Overhead Crane Safety

Operation and safety .

OVERHEAD CRANE SAFETY Pua@alh2

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Safe Rigging Practices

Know How to Do It Right! Then Do It Right!

Job Site Considerations The handling, setting and erection of materials and equipment is a hazardous occupation. Each operation presents its own peculiar problems and no two jobs are alike. With proper consideration taken, each job can be performed free of bodily harm to the employee and without damage to the equipment. 3

Job Site Considerations The person authorized and qualified to do rigging must always pay close attention to details. One careless moment or act can result in serious injury or death and tremendous property damage. Proper rigging is an art and should never be left to the inexperienced. If you don’t know how to do it properly, then don’t attempt it. 4

Job Site Considerations Persons performing rigging tasks usually already have two strikes against them when they start! 2. Unfavorable Job conditions. 3. Job Schedule to meet. 5

Rigging Selection Very rarely does the average worker on a construction site get the opportunity to actually pick the rigging. It is normally purchased by a supervisor, the Company Purchasing Department or it is sent out from another project. This in itself can create serious problems. 6

Rigging Selection The rigging capacity and the material to be lifted must match. Using too small capacity rigging or components is just asking for an accident to happen. 2. Who is responsible (competent/qualified) for the rigging? a.

Communications Established? 7

Rigging Selection 2. Is the Equipment in Acceptable Condition? a. Appropriate Type? b. Proper Identification? C. Properly Inspected? 8

Rigging Selection 1. Are the Working Load Limits Adequate? a. What is the weight of the load? b. Where is the center of gravity? c. What is the sling angle? d. Will there be side loading? e. Capacity of the gear?

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Rigging Selection 4. Will the Load be Under Control? a.

Tag Line available?

b.

Is there any possibility of fouling?

c.

Clear of Personnel?

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Rigging Selection 1. Are there any Unusual Loading or Environmental Conditions? a. Wind? b. Temperature? c. Surfaces?

(Ice, Suction, Water)

d. Unstable Object(s)? 11

The Users Responsibilities

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The Users Responsibilities Crane Operator Rigger

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The Users Responsibilities Utilize Appropriate Rigging Gear Suitable For Overhead Lifting. Utilize The Rigging Gear Within Industry Standards And The Manufacturers Recommendations. Conduct Regular Inspection And Maintenance Of The Rigging Gear. 14

Basic Sling Operating Practices (ANSI B30.9) Whenever any sling is used, the following practices shall be observed! 2. Slings that are damaged or defective shall not be used. 3. Slings shall not be shortened with knots or bolts or other makeshift devices. 15

Basic Sling Operating Practices (ANSI B30.9) • Sling legs shall not be kinked. • Slings shall not be loaded in excess of their rated capacity. • Slings used in a Basket Hitch shall have the load balanced to prevent slippage. • Slings shall be securely attached to the load.

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Basic Sling Operating Practices (ANSI B30.9) 1. Slings shall be padded or protected from the sharp edges of their loads. 2. Suspended loads shall be kept free of obstructions. 3. All employees shall be kept clear of loads about to be lifted and of suspended loads. 17

Basic Sling Operating Practices (ANSI B30.9)

10. Hands or fingers shall not be placed between the sling and it’s load while the sling is being tightened around the load.

11. Shock loading is prohibited. 12. A sling shall not be pulled from under a load when the load is resting on the sling. 18

Basic Sling Operating Practices (ANSI B30.9) INSPECTION Each day before being used, the sling and all fastenings and attachments shall be inspected for damage and defects by a competent person designated by the employer. Additional inspections shall be performed during sling use as often as necessary to assure the safety of the operation. 19

Basic Sling Operating Practices (ANSI B30.9) REPLACEMENT Severe localized Abrasion or Scraping. Ten Randomly Distributed Broken Wires in one Rope Lay, or Five Broken Wires in One Rope Strand in One Rope Lay. Evidence of Heat Damage. (Cut with a Torch)

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Basic Sling Operating Practices (ANSI B30.9) REPLACEMENT Kinking, Crushing, Birdcaging, or Any Damage Resulting in Distortion of the Rope Structure. Damaged, Distorted or Field Welded Hooks. Damaged or Worn End Attachments. If In Doubt, Don’t Use It! 21

Definitions Balanced – load equally distributed on each side of the point of support. Breaking strength – the approximate point, when under maximum load, the load handling device fails.

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Definitions Balanced – load equally distributed on each side of the point of support. Bridle sling – A sling composed of multiple legs gathered in a fitting that goes over the lifting hook. Competent person – selected or assigned by the employer as being qualified to perform a specific job. Factor of safety – ratio of breaking strength to the force to be applied. 23

Definitions Hitch “Basket” - loading with the sling passed under the load and both ends on the hook or a single master link.

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Definitions Hitch “Choker” – loading with the sling passed through one eye and suspended by the other.

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Definitions Hitch “Vertical” – loading with the the load suspended vertically on a single part or leg of the sling.

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Definitions Master link – a steel link or ring used to support all legs of a chain or wire rope sling.

Mousing – lashing between the neck and the tip of a hook to prevent the load coming off. Rated capacity – the maximum allowable working load. 27

Definitions Rigging – the connecting of a load to a source of power so that it can be lifted and moved safely and predictably. Safe working load – the maximum allowable working load established by the manufacturer. Sheave – a wheel with a grooved circumference over which a rope is bent.

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Definitions Wire rope – consists of many individual wires laid into a number of strands which are in turn, laid around a center core.

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Safety Factors To guard against failure of a wire rope in service, the actual load on the rope should only be a fraction of the breaking strength. The safety factor includes reduced capacity of the rope below it’s stated breaking strength due to wear, fatigue, corrosion, abuse, and variations in size and quality.

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Wire Rope Construction

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Wire Rope Construction

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Wire Rope Capacities

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Wire Rope Capacities

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Wire Rope Sling Capacities

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Wire Rope Sling Choker Adjustments

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Types of Wire Wire Rope Slings

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Type of Wire Wire Rope Sling Damage

Birdcage damage 38

Type of Wire Wire Rope Sling Damage

Damage as a result of a kink in the wire rope 39

Synthetic Slings

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Synthetic Slings Sling capacity varies from manufacturer to manufacturer, no set standard like wire rope has. User must look at Individual Sling Capacity Tag to determine Safe Lifting Capacity of that sling. If the Tag is not readable or is missing, Do not use it! Inspect sling before each days use, and as often as necessary during the day to assure safety of sling! Sharp edges can slice a sling in two without warning as the load is tensioned. Use softeners or padding on corners. 41

Chain Slings Only Grade 8 or better ALLOY Chain can be used for overhead lifting purposes! All chain is not rated the same! Chain must have a capacity tag attached to it. Chains will withstand more rough handling and abuse, but a chain with the same rated lifting capacity of wire rope will be much larger in diameter and heavier in weight. Chains must be inspected daily before use and as often as necessary during use to assure safety. It is the riggers responsibility to do the inspections! 42

Chain Slings

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Rigging Protection From Cutting or Slipping Softeners, padding or use of blocking..

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Protecting Rigging From Damage or Environment Rigging components are expensive to buy and to replace! Use them properly and store them properly! Keep wire rope slings lubricated and all rigging stored out of the weather. Treat the rigging as though your life depended on it! Because it does if it fails! Don’t use makeshift rigging or attempt to repair any rigging components. Knots tied in rigging reduces the strength by 50% or more! 45

How Would You Rig This? What would you need in the way of rigging materials?

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How Would You Rig This? What would you need in the way of rigging materials?

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How Would You Rig This? Would it matter if the tank were full or empty?

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Removing Jewelry and Wearing Gloves! Cause? Not wearing gloves and not taking off the ring.

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Any Questions?

If the student hasn’t learned, the instructor hasn’t taught! 50

Operational safety And Daily check 51

OVERHEAD AND GANTRY CRANE OPERATION • Hoist operators must inspect equipment daily before use. • Do not operate a crane or hoist if limit switches, steel ropes, chains or other components are worn or in disrepair. • Replace nylon or web slings immediately if excessively worn.

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OVERHEAD AND GANTRY CRANE OPERATION • Associates in the direction of travel be warned to move and remain lifted load at all times.

should clear of a

• Loads should not be suspended over personnel below. • Under no circumstances may anyone ride the hook or load. • Directional movement should be made smoothly and deliberately. Avoid rapid movements in any direction. 53

OVERHEAD AND GANTRY CRANE OPERATION • Do not exceed the rated load capacity of the crane, hoist, chain, cable, slings, or other component. • Slings, load chains and other lifting devices must be fully and securely seated in the hook before moving a load. Remove slack from the sling, chain, or cable before lifting a load. 54

OVERHEAD AND GANTRY CRANE OPERATION • Use the following practices to avoid swinging loads: > Locate the hoist directly above the lifting point of the load before lifting. > Lower loads directly below the hoist. > Keep hoisting ropes vertical. Do not pull or push the load. > Maintain two full wraps of cable on the hoisting drum. 55

OVERHEAD AND GANTRY CRANE OPERATION • When lifting loads at or near capacity, test the hoist brakes by returning the master switch or push button to the “OFF” position after raising the load a few inches off the floor. If the brakes do not hold, lower the load to the floor slowly and do not operate the crane. Report the situation immediately and DO NOT USE until repaired.

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OVERHEAD AND GANTRY CRANE OPERATION • Ensure that all loads are lifted high enough to clear obstructions before moving the bridge or trolley. Whenever possible, maintain a minimum clearance of one foot above loads and to the sides. Raise the load only to the height necessary to clear lower objects. • Never pull a hoist by the cable.

pendant

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OVERHEAD AND GANTRY CRANE OPERATION • Never leave the controls unattended while a load is suspended. If it becomes necessary to leave the controls, lower the load to the floor. • Familiarize yourself with the location of the disconnect switch. • If loss of electrical power occurs, place controls in the “OFF” position to prevent unexpected startup upon restoration of power. 58

OVERHEAD AND GANTRY CRANE OPERATION • Disconnect power to a hoist that is unsafe or in need of repair. Arrange to have the disconnect switch locked and the control panel tagged with and “Out of Order” or “Do Not Operate” tag. Never operate a hoist that has been tagged with an “Out of Order” or “Do Not Operate” tag, or is your opinion, UNSAFE TO OPERATE…

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HOISTS / CRANES Daily Inspection Checklist • Check for any loose or missing parts. • Check end stops. End stops prevent the trolley from running off the beam. • Know the location of disconnect switch that will cut the power off only to the hoist or crane. Be sure it is readily accessible and not blocked.

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HOISTS / CRANES Daily Inspection Checklist • Make sure all control buttons are labeled to indicate their function. W Operate each button to make sure it functions properly, releases immediately, and does not stick.

N

E

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• Check upper hoist limit switch by slowly raising the block to trip the switch. • Lower the hoist block to activate the lower limit switch if the hoist is so equipped, leaving at least one turn of rope on the take-up drum. 61

HOISTS / CRANES Daily Inspection Checklist • Make sure wire rope is properly seated in its drum and sheave grooves without any slack or overlapping. • Operate the crane or hoist several feet in each direction that it travels. Listen for any unusual noises. Look for any jerky movements. • When moving an A frame hoist, take care to ensure that the wheels on each side stay on the track. 62

HOISTS / CRANES Daily Inspection Checklist • Check all hooks. Hooks should not be cracked, stretched, bent, or twisted. Each hook must have a safety latch that automatically closes the throat of the hook. If the latch is bent, spring is broken, or is otherwise damaged the latch must be repaired before use. Hooks should rotate freely in block assembly without any “grinding” felt or heard. 63

HOISTS / CRANES Daily Inspection Checklist • Check the block assembly for structural damage or cracks in any components. Sheaves should rotate freely without any grinding felt or heard coming from the bearings. The sheave guard must be unbroken and intact. No part of the sheave guard should be in contact with the wire rope or sheave.

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HOISTS / CRANES Daily Inspection Checklist •

Check the wire rope by lowering the block to the lowest level and looking for the following conditions. If any of these conditions are observed, they should be reported immediately. > Reduced diameter of the rope. This may indicate the rope has been stretched, has lost its inner core support, or has worn outside wires. > Any number of broken strands of wires. > Kinked, crushed, cut, or “bird caged” wiring, or wiring with heat damage.

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HOISTS / CRANES Daily Inspection Checklist •

Check load chain for damage, wear at contact points, cracks, or distorted (bent, twisted, or stretched) links. Inspect all mechanical coupling links to insure linking pins are secure and in good condition. Report unsafe conditions immediately.

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HOISTS / CRANES Daily Inspection Checklist •

Check the condition and capacity of nylon or synthetic web slings. Capacity ratings must be legible on the manufacturer’s label. The capacity of the sling being used must be adequate for the load and attachment method. Replace slings immediately if excessive wear occurs.

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Any Questions?

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