1Omaha District

CRANE SAFETY

Safety and Occupational Health

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Crane Cab Documentation

All Cranes shall have the following documentation in cab at all times.•Crane Operating Manual developed by manufacturer, and specific to model.

•Load-Rating Chart. Located on chart; Make & Model, Serial Number, Manufactured Year, Load Rating for all Configurations, Recommended Reeving for Hoist Line, Operating Limits in Windy or Cold Weather Conditions.

•Durable Load Chart fixed at a location visible to operator while seated at the control station.

•Crane Log Book (Hours, Crane Inspections, Maintenance, Repair) Updated Daily and Signed by Operator and Supervisor.

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• Shall have written proof of qualification for the particular piece of equipment.

• Shall be valid no longer than 5 years from date of issuance.

• Prior to re-issuance of qualification crane operator must have attended at least 8 hours of crane safety training; passed an operational examination; and passed a physical examination within 2 years.

• Physical examination for operators are required to be conducted biennially and any time thereafter if indicated by a medical condition that may impact safe operation of the crane. Written proof signed by a physician stating that the crane/derrick operator has had physical examination and meets requirements in Appendix G.

Operator Qualification

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Crane Operator Responsibilities

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• The operator shall not leave the controls while a load is suspended.

• Before leaving the crane unattended, the operator shall:– Land any load, bucket, lifting magnet, or other device– Disengage master clutch– Set travel, swing, boom brakes, and other locking devices– Put controls in neutral position– Secure crane against accidental travel, and stop engine

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Activity Hazard Analysis (AHA)

• An AHA shall be developed and implemented for crane set-up and set-down procedures (mobilization, assembly or erection, dismantling, and demobilization) .

• Work will not begin until the AHA has been accepted for the work activity, including the contractor, subcontractor (s), and Government on-site representatives at preparatory and initial control phase meetings.

• Competent/Qualified personnel shall be listed on AHA, and proof of competency/qualification shall be submitted to GDA

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Crane Inspections

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• Inspections of cranes and derricks shall be in accordance with the manufacturer's recommendations.

• A qualified person shall conduct inspections that cover, at the minimum, the items listed in Appendix H.

• The Contractor shall notify the GDA at least 24 hours prior to any inspections/tests so that the GDA may be available to observe the inspection/test. There are basically five types of inspections:

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Crane Inspections

Types of Inspections1. Initial Inspection: Before initial use, a qualified person shall inspect

all new and altered cranes to ensure compliance with all applicable standards

2. Functional Test Inspection: Before every operation at the beginning of each shift of the crane, the operator or designated person shall conduct start-up (pre-operational as follows:

a. If check lists are used for start-up (pre-operational) inspections, a copy of the checklist shall be maintained on-site. If checklists are not used, the operator or designated person shall indicate the successful completion of the inspection.

3. Frequent Inspection: Visual and audible examination of the crane. The crane operator or designated person shall conduct frequent inspection as follows:

a. Normal Service - Monthly, Heavy Service - Weekly to Monthly, Severe Service – Daily to weekly

4. Periodic Inspection: Visual and audible examination of the crane. The crane operator or designated person shall conduct frequent inspection as follows

a. Normal Service - Yearly, Heavy Service - Yearly, Severe Service – Quarterly

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Crane Performance Testing

• A qualified person shall conduct performance tests in accordance with ANSI/ASME, OSHA, and manufacturer’s recommendations. At minimum, performance testing shall meet the requirements in Appendix I. Test loads shall not be less than 110% anticipated load and shall not exceed 100% manufacturer’s load rating capacity chart at the configuration of the test.

• Written reports of the performance test , showing test procedures, and confirming the adequacy of repairs or alterations, shall be maintained with the crane or at the on-site project.

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Operational Performance Test

• Shall be conducted in Accordance to Appendix I:– Before initial use of crane in which a load bearing or

load controlling part or component, brake, travel component, or clutch have been altered, replaced or repaired.

– Every time a crane is reconfigured or reassembled after disassembly.

– Every time a crane is brought onto a USACE project– Every year

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• Shall be conducted in Accordance to Appendix I:– Before initial use of crane in which a load bearing or

load controlling part or component, brake, travel component, or clutch have been altered, replaced or repaired.

– Every time a crane is reconfigured or reassembled after disassembly.

– Every 4 years

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Load Performance Test

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Required Crane Safety Devices

• All Cranes shall be equipped w/ the following devices:– A2B, Anti-Two Blocking Device– Fire Extinguisher / minimum rating 10-B-C– Boom Angle Indicator– Load Moment Indicator or Load Indicator– Crane Level– Drum Rotator Indicators (Mfct. Before 1990.)– Boom Angle or Radius Indicator within operator view– Cable Support Booms

• Boom Stops• Boom Hoist-Disengaging Device

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Required Crane Safety Devices

Load Indicator Boom Angle Indicator Anti-Two Blocking

Boom Stops Boom Hoist Disconnect Level

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A2B Anti-Two Blocking

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A2B Anti-Two Blocking

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A2B Anti-Two Blocking

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Out-Riggers

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• When the load to be handled and/or the operating radius require the use of outriggers, or anytime when outriggers are used, outriggers shall be fully extended to the appropriate setting indicated by the load chart.

• The outriggers will be deployed so that the weight of the machine is totally removed from the wheels at every setting.

• Outrigger floats must be securely attached• Any blocking under the outrigger float

should be at least three times larger in area than the float, it should be rigid and completely support the total area.

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Out-Riggers

Do not block under the outrigger beam.

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Leveling of Cranes

Boom Length and Radius

Capacity Lost as Results of Crane out of Level By:

1 Degree 2 Degrees 3 Degrees Short Boom / Minimum Radius

10%

20%

30%

Short Boom / Maximum Radius

8%

15%

20% Long Boom / Minimum Radius

30%

41%

50% Long Boom / Maximum Radius

5%

10%

15%

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Electrical Clearances

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• Danger is greater from high voltage transmission lines where flashover can occur without actual contact.

TABLE 11-1MIMIMUM CLEARANCE FROM ENERGIZED OVERHEAD ELECTRIC LINES

Nominal system voltage Minimum rated clearance

0 - 50 kV 9.8 (3 m)

51 - 200kV 14.7 (4.5 m)

201 - 300 kV 19.7 (6 m)

301 to 500 kV 24.6 (7.5 m)

501 - 750 kV 34.4 (10.5 m)

751 - 1000 kV 44.3 (13.5 m)

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What Defines a Critical Lift?• Load weight is 75% of the rated capacity of crane.• Load is out of operators view.• Lifts with more than one crane.• Non-routine, technically difficult rigging.• Hoisting personnel with a crane.• Any lift that crane operator believes should be.

Protocol for a Critical Lift• Before making a critical lift, the qualified person, in

conjunction with the crane operator, lift supervisor, and rigger, shall prepare a critical lift plan.

• The plan shall be documented and a copy shall be provided to the GDA.

• The plan shall be reviewed and signed by all personnel involved with the lift including GDA.

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Critical Lifts

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Questions?Contact your Safety Office

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In Addition to Crane Safety, A Lifting & Rigging Safety Presentation is

Currently Being Developed.Check the Safety Internal Web-Site to

View.