managing crane safety

1Rev. 05-28--02© 2000 CIA, Inc.

Managing Crane Safety

2Rev. 05-28--02© 2000 CIA, Inc.

Crane Institute of America is the nation’s leading provider of training services to the lifting industry. We offer a wide variety of safety programs for operators, supervisors, and inspectors of mobile cranes, overhead cranes, and offshore cranes, as well as rigging and other lifting equipment including forklifts and aerial lifts. Train-the-trainer programs for those wishing to set up or enhance their own training programs are also available.

Our team of instructors is among the most qualified in theindustry and our presentations are consistently acclaimed both for the quality and breadth of their content and theirmotivational style.

Crane Institute of America seminars are offered at cities across the country. Alternately, we can tailor a program to your specific needs and equipment and present it at your company’s facility.

About Crane Institute of America

3Rev. 05-28--02© 2000 CIA, Inc.

The need to get the job done doesn’t add any capacity to the crane!

4Rev. 05-28--02© 2000 CIA, Inc.

FACTS:

… are relatively more serious than other construction accidents.

… are the most costly in terms of insurance claims.

… result in more construction fatalities than any other single cause.

CRANE ACCIDENTS…

5Rev. 05-28--02© 2000 CIA, Inc.

One out of every five deaths is crane related!

One out of every five deaths is crane related!

CONSTRUCTION FATALITIES

20%

6Rev. 05-28--02© 2000 CIA, Inc.

CAUSES OF MOBILE CRANE FATALITIES

Electrocution44%

Rigging15%

Load Handling14%

Operator Error 7%

Overload 7%

Dismantling Boom 5%

Wire Rope Failure 3%

Miscellaneous 3%

Struck by Crane 3%

7Rev. 05-28--02© 2000 CIA, Inc.

Support Failure31.5%

High Wind1.6%

Machinery &Structural Failure

11.2%

MAIN CAUSES OF MOBILE CRANE ACCIDENTS

Failure to Use Outriggers

22.6%

Operator Error33.1%

8Rev. 05-28--02© 2000 CIA, Inc.

What does your groupfeel are the major problems or concerns facing Supervisors and Managers involved in crane and rigging operations?

9Rev. 05-28--02© 2000 CIA, Inc.

You Be The Lawyer(How to Reduce Your Liability

Exposure)

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You Be The Lawyer(How to Reduce Your Liability

Exposure)

Defendants Negligence

11

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Why Mobile Cranes

Present Potential for Accidents

Why Mobile Cranes

Present Potential for Accidents

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All cranes are large and powerful.

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All loads are heavy.

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Cranes are designed to defy the “law of gravity”.

15

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Cranes lift loads in close proximityto people.

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To maintain control, there are a tremendous number of factors that must be taken into

consideration…

Why Mobile CranesPresent Potential for

Accidents

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For example, capacities are based on a crane in “like new” condition.

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Level ground conditions and wind are other significant factors.

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Always remember that loads are lifted near people.

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Finally, capacities vary at different boom angles, lengths and radii.

59°

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Why Do Accidents Happen?

Why Do Accidents Happen?

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Mental

Wrong AttitudeWay crane is perceived.

Wrong Assumptions

Takes little skill to operate.

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ACCIDENTS

Accident prevention takes place first in the mind. Thinking has to change!

WRONG ACTIONSAllows unqualified personnel to operate cranes

Physical

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ACCIDENTS

OPER

ATOR

CO

MPETEN

CY

CRAN

E

TECH

NO

LOG

Y

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Rev. 05-28--02© 2000 CIA, Inc.

Grove RT865 65 Ton Capacity36 ft. - 146 ft. Boom (Power Pinned Fly) PCSA Class 10-312 85% of Tipping

EXAMPLE ONLY: Not to be used as an actual load chart.

ON OUTRIGGERS FULLY EXTENDED — OVER THE FRONT

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On Outriggers Fully Extended - 360°Example Only: Not to be used as an actual load chart.

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Jib Capacities In Pounds28ft. “A” Frame Jib On Outriggers - 360°

NOTES FOR JIB CAPACITIES

1. All capacities are in pounds. Capacities are based on structural strength of 28 ft. and 32 ft. boom extension combination at given main boom angle regardless of main boom length. Note: Two part lifting service is required with Krueger LMI; at any other time, single or two part line may be used.2. WARNING: Operation of machine with heavier loads than the capacities listed is strictly prohibited. Machine tipping with jib occurs rapidly and without advance warning.3. 28 FT. JIB WARNING: For main boom length with power pinned fly extended greater than 82 ft. with 32 ft. boom extension and 28 ft. jib in working position, the boom angle must not be less than 40° since loss of stability will occur causing a tipping condition. The boom angle is not restricted for main boom length with power pinned fly extended equal to or less than 82 ft. This warning applies for jib erection purposes also.4. WARNING: Lifting on rubber with 32 ft. boom extension or 28 ft. jib and 32 ft. boom extension combination is prohibited.5. Reference radii listed are for fully extended main boom only.

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Weight Reductions For Load Handling Devices

Hook Block65 Ton, 5 Sheave 1,900 lbs.15 Ton, 1 Sheave 580 lbs10 Ton Headache Ball 500 lbs.7½ Ton Headache Ball 300 lbs.Auxiliary Boom Head 220 lbs.

† Reduction of main boom capacities • ††Reduction of 32 ft. extension capacities

NOTE: All load handling devices and boom attachments are considered part of the load and suitable allowances MUST BE MADE for their combined weights. Weights are for grove furnished equipment

Main Hoist Line, SWL = 14,605 lbs.Auxiliary Hoist Line, SWL = 8,700

Load Line = 1 lb. per ft.

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On Rubber CapacitiesExample Only: Not to be used as an actual load chart

Maximum Permissible Boom Length is (a) 36 ft. (e) 68 ft. (b) 44 (f) 76 (c) 52 (g) 82 (d) 60 (h) 88

29.5 X 25 (28 ply) TIRES 33.25 X 29 (26 ply) TIRES

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Lifting Area DiagramsExample Only: Not to be used as an actual load chart.

Rear axle oscillation lockouts must be set to maintain 360 capacities.

Note: Bold lines determine the limiting position of any load for operation within any working areas indicated.

Note: Bold lines determine the limiting position of any load for operation within working areas indicated.

Note: Over the side capacities can be lifted in the over the rear area.

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RANGE DIAGRAM 28 ft. Jib

Jib Offset

5° Offset17° Offset30° Offset

146 ft. B

oom (3

2 ft. e

xt. + 11

4)

120

ft. B

oom (3

2 ft.

ext

. + 8

8 ft.

)

114

ft. B

oom

75°

70°

65°

60°

55°

50°

45°

40°

35°

30°

25°

20°

15°

10°

5°0°

88 ft

. Boom

82 ft

. Boom

76 ft

. Boom

68 ft

. Boom

60 ft

. Boom

52 ft

. Boom

44 ft

. Boom

36 ft

. Boom

HO

OK

ELE

VATIO

N IN

FEET

OPERATING RADIUS FROM AXIS OF ROTATION IN FEET

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Division of Load Charts

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Division of Load Charts

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You Be The Crane Operator

33 ft. radius

106 ft. B

OO

M LE

NG

TH

Gross CapacityABH Erected

10’ Wire Rope

7.5 Ton Headache Ball

Boom Extension

& Jib Stowed

68°15 Ton Hook Block

100 lbs. Rigging

Maximum Net Load

-100 lbs.

Minimum Parts of Line ______

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PARAMATERS: On Outriggers Fully Extended _____ On Rubber _____ Hoisting From The Main Boom _____ Fly _____ Extension _____ Jib _____

Boom Length: _____ Ft. Radius: _____ Ft. Boom Angle: _____ DegreesFly: Extended _____ Retracted _____.

_____ Boom Extension: Stowed _____ Erected _____ __________ Lbs._____ Jib: Stowed _____ Erected _____ Offset _____ __________ Lbs.

Auxiliary Boom Head: Erected _____ Off _____ __________ Lbs._____ Part(s) Wire Rope _____ Ft. Beneath: ________ __________ Lbs.

_____ Ton Block: ________ __________ Lbs._____ Ton Ball: ________ __________ Lbs.

Rigging: __________ Lbs.¶ Total Deductions: —_________ Lbs.

· Gross Capacity over the Front _____ 360° _____: __________ Lbs.¸ Subtract Total Deductions: __________ Lbs.

¹ Maximum Net Load that can be lifted: __________ Lbs.º Minimum Part(s) of Line Required: ________ Part(s)

44

4106 33 68

32’ 428’ 4

……....

41 10 ABH

AUX7½15 MAIN

4


100

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33 ft. radius

106 ft. B

OO

M LE

NG

TH


10’ Wire Rope


Boom Extension

& Jib Stowed


100 lbs. Rigging

Maximum Net Load

-100 lbs.

-1063 lbs.


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Rev. 05-28--02© 2000 CIA, Inc.


Boom Length: _____ Ft. Radius: _____ Ft. Boom Angle: _____ DegreesFly: Extended _____ Retracted _____







44

4106 33 68

32’ 428’ 4

……....1,063

41 10 ABH

AUX7½100

15 MAIN

4


42

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44

4106 33 68

……....

100

1,06332’ 428’ 4

41 10 ABH

AUX7½15 MAIN

4


43

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33 ft. radius

106 ft. B

OO

M LE

NG

TH


10’ Wire Rope


Boom Extension

& Jib Stowed


100 lbs. Rigging

Maximum Net Load

-100 lbs.

-1063 lbs.

-220 lbs.


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44

4106 33 68

32’ 428’ 4

……....1,063

22041 10 ABH

AUX7½15 MAIN

4

100


46

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44

4106 33 68

……....

100

1,06332’ 428’ 4

41 10 ABH

AUX7½15 MAIN

4

220


47

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33 ft. radius

106 ft. B

OO

M LE

NG

TH


10’ Wire Rope


-220 lbs.

Boom Extension

& Jib Stowed


100 lbs. Rigging

Maximum Net Load

-1063 lbs.

-100 lbs.

-10 lbs.


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44

4106 33 68

……....

100

1,06332’ 428’ 4

41 10 ABH

AUX7½15 MAIN

4

22010


50

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44

4106 33 68

……....

220

100

1,06332’ 428’ 4

41 10 ABH

AUX7½15 MAIN

4

10


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33 ft. radius

106 ft. B

OO

M LE

NG

TH


10’ Wire Rope


-220 lbs.

-10 lbs.

Boom Extension

& Jib Stowed


100 lbs. Rigging

Maximum Net Load

-1063 lbs.

-580 lbs.-100 lbs.


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44

4106 33 68

……....

220

100

1,06332’ 428’ 4

41 10 ABH

AUX7½15 MAIN

4

10580


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44

4106 33 68

……....

220

100

1,06332’ 428’ 4

41 10 ABH

AUX7½15 MAIN

4

10580


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33 ft. radius

106 ft. B

OO

M LE

NG

TH


10’ Wire Rope


-220 lbs.

Boom Extension

& Jib Stowed


100 lbs. Rigging

Maximum Net Load

-1063 lbs.

-10 lbs.

-100 lbs.

-300 lbs.


-580 lbs.

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44

4106 33 68

……....

220

100

1,06332’ 428’ 4

41 10 ABH

AUX7½15 MAIN

4

10580300


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44

4106 33 68

32’ 428’ 4

……....1,063

220

104

1 10 ABH

AUX7½100

2,273

58015 MAIN

4

300


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44

4106 33 68

32’ 428’ 4

……....1,063

220

104

1 10 ABH

AUX7½100

2,273

58015 MAIN

4


300

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On Outriggers Fully Extended - 360°Example Only: Not to be used as an actual load chart.

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Rev. 05-28--02© 2000 CIA, Inc.


33 ft. radius

106 ft. B

OO

M LE

NG

TH


10’ Wire Rope


Boom Extension

& Jib Stowed


100 lbs. Rigging

Maximum Net Load

-1063 lbs.

-220 lbs.

-10 lbs.

-300 lbs.

22,650 lbs.

-580 lbs.-100 lbs.


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44

4106 33 68

32’ 428’ 4

……....1,063

220

104

300

1 10 ABH

AUX7½100

2,27322,650

58015 MAIN

4


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44

4106 33 68

32’ 428’ 4

……....1,063

220

104

300

1 10 ABH

AUX7½100

2,27322,650

-2,273

58015 MAIN

4


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44

4106 33 68

32’ 428’ 4

……....1,063

220

104

300

1 10 ABH

AUX7½100

2,27322,650

-2,27320,377

58015 MAIN

4


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Rev. 05-28--02© 2000 CIA, Inc.


33 ft. radius

106 ft. B

OO

M LE

NG

TH


10’ Wire Rope


22,650 lbs.

-220 lbs.

-10 lbs.

Boom Extension

& Jib Stowed


100 lbs. Rigging

Maximum Net Load

-300 lbs.

-1063 lbs.

-580 lbs.

-100 lbs.

20,377 lbs.

Minimum Parts of Line ______Minimum Parts of Line ______

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Rev. 05-28--02© 2000 CIA, Inc.

Parts of Line

÷ Safe Working Load

Minimum Parts of Line =

Load + Rigging + Load Blockor Ball

Min Parts Line = 21,057 ÷ 14,605

21,057 ÷ 14,605

Suspended Weight

1.44



Rounded to 2

67

Rev. 05-28--02© 2000 CIA, Inc.









44

4106 33 68

32’ 428’ 4

……....1,063

22010

4

300

1 10 ABH

AUX7½100

2,27322,650

-2,27320,377

2

58015 MAIN

4


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Rev. 05-28--02© 2000 CIA, Inc.



33 ft. radius

106 ft. B

OO

M LE

NG

TH


10’ Wire Rope


22,650 lbs.

-220 lbs.

-10 lbs.

Boom Extension

& Jib Stowed


100 lbs. Rigging

Maximum Net Load

-300 lbs.

-1063 lbs.

-580 lbs.

-100 lbs.

20,377 lbs.

2

69

Rev. 05-28--02© 2000 CIA, Inc.

Boom Extension

& Jib Stowed

65 Ton Hook Block

100 lbs. Rigging

Maximum Net Load

Gross Capacity

30 ft. radius

68 ft. Boom

Length

60.5°

-1,063 lbs.

-100 lbs.

You Be The Crane Operator #2


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Rev. 05-28--02© 2000 CIA, Inc.

Boom Extension

& Jib Stowed -1,063 lbs.

65 Ton Hook Block

100 lbs. Rigging

Maximum Net Load

Gross Capacity

30 ft. radius

68 ft. Boom

Length

60.5°


-1,900 lbs.-100 lbs.



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Rev. 05-28--02© 2000 CIA, Inc.

-100 lbs.

-1,063 lbs.

-1,900 lbs.

Boom Extension

& Jib Stowed

65 Ton Hook Block

100 lbs. Rigging

Maximum Net Load

Gross Capacity

30 ft. radius

68 ft. Boom

Length

60.5°



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Rev. 05-28--02© 2000 CIA, Inc.

-100 lbs.

-1,063 lbs.

-1,900 lbs.

Boom Extension

& Jib Stowed

65 Ton Hook Block

100 lbs. Rigging

Maximum Net Load

Gross Capacity

30 ft. radius

68 ft. Boom

Length

60.5°

46,650 lbs.



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Rev. 05-28--02© 2000 CIA, Inc.

Boom Extension


65 Ton Hook Block

100 lbs. Rigging

Maximum Net Load

Gross Capacity

30 ft. radius

68 ft. Boom

Length

60.5°-1,900 lbs.-100 lbs.

43,587 lbs.

46,650 lbs.



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Rev. 05-28--02© 2000 CIA, Inc.

Boom Extension


65 Ton Hook Block

100 lbs. Rigging

Maximum Net Load

Gross Capacity

30 ft. radius

68 ft. Boom

Length

60.5°-1,900 lbs.-100 lbs.

43,587 lbs.

46,650 lbs.



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Rev. 05-28--02© 2000 CIA, Inc.

Parts of Line




Min Parts Line = 45,587 ÷ 14,605

45,587 ÷ 14,605

Suspended Weight

3.121 = 45,587 ÷ 14,605



Rounded to 4

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Rev. 05-28--02© 2000 CIA, Inc.

Boom Extension


65 Ton Hook Block

100 lbs. Rigging

Maximum Net Load

Gross Capacity

30 ft. radius

68 ft. Boom

Length

60.5°-1,900 lbs.-100 lbs.

43,587 lbs.

46,650 lbs.


4Minimum Parts of Line ______

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44

468 30 60.5

32’ 428’ 4

……....1,063

1,900

1003,063

46,6503,063

43,5874

MAIN65

4


4

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Rev. 05-28--02© 2000 CIA, Inc.

30 ft. radius

80 ft. Boom

Length

65.5°65 Ton Hook Block

90 lbs. Rigging

Maximum Net Load

Gross Capacity15’ Wire Rope

Extension & Jib Erected


17° offset



-15 lbs.

-90 lbs.



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Rev. 05-28--02© 2000 CIA, Inc.

-90 lbs.

30 ft. radius

80 ft. Boom

Length


90 lbs. Rigging

Maximum Net Load




17° offset-15 lbs.

-9,396 lbs.



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Rev. 05-28--02© 2000 CIA, Inc.

30 ft. radius

80 ft. Boom

Length


90 lbs. Rigging

Maximum Net Load




17° offset-15 lbs.

-9,396 lbs.


-300 lbs.

-90 lbs.



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Rev. 05-28--02© 2000 CIA, Inc.

-90 lbs.

30 ft. radius

80 ft. Boom

Length


90 lbs. Rigging

Maximum Net Load




17° offset-15 lbs.

-9,396 lbs.

-300 lbs.


-1,900 lbs.



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Rev. 05-28--02© 2000 CIA, Inc.

-90 lbs.

30 ft. radius

80 ft. Boom

Length


90 lbs. Rigging

Maximum Net Load




17° offset


-90 lbs.

-15 lbs.

-9,396 lbs.

-300 lbs.

-1,900 lbs.


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Rev. 05-28--02© 2000 CIA, Inc.

-90 lbs.

30 ft. radius

80 ft. Boom

Length


90 lbs. Rigging

Maximum Net Load




17° offset


40,450 lbs.

-90 lbs.

-15 lbs.

-9,396 lbs.

-300 lbs.

-1,900 lbs.


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Rev. 05-28--02© 2000 CIA, Inc.

-90 lbs.

30 ft. radius

80 ft. Boom

Length


90 lbs. Rigging

Maximum Net Load




17° offset


40,450 lbs.

-90 lbs.

-15 lbs.

-9,396 lbs.

-300 lbs.

-1,900 lbs.

28,749 lbs.


85

Rev. 05-28--02© 2000 CIA, Inc.


-90 lbs.

30 ft. radius

80 ft. Boom

Length


90 lbs. Rigging

Maximum Net Load




17° offset-15 lbs.

-9,396 lbs.

-300 lbs.

-1,900 lbs.

28,749 lbs.


3

PARTS = 30,739 ÷ 14,605

40,450 lbs.

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44

480 30 66.5

32’ 428’

AUX

……....9,396

1,900

903,063

40,45011,70128,749

3

MAIN65

4

7.5 300

1


44

1515 JIB

87

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LIFTCRANECAPACITIES

89

Rev. 05-28--02© 2000 CIA, Inc.

200 Ton Load Block

300 lbs. Rigging -300 lbs.

Maximum Net Load

Gross Capacity

Wire Rope (6 parts)

Crawlers

Extended

90 Ft. Boom

80,700


Minimum Parts of Line ______ 50 ft. Radius

90

Rev. 05-28--02© 2000 CIA, Inc.


50 ft. Radius

Maximum Net Load

Gross Capacity

Wire Rope (6 parts)

Crawlers

Extended

90 Ft. Boom

200 Ton Load Block



80,700

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Rev. 05-28--02© 2000 CIA, Inc.

80,700


Maximum Net Load

Gross Capacity

Wire Rope (6 parts)

Crawlers

Extended

90 Ft. Boom

200 Ton Load Block


Total wire rope weight =


x Weight per Footx Boom Length Parts

50 ft. Radius

92

Rev. 05-28--02© 2000 CIA, Inc.

80,700


50 ft. Radius

Maximum Net Load

Gross Capacity

Wire Rope (6 parts)

Crawlers

Extended

90 Ft. Boom

Total wire rope weight =

x Weight per Footx Boom Length Parts

200 Ton Load Block

300 lbs. Rigging

6 x 90 =540 X 2.34 = 1263.6-1,264 lbs.

-300 lbs.


93

Rev. 05-28--02© 2000 CIA, Inc.

50 ft. Radius

-1,264 lbs.

200 Ton Load Block


Maximum Net Load

Gross Capacity

Wire Rope (6 parts)

Crawlers

Extended

90 Ft. Boom

-4,740 lbs.



80,700

94

Rev. 05-28--02© 2000 CIA, Inc.

50 ft. Radius

-1,264 lbs.

200 Ton Load Block

300 lbs. Rigging

-4,740 lbs.

-300 lbs.

Maximum Net Load

Gross Capacity

Wire Rope (6 parts)

Crawlers

Extended

90 Ft. Boom

80,700

74,396 lbs.

Suspended Weight = 74,396


Minimum Parts of Line ______Minimum Parts of Line ______3

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Rev. 05-28--02© 2000 CIA, Inc.

PARAMATERS: Crawlers Retracted _____ Crawlers Extended _____ Hoisting From The: Boom _____ Jib _____

Boom Length: _____ Ft. Radius: _____ Ft. Boom Angle: _____ Degrees._____ Ft. Jib Offset ________ __________ Lbs.

_____ Sheave Upper Boom Pt.: ________ __________ Lbs._____ Ft. Wire Rope Beneath: ________ __________ Lbs.

Ft. Wire Rope Beneath: ________ __________ Lbs._____ Ton Block: ________ __________ Lbs.

_____ Ton Ball: ________ __________ Lbs.Rigging: __________ Lbs.

¶ Total Deductions: —_________ Lbs.· Gross Capacity: __________ Lbs.

¸ Subtract Total Deductions: __________ Lbs.¹ Maximum Net Load that can be lifted: __________ Lbs.

º Minimum Part(s) of Line Required: ________ Part(s)

44

90 50

540

--

Boom 1,264

200 Main 4,740

3006,304

80,7006,304

74,3963


96

Rev. 05-28--02© 2000 CIA, Inc.

-300 lbs.

Gross Capacity30 Ft. Jib

15 Ft. Wire Rope

15 Ton Headache Ball

130 Ft. Boom

Wire Rope - 6 Parts

200 Ton Block

300 lbs. Rigging

Maximum Net Load

40 Ft. RadiusCrawlers Extended

107,600 lbs.


Minimum Prts of Line ______Minimum Parts of Line ______

97

Rev. 05-28--02© 2000 CIA, Inc.


15 Ft. Wire Rope


130 Ft. Boom

Wire Rope - 6 Parts

200 Ton Block

300 lbs. Rigging

Maximum Net Load


107,600 lbs.

-3,000 lbs.

-300 lbs.



98

Rev. 05-28--02© 2000 CIA, Inc.


15 Ft. Wire Rope


130 Ft. Boom

Wire Rope - 6 Parts

200 Ton Block

300 lbs. Rigging

Maximum Net Load


107,600 lbs.

-3,000 lbs.-36 lbs.

-300 lbs.



99

Rev. 05-28--02© 2000 CIA, Inc.


15 Ft. Wire Rope


130 Ft. Boom

Wire Rope - 6 Parts

200 Ton Block

300 lbs. Rigging

Maximum Net Load


107,600 lbs.

-3,000 lbs.-36 lbs.

-900 lbs.

-300 lbs.



100

Rev. 05-28--02© 2000 CIA, Inc.


15 Ft. Wire Rope


130 Ft. Boom

Wire Rope - 6 Parts

200 Ton Block

300 lbs. Rigging

Maximum Net Load


107,600 lbs.

-3,000 lbs.-36 lbs.

-900 lbs.

-1,826 lbs.



101

Rev. 05-28--02© 2000 CIA, Inc.


15 Ft. Wire Rope


130 Ft. Boom

Wire Rope - 6 Parts

200 Ton Block

300 lbs. Rigging

Maximum Net Load


107,600 lbs.

-3,000 lbs.-36 lbs.

-900 lbs.

-1,826 lbs.

-4,740 lbs.

-300 lbs.

96,798 lbs.


Minimum Parts of Line ______Minimum Parts of Line ______

Suspended Weight = 101,8384

102

Rev. 05-28--02© 2000 CIA, Inc.

10,802

PARAMATERS: Crawlers Retracted _____ Crawlers Extended _____ Hoisting From The: Boom _____ Jib _____

Boom Length: _____ Ft. Radius: _____ Ft. Boom Angle: _____ Degrees._____ Ft. Jib Offset ________ __________ Lbs.

_____ Sheave Upper Boom Pt.: ________ __________ Lbs._____ Ft. Wire Rope Beneath: ________ __________ Lbs.

Ft. Wire Rope Beneath: ________ __________ Lbs._____ Ton Block: ________ __________ Lbs.

_____ Ton Ball: ________ __________ Lbs.Rigging: __________ Lbs.

¶ Total Deductions: —_________ Lbs.· Gross Capacity: __________ Lbs.

¸ Subtract Total Deductions: __________ Lbs.¹ Maximum Net Load that can be lifted: __________ Lbs.

º Minimum Part(s) of Line Required: ________ Part(s)

44

130 40 --

Boom 1,826

200 Main 4,740

30010,802

107,600

96,7986

30 3,000


103

Rev. 05-28--02© 2000 CIA, Inc.

co

de

o

ffe

de

ral

reg

ula

tio

ns

29PART 1926

Revised as of J u ly 1 , 1990

OSHA Compliance

Industry Standards, Incorporated by Reference have the same force as law.

U S A S T A N D A R D

SAFETY C O DE FO R C RANES, DERRIC KS,HO ISTS,J AC KS AND SLING S

C RAWLER, LO C O M O TIVEAND TRUC K C RANES

Pa rtia l Re visio n o f USAS B30.2-1943

Na va l Fa c ilitie s Eng ine e ring C o m m a nd ,U.S. De p a rtm e nt o f the Na vy

The Am e ric a n So c ie ty o f M e c ha nic a l Eg ine e rs

MOBILE HYDRAULICCRANE STANDARDS

PCSA STANDARD NO. 2

A BU REA U OF CON S TRU CTION IN DU S TRY

M A N U FA CTU RERS A S S OCIATION

DEVELOP ED AN D COM P ILED B Y

A B ureau of Construction Industry M anufacturers Association

104

Rev. 05-28--02© 2000 CIA, Inc.

Levels of Crane SafetyGoal = Provide the SAFEST crane and rigging environment that is

reasonable and practical.

Compliance with OSHA RegulationsIncorporated Industry Standards

Law11

Compliance with: OSHA Regulations

Current Industry Standards

Voluntary22

Compliance with: OSHA Regulations

Current Industry StandardsAccepted Industry Practices

Voluntary33

INC

REA

SED

CR

AN

E S

AFE

TY

DEC

REA

SE IN

LIA

BIL

ITY

105

Rev. 05-28--02© 2000 CIA, Inc.

Training ModelFor Mobile Crane Operators

Identification of Components

Technical Data

Pre-Operational Inspection

Load Charts

Assembly & Disassembly

Set Up

Safe Operating Procedures

Responsibilities

Basic Rigging

Applicable Safety Standards

Hand Signals

Crane Manufacturer’s Requirements

4

4

4

4

4

4

4

4

4

4

4

4

106

Rev. 05-28--02© 2000 CIA, Inc.

Responsibilities

PersonResponsibleFor Lift

•Shall determine that the load weight does not exceed the crane’s rated capacity.

Operator

•Shall be responsible for those operations under their direct control.

•Shall respond to signals from the appointed signal person.

•Shall seek supervision when there are safety concerns.

SignalPerson

•Shall use standard hand signals unless voice communication is utilized.

107

Rev. 05-28--02© 2000 CIA, Inc.

Responsibilities

Lift Director

• Shall see that the crane is level and, where necessary, blocked.

• Shall see that the load is secure and balanced before it is lifted.

• Shall see that lift and swing path are clear.• Shall clear crane swing radius of all personnel.

MultipleCrane Lift

There shall be one designated person responsible

for the operation who: • Shall analyze operation and instruct all personnel

in proper positioning, rigging, and movements. • Shall make decisions as necessary to reduce

crane ratings, load position, boom location,

ground support, and speed of movement.

108

Rev. 05-28--02© 2000 CIA, Inc.

Management & Supervision

I N S P E C T I O N

109

Rev. 05-28--02© 2000 CIA, Inc.

Inspection

1. Preventive Maintenancea. Required/Recommended

2. Compliance Inspectiona. Initial - baseline data, history fileb. Operator safety check - each shift functional, physicalc. Minimum monthly - critical partsd. Minimum annual - the whole crane

110

Rev. 05-28--02© 2000 CIA, Inc.

Inspector Qualificationand Credentials

OSHA: Competent person - One who is capable of identifying existing and predictable hazards, and has authorization to take prompt corrective measures to eliminate them.

ANSI: Qualified person - A person who, by possession of recognized degree in an applicable field or certificate of professional standing, or who, by extensive knowledge, training and experience, has successfully demonstrated the ability to solve or resolve problems related to the subject matter and work.

111

Rev. 05-28--02© 2000 CIA, Inc.

Levels of InspectionGoal = Provide the SAFEST crane that is reasonably and practically

possible.

• Inspect to OSHA regulations• Inspect to ANSI B30.5 1968 & PCSA 2• Inspect to crane manufacturer’s inspection

requirements

Law11

Inspect to level 1Inspect to latest ANSI & PCSA standards

Voluntary22

• Inspect to levels 1 & 2• Equip crane with safety devices and operator

aids that are reasonable and reliable• Inspect to Industry practices

Voluntary33IN

CR

EA

SED

CR

AN

E S

AFE

TY

DEC

REA

SE IN

LIA

BIL

ITY

112

Rev. 05-28--02© 2000 CIA, Inc.

Operating Cranes Within Prohibitive Zone

THIS AREA SHOULDBE AVOIDED

CRANE SHALL NOT BE USED TOHANDLE MATERIALS IN THIS AREA

PROHIBITED ZONE

113

Rev. 05-28--02© 2000 CIA, Inc.




PROHIBITED ZONE

114

Rev. 05-28--02© 2000 CIA, Inc.



PROHIBITED ZONE

Boom shall not be positioned beyond this line.


115

Rev. 05-28--02© 2000 CIA, Inc.

Required Clearance



PROHIBITED ZONE

116

Rev. 05-28--02© 2000 CIA, Inc.

Working Near Power Lines

PROHIBITED ZONE

117

Rev. 05-28--02© 2000 CIA, Inc.

Handling Loads Stored Under Electric Power Lines

PROHIBITED ZONESEE TABLE 1

118

Rev. 05-28--02© 2000 CIA, Inc.

Site Assessment

CHECKLIST • Lift engineering available? • Operators / riggers / signal persons qualified and designated? • Site prepared for crane and load delivery? • Adequate space for safe assembly and crane set-up? • Bearing capacity of the crane’s foundation area determined? • Blocking or mats needed? • Underground hazards present (pipes, tanks, cavities, etc.)? • Crane located a safe distance from excavations / unsupported soil slopes? • Any electrical hazards within boom’s reach? • Has power company been contacted? • Signal person designated to watch power lines? • Obstructions in load / swing path? • Crane barricaded? • Lifted load remain clear of all obstructions throughout lifting path? • Adequate lighting? • Load weight determined? • Correct rigging equipment available? • Do weather conditions constitute a hazard to lift personnel? • Non-essential personnel protected?

YES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NOYES NO

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:

4444444444444444444

119

Rev. 05-28--02© 2000 CIA, Inc.

Rigging ProblemsProblem #1

Wire Rope:Wire rope sling size requiredShackle size requiredEyebolt size required

2,825 lbs.

120

Rev. 05-28--02© 2000 CIA, Inc.

Rigger’s Capacity Card

Notes: (1) These values are based on slings being vertical. If they are not vertical, the rated load (rated capacity) shall be reduced. (2) These values only apply when the D/d ratio is 25 or greater.

D = Diameter of curvature around which the body of the sling is bent.D = Diameter of rope.

2,825 lbs.

121

Rev. 05-28--02© 2000 CIA, Inc.



7/16”

2,825 lbs.

122

Rev. 05-28--02© 2000 CIA, Inc.


2,825 lbs.

123

Rev. 05-28--02© 2000 CIA, Inc.



2,825 lbs.

7/16”

7/16”

124

Rev. 05-28--02© 2000 CIA, Inc.


2,825 lbs.

125

Rev. 05-28--02© 2000 CIA, Inc.



2,825 lbs.

7/16”

7/16”5/8”

126

Rev. 05-28--02© 2000 CIA, Inc.


Chain:Alloy chain size requiredShackle size requiredEyebolt size required

3,175 lbs.

127

Rev. 05-28--02© 2000 CIA, Inc.


Notes: (1) Rating of multileg slings adjusted for angle of loading between the inclined leg and the horizontal plane of the load. (2) Quadruple sling rating is same as triple sling because normal lifting practice may not distribute load uniformly to all 4 legs

3,175 lbs.

133

Rev. 05-28--02© 2000 CIA, Inc.


Synthetic Web:Web sling size requiredShackle size requiredEyebolt size required

2,200 lbs.

137

Rev. 05-28--02© 2000 CIA, Inc.

7/16"Wire rope sling size required ________Shackle size required________Eye bolt size required________


138

Rev. 05-28--02© 2000 CIA, Inc.

Determining Sling Loading

STEPS:1. Determine sling angle2. Select corresponding Load Angle Factor3. Multiply weight of the load by Load Angle Factor to get total load on sling legs.4. Divide total load by number of sling legs.

3. 6,500 X 1.155 = 7,508

1. Sling angle =

2. Load Angle Factor =

60°

1.155

3,754 pounds per sling leg4. 7,508 ÷ 2 =

139

Rev. 05-28--02© 2000 CIA, Inc.

7/16"1/2"

3,754

Wire rope sling size required ________Shackle size required________Eye bolt size required________


142

Rev. 05-28--02© 2000 CIA, Inc.

65°

10,000 Lbs.

3. 10,000 X 1.104 = 11,040

1. Sling angle =


65°

1.104


3/8"Wire rope sling size required ________Shackle size required________Eye bolt size required________


145

Rev. 05-28--02© 2000 CIA, Inc.

3"

60°

4,400 Lbs.

Synthetic web sling size required ________Shackle size required________Eye bolt size required________


146

Rev. 05-28--02© 2000 CIA, Inc.

60°

4,400 Lbs.

3. 4,400 X 1.155= 5,082

1. Sling angle =


60°

1.155


3"Synthetic web sling size required ________Shackle size required________Eye bolt size required________


147

Rev. 05-28--02© 2000 CIA, Inc.

Synthetic web sling size required ________Shackle size required________Eye bolt size required________60°

4,400 Lbs.

2,541

3"7/16"


148

Rev. 05-28--02© 2000 CIA, Inc.

Synthetic web sling size required ________Shackle size required________Eye bolt size required________60°

4,400 Lbs.

2,541

3"7/16"7/8"


151

Rev. 05-28--02© 2000 CIA, Inc.

A critical lift would exist:

… if the gross load is too close to the gross capacity

of the crane, leaving little margin for error.

… if the load is hazardous and likely to blow up, catch fire or cause damage due to its basic makeup.

… if the lift plan called for moving the load over operating equipment or machinery.

… there were more than one crane attached to the load.

152

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

30 ft. RADIUS

68 ft. BO

OM

LENG

TH

ABH Erected

10’ Wire Rope

10 TonHeadache Ball

Extension &Jib Stowed

65 tonHook Block

100 lbs. Rigging60°

60.5°

Net Load Wt. 40,015 lbs.

What is the rated capacity?

153

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:

1.Crane ConfigurationCrane Manufacturer ______________ Model No. ____________ I.D. No. __________Counter Wt. _____ On Outriggers _____ On Tires _____ Crawlers Ext._____ Ret._____

2.ParametersHoisting from the:Boom____ Manual Section____ Ext.____ Jib____ Over Front____ Side____ Rear____Maximum Load Radius ____________

Corresponding Boom Angle ____________Corresponding Boom Length ____________Rated Capacity _________________ % of Rated Capacity __________Net Load Weight __________________ lbs. Boom Extension Weight +__________________ lbs. Jib Weight +__________________ lbs. Auxiliary Boom Head Weight +__________________ lbs. Load Block Weight +__________________ lbs. Overhaul Ball Weight +__________________ lbs. Hoist Line Weight +__________________ lbs. Rigging Weight +__________________ lbs.Gross Load Weight __________________ lbs.Minimum Parts of Line Required __________ PartsNote: Use separate sheet for multiple crane lifts.

3.Load and RiggingDescription of Load ___________________________________________________________Net Load Weight ________________ Location of Load CG __________________________Lifting Beam Capacity ________________ Tension on Lift Points _______________Sling Size ____________ Shackle Size ____________ Eyebolt Size ____________Other _______________________________________________________________________

Grove RT 865X

30X

60.568

X

46,650

Boiler40,015 Centered

NANA

40,015

100

154

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift

30 ft. RADIUS

68 ft. BO

OM

LENG

TH

ABH Erected

10’ Wire Rope

10 TonHeadache Ball


65 tonHook Block


60.5°


155

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:




3.Load and RiggingDescription of Load ___________________________________________________________Net Load Weight ________________ Location of Load CG __________________________Lifting Beam Capacity ________________ Tension on Lift Points _______________Sling Size ____________ Shackle Size ____________ Eyebolt Size ___________Other _______________________________________________________________________

Grove RT 865X

30X

60.568

X

46,65040,015


NANA

1063

100

156

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift

30 ft. RADIUS

68 ft. BO

OM

LENG

TH

ABH Erected

10’ Wire Rope

10 TonHeadache Ball


65 tonHook Block


60.5°



157

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:





Grove RT 865X

30X

60.568

X

46,65040,015

1063


NANA

220

100

158

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift

30 ft. RADIUS

68 ft. BO

OM

LENG

TH

ABH Erected

10’ Wire Rope

10 TonHeadache Ball


65 tonHook Block


60.5°



159

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:




3.Load and RiggingDescription of Load ___________________________________________________________Net Load Weight ________________ Location of Load CG __________________________Lifting Beam Capacity ________________ Tension on Lift Points _______________Sling Size ____________ Shackle Size ____________ Eyebolt Size ____________Other ______________________________________________________________________

Grove RT 865X

30X

60.568

X

46,65040,015

1063

220


NANA

1900

100

160

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift

30 ft. RADIUS

68 ft. BO

OM

LENG

TH

ABH Erected

10’ Wire Rope

10 TonHeadache Ball


65 tonHook Block


60.5°



161

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:



Corresponding Boom Angle ____________Corresponding Boom Length ____________Rated Capacity _________________ % of Rated Capacity

__________Net Load Weight __________________ lbs. Boom Extension Weight +__________________ lbs. Jib Weight +__________________ lbs. Auxiliary Boom Head Weight +__________________ lbs. Load Block Weight +__________________ lbs. Overhaul Ball Weight +__________________ lbs. Hoist Line Weight +__________________ lbs. Rigging Weight +__________________ lbs.Gross Load Weight __________________ lbs.Minimum Parts of Line Required __________ PartsNote: Use separate sheet for multiple crane lifts.

3.Load and RiggingDescription of Load

___________________________________________________________Net Load Weight ________________ Location of Load CG

__________________________Lifting Beam Capacity ________________ Tension on Lift Points _______________Sling Size ____________ Shackle Size ____________ Eyebolt Size ____________Other

_______________________________________________________________________

Grove RT 865X

30X

60.568

X

46,65040,015

1063

2201900

100


NANA

500

162

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift

30 ft. RADIUS

68 ft. BO

OM

LENG

TH

ABH Erected

10’ Wire Rope

10 TonHeadache Ball


65 tonHook Block


60.5°




163

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:





Grove RT 865X

30X

60.568

X

46,65040,015

1063

2201900

500

100


NANA

10

164

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:





Grove RT 865X

30X

60.568

X

46,65040,015

1063

2201900

50010


NANA

10043,808

165

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:





Grove RT 865X

30X

60.568

X

46,65040,015

1063

2201900

50010


NANA

10043,808

166

Rev. 05-28--02© 2000 CIA, Inc.

Parts of Line




Min Parts Line = 40,015 ÷ 14,605

40,015 14,605

Suspended Weight

Rounded to 32.73 = 40,015 ÷ 14,605

167

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:








_______________________________________________________________________

Grove RT 865X

30X

60.568

X

46,65040,015

1063

2201900

50010

10043,808


NANA

3

168

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift

30 ft. RADIUS

68 ft. BO

OM

LENG

TH

ABH Erected

10’ Wire Rope

10 TonHeadache Ball


65 tonHook Block


60.5°


169

Rev. 05-28--02© 2000 CIA, Inc.

Determining Sling Loading

3. 40,015 X 1.155= 46,217.33

1. Sling angle =


60°

1.155

4. 46,217.33 ÷ 2 = 23,108.67 pounds per sling leg

60°

60.5°

170

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:





Grove RT 865X

30X

60.568

X

46,65040,015

1063

2201900

50010

10043,808

3


NA 23,209NA

171

Rev. 05-28--02© 2000 CIA, Inc.


Notes: (1) These values are based on slings being vertical. If they are not vertical, the rated load (rated capacity) shall be reduced. (2) These values only apply when the D/d ratio is 25 or greater.

D = Diameter of curvature around which the body of the sling is bent.D = Diameter of rope.40,015 lbs.

172

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:








_______________________________________________________________________

Grove RT 865X

30X

60.568

X

46,65040,015

1063

2201900

50010

10043,808

3


NA 23,2091 1/8 NA

174

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:





Grove RT 865X

30X

60.568

X

46,65040,015

1063

2201900

50010

10043,808

3


NA 23,2091 1/4 1 1/4 NA

% of Rated Capacity = Gross Load Wt. ÷ Rated Capacity

175

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:





Grove RT 865X

30X

60.568

X

46,65040,015

1063

2201900

50010

10043,808

3


NA 23,2091 1/4 1 1/4 NA

43,808 ÷ 46,65093.9% =

Rounded to 94%

% of Rated Capacity = Gross Load Wt. ÷ Rated Capacity

176

Rev. 05-28--02© 2000 CIA, Inc.

Critical Lift Plan

Prepared by:

Operator:

Craft Supervisor:

Date:

Lift Supervisor:

Project Engr./Mgr.:





Grove RT 865X

30X

60.568

X

46,650 9440,015

1063

2201900

50010

10043,808

3


NA 23,2091 1/4 1 1/4 NA

177

Rev. 05-28--02© 2000 CIA, Inc.

With 94% of Gross Capacity being used,that means there is a 6% margin for error.

Manufacturer instructions only applyto a crane setup and operated under

perfect conditions.

Is the ground firm enough?

Is the load weight known exactly?

Is the wind blowing at all?

How old is the crane?

What about real time changes to the lift plan?

181

Rev. 05-28--02© 2000 CIA, Inc.

… are relatively more serious than other construction equipment accidents.

… result in more construction fatalities than any other single cause.

… are usually the result of a combination of factors.

CRANE ACCIDENTS

SUMMARY:

182

Rev. 05-28--02© 2000 CIA, Inc.

CRANE ACCIDENTS

The main cause of mobile crane accidents is improper set-up, followed by operator error.

Almost all crane accidents are foreseeable, and preventable.

SUMMARY:

183

Rev. 05-28--02© 2000 CIA, Inc.

About Crane Institute of AmericaAll our training programs and materials are produced in-house, including our six-part video series on safe craning practices. Videos currently available include:

Hand Signal CommunicationPre-Operational Inspection

How to Properly Interpret a Load ChartWorking Cranes Near Power Lines

Set-Up for SafetyOverhead Crane Safety.

All are available for purchase. Contact Crane Institute of America for details at:

1-800-832-2726 or write us at :

1063 Maitland Center Commons, 100Maitland, FL 32751

184

Rev. 05-28--02© 2000 CIA, Inc.

COPYRIGHT NOTICE

The entire contents of this program, including all slides and written material, are protected under U.S. and

international and copyright law.

Unauthorized reproduction of this program, in wholeor in part, is a Federal crime punishable by fines

and/or imprisonment.

Crane Institute of America, Inc. vigorously pursuesall violations of its copyright to the fullest extent permitted

under criminal and civil law.

managing crane safety

Documents

jib capacities

main boom length

main boom angle

dismantling boom

crane safety

different boom angles

jib warning

boom extension combination