Cranes. Upon Completion. Subpart N. Participants will understand: » Scope of the new standard. » General overview including:

Transcription

1 Cranes Subpart N Upon Completion Participants will understand:» Scope of the new standard» General overview including:» Role of the Controlling Contractor,» Predictable hazards in the workplace,» Barricades requirements,» Electrical hierarchy, and» Hand Signals. 1

2 Big Blue Video 2

3 This subpart does not cover:» (1) Machinery converted or adapted for a non-hoisting/lifting use.» (2) Power shovels, excavators, wheel loaders, backhoes, loader backhoes, track loaders.» (3) Automotive wreckers and tow trucks.» (4) Digger derricks when used for augering holes for electric and telecommunication poles.» (8) Powered industrial trucks (forklifts), except when configured to hoist and lower with a winch or hook.» (13) Tree trimming and tree removal work.» (15) Roustabouts.» (16) Helicopter cranes. 3

4 » (17) Material Delivery» (i) Articulating/knuckle-boom truck cranes that deliver materials If truck crane is equipped with a properly functioning automatic overload prevention device.» Unless:» (A) The articulating/knuckle-boom crane is used to hold, support or stabilize the material to facilitate a construction activity, Controlling Contractor» An employer / entity that is a prime contractor, general contractor, construction manager that has the overall responsibility for the construction of the project» (e) The duties of controlling entities under this subpart include, but are not limited to, the duties specified in (c), (e) and (b). 4

5 » (c) The controlling entity must:» (1) Ensure ground preparations.» (2) Locate and inform regarding voids, tanks, utilities» (e) Assembly Disassembly (A/D) Director and Operator must communicate concerns to the controlling entity Ground conditions» (b) Equipment must not be assembled or used unless ground conditions are firm, drained, and graded level within the tolerances allowed by the manufacturer. 5

6 Power Line Video Power line safety» (1) Identify the work zone by either:» (i) Demarcating boundaries or;» (ii) Defining the work zone as the area 360 degrees around the equipment, up to the equipment s maximum working radius.» Crane vs. Power line 6

7 » (2) When working within 20 feet to a power line, the employer must meet one of the following options:» (i) Option (1) De-energize and visibly ground. Confirm from the utility» (ii) Option (2) 20 foot» (iii) Option (3) Table A (b) Preventing encroachment» When using (2) or (3), all of the following requirements must be met:» (1) Conduct a planning meeting with the operator and all workers in the area of the equipment or load. Review the location of the line(s), and the measures to prevent encroachment/electrocution. 7

8 » (2) Tag lines must be non-conductive.» (3) Erect and maintain an elevated warning line, barricade, or line of signs» equipped with flags» at 20 feet from the power line or;» at the minimum approach distance under Table A» if the operator is unable to see the line, a dedicated spotter must be used» (4) Implement at least one of the following measures:» (i) A proximity alarm» (ii) A dedicated spotter» (iii) A device that automatically warns the operator when to stop movement» (iv) A device that automatically limits range of movement» (v) An insulating link/device, 8

9 (c) Voltage information.» Where Option (3) of this section is used:» The utility owner/operator must provide voltage information within (2) two working days of the employer s request. Operations below power lines» (1) No part of the equipment, load line, or load is allowed below a power line except:» When the boom or equipment fully extended is not within 20feet Avoid this area Prohibited Zone 20 Boom shall not be positioned beyond this line Cranes shall not handle material in this area 9

10 (g) Training.» (1) The employer must train each operator and crew member assigned to work with the equipment on all of the following:» (i) Procedures for contact with a power line that includes:» (A) Danger of electrocution.» (B) remaining inside an electrified cab.» (C) The safest means of evacuating energized equip.» (D) The energized zone around the equipment» (E) Avoid approaching or touching the equipment and the load.» (F) Safe clearance distance from power lines. 10

11 » (ii) Power lines are presumed to be energized unless the utility owner/operator confirms that the power line has been and continues to be de-energized and it is visibly grounded at the worksite.» (iii) Power lines are presumed to be uninsulated» (v) The procedures to be followed to properly ground equipment and the limits of grounding.» (g)(2) Employees working as dedicated spotters must be trained.» (3) Training under this section must be administered in accordance with (g). 11

12 Dedicated spotter (power lines): Responsibility: 1. separation between the power line and the equipment. 2. Ensure that the minimum approach distances are not breached. Table A Voltage (nominal, kv, AC) Minimum clearance distance (feet) up to over 50 to over 200 to over 350 to over 500 to over 750 to 1, over 1,000 (as established by the utility) 12

13 Operation.» (a) Must comply with all manufacturer procedures» (b) Unavailable operation procedures:» (1) the employer must develop and have them signed by a registered professional engineer. (c) Accessibility of procedures.» (1) Load charts, recommended operating speeds, special hazard warnings, instructions, and operator s manual, must be in the cab at all times. 13

14 (o) Compliance with rated capacity (RP)» (1) Cannot exceed RP.» (3) load must be verified within the RP» (i) Calculating weight using a load weighing device 14

15 Cellular phones» (d) The operator must not engage in any practice or activity that diverts his/her attention while actually engaged in operating the equipment, such as the use of cellular phones» (other than when used for signal communications). (u) Traveling with a load.» (2) If allowed, by the manufacturer, the employer must ensure that:» (i) A competent person must be present and consider:» Reduced rated capacity, load position,» Boom location, ground support,» Travel route, overhead obstructions,» Speed of movement necessary to ensure safety» Tire pressure 15

16 » (v) Rotational speed must reduce swing to a radius at which it can be controlled.» (w) A tag line must be used if necessary to prevent rotation of the load that would be hazardous.» (y) The operator must obey a stop signal, irrespective of who gives it Authority to stop» Whenever there is a safety concern, the operator has the authority to stop and refuse to handle loads - until a qualified person has determined that safety has been assured. 16

17 Waikato Video Signals general reqs.» (a) A signal person must be provided when:» (1) The P of O is not in full view.» (2) When traveling, with obstructed view.» (3) Operator or hander determines that it is necessary. 17

18 (b) Types of signals.» Signals must be by hand, voice, audible, or new signals.» (c) Hand signals.» (1) The standard hand signals must be used (see Appendix A of this subpart).» Exception: Where the Standard Method for hand signals is infeasible, or an attachment is not covered Non-standard hand signals.» (2) When using non-standard hand signals, the signal person, operator, and lift Director (where there is one) must contact each other prior to the operation and agree on the non-standard hand signals that will be used. 18

19 (d) New signals.» Signals other than hand, voice, or audible signals may be used where the employer demonstrates that:» (1) The new signals provide are equally» (2) The new signals comply with a national consensus standard (e) Suitability.» Signals and the means of transmitting the signals to the operator must be appropriate for the site conditions. 19

20 » (f) Signaling must be continuous.» (h) Only one person may give signals at a time, except in an emergency» Operator must obey a stop or emergency stop signal» (k) All signal must be given from the operator s direction perspective Signals radio/electronic» (a) Device(s) used to transmit signals must be tested on site before beginning operations.» (b) Signal transmission must be through a dedicated channel,» (c) The operator s reception of signals must be by a hands-free system. 20

21 Signals voice signals» (a) Prior to beginning operations, the operator, signal person and AD (if there is one), must agree on the voice signals.» Another meeting is required when:» another worker is added or substituted,» a voice signal is to be changed.» (b) Each voice signal must contain the following three elements, given in the following order: 1. function (such as hoist, boom, etc.), 2. direction; distance and/or speed; 3. stop command, function.» (c) The operator, signal person and AD (if there is one), must be able to communicate in the language used. 21

22 Signals hand signal chart.» Hand signal charts must be either posted on the equipment or conspicuously posted in the vicinity of the hoisting operations. 22

23 Work area control.» (a) Swing radius hazards.» (2) Employers must:» (i) Train each employee on or near the equipment.» (ii) Erect a boundary around the hazard areas. (3) Working in the hazard area.» (i) Operator must be informed before entering.» (b) Where any part of a crane is within the working radius of another crane, the controlling entity must institute a system to coordinate operations. 23

24 Keeping clear of the load» (a) Hoisting routes that minimize the exposure to hoisted loads must be used,» (b) While the load is not moving, no employee exposed, except for:» (1) Hooking, unhooking or guiding a load;» (2) Initial attachment to a component or structure;» (3) A concrete hopper or bucket. 24

25 » (c) When employees are exposed, all must be met:» (1) Rigged to prevent displacement.» (2) Self-closing latches or equivalent» (3) Rigged by a qualified rigger. (d) Receiving a load.» Only employees needed to receive a load are permitted to be within the fall zone.» (e) During a tilt-up or tilt-down operation:» (1) No employees directly under the load.» (2) Only employees essential to the operation are permitted in the fall zone (but not directly under the load). 25

26 Operator qualification and certification.» (b) Option (1): Certification by an accredited crane operator testing organization.» (c) Option (2): Qualification by an audited employer program.» (d) Option (3): Qualification by the U.S. military» (e) Option (4): Licensing by a government entity. (k) Phase-in.» (1) The provisions of this section are applicable November 9, 2010, except for paragraphs (a)(2) and (f) which are applicable November 9,

27 » (2) all of the requirements in paragraphs (k)(2)(i) and (ii) of this section apply until November 9, 2014» (i) The employer must ensure that operators are competent to operate the equipment.» (ii) Where an employee assigned to operate machinery does not have the required knowledge or ability to operate the equipment safely, the employer must train and evaluate that employee prior to operating the equipment Signal person quals.» (1) Option (1) Third party qualified evaluator. With documentation.» (2) Option (2) Employer s qualified evaluator. Assessment and Documentation meeting Qualification Requirements. 27

28 Signal Certifications» (3) Documentation for whichever option must be on-site.» The documentation must specify each type of signaling (e.g. hand signals, radio signals, etc.) for which the signal person is trained. (c) Qual. Requirements» Each signal person must:» (1) Know and understand signals used.» Hand Signals - Standard Method.» (2) Be competent in the type of signals used. 28

29 » (3) Have a basic understanding of equipment operation and limitations, including the crane dynamics involved in swinging and stopping loads and boom deflection from hoisting loads.» (4) Know and understand the relevant requirements of the standard.» (5) Demonstrate proficiency through an oral or written test, and through a practical test Training» The employer must provide training as follows:» (a) Overhead power lines.» (b) Signal persons.» (c) Operators.» (d) Competent persons and qualified persons.» (e) Crush/pinch points. (f) Tag-out. 29

30 (g) Training administration.» (1) The employer must evaluate each employee required to be trained under this subpart.» (2) The employer must provide refresher training when, there is an indication that retraining is necessary. (4) Latching hooks» (i) Hooks must be equipped with latches, except where:» (ii) Hooks without latches, or with latches removed or disabled:» (A) A qualified person has determined that it is safer» (B) Routes for the loads are pre-planned» (iii) The latch must close the throat opening and be designed to retain 30

31 Safety devices.» (a) Required safety devices:» (1) Horn, Crane level indicator, boom stops, jib stops and foot pedal brake locks.» (5) Hydraulic outrigger and hydraulic stabilizer jacks must have an integral holding device/check valve.» (6) Equipment on rails must have rail clamps and rail stops» (b) Operations must not begin, work must stop, equipment is tagged and removed from service.» Alternative measures are not permitted. 31

32 Operational aids» (5) Category I operational aids must be repaired no later than 7 calendar days:» (6) Category II operational aids must be repaired no later than 30 calendar days or within 7 days of receipt of the parts (f) Inspections.» (2) Pre-erection inspection» (3) Post-erection inspection» (4) Monthly» (5) Annual 32

33 (f) Tag-out.» Tags must be placed in the cab in a conspicuous location stating that the equipment is out of service and is not to be used. 33

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35 Rigging 35

36 K tower crane» Six regulation football fields 36

37 K tower crane» Monuments of the World and the K L shown together in true scale. Erection Sequence - Simplified Silhouette 37

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39 Service Cranes 39

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41 Counterweight Trolleys Jib Tie Bars 41

42 Main Winch Trolleys 42

43 Trolleys 43

44 Thank You 44

45 Competent Signal Person OBJECTIVES» O.S.H.A. regulations pertaining to Signaling» Review basic crane terms» Competent Signal Person role 45

46 Signal person qualifications» Provide a copy of applicable standard» (a)(c) prior to giving any signals, these requirements must be met» You must be trained» Not Portable» Certificate (wallet card) on-site» Each signal person must:» (1) Know and understand the type of signals used.» (2) Be competent in the application of the type of signals used.» (3) Have a basic understanding of equipment operation and limitations, including the crane dynamics involved in swinging and stopping loads and boom deflection from hoisting loads. 46

47 » Each signal person must:» (2) Be competent» capable of identifying existing and predictable hazards which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.» (4) Know and understand the relevant requirements of through and » (5) Demonstrate that he/she meets the requirements through an exam and practical test. 47

48 Rigging Requirement» Qualified rigger: a rigger who meets the criteria for a qualified person.» Qualified: a person who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, successfully demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project.» This is not a rigging class Basic Crane Terms 48

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54 Responsibilities» Ensure the safety of the site and the crew» Use and have access to all necessary information, tools, and equipment» Evaluate the site» Verify all barricades are in place» Guide the operator through the lift and landing 54

55 Safety of the site and crew» You are directly responsible for the outcome of every lift you make.» You are responsible for completing all activities and actions necessary to make each lift safe.» You must not lift if you can not meet the requirements of this class.» You have the authority to stop and or refuse a lift. Information, tools, and equipment» Crane information» Weight of the load» Site plans» Lift plan» Inspections» Hand signals chart» Training of others 55

56 Information, tool, and equipment» Meetings» Barricades» Scales» Shipping tickets» Radios» Spotters» Gloves, danger lines, vests, signs, fall protection, etc.. Site Evaluation» Review the site plan» Underground utilities» Underground tanks and voids» Excavations and trenches» Buildings, signs, obstructions, noise» Personnel» Public and pedestrians 56

57 Site Evaluation» Ground conditions» Asphalt (above 90 degrees F)» Settling» Weather Site Evaluation» Overhead power lines» Greatest hazard involving cranes» Accounts for the greatest number of deaths» 20» Designated spotters may be required» Written conformation from utility of all deenergized lines 57

58 Barricades» Demarcation line site perimeter» Warning line 20 from power line» Work area notification personnel protection» Danger area notification - personnel protection» Swing radius line around crane +2 from and obstruction Guiding the operator» Leverage» Center of Gravity» Tipping axis» Strength» Stability» Level inertia» Centrifugal force 58

59 Leverage» Leverage is using the weight of one object to move the weight of another object Calculating Leverage 59

60 Center of Gravity Lifting a load with leverage 60

61 Tipping Axis Calculating Leverage 61

62 Strength vs Stability» Strength is the cranes ability to resists structural failure» Stability is the cranes ability to resist tipping» Note: A crane can fail (structurally) on a normal lift if it has been overloaded on a previous lift or as a result of inadequate maintenance Load Charts» Specific to each manufacturer» Apply to properly used and maint. equipment only» Special notes 62

63 Poor Equipment Condition» Immediately report to operator and supervision and stop the lift Crane Level 63

64 Inertial, Side Loading and Swing Rate» An object in motion will stay in motion» High swing rate» Stopping and starting Swing Rate, Load Radius and Centrifugal Force» What happens to the load radius if I increase the swing rate? 64

65 Shock Loading and Snatching» Speed» Gradual acceleration and deceleration» Contact with load» Cable 65

66 Reeving» Symmetrical 66

67 Wind» Follow Manufacturer s requirements» mph use extreme caution» 30 mph stop» Big Blue Duty Cycle» Duty cycle operation are conducted at high speed and repetitive» Steel erection and concrete» Load capacities are reduced by 20%» Different load chart 67

68 Operational Aids» Anti-two blocking» Boom angle indicator» Boom Stops» Jib Stops» Boom Hoist drum Disconnects» Boom length indicator» Rated load indicator» LMI» Hoist Drum Rotation indicator» Wind Indicator» All manufacturer required aids present or tag out the crane LMI and Weighing the Load» All loads must be weighed using a load weighing device» A LMI is not acceptable for the purpose 68

69 Choosing a signal type» Must be suitable for the lift» Hand» Audible» Voice» New Signals» Posting requirements» Meeting requirements» Changing signals» Adding employees» Critical lifts Hoisting the load» Face the operator» Move slow to avoid shock» Ensure the operator is watching you» Never lift over anyone's head» Lift inside the work area only 69

70 Hoisting the load» Never leave a load unattended» Never loose line of site on a load under your control» Stay clear of the load» Understand:» You are controlling the crane» It will do exactly what you signal Hoisting the load» Raise the load a few inches» Move slow and deliberately» Only one person can signal the crane at a time (except a stop command)» Multi crane lifts» Plan every lift as if it were going to fail 70

71 In an Emergency» State the emergency» Immediately lower the load if possible» Even if it mean loosing the load?» Even if it means crushing the building?» Why? (e) Suitability. Signals and the means of transmitting the signals to the operator must be appropriate for the site conditions. 71

72 (f) Signaling must be continuous Signals radio/electronic (a) Device(s) used to transmit signals must be tested on site before beginning operations. (b) Signal transmission must be through a dedicated channel, (c) The operator s reception of signals must be by a hands-free system. 72

73 Signals voice signals (a) Prior to beginning operations, the operator, signal person and AD (if there is one), must agree on the voice signals. Another meeting is required when: another worker is added or substituted, a voice signal is to be changed. (b) Each voice signal must contain the following three elements, given in the following order: function (such as hoist, boom, etc.), direction; distance and/or speed; stop command, function. (c) The operator, signal person and AD (if there is one), must be able to communicate in the language used. 73

74 Signals hand signal chart. Hand signal charts must be either posted on the equipment or conspicuously posted in the vicinity of the hoisting operations. 74

75 Review Hand Signals» In class demonstration» In class practical exam» Written exam» Note: You are not a qualified rigger as a result of this class! You cannot rig a load until you are a qualified rigger. Qualified Rigger 75

76 OBJECTIVES» Meet O.S.H.A. requirements for a Qualified rigger for nylon and wire slings as well as simple hitches, general and miscellaneous rigging.» Understand basic safe sling use.» Be able to identify and describe conditions for sling s replacement. Basic Crane Terms 76

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79 Wedge Socket 79

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82 Definitions» Sling: An assembly which connects the load to the material handling (lifting) equipment.» Working Load Limit WLL: The Working Load Limit is the maximum load which should ever be applied to the product. (excludes extreme temp situations) 82

83 Definitions» Breaking Strength/Ultimate Strength: The average force at which the product, in the condition it would leave the factory, has been found by representative testing to break.» Side Loading : UNTESTED loads applied in all un-tested/un-certified directions. Definitions» Safety Factor: Term usually computed by dividing the Breaking Strength by the WLL and generally expressed as a ratio. For example: 5 to 1.» Dynamic Load / Shock Load: The forces applied to the crane as a result of a load in motion. 83

84 Definitions» Safety Factor: Term usually computed by dividing the Breaking Strength by the WLL and generally expressed as a ratio. For example: 5:1» Dynamic Load / Shock Load: The forces applied to the crane as a result of a load in motion. Shock Loading and Snatching» Speed» Gradual acceleration and deceleration» Contact with load» Cable 84

85 Safety Factor» 5:1 is chosen most frequently for wire rope and the minimum requirement from ASME.» 10:1 is required when slings are used to carry personnel.» Responsibility for knowing the design factor rests with the user. 85

86 Working Load Limit (WLL)» Based on the first product use» Static load» Specific to each hitch» Reduced by many forces that you will learn to calculate today Load vs. Capacity 86

87 Capacity Strength vs. Stability» Strength: ability to resists structural failure» Stability: ability to resist tipping» Note: A crane can fail on a normal lift if it has been overloaded on a previous lift or as a result of inadequate maintenance 87

88 Leverage» Leverage is using the weight of one object to move the weight of another object Calculating Leverage 88

89 Outriggers and Leverage Center of Gravity 89

90 Identifying C of G Lifting a load with leverage 90

91 Tipping Axis Calculating Leverage 91

92 Load Charts» Specific to each manufacturer» Apply to properly used and maint. equipment only» Special notes Poor Equipment Condition» Immediately report to operator and supervision and stop the lift 92

93 Crane Level Inertia, Side Loading and Swing Rate» An object in motion will stay in motion» High swing rate» Stopping and starting 93

94 Swing Rate, Load Radius and Centrifugal Force» What happens to the load radius if I increase the swing rate? 94

95 Boom / Range Diagram Backward Stability 95

96 Reeving» Symmetrical Wind» Follow Manufacturer s requirements» mph use extreme caution» 30 mph stop» Big Blue 96

97 Duty Cycle» Duty cycle operation are conducted at high speed and repetitive» Steel erection and concrete» Load capacities are reduced by 20%» Different load chart Rigging Equipment» Fittings, Sheaves, Shackles, Blocks, Sockets, Hooks, Eyes, Turnbuckles» Chains, Slings, Ropes, Latches, Clamps,» Softeners 97

98 Wire Rope Wire Rope» Usually a "core" member to increase flexibility» Fiber Core (FC)» Wire Strand Core (WSC)» Independent Wire-rope Core (IWRC) 98

99 Wire Rope Efficiency Rating» Object diameter divided by the wire diameter 99

100 Efficiency Rating D/d 100

101 Maintenance and Lubrication Rigging Inspection» SSC Qualified riggers are responsible for the inspection and maintenance of ALL rigging components: 1. Full inspection - Daily 2. Visual - Before each use 3. Documented - frequent and regular a. Delivery 101

102 Inspection» Mechanical damage due to rope movement over sharp edge projection while under load. Valley Break 102

103 Kinked Fatigue 103

104 Drum Crushing Coorosion» Corrosion of severe degree caused by immersion of rope in chemically treated water. 104

105 Fractures Twists 105

106 Wire Rope Inspection» Break up of IWRC resulting from high stress application. Note nicking of wires in outer strands. Wire Rope Inspection» Multi strand rope birdcaged due to torsion <> unbalance. Typical of build up seen at anchorage end of multifall crane application. 106

107 Wire rope clips Shackles 107

108 Shackles Turnbuckles» Used to balance a load and adjust tension 108

109 Lifting rings and Links 109

110 Eye Bolts» Every eye bolt must be plainly marked with sufficient information to enable a worker using it to determine its maximum rated load (Regulation 851, section 51(1)(c)) Sholderless Eye Bolt 110

111 Sholderless Eye Bolt Eye Bolt Rigging Failure 111

112 Eye Bolt Rigging Failure Shouldered Eye Bolt» The eye bolt must be screwed into the load until the shoulder fits flat» To ensure the shoulder is firmly seated on the surface of the load a metal washer may be used under the shoulder» Ensure eye has been correctly aligned with the chain or sling 112

113 Shouldered Eye Bolts» P applied at an angle from the axis of the bolt.» The chain or sling must be in the plane of the eye Correct Loading Shouldered Eye Bolts Degrees from eye bolt axis or chain or sling: 15 Degrees 55% 30 Degrees 35% 45 Degrees 25% 90 Degrees 20% Percentage of stamped load - lifting capacity available: 113

114 Swivel Hoist Rings» In any situation where there is doubt about the safety of using eye bolts, it is recommended that swivel hoist rings be used instead Industrial Cranes» Power hoist: usually electric or air operated» Chain hoist / chain fall: Hand operated 114

115 Rigging» Always use rigging to connect the load to the hook Chains» Tagging Permanently affected» Worn links Remove from service (10%)» Nicks and gouges file up to (10%)» Should hinge freely Sizes 1.1/2" and Larger - DOMESTIC 115

116 Slings Slings 116

117 Inspection» Regularly Inspect products for visible damage, cracks, wear, elongation, rust, burns, tears, cuts, stitching failure, etc.» Protect all products from corrosion.» No product can keep operating at its rated capacity indefinitely. Inspection 117

118 Inspection of Equipment (general)» Frequency of inspection will depend on environmental conditions, application, storage of product prior to use, frequency of use, etc.» Immediately withdraw defective items from service. Inspection of Equipment» Destroy, rather than discard, items that have been judged defective. 118

119 Inspection of Equipment (Nylon)» Load capacity tag is missing.» Acid or caustic burns on the sling.» Snags, punctures, tears, or cuts.» Stitching is broken or worn. Inspection» The sling stretching» Many manufacturers incorporate a red wear cord inside of the sling. If this red wear cord can be readily seen, remove it immediately» Red cord vs. OSHA 119

120 Softeners Hitch Types 120

121 Hitch Application» Basket: Loads designed for basket hitch seldom used in SSC application» Choker: Most common used hitch for SSC applications» Straight: Used with engineered lifting points Sling Angle 121

122 Sling Angle Sling Angle 122

123 General Rigging Safety» Never rest a load on a sling, or pinch a sling between the load and any adjacent surface.» A sling should never be pulled from under a load while the load is resting on the sling.» Keep loads balanced to prevent overloading. General Rigging Safety» Slings should be stored off of the floor and out of the weather. 123

124 General Rigging Safety» Keep out from under a raised loads.» Line of force» Barricades» Conduct all lifting operations in such a manner, that if there were an equipment failure, no personnel would be injured. General Rigging Safety» Components must match.» Attachments must be properly installed» You are only as strong as your weakest component» Components must have a WLL at least equal to the product with which they are used. 124

125 Tag Lines» Tag line placement» Opposing lines» Never wrap around your hand or body» Body position Electrical Hazards» 20» Demarcation Line» Warning Line» Spotter» Video 125

126 Lift Mechanics Evaluate the site Evaluate ground conditions Complete a lift plan Verify the training of the rigger Verify the training of the Signal Person Complete a pre-lift meeting Install all barricades Lift Mechanics Know weight of load Know lifting capacity of machine performing lift Know capacities / limitations of all rigging components Know center of gravity for load 126

127 Lift Mechanics (Cont.) Estimate sling angle Know WLL Estimate possibilities of shock loading Side Loading Calculate WLL at estimated angle Identify all sharp edges Bridle Sling Lift Mechanics (Cont.) Know unusual loading, communication or environmental conditions Know wind speed and effect on load Know temperature and effect on rigging components Know all surfaces Identify all unstable objects 127

128 Lift Mechanics (Cont.) Choose sling Look at sling Identification plates Inspect for defects Rig load Verify WLL at actual sling angle Lift Mechanics (Cont.) Attach tag line Verify all personnel are removed from danger area Lift load Control Load movement Lift into position Stop the lift immediately if you identify any problems 128

129 When Rigging Fails When Rigging Fails 129

130 When Rigging Fails When Rigging Fails 130

131 Rigging Failure Rigging Failure 131

132 CRANE SUMMARY Meetings: 1. Assembly Disassembly (A/D) Crew instructions meeting 2. Power Line Planning Meeting 3. Signal review meeting 4. Pre lift Personnel Platform (PP) meeting 5. Multi Crane lift meeting written plan required 6. DAS Critical lift when triggers are met Training 1. A/D Qualified Person 2. A/D Competent Person 3. Spotter training 4. Power Line training all exposed 5. Signaling 3 rd party training with card 6. Fall Protection 7. Work Area Controls training 8. Rigger training Qualified Person 9. Certified Crane Operator (CCO) Operator Competent Person Training 11. Lock out Tag out Training operators Controlling Contractor 1. Have Ground Condition duties attain specific requirement from crane co. verify locates are called in. cross reference URD. 2. A/D Director can communicate directly to Controlling Contractor 3. Coordinated multiple cranes on site / campus Engineer 1. Determines if Host Structure can handle jumping at each jump 2. When asked by qualified person 3. Designs PPs 4. Signs off on employer written crane documents Competent Person 1. A/D Director 2. Determines the effect of weather conditions (makes the call) 3. Oversees re spooling 4. Has specific duties during: a. Traveling with loads b. Trail Lifts for PP c. Proof Tests for PP 5. Makes unattended load determination 6. Operators must be Competent Person 7. All Signalers must be Competent Persons 8. Makes wind and weather conditions call for stop work Qualified 1. A/D Director 2. Is the only person who can override a stop work order 3. Riggers 4. Oversees PP set up 5. Only Qualified employees can operator platforms that have controls 6. Determines the need for an engineer regarding PP 7. Makes the Safety Latch determination on the ball and hook

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135 DAS Required Handout for Signal Person Training OSHA Standards Part 1926 Subpart CC Cranes & Derricks in Construction - Signals Signals general requirements. (a) A signal person must be provided in each of the following situations: (1) The point of operation, meaning the load travel or the area near or at load placement, is not in full view of the operator. (2) When the equipment is traveling, the view in the direction of travel is obstructed. (3) Due to site specific safety concerns, either the operator or the person handling the load determines that it is necessary. (b) Types of signals. Signals to operators must be by hand, voice, audible, or new signals. (c) Hand signals. (1) When using hand signals, the Standard Method must be used (see Appendix A of this subpart). Exception: Where use of the Standard Method for hand signals is infeasible, or where an operation or use of an attachment is not covered in the Standard Method, nonstandard hand signals may be used in accordance with paragraph (c)(2) of this section. (2) Non-standard hand signals. When using non-standard hand signals, the signal person, operator, and lift director (where there is one) must contact each other prior to the operation and agree on the non-standard hand signals that will be used. (d) New signals. Signals other than hand, voice, or audible signals may be used where the employer demonstrates that: (1) The new signals provide at least equally effective communication as voice, audible, or Standard Method hand signals, or (2) The new signals comply with a national consensus standard that provides at least equally effective communication as voice, audible, or Standard Method hand signals. (e) Suitability. The signals used (hand, voice, audible, or new), and means of transmitting the signals to the operator (such as direct line of sight, video, radio, etc.), must be appropriate for the site conditions. (f) During operations requiring signals, the ability to transmit signals between the operator and signal person must be maintained. If that ability is interrupted at any time, the operator must safely stop operations requiring signals until it is reestablished and a proper signal is given and understood. (g) If the operator becomes aware of a safety problem and needs to communicate with the signal person, the operator must safely stop operations. Operations must not resume until the operator and signal person agree that the problem has been resolved. (h) Only one person may give signals to a crane/derrick at a time, except in circumstances covered by paragraph (j) of this section. (i) [Reserved.] (j) Anyone who becomes aware of a safety problem must alert the operator or signal person by giving the stop or emergency stop signal. (NOTE: (y) requires the operator to obey a stop or emergency stop signal). (k) All directions given to the operator by the signal person must be given from the operator s direction perspective. (l) [Reserved.] (m) Communication with multiple cranes/derricks. Where a signal person(s) is in communication with more than one crane/derrick, a system must be used for identifying the crane/derrick each signal is for, as follows: (1) for each signal, prior to giving the function/direction, the signal person must identify the crane/derrick the signal is for, or (2) must use an equally effective method of identifying which crane/derrick the signal is for Signals radio, telephone or other electronic transmission of signals. Page 1 of 3

136 (a) The device(s) used to transmit signals must be tested on site before beginning operations to ensure that the signal transmission is effective, clear, and reliable. (b) Signal transmission must be through a dedicated channel, except: (1) Multiple cranes/derricks and one or more signal persons may share a dedicated channel for the purpose of coordinating operations. (2) Where a crane is being operated on or adjacent to railroad tracks, and the actions of the crane operator need to be coordinated with the movement of other equipment or trains on the same or adjacent tracks. (c) The operator s reception of signals must be by a hands-free system Signals voice signals additional requirements. (a) Prior to beginning operations, the operator, signal person and lift director (if there is one), must contact each other and agree on the voice signals that will be used. Once the voice signals are agreed upon, these workers need not meet again to discuss voice signals unless another worker is added or substituted, there is confusion about the voice signals, or a voice signal is to be changed. (b) Each voice signal must contain the following three elements, given in the following order: function (such as hoist, boom, etc.), direction; distance and/or speed; function, stop command. (c) The operator, signal person and lift director (if there is one), must be able to effectively communicate in the language used Signals hand signal chart. Hand signal charts must be either posted on the equipment or conspicuously posted in the vicinity of the hoisting operations Signal person qualifications. (a) The employer of the signal person must ensure that each signal person meets the Qualification Requirements (paragraph (c) of this section) prior to giving any signals. This requirement must be met by using either Option (1) or Option (2) of this section. (1) Option (1) Third party qualified evaluator. The signal person has documentation from a third party qualified evaluator (see Qualified Evaluator (third party), for definition) showing that the signal person meets the Qualification Requirements (see paragraph (c) of this section). (2) Option (2) Employer s qualified evaluator. The employer s qualified (see Qualified Evaluator (not a third party), for definition) evaluator assesses the individual and determines that the individual meets the Qualification Requirements (see paragraph (c) of this section) and provides documentation of that determination. An assessment by an employer s qualified evaluator under this option is not portable other employers are not permitted to use it to meet the requirements of this section. (3) The employer must make the documentation for whichever option is used available at the site while the signal person is employed by the employer. The documentation must specify each type of signaling (e.g. hand signals, radio signals, etc.) for which the signal person meets the requirements of paragraph (c) of this section. Page 2 of 3

137 (b) If subsequent actions by the signal person indicate that the individual does not meet the Qualification Requirements (see paragraph (c) of this section), the employer must not allow the individual to continue working as a signal person until re-training is provided and a re-assessment is made in accordance with paragraph (a) of this section that confirms that the individual meets the Qualification Requirements. (c) Qualification Requirements. Each signal person must: (1) Know and understand the type of signals used. If hand signals are used, the signal person must know and understand the Standard Method for hand signals. (2) Be competent in the application of the type of signals used. (3) Have a basic understanding of equipment operation and limitations, including the crane dynamics involved in swinging and stopping loads and boom deflection from hoisting loads. (4) Know and understand the relevant requirements of through and (5) Demonstrate that he/she meets the requirements in paragraphs (c)(1) through (4) of this section through an oral or written test, and through a practical test. Page 3 of 3

138 Dow AgroSciences Signal Person Test Signal Person Test Instructor: Doug Condon Name: Class: Hand Signaling Date: Results: Instructions Please select the correct answer to the following questions: Part I: Hand Signals 1) Identify this signal a. Hoist/Cable Up b. Boom Up c. Move Slowly 2) Identify this signal a. Travel b. Retract Boom (telescoping) c. Swing 3) Identify this signal a. Dog Everything b. Stop c. Move Slowly 4) Identify this signal a. Travel (one track) b. Lower c. Use Whipline (auxiliary hoist) Page 1 of 6

139 5) Identify this signal a. Raise Boom b. Travel One Track c. Raise Boom & Lower Load 6) Identify this signal a. Dog Everything b. Emergency Stop c. Swing 7) Identify this signal a. b. Retract Boom (telescoping) Lower Boom & Raise Load c. Use Main Hoist 8) Identify this signal a. Travel Both Tracks b. Extend Boom (telescoping) c. Lower Boom 9) Identify this signal a. Hoist Cable Down b. Lower Boom c. Swing 10) Identify this signal a. Stop b. Travel c. Swing Left Page 2 of 6

140 11) Identify this signal a. Travel Both Tracks b. Emergency Stop c. Dog Everything 12) Identify this signal a. Retract Boom (telescoping) b. Lower Boom & Raise Load c. Use Main Hoist 13) Identify this signal a. Travel b. Travel (both tracks) c. Move Slowly 14) Identify this signal a. Raise b. Extend Boom (telescoping) c. Emergency Stop 15) Identify this signal a. Raise Boom & Lower Load b. Stop c. Extend Boom (telescoping) 16) Identify this signal a. Lower Boom b. Travel c. Use Whipline (auxiliary hoist) Page 3 of 6

141 17) Identify this signal a. Lower b. Lower Boom c. Dog Everything 18) Identify this signal a. Use Main Hoist b. Hoist c. Stop 19) Identify this signal a. Cable Up Slow b. Travel c. Lower Boom 20) Identify this signal a. Hoist b. Extend Boom (telescoping) c. Raise Boom Page 4 of 6

142 Part II: Signal Person Responsibilities 1) A signal person is responsible for evaluating the site conditions to: 2) a. Ensure the safety of the work area & site crew b. Identify utilities and underground tanks c. Identify proximity of excavations & trenches d. All of the above A signal person is responsible for ensuring which types of warning lines & barricades are in place: a. Work area, warning line & swing radius b. Demarcation line c. Danger tape 3) A crane out of level can reduce the capacity how much? a. 10% b. 25% c. 50% 4) What must you have to be a competent person? a. Certificate on site b. Complete training c. Complete an exam and practical test d. All of the above 5) High swing rate will: a. Increase the load radius b. Impose side loads c. Increase production d. a & b e. All of the above 6) Duty cycle can reduce a crane s capacity by: a. 10% b. 20% c. 30% d. 50% 7) A competent signal person must be able to identify: a. All hazards b. Drunk operators c. Predictable hazards d. Load weights Page 5 of 6

143 8) If an operational aid required by the manufacturer is bad or missing I have: a. 7 Days to fix it b. 30 Days to fix it c. 0 Days I must lock and tagout the crane d. 0 Days I refuse to lift and inform the operator they must lock & tagout the crane 9) I must have a if the hand/voice signals change: a. Lunch/Break b. Meeting c. Arm band d. New operator 10) My signaling can cause: a. Changes in leverage b. Changes in center of gravity for the load c. Inertia & impact loading d. Centrifugal force e. All of the above Page 6 of 6

144 Dow AgroSciences Rigging Safety Class Test Instructor: Doug Condon Name: Class: Rigging Date: Results: Instructions Please select the correct answer to the following questions: 1) To be a rigger I must be: a. A competent rigger b. A qualified rigger c. A supervisor 2) Rigging of personnel platforms must have: a. A 5:1 safety factor b. A 2:1 safety factor c. A 10:1 safety factor 3) A load in motion is: a. A static load b. A dynamic load c. A swinging load 4) Net load + = gross load a. Rigging b. Wire rope c. Block d. All of the above Page 1 of 5

145 5) Capacity is reduced by: 6) a. Base configuration b. Quadrant c. Load radius d. Boom angle e. All of the above A 100,000 lbs crane with a length of 6 from the center of gravity to tipping axis has how much leverage? a. 600,000 b. 800,000 c. 60,000 7) How far must all loads stay away from power lines? a. 5 b. 10 c. 20 8) 6x19 IWRC RH OL has how many wires per strand? a. 6 b. 18 c. 19 Figure 1 1 9) Using Figure 1 1, Calculate the % of efficiency using the D/d ratio if D=80 and d=2 a. 1 b. 50% c. 40 d. 95% 10) I must inspect all rigging equipment: a. Daily b. Frequently & regularly c. Before each pick Page 2 of 5

146 d. All of the above Figure ) Using Figure 2 1, Which wire rope clip configuration is correct? a. Top b. Middle c. Bottom 12) All slings must have: a. Manufacturer s name and trademark b. Red cords c. Rated loads for type of hitches used d. A & C e. All of the above 13) I can use a damaged sling for incidental lifts a. True b. False 14) The radius of contact between the edge of a load and wire rope sling should be: a. 4 lays b. 2 lays c. 1 lay 15) This hitch is the strongest: a. Vertical b. Choker c. Basket Page 3 of 5

147 16) Using Figure 3 1, Calculate the weight per leg: a. 100,000 per leg b. 50,000 per leg c. 75,000 per leg Figure 3 1 Figure ) In Figure 4 1, Is this crane conducting a safe pick? a. Yes b. Yes, if I use a spotter c. No Page 4 of 5

148 18) In Figure 4 1, What is the reduced capacity of this crane? a. 200,000 lbs b. 100,000 lbs c. 100,000 lbs but not safe to lift Figure ) Using Figure 5 1, What sling size? a. 50,000 lbs sling b. 100,000 lbs sling c. 200,000 lbs sling d. 300,000 lbs sling Page 5 of 5