Cranes and Derricks OSHA 1926.453

1. K N H NEAL, KUHN & HUFFSTEDER, INC. Safety / Risk Management Consulting Group Cranes and Derricks OSHA 1926.453

2. Crane and Hoist Safety • 1999 will see approximately 125,000 cranes in operation with an additional 100,000 in general industry. • Approximately 250,000 crane operators • Averaging 1 death per thousand operators

3. Crane and Hoist Safety • Many cranes are located in populated areas and the risk to civilians is increasing. • Safe clearance on the site is essential although not always possible.

4. Crane and Hoist Safety • OSHA programs • Last standard update was in the 70’s • Many advancements have been made, but not addressed

5. GENERAL REQUIREMENTS • The employer shall comply with the manufacturer’s specifications and limitations applicable to the operation of any and all cranes and derricks. • There is a very large percentage of accidents caused by human error in exceeding the recommended limits !!!!!!

6. General Requirements • Modifications • No modifications or additions which affect the capacity or safe operation of the equipment shall be made by the employer without the manufacturer's written approval and if changes are made, the capacity, operation, and maintenance instruction plates, tags, or decals, shall be changed accordingly. In no case shall the original safety factor of the equipment be reduced.

7. General Requirements • Modifications • Many failures result from personnel adding to or modifying the crane in manners which it was not designed. • Typical modifications • Adding of a torque arm • Adding a “Jib” • Adding of a power pack

8. General Requirements • Rated load capacities, and recommended operating speeds, special hazard warnings etc. SHALL be conspicuously posted on all equipment. They shall be visible to the operator when at the controls.

9. General Requirements • Hand signals shall be those prescribed by the applicable ANSI for the type crane in use. An illustration of the signals shall be posted at the job site.

10. General Requirements • The employer shall designate a competent person who shall inspect all machinery and equipment prior to each use as well as during use.

11. General Requirements • Daily Inspections Inspected ?? Yes or No

12. General Requirements • Daily Inspections

13. General Requirements • Daily inspections Rusted and Bent This needs to be replaced prior to use.

14. COMPETENT PERSON • What constitutes a “Competent Person” ????

15. Competent Person • A “ Competent Person” is one who is able to recognize and correctactual and/or potential hazards involved with crane operation; knows how to safely operate the crane AND who has the Authority to ensure a safe operation.

16. General Requirements • A thorough, annual inspection of the hoisting machinery shall be made by a competent person, or by a government or private agency recognized by the U.S. Department of Labor.

17. WIRE ROPE • Terminology

18. WIRE ROPE • Wire rope shall be taken out of service for a number of reasons and should be inspected daily.

19. Wire Rope • Reasons for removal from service • In Running Ropes, Six randomly distributed broken wires in one lay or three broken wires in one strand in one lay.

20. Wire Rope • Reasons for removal from service • Wear of 1/3 the original diameter of outside individual wires, Kinking, crushing, bird caging, or any other damage resulting in distortion of the rope structure. • Evidence of any heat damage from any cause.

21. Wire Rope • Reasons for removal from service • Reductions from nominal diameter of: Only a competent person with the proper calipers can make this determination Rope Size Reduction Up to 5/16” < 1/64” 3/8” - 1/2” < 1/32” 9/16” - 3/4” <3/64” 7/8” - 1 1/8” < 1/16” 1 1/4” - 1 1/2” < 3/32”

22. Wire Rope • Reasons for removal from service • Reductions from nominal diameter of rope • WHO REMEMBERS ALL THE MEASUREMENTS OF THE LAST OVERHEAD ??? Cranes are the one piece of equipment that really need the charts etc.

23. PROPER SET-UP • Level • Stable • Clearance • Reach

24. BASIC RIGGING • No matter what size crane or hoist, it still is dependent on the rigging setup Tension = 8 TONS Tension = 15.5 TONS 300 150 8 TONS 8 TONS

25. BASIC RIGGING • Load charts Chain size Single 600 > 450> 300> 7/32 2,500 4,300 3,550 2,500 9/32 4,100 7,100 5,800 4,100 3//8 7,300 12,600 10,300 7,300 1/2 13,000 22,500 18,400 13,000 5//8 20,300 35,000 28,500 20,300 Load charts apply to all components of the lift: Master links, Grab hooks, Chains, Web slings etc.

26. BASIC RIGGING • Protecting the overall stability of the rig by using throat latches. • Must be in place and functional

27. BASIC RIGGING • Rigging it properly Load blocks etc. must be rigged properly.

28. Guarding • All moving parts of the crane shall be properly guarded to prevent accidental contact with personnel • Belts Sprockets • Gears Drums • Shafts Fly wheels • Pulleys Chains • Other moving parts

29. Guarding • Swing radius protection • Accessible areas within the swing radius of the rear rotating part of the crane , either permanently or temporarily mounted, shall be barricaded to prevent employees being struck. • OSHA has made an interpretation on this issue that strikes down a lot of current ideas.

30. Guarding • Swing radius protection A very dangerous situation unless protected.

31. Guarding • All exhaust pipes etc. shall be protected from employee contact.

32. Guarding • ALL windows in cabs shall be of safety glass, or equivalent that introduces no visible distortion to the operator.

33. Guarding • Where necessary for rigging or service, a ladder or steps shall be provided for access to the cab roof. • Guardrails, handholds and steps shall be provided for easy access to the car and cab. • Platforms etc. shall have anti-skid walking surfaces.

34. Fire Protection • At least a 5BC rated fire extinguisher shall be available at all operator stations or cabs of equipment.

35. ELECTRICAL SAFETY • Your primary means of protection is to have all exposed overhead electrical lines de-energized when working in the area. • Real life dictates that this is usually not the case.

36. Electrical Safety • When lines cannot be de-energized, proper clearance must be maintained: VOLTAGE MINIMUM CLEARANCE 50 kV or below 10 Feet < 50 kV 10 Feet + 0.4” for each 1kV over50 kV up to and including 345 kV > = 750 kV 16 Feet These are MINIMUMS !!!!

37. Electrical Safety • Things to consider when deciding on the “Clearance” • 1. Clearance from What ?? • 2. Drift • 3. Load swing (Tag Lines) • 4. Boom and Jib

38. Electrical Safety • A person SHALL be designated to observe clearance of the equipment and give timely warning for all operations where it is difficult for the operator to maintain the desired clearance by visual means.

39. Electrical Safety • Monitor Person MUST have absolute authority to stop the operations and can only be overridden by the operator on the side of safety. • ie: Monitor says OK, Operator says STOP

40. Electrical Safety • Overhead lines • Any overhead wire shall be considered to be an energized line unless and until the person owning such line or the electrical utility authorities indicate that it is not an energized line and it has been visibly grounded;

41. Electrical Safety • INDUCED ELECTRICAL CHARGES • Prior to work near transmitter towers where an electrical charge can be induced in the equipment or materials being handled, the transmitter shall be de-energized or tests shall be made to determine if electrical charge is induced on the crane. The following precautions shall be taken when necessary to dissipate induced voltages:

42. Electrical Safety • INDUCED ELECTRICAL CHARGES • The following precautions shall be taken when necessary to dissipate induced voltages: • The equipment shall be provided with an electrical ground directly to the upper rotating structure supporting the boom;

43. Electrical Safety • INDUCED ELECTRICAL CHARGES • Ground jumper cables shall be attached to materials being handled by boom equipment when electrical charge is induced while working near energized transmitters. Crews shall be provided with nonconductive poles having large alligator clips or other similar protection to attach the ground cable to the load.

44. Electrical Safety • INDUCED ELECTRICAL CHARGES • Combustible and flammable materials shall be removed from the immediate area prior to operations

45. Suspended loads, picking the load • All employees shall be kept clear of loads about to be lifted and of suspended loads. This employee was killed because he was adjacent to an improperly lifted load. The hoist line was not vertical over the load causing it to swing and fall on the employee.

46. ACCIDENTS FAMOUS LAST WORDS: I’TLL NEVER HAPPEN HERE !!

47. ACCIDENTS The operator was asked, by the project rigging superintendent, to walk the above 4000 Manitowoc with 300 feet of boom off of the mats it was sitting on onto soft soil. The operator told the super, "I'll do what you want, but if I do, the crane will turn over." The rigging superintendent replied, "That is not your problem, let me worry about that. You are to operate the crane and follow instructions from supervision." With that, the operator got back in the seat, made sure the area was clear of other workers, knuckled the crane into travel, set the throttle at a slow speed and climbed off of the crane. No, fatalities, no injuries. Believe it or not, neither man was fired.

48. ACCIDENTS The crane was left on a barge near the edge of a river over a week-end. Rain upstream caused the river to rise and wash the sand from under one end of the barge. Out of four barges left on the bank, two went into the river, one was lost and never found. An expensive lesson for the contractor.

49. ACCIDENTS The above hydraulic crane was turned over by a young operator in Puerto Ordez, Venezuela in 1979. He picked a load up (precast concrete stadium seats) near the crane with his boom up at a high degree of angle. He proceeded to boom down and before he realized that he had more load than the crane could handle, at the radius the load had reached, it was too late. He tried to get down on the load, but since the crane was hydraulic, he couldn't let it down fast enough. Fortunately the operator jumped clear before it crushed the cab.Isn't it amazing how we all tend to learn faster after a "Been There - Done That" experience.

50. ACCIDENTS The roll-over protection landed on my left knee and pinned me down. It took an hour and forty-five minutes to get another machine to the site to lift it off of me. Diesel was running under me, and I was losing blood fast. My left arm was broken in five places and all but mangled. I now have a steel plate in it holding the five breaks together. I lost about fifty percent use of the arm. Thank God, I can still pull control levers with it.Am I now paranoid about seat belts? You bet. When I mount a piece of rubber tired equipment now, the first thing I do is fasten the seat belt. I pulled a stupid stunt, but I will not be fool enough to do it again. Been There, Done That It is very embarrassing to publicize this, especially since that is me, Doyle Peeks, trapped under that 580 Case loader/backhoe. I have put this here in hopes it may keep someone else from repeating what I did. The accident happened on October 6, 1988 near Dallas, Texas on Lake Ray Hubbard. I had well over thirty-five years of operating experience. I just got too confident. I thought I could go running down a slopped embankment without rolling the machine. I had always thought that if a machine ever started to roll that I could hang on to something and not be thrown off of the machine. Boy, was I ever wrong. It happened so fast, I was on the ground before I knew what was happening. I grabbed at everything I could and couldn't find a thing to hold on to.