane
Signals
Crane
Signals
Cranes (Cont.)
Selection and training of operators:
• Age: 18+
• Language: Understand spoken and written words/instructions.
• Physical: Physical fitness, visual acuity, depth perception, manual
dexterity, etc.
• Knowledge: Basic knowledge of the equipment, its usage,
inspection, maintenance, etc.
• Skills: Demonstrated proficiency in classroom and onsite. Maintain
a file that clearly documents the operator’s KSA.
• Note: Smoothness is a sign of a good crane operator.
Inspection
• Overhead and gantry cranes must be inspected according
to ANSI/ASME B30.2.
• New laws for operators of cranes are being enacted by
state laws and pending OSHA changes.
• Certification of cranes by state laws are required at least
annually by certified crane inspector.
• Repairs of cranes should be performed by qualified
individuals.
• Do performance testing of hoisting equipment prior to
placing it in service.
• Perform regular pre-shift and on-shift inspections to
ensure safe to operate.
Crane Operating Rules
• Review the list of Crane Manufacturer Association of
America, Inc. operating rules for crane operators.
• Review the maintenance safety rules from ANSI/ASME
B30.2 for Overhead and Gantry Cranes.
Overhead Cranes
• An overhead crane may be operated either from a cab or
from the floor.
• All control handles must be clearly identified by signs and
by shape or position so that an operator, while keeping
contact with the signaler, can identify each control by
touch.
• Keep controls in identical positions if multiple cranes are
used in one location.
Overhead Cranes (Cont.)
Overhead Cranes (Cont.)
• General information:
• It is important that the operator have a safe route to and from the
cab.
• In the event of an emergency, the operator must have a safe
egress regardless of the position of the crane on the runway.
• A fire extinguisher should be located inside the cab.
Storage Bridge and Gantry Crane
• Storage bridge cranes and gantry cranes travel on rails
that are on ground level.
• Gantry cranes typically have short spans, whereas
storage bridge cranes typically have large spans and may
be used to move large amounts of coal or ore.
• Access to the cab is by ladder on one of the crane legs.
• Keep track repaired and cleaned.
• Provide warning devices to indicate crane travel.
Gantry crane
Storage Bridge and
Gantry Crane (Cont.)
• Guidelines:
• An audible alert should sound each time the travel controller handle
is moved from the off position.
• The operator should apply the rail clamps at any point in time when
the operator is not in the cab.
• Cranes of this nature are typically exposed to the elements;
therefore they require additional inspection and maintenance
procedures.
Monorail
• Definition: A monorail is a system consisting of one or
more independent trolleys, supported from or within an
overhead track, from which the hoists are suspended.
• Three types:
1. Hand-operated: material raised with hand-powered hoist and
trolley propelled by hand
2. Semi-hand-operated: power hoist and is moved horizontally by
hand
3. Power-operated: electrically actuated for both vertical and
horizontal movements
Monorail (Cont.)
Jib Crane
• Definition: A jib crane is capable of lifting, lowering, and
rotating a load within a circular arc by a rotating arm or jib.
The jib and trolley are typically supported or mounted
from a building wall, column or pillar.
• The hoist, which is used to lift the loads, is suspended
from the trolley that travels on the jib boom.
• Note: A qualified engineer should determine if the
structure is sufficient to support the crane.
Jib Crane (Cont.)
Derricks
• Main types of derricks
• a-frame derrick
• stiff-leg derrick
• guy derrick
• Safeguards
• An aerial basket must be equipped with safety belts/lanyards and a
means for attaching the lanyard to the equipment.
• Lanyards should be long enough to allow movement only inside the
basket and prevent climbing onto the rim.
• Thoroughly train workers in the use of equipment before use.
• Proper footing for the wheels and outriggers should be provided.
Aerial Baskets
(Cont.)
• What potential hazards
are you able to identify in
this picture?
Crabs and Winches
• Safety concerns
• Install some form of brake or safety lowering device.
• Anchor portable units securely against the pull of the hoisting rope
or chain.
• The operator should be positioned away from the direct line of pull.
• Gears should be fully guarded.
• Barricade guards should be used to protect workers from flying
strands of wire.
• A small lever should be welded to the locking pawl to help prevent
hand/finger injuries.
Block and Tackle
• Safety factor of 10 is recommended for determining the
safe working load of Manila rope (falls) in a block-and-
tackle assembly.
• Allows for (1) error in estimating the weight of the load, (2) vibration
or shock in handling the load on the tackle, (3) loss of strength at
knots and bends, and (4) deterioration of the rope due to wear or
other causes.
• Governing factor is usually the safe working load of the
blocks rather than the falls (rope).
• Protect personnel from injuries during use of the pulley
and rope.
• Caution when using wire instead of fiber ropes.
Block and Tackle (Cont.)
• To find the required breaking strength for new rope:
• For each sheave 3 in. in diameter or larger, add 10% to the
weight of the load to compensate for friction loss.
• Divide this figure by the number of ropes or parts running
from the movable block.
• Multiply the resultant figure by a safety factor of 10.
EXAMPLE:
• A load weighs 2,000 lb, and the tackle consists of two double
blocks—four sheaves, four rope parts at the moveable block.
• Friction loss (10% per sheave) = 40% or 800 lb
• 2,000 + 800 = 2,800 lb., divided by 4 = 700 lb.
• Applying the safety factor of 10 (10 700) gives 7,000 lb., the
required breaking strength of the rope.
• Look up on the manufacturer’s rope tables the proper size rope for
the breaking strength that you have calculated.
Tiering Hoists and Stackers
• Tiering hoists (called stacking elevators, portable elevator,
tiering machine, or platform hoist) are designed to raise
material in a vertical line on a moving platform.
• Used in warehouses for piling and storing materials.
• Operated electrically or manually.
• Should have a braking device permitting safe lowering of
the platform. Workers do not ride platforms.
• Protect the tiering machine from tipping over.
Conveyors
Conveyors (Cont.)
• Definition: A horizontal, inclined, or vertical device for
moving or transporting bulk material, packages, or
objects, in a path predetermined by the design of the
device and having points of loading and discharge.
Conveyors (Cont.)
• General precautions:
• Signed for loading points and safe load limit.
• Moving parts must be protected by guards.
• Underpasses should have sheetmetal ceilings.
• Special fire protection devices must be utilized at any point in which
a conveyor passes through a fire wall.
• Guard conveyors for handrails and toeboards.
• Protect workers from falling materials.
• Provide crossovers or underpasses with proper safeguards for
passage over or under all conveyors.
• All conveyors within 6’ 8” of a walkway that is meant to serve as an
exit route must be in compliance with NFPA 101, Life Safety Codes.
Conveyors (Cont.)
• Operation precautions:
• The start button should be located in an area where the operator
has the greatest field of view of the corresponding conveyor.
• Start-stop devices must be clearly labeled.
• If conveyor passes through a wall or floor, equip each side with
starting and stopping devices.
• Emergency stopping devices must not be located more than 75 ft
apart along walkways.
• Provide anti-run-away and backstop devices.
• Workers must wear properly fitting clothes and PPE.
• Control dust levels with exhaust hoods and good ventilation.
• Use proper electrical rated fixtures.
Conveyors (Cont.)
• Maintenance:
• The conveyor must be locked out, prior to any maintenance work
being performed. The worker should carry the only key to the lock.
• If two or more gangs will perform the work, they should follow
OSHA standard 1910.147 for lock out/tag out.
• Maintenance personnel should have access to change positions of
pulleys, sprockets, or sheaves to compensate for normal working
conditions.
• Provide guards for the on-running belt.
• Use fixed scrapers and revolving brushes to clean drums or pulleys
instead of workers attempts by hand.
• Use guards in front of pinch points.
• Guard sides to prevent contact.
Conveyors (Cont.)
• Frequent causes of injuries:
• attempting repairs on moving conveyors
• attempting to cross over moving belts
• attempting to ride moving belts
Conveyors (Cont.)
• Unique hazards:
• Dust explosions are a major concern in conveyor systems used for
transporting grain or similar products. (silo)
• Portable conveyors must be equipped with locking devices to keep
the belt and conveyor stable.
Types of Conveyors