Contents Frequency of Inspection... 80 Key Items of Inspection... 81 Physical Walk-Round Inspection... 82 Wire Rope Inspection...83-86 Functional Test... 87 Safety Devices and Operational Aids... 88 Cranes Not in Regular Service... 89 79
Frequency of Inspection OSHA requires all mobile cranes to be inspected regularly. An each shift inspection (often referred to as the pre-operational inspection) must be made by a competent person each shift before the crane is used. This is a visual inspection and is usually performed by the crane operator. Since the crane must be in a safe operating condition at all times, this inspection essentially continues the whole time the crane is in use. OSHA also requires a monthly inspection by a competent person and a comprehensive inspection of the entire crane at least annually by a qualified person, with disassembly required as necessary to complete the inspection. Both monthly and annual inspections require that records be kept. Severity of use/conditions or the crane manufacturer may require that the crane be inspected more frequently. 80
Key Items of Inspection Using the criteria in OSHA 29 CFR 1926.1400 and ASME B30.5, and inspection items provided by the manufacturer, the competent person, which is normally the crane operator, should at a minimum, inspect the specific items of the crane illustrated below. The focus of the inspection should be on those items that are subject to change from day to day or shift to shift. Also, ground conditions around the crane must be inspected for proper support around outriggers/stabilizers and support foundations. Hoist rope and reeving All operational aids and safety devices Fluid levels (crankcase oil, coolant, hydraulic oil, etc.) Electrical equipment Control and drive mechanisms (hoist, swing, steering, etc.) Fire extinguisher installed in the cab or machinery housing Air/Hydraulic system (hoses, valves, etc.) Hooks and latches Cab windows and equipment Tires 81
Physical Walk-Round Inspection The operator should also perform a walk-round inspection of the entire crane observing for any apparent deficiencies or safety hazards. Additional areas to inspect include the carrier or car body, outriggers or crawlers, drive train, upper works, hoist rope and booms and jibs. Welds End connections Lacings Check chords for damage and straightness Any deficiency that constitutes a safety hazard must be corrected before continued use of the crane. Be especially vigilant regarding boom sections, extensions and jibs. Jib Sheaves Hoist rope Ball and Hook Hook block Boom Tires 82 Outriggers
Wire Rope Inspection Removal from Service All running and standing wire ropes must be visually inspected for apparent safety hazards prior to each shift by a competent person. The inspection should cover at least the wire rope, running and standing, that is expected to be used during the shift. Booming down or opening the wire rope is not required as part of this inspection. If any of the following conditions are determined by a qualified person to constitute a safety hazard, the crane must be taken out of service until the wire rope is replaced. Significant distortion such as kinking, crushing, unstranding, birdcaging, signs of core failure or steel core protrusion between the outer strands Broken or cut strands Significant corrosion Electric arc damage from a source other than power lines Heat damage Improperly applied end connections Significantly corroded, cracked, bent or worn end connections Kinking Birdcaging Cracked End Connection 83
Wire Rope Inspection Removal from Service Only the surface wires need be inspected. Under no circumstances should the rope be opened up. OSHA requires running ropes (main and auxiliary hoists, boom hoist) to be taken out of service when any of the following conditions exist: 6 randomly distributed broken wires in one lay length, or 3 broken wires in one strand in one lay length. The term lay length refers to the distance it takes for a strand to make a complete revolution around the core. Lay Length Broken Wires More than a 5% reduction in nominal diameter. 84
Wire Rope Inspection Removal from Service Other damage which would require the rope to be removed from service includes: In rotation resistant ropes: 2 randomly distributed broken wires in 6 rope diameters, or 4 randomly distributed broken wires in 30 rope diameters. One outer wire broken at the point of contact with the core of the rope which protrudes or loops out from the rope structure. Core Protrusion In standing ropes, more than 2 broken wires in one rope lay located in rope beyond end connections, and/or more than 1 broken wire in a rope lay located at an end connection. This wire rope and end connection must be replaced. 85
Wire Rope Inspection Critical Areas The competent person must pay close attention to the following critical areas during the inspection. Rotation resistant wire rope in use. Wire rope being used for boom hoists and luffing hoists, particularly at reverse bends. Wire rope at flange points, crossover points and repetitive pickup points on drums. Wire rope at or near terminal ends. Wire rope in contact with saddles, equalizer sheaves or other sheaves where rope travel is limited. Wear and damage to wire rope is more likely at contact points such as cross-over points, sheaves for running ropes and especially equalizer sheaves. Crossover Point Wire Rope Retainers Corrugation of sheaves (often a sign of overloading) can indicate wire rope damage. 86
Functional Test Before each use of the crane, the operator should also run the crane through all its functions for smooth and operation. This would include boom up/down; telescoping the boom in/out; hoisting up/down; swinging the boom left/right and extending/retracting outrigger beams and/or stabilizers. Telescoping the Boom Booming Hoisting In addition to the pre-operational inspection, the operator should monitor the crane during operation for any potential deficiencies or hazards. 87
Safety Devices and Operational Aids Prior to each shift, particular care should be taken to check all operational aids such as: anti-two-block devices; load weight, load moment, boom angle, and boom length indicators; etc. This must be done in accordance with the manufacturer s written instructions. Any device not in proper working order will require that the crane be taken out of service, unless a Temporary Alternative Measure is put in place. Load Weight or Load Moment Indicator Boom Angle Indicator Anti-Two-Blocking Device If one of the following safety devices is not in proper working order, the crane must be taken out of service: Crane level indicator Boom stops Jib stops Foot pedal brakes must have locks Hydraulic outrigger jacks and hydraulic stabilizer jacks Horn 88
Cranes Not in Regular Service OSHA requires that before being used, cranes which have been idle for three months or more must be given a monthly inspection by a qualified person. As part of this inspection, the crane manufacturer may require a more comprehensive or frequent schedule of inspection regarding safety devices, operational aids, critical parts of control system, power plant, braking system, load-sustaining structural components, load hook, or operating mechanisms. A monthly inspection must be performed on cranes idle for three months or more. 89
Contents Site Preparation... 91 Preparing the Work Area... 92 Positioning the Crane... 93 Maintaining Clearances... 94 Assembly and Disassembly... 95 Lattice Boom and Jibs...96-98 Telescoping Boom Extensions and Jibs...99-100 Dealing With Unstable Ground... 101 Setup on Soft Surfaces... 102 Use of Outriggers...103-105 Use of Blocking...106-108 Lifting On Rubber... 109 Leveling the Crane...110-112 90
Site Preparation Setting the crane up properly is one of the most important aspects of a crane operation. In fact, a study of accidents reveals that over 50% of accidents are caused because the crane is set up improperly. The person responsible for the crane operation (supervisor, lift director) must ensure that the area of the crane is adequately prepared. This includes: Access roads, ground or supporting surfaces will support the crane and loads. Blocking or mats are utilized when conditions require. Sufficient room to assemble and disassemble the crane. The crane barricaded to prevent entry of unauthorized personnel and the public. Power lines de-energized or clearances from power lines maintained. Information such as load weights provided to operators and riggers. Also see Responsibilities of Supervisor and Lift Director pgs 130-133 91
Preparing the Work Area Grade if necessary to ensure a firm and reasonably level site for the crane to travel and operate safely. Some site conditions may even require that the soil be compacted. Firm and reasonably level surface No buried pipes, utilities, sewers, tanks, etc. If the crane is set up on a structure, the person responsible for the lift must ensure that the structure will support the crane and loads lifted. 92
Positioning the Crane Contact with power lines is the leading cause of crane related fatalities. If possible, position the crane at least a boom s length away from the prohibited zone. See chapter Working Cranes Around Power Lines for more information. Prohibited Zone Try to position the crane so that the load is initially lifted from the least stable area of the crane and swung to the most stable area. If tipping should occur, it will be when the load is first lifted, rather than later in the lift should the load be higher off the ground. In the case of most rough terrain cranes, this would mean lifting the load over the side (least stable area) and swinging to the front (most stable area). 93
Maintaining Clearances To prevent personnel from being struck or crushed, position the crane so that a minimum of two feet is maintained between the counterweight and any obstacle. To further minimize the risk of personnel being injured, barricades should be erected around the swing radius of the outer most part of the crane. Unauthorized personnel must not be allowed inside this area. 94
Assembly and Disassembly There have been numerous accidents when assembling and disassembling lattice booms and jibs and while erecting and stowing extensions and jibs on telescoping boom cranes; resulting in serious injury and loss of life. In most cases, a failure to follow the crane manufacturer s procedures was the cause. It is therefore of upmost importance that the manufacturer s procedures be followed without exception or compromise. Crane Manual Crane Manual Assembly and disassembly must be directed by competent and qualified person(s) who have a knowledge and understanding of the procedures to be followed. This person(s) must ensure that the personnel involved in the assembly and disassembly understand their tasks and the hazards associated with the tasks, such as positions and locations to avoid. All rigging work must be done by qualified riggers. Upon completion of assembly, the equipment must be inspected by a qualified person to assure that it is configured in accordance with the manufacturer equipment criteria. 95
Lattice Booms and Jibs Site supervision must ensure that there is sufficient room to assemble and disassemble lattice booms and jibs. Ample distance must be maintained between potential hazards such as power lines, subsurface conditions, slopes, and obstructions. The following are principles which generally apply to the assembly and disassembly of both lattice booms and jibs. Do not remove any pins, top or bottom, on any section between the crane and pendant attachment points when pendants are in tension. If top pins are removed between the crane and pendant attachments, the boom can separate and fall. This can be particularly hazardous when unpinning long booms. If bottom pins are removed between the crane and where pendants are attached, the boom will separate and fall. 96
Lattice Booms and Jibs Do not remove any pins, top or bottom on any section between uppermost boom section and crane until all sections are supported and pendant lines relieved of tension. Ensure that the cantilevered length of boom does not exceed the maximum length allowed by the crane manufacturer. Only the bottom pins can be removed beyond pendant attachment. Cantilevered Length Bottom pins can be removed Do not remove top pins. If top pins are removed beyond pendant attachment points, the boom will separate and fall. 97
Lattice Booms and Jibs Blocking material placed under boom sections is a common way to provide support. Pins can be safely removed when boom sections are supported. Whenever possible, avoid placing any part of the body inside or over the boom, particularly when unpinning sections. No part of the body is to be placed under the boom or jib while inserting or removing pins. Using a bar is one way to avoid this. Also, pins should be inserted so they can be removed from outside the boom. To increase the crane s stability when raising and lowering a long boom, leave or set the load block and/or overhaul ball on the ground. 98
Telescoping Boom Extensions and Jibs As telescoping boom cranes evolved over the years, their ability to lift loads to higher elevations has increased dramatically due largely to the addition and lengthening of jibs and/or extensions. Jibs and extensions are stowed to the side of the main boom by way of pins or latching devices where they can easily be attached to the boom head. Position telescoping boom cranes where there is room to extend manual sections and enough area to stow and erect boom extensions/ jibs. Stowing Extensions/Jibs Make sure the extension/jib is securely attached to side of boom before removing attachment pins from boom head. Failure to do this will result in jib falling from crane. Pins Attachment Points Do Not Detach Unless Attached. 99
Telescoping Boom Extensions and Jibs Make sure the extension/jib is unpinned from the main boom before the boom is extended. Failure to do this can result in severe damage to attachment points. Attachment Points Securing pin or device Do not raise the boom without first ensuring that the extendable jib is secured in the extended position. If not secured, jib will crash back in, resulting in damage and ball and/or load dropping. 100
Dealing With Unstable Ground Cranes should be set up a safe distance from buildings under construction, since the surrounding ground is often infill and a poor support base for the crane. Avoid setting up on or near trenches, excavations, and shoring locations. Avoid unseen dangers such as underground pipes, sewers, tanks, etc. Vibration, crane weight, and load weight could cause them to collapse. 101
Setup on Soft Surfaces The combined weight of the crane and load must never exceed the bearing capacity of the surface where the crane is set up. On soft surfaces a working base formed by timber mats may have to be used to support the crane and loads. Lifting on outriggers, especially over just one, can create ground bearing pressures that are very high. Floats that are inadequately supported can cause the supporting surface to give way, resulting in the crane turning over. To prevent the crane from sinking or settling, timber or steel mats must be used when set up on surfaces such as soft ground, asphalt or backfilled material. Ground pressure is greatest, on crawler cranes, when the boom is over the corner and least when over the side. Under certain conditions crawler cranes can create greater ground pressure then cranes using outriggers. 102
Use of Outriggers Since the use of outriggers provide the crane with more stability than tires, outriggers should be used regardless of the weight of the load. Whenever possible they should be fully extended, or extended as specified by the manufacturer. Each outrigger must be visible to the operator or to a signal person during extending or retracting. For the on-outriggers capacity chart to apply, all outriggers must be fully extended. On-rubber capacities must be used when the crane manufacturer has provided capacities for partially extended outriggers. Some crane manufacturers provide capacity charts for partially extended outriggers. Most manufacturers require that onrubber capacities be used. When loads are handled in an area where an outrigger is not fully extended, capacity loss can be over 50%. 103
Use of Outriggers The crane must be set up with all tires relieved of the crane s weight. Even better is to have the tires off the ground or supporting surface. This ensures that the tipping fulcrum is stabilized and the undercarriage is utilized to maximize counterweight. Before lifting with partially extended outrigger beams, make sure the manufacturer allows this practice. A partially extended outrigger beam can cause stress in the wrong areas, resulting in damage to the outrigger box and beam. Some crane manufacturers provide capacity charts for lifting with partially extended outrigger beams. When doing so, instructions must be carefully followed, including pinning or securing beams if required. 104
Use of Outriggers Ensure that keepers are properly installed, otherwise the pad and stabilizer could separate during crane operations. If stabilizers are equipped with screw down or pin locks, make sure these are engaged. 105
Use of Blocking Blocking allows the weight of the crane and load to be distributed over a greater surface area. Blocking should be used under all outrigger floats. Ensure blocking is level and that the outrigger pad is at 90 to the stabilizer. 90 Wrong Blocking must always be placed under the outrigger pads, never under the outrigger beams. Beams are not designed to take such loads, and the crane could become much less stable. 106
Use of Blocking Without blocking, ground pressure is higher. With blocking, ground pressure is reduced. Use blocking that has the strength to prevent crushing, bending, or shear failure. Blocking must also be strong enough to span soft spots in the ground and strong enough to support the crane and load weight. Hardwood or fir Thrubolts TESTS CONDUCTED BY CRANE MANUFACTURER Properly Blocked Span Blocking Corner Blocking Pad failed at 210,000 lbs. Pad failed at 140,000 lbs. 70% of proper blocking. Pad failed at 110,000 lbs. 50% of proper blocking. 107
Use of Blocking As a general rule, blocking should be at least three times the surface area of the pad. Blocking must also completely support the float and transmit the load to the supporting surface. Bolt blocking together to prevent it from separating. Wrong To prevent shifting or toppling ensure stacked blocking is stable. Blocking under the ends of the crawlers will improve crawler crane stability by keeping the tipping axis at the sprocket (or idler) and not at the roller. Crane must not be traveled off blocking with a load suspended. Blocking Tipping Axis 108
Unless it is absolutely necessary, lifting while set up on tires should be avoided. Capacities are much less compared to lifting when on outriggers and the crane cannot be leveled when lifting on rubber. However, when operations on rubber are required, the following areas, including the manufacturer s instructions, must be carefully followed: Carrier brakes are applied. Axle lockouts function properly. Working area is firm and level. Tires are in good condition and correct type and size. Tire pressure is per manufacturer s specifications. Wheels are in line with the carrier. Do not lift with jibs, extensions, or manual sections. Allow for tire and boom deflection. Boom Deflection Lifting On Rubber Tire Deflection 109
Leveling the Crane Load chart capacities are based on the crane being level within 1%. Accurate leveling of the crane is therefore essential for safe lifting. Use a crane level indicator (commonly known as a bubble or target level) for initial leveling, but don t rely on this level for precision or final leveling. Use a carpenter s level placed under or close to the boom foot for an accurate measure of level. Level the rear of the crane (front for rough terrain). Swing the boom 90 to the side and check for level again. Also check for level regularly during crane operation. Swing to Side Over Rear Over Side Accurate leveling of the crane is particularly important when setting up on a grade. 110
Leveling the Crane A similar two-part procedure (over front and over side) can also be used to check level using the hoist line as a plumb bob. This procedure cannot be used to level a crawler crane or a crane working on rubber; they are only as level as the surface they are sitting on. Possible Capacity Loss Due To Being Out Of Level Boom Length and Radius Short Boom, Minimum Radius Short Boom, Maximum Radius Long Boom, Minimum Radius Long Boom, Maximum Radius Capacity Lost When Out of Level 1 2 3 10% 20% 30% 8% 15% 20% 30% 41% 50% 5% 10% 15% This table shows the capacity loss that is possible for a specific lattice boom crane. Information like this can be obtained from all crane manufacturers. 111
Leveling the Crane Particular care must be taken to ensure the supporting surface under crawler cranes and cranes operating on rubber is level before making the lift. When lifting entirely on rubber, the crane will be only as level as the surface where it is sitting. Make sure the ground or surface is reasonably level before making the lift. Make sure the tires are in good condition and inflated properly. Also ensure that the axle lock-out functions. 112
Crawler, Locomotive and Truck Cranes 1910.180(a) Definitions applicable to this section (1) A crawler crane consists of a rotating superstructure with power plant, operating machinery, and boom, mounted on a base, equipped with crawler treads for travel. Its function is to hoist and swing loads at various radii. (2) A locomotive crane consists of a rotating superstructure with power plant, operating machinery and boom, mounted on a base or car equipped for travel on railroad track. It may be self-propelled or propelled by an outside source. Its function is to hoist and swing loads at various radii. (3) A truck crane consists of a rotating superstructure with power plant, operating machinery and boom, mounted on an automotive truck equipped with a power plant for travel. Its function is to hoist and swing loads at various radii. (4) A wheel mounted crane (wagon crane) consists of a rotating superstructure with power plant, operating machinery and boom, mounted on a base or platform equipped with axles and rubber-tired wheels for travel. The base is usually propelled by the engine in the superstructure, but it may be equipped with a separate engine controlled from the superstructure. Its function is to hoist and swing loads at various radii. (5) An accessory is a secondary part or assembly of parts which contributes to the overall function and usefulness of a machine. (6) Appointed means assigned specific responsibilities by the employer or the employer s representative. OSHA 1910.180 General Industry (7) ANSI means the American National Standards Institute. (8) An angle indicator (boom) is an accessory which measures the angle of the boom to the horizontal. (9) The axis of rotation is the vertical axis around which the crane superstructure rotates. (10) Axle means the shaft or spindle with which or about which a wheel rotates. On truck- and wheel-mounted cranes it refers to an automotive type of axle assembly including housings, gearing, differential, bearings, and mounting appurtenances. (11) Axle (bogie) means two or more automotivetype axles mounted in tandem in a frame so as to divide the load between the axles and permit vertical oscillation of the wheels. (12) The base (mounting) is the traveling base or carrier on which the rotating superstructure is mounted such as a car, truck, crawlers, or wheel platform. (13) The boom (crane) is a member hinged to the front of the rotating superstructure with the outer end supported by ropes leading to a gantry or A-frame and used for supporting the hoisting tackle. (14) The boom angle is the angle between the longitudinal centerline of the boom and the horizontal. The boom longitudinal centerline is a straight line between the boom foot pin (heel pin) centerline and boom point sheave pin centerline. (15) The boom hoist is a hoist drum and rope reeving system used to raise and lower the boom. The rope system may be all live reeving or a combination of live reeving and pendants. (16) The boom stop is a device used to limit the angle of the boom at the highest position. (17) A brake is a device used for retarding or stopping motion by friction or power means. (18) A cab is a housing which covers the rotating superstructure machinery and/or operator s station. On truck-crane trucks a separate cab covers the driver s station. (19) The clutch is a friction, electromagnetic, hydraulic, pneumatic, or positive mechanical device for engagement or disengagement of power. (20) The counterweight is a weight used to supplement the weight of the machine in providing stability for lifting working loads. (21) Designated means selected or assigned by the employer or the employer s representative as being qualified to perform specific duties. (22) The drum is the cylindrical members around which ropes are wound for raising and lowering the load or boom. (23) Dynamic (loading) means loads introduced into the machine or its components by forces in motion. (24) The gantry (A-frame) is a structural frame, extending above the superstructure, to which the boom support ropes are reeved. 2014 Crane Institute America, LLC. All rights reserved. 72
1910.180(a) Definitions...(cont d) (42) Tackle is an assembly of ropes and sheaves arranged for hoisting and pulling. (43) Travel means the function of the machine moving from one location to another, on a jobsite. (45) The travel mechanism is the machinery involved in providing travel. (46) Wheelbase means the distance between centers of front and rear axles. For a multiple axle assembly the axle center for wheelbase measurement is taken as the midpoint of the assembly. (47) The whip line (auxiliary hoist) is a separate hoist rope system of lighter load capacity and higher speed than provided by the main hoist. (48) A winch head is a power driven spool for handling of loads by means of friction between fiber or wire rope and spool. (25) A jib is an extension attached to the boom point to provide added boom length for lifting specified loads. The jib may be in line with the boom or offset to various angles. (26) Load (working) means the external load, in pounds, applied to the crane, including the weight of load-attaching equipment such as load blocks, shackles, and slings. (27) Load block (upper) means the assembly of hook or shackle, swivel, sheaves, pins, and frame suspended from the boom point. (28) Load block (lower) means the assembly of hook or shackle, swivel, sheaves, pins, and frame suspended by the hoisting ropes. (29) A load hoist is a hoist drum and rope reeving system used for hoisting and lowering loads. (30) Load ratings are crane ratings in pounds established by the manufacturer in accordance with paragraph (c) of this section. (31) Outriggers are extendable or fixed metal arms, attached to the mounting base, which rest on supports at the outer ends. (32) Rail clamp means a tong-like metal device, mounted on a locomotive crane car, which can be connected to the track. (33) Reeving means a rope system in which the rope travels around drums and sheaves. (34) Rope refers to a wire rope unless otherwise specified. (35) Side loading means a load applied at an angle to the vertical plane of the boom. (36) A standby crane is a crane which is not in regular service but which is used occasionally or intermittently as required. (37) A standing (guy) rope is a supporting rope which maintains a constant distance between the points of attachment to the two components connected by the rope. (38) Structural competence means the ability of the machine and its components to withstand the stresses imposed by applied loads. (39) Superstructure means the rotating upper frame structure of the machine and the operating machinery mounted thereon. (40) Swing means the rotation of the superstructure for movement of loads in a horizontal direction about the axis of rotation. (41) Swing mechanism means the machinery involved in providing rotation of the superstructure. 1910.180(b) General requirements (1) Application. This section applies to crawler cranes, locomotive cranes, wheel mounted cranes of both truck and selfpropelled wheel type, and any variations thereof which retain the same fundamental characteristics. This section includes only cranes of the above types, which are basically powered by internal combustion engines or electric motors and which utilize drums and ropes. Cranes designed for railway and automobile wreck clearances are excepted. The requirements of this section are applicable only to machines when used as lifting cranes. (2) New and existing equipment. All new crawler, locomotive, and truck cranes constructed and utilized on or after August 31, 1971, shall meet the design specifications of the American National Standard Safety Code for Crawler, Locomotive, and Truck Cranes, ANSI B30.5 1968, which is incorporated by reference as specified in Sec. 1910.6. Crawler, locomotive, and truck cranes constructed prior to August 31, 1971, should be modified to conform to those design specifications by February 15, 1972, unless it can be shown that the crane cannot feasibly or economically be altered and that the crane substantially complies with the requirements of this section. (3) Designated personnel. Only designated personnel shall be permitted to operate a crane covered by this section. 2014 Crane Institute America, LLC. All rights reserved. 73
1910.180(c) Load ratings (1) Load ratings where stability governs lifting performance. (i) The margin of stability for determination of load ratings, with booms of stipulated lengths at stipulated working radii for the various types of crane mountings, is established by taking a percentage of the loads which will produce a condition of tipping or balance with the boom in the least stable direction, relative to the mounting. The load ratings shall not exceed the following percentages for cranes, with the indicated types of mounting under conditions stipulated in paragraphs (c)(1)(ii) and (iii) of this section. Type of Maximum load ratings crane mounting (% of topping loads) Locomotive, without outriggers: Booms 60 feet or less.......................... 85 (1) Booms over 60 feet............................ 85 (1) Locomotive, using outriggers fully extended............. 80 Crawler, without outriggers.......................... 75 Crawler, using outriggers fully extended................ 85 Truck and wheel mounted without outriggers or using outriggers fully extended....................... 85 Footnote (1). Unless this results in less than 30,000 pound-feet net stabilizing moment about the rail, which shall be minimum with such booms. (ii) The following stipulations shall govern the application of the values in paragraph (c)(1)(i) of this section for locomotive cranes: (a) Tipping with or without the use of outriggers occurs when half of the wheels farthest from the load leave the rail. (b) The crane shall be standing on track which is level within 1 percent grade. (c) Radius of the load is the horizontal distance from a projection of the axis of rotation to the rail support surface, before loading, to the center of vertical hoist line or tackle with load applied. (d) Tipping loads from which ratings are determined shall be applied under static conditions only, i.e., without dynamic effect of hoisting, lowering, or swinging. (e) The weight of all auxiliary handling devices such as hoist blocks, hooks, and slings shall be considered a part of the load rating. (iii) Stipulations governing the application of the values in paragraph (c)(1)(i) of this section for crawler, truck, and wheel-mounted cranes shall be in accordance with Crane Load-Stability Test Code, Society of Automotive Engineers (SAE) J765, which is incorporated by reference as specified in Sec. 1910.6. (iv) The effectiveness of these preceding stability factors will be influenced by such additional factors as freely suspended loads, track, wind, or ground conditions, condition and inflation of rubber tires, boom lengths, proper operating speeds for existing conditions, and, in general, careful and competent operation. All of these shall be taken into account by the user. 1910.180(d) Inspection classification (1) Initial inspection. Prior to initial use all new and altered cranes shall be inspected to insure compliance with provisions of this section. (2) Regular inspection. Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the critical components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as frequent and periodic, with respective intervals between inspections as defined below: (i) Frequent inspection: Daily to monthly intervals. (ii) Periodic inspection: 1- to 12-month intervals, or as specifically recommended by the manufacturer. (3) Frequent inspection. Items such as the following shall be inspected for defects at intervals as defined in paragraph (d)(2)(i) of this section or as specifically indicated including observation during operation for any defects which might appear between regular inspections. Any deficiencies such as listed shall be carefully examined and determination made as to whether they constitute a safety hazard: (i) All control mechanisms for maladjustment interfering with proper operation: Daily. (ii) All control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter. (iii) All safety devices for malfunction. (iv) Deterioration or leakage in air or hydraulic systems: Daily. (v) Crane hooks with deformations or cracks. For hooks with cracks or having more than 15 percent in excess of normal throat opening or more than 10 deg. twist from the plane of the unbent hook. 2014 Crane Institute America, LLC. All rights reserved. 74
1910.180(d) Inspection...(cont d) (vi) Rope reeving for noncompliance with manufacturer s recommendations. (vii) Electrical apparatus for malfunctioning, signs of excessive deterioration, dirt, and moisture accumulation. (4) Periodic inspection. Complete inspections of the crane shall be performed at intervals as generally defined in paragraph (d)(2)(ii) of this section depending upon its activity, severity of service, and environment, or as specifically indicated below. These inspections shall include the requirements of paragraph (d)(3) of this section and in addition, items such as the following. Any deficiencies such as listed shall be carefully examined and determination made as to whether they constitute a safety hazard: (i) Deformed, cracked, or corroded members in the crane structure and boom. (ii) Loose bolts or rivets. (iii) Cracked or worn sheaves and drums. (iv) Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and locking devices. (v) Excessive wear on brake and clutch system parts, linings, pawls, and ratchets. (vi) Load, boom angle, and other indicators over their full range, for any significant inaccuracies. (vii) Gasoline, diesel, electric, or other power plants for improper performance or noncompliance with safety requirements. (viii) Excessive wear of chain-drive sprockets and excessive chain stretch. (ix) Travel steering, braking, and locking devices, for malfunction. (x) Excessively worn or damaged tires. (5) Cranes not in regular use. (i) A crane which has been idle for a period of one month or more, but less than 6 months, shall be given an inspection conforming with requirements of paragraph (d)(3) of this section and paragraph (g)(2)(ii) of this sec- tion before placing in service. (ii) A crane which has been idle for a period of six months shall be given a complete inspection conforming with requirements of paragraphs (d) (3) and (4) of this section and paragraph (g)(2)(ii) of this section before placing in service. (iii) Standby cranes shall be inspected at least semiannually in accordance with requirements of paragraph (d)(3) of this section and paragraph (g)(2)(ii) of this section. Such cranes which are exposed to adverse environment should be inspected more frequently. 75 (6) Inspection records. Certification records which include the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, of the crane which was inspected shall be made monthly on critical items in use such as brakes, crane hooks, and ropes. This certification record shall be kept readily available. 1910.180(e) Testing (1) Operational tests. (i) In addition to prototype tests and quality-control measures, each new production crane shall be tested by the manufacturer to the extent necessary to insure compliance with the operational requirements of this paragraph including functions such as the following: (a) Load hoisting and lowering mechanisms. (b) Boom hoisting and lower mechanisms. (c) Swinging mechanism. (d) Travel mechanism. (e) Safety devices. (ii) Where the complete production crane is not supplied by one manufacturer such tests shall be conducted at final assembly. (iii) Certified production-crane test results shall be made available. (2) Rated load test. (i) Written reports shall be available showing test procedures and confirming the adequacy of repairs or alterations. (ii) Test loads shall not exceed 110 percent of the rated load at any selected working radius. (iii) Where rerating is necessary: (a) Crawler, truck, and wheel-mounted cranes shall be tested in accordance with SAE Recommended Practice, Crane Load Stability Test Code J765 (April 1961). (b) Locomotive cranes shall be tested in accordance with paragraph (c)(1)(i) and (ii) of this section. (c) Rerating test report shall be readily available. (iv) No cranes shall be rerated in excess of the original load ratings unless such rating changes are approved by the crane manufacturer or final assembler. 2014 Crane Institute America, LLC. All rights reserved.
1910.180(f) Maintenance procedures General. After adjustments and repairs have been made the crane shall not be operated until all guards have been reinstalled, safety devices reactivated, and maintenance equipment removed. 1910.180(g) Rope inspection (1) Running ropes. A thorough inspection of all ropes in use shall be made at least once a month and a certification record which includes the date of inspection, the signature of the person who performed the inspection and an identifier for the ropes shall be prepared and kept on file where readily available. All inspections shall be performed by an appointed or authorized person. Any deterioration, resulting in appreciable loss of original strength shall be carefully observed and determination made as to whether further use of the rope would constitute a safety hazard. Some of the conditions that could result in an appreciable loss of strength are the following: (i) Reduction of rope diameter below nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires. (ii) A number of broken outside wires and the degree of distribution of concentration of such broken wires. (iii) Worn outside wires. (iv) Corroded or broken wires at end connections. (v) Corroded, cracked, bent, worn, or improperly applied end connections. (vi) Severe kinking, crushing, cutting, or unstranding. (2) Other ropes. (i) Heavy wear and/or broken wires may occur in sections in contact with equalizer sheaves or other sheaves where rope travel is limited, or with saddles. Particular care shall be taken to inspect ropes at these locations. (ii) All rope which has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed shall be given a thorough inspection before it is used. This inspection shall be for all types of deterioration and shall be performed by an appointed or authorized person whose approval shall be required for further use of the rope. A certification record which includes the date of inspection, the signature of the person who performed the inspection, and an identifier for the rope which was inspected shall be prepared and kept readily available. (iii) Particular care shall be taken in the inspection of nonrotating rope. 1910.180(h) Handling the load (1) Size of load. (i) No crane shall be loaded beyond the rated load, except for test purposes as provided in paragraph (e) of this section. (ii) When loads which are limited by structural competence rather than by stability are to be handled, it shall be ascertained that the weight of the load has been determined within plus or minus 10 percent before it is lifted. (2) Attaching the load. (i) The hoist rope shall not be wrapped around the load. (ii) The load shall be attached to the hook by means of slings or other approved devices. (3) Moving the load. (i) The employer shall assure that: (a) The crane is level and where necessary blocked properly. (b) The load is well secured and properly balanced in the sling or lifting device before it is lifted more than a few inches. (ii) Before starting to hoist, the following conditions shall be noted: (a) Hoist rope shall not be kinked. (b) Multiple part lines shall not be twisted around each other. (c) The hook shall be brought over the load in such a manner as to prevent swinging. (iii) During hoisting care shall be taken that: (a) There is no sudden acceleration or deceleration of the moving load. (b) The load does not contact any obstructions. 2014 Crane Institute America, LLC. All rights reserved. 76
1910.180(h) Handling the load (cont d) (xiv) Before traveling a crane with load, a designated person shall be responsible for determining and controlling safety. Decisions such as position of load, boom location, ground support, travel route, and speed of movement shall be in accord with his determinations. (xv) A crane with or without load shall not be traveled with the boom so high that it may bounce back over the cab. (xvi) When rotating the crane, sudden starts and stops shall be avoided. Rotational speed shall be such that the load does not swing out beyond the radii at which it can be controlled. A tag or restraint line shall be used when rotation of the load is hazardous. (xvii) When a crane is to be operated at a fixed radius, the boom-hoist pawl or other positive locking device shall be engaged. (xviii) Ropes shall not be handled on a winch head without the knowledge of the operator. (xix) While a winch head is being used, the operator shall be within convenient reach of the power unit control lever. (4) Holding the load. (i) The operator shall not be permitted to leave his position at the controls while the load is suspended. (ii) No person should be permitted to stand or pass under a load on the hook. (iii) If the load must remain suspended for any considerable length of time, the operator shall hold the drum from rotating in the lowering direction by activating the positive controllable means of the operator s station. (iv) Side loading of booms shall be limited to freely suspended loads. Cranes shall not be used for dragging loads sideways. (v) No hoisting, lowering, swinging, or traveling shall be done while anyone is on the load or hook. (vi) The operator should avoid carrying loads over people. (vii) On truck-mounted cranes, no loads shall be lifted over the front area except as approved by the crane manufacturer. (viii) The operator shall test the brakes each time a load approaching the rated load is handled by raising it a few inches and applying the brakes. (ix) Outriggers shall be used when the load to be handled at that particular radius exceeds the rated load without outriggers as given by the manufacturer for that crane. Where floats are used they shall be securely attached to the outriggers. Wood blocks used to support outriggers shall: (a) Be strong enough to prevent crushing. (b) Be free from defects. (c) Be of sufficient width and length to prevent shifting or toppling under load. (x) Neither the load nor the boom shall be lowered below the point where less than two full wraps of rope remain on their respective drums. (xi) Before lifting loads with locomotive cranes without using outriggers, means shall be applied to prevent the load from being carried by the truck springs. (xii) When two or more cranes are used to lift one load, one designated person shall be responsible for the operation. He shall be required to analyze the operation and instruct all personnel involved in the proper positioning, rigging of the load, and the movements to be made. (xiii) In transit the following additional precautions shall be exercised: (a) The boom shall be carried in line with the direction of motion. (b) The superstructure shall be secured against rotation, except when negotiating turns when there is an operator in the cab or the boom is supported on a dolly. (c) The empty hook shall be lashed or otherwise restrained so that it cannot swing freely. 1910.180(i) Other requirements (1) Rail clamps. Rail clamps shall not be used as a means of restraining tipping of a locomotive crane. (2) Ballast or counterweight. Cranes shall not be operated without the full amount of any ballast or counterweight in place as specified by the maker, but truck cranes that have dropped the ballast or counterweight may be operated temporarily with special care and only for light loads without full ballast or counterweight in place. The ballast or counterweight in place specified by the manufacturer shall not be exceeded. (3) Cabs. (i) Necessary clothing and personal belongings shall be stored in such a manner as to not interfere with access or operation. 2014 Crane Institute America, LLC. All rights reserved. 77
1910.180(i) Other requirements (cont d) (ii) Tools, oil cans, waste, extra fuses, and other necessary articles shall be stored in the tool box, and shall not be permitted to lie loose in or about the cab. (4) Refueling. (i) Refueling with small portable containers shall be done with an approved safety type can equipped with an automatic closing cap and flame arrester. Refer to 1910.155 (c)(3) for definition of approved. (ii) Machines shall not be refueled with the engine running. (5) Fire extinguishers. (i) A carbon dioxide, dry chemical, or equivalent fire extinguisher shall be kept in the cab or vicinity of the crane. (ii) Operating and maintenance personnel shall be made familiar with the use and care of the fire extinguishers provided. (6) Swinging locomotive cranes. A locomotive crane shall not be swung into a position where railway cars on an adjacent track might strike it, until it has been ascertained that cars are not being moved on the adjacent track and proper flag protection has been established. 1910.180(j) Operations near overhead lines (1) For operations near overhead electric lines, see 1910.333(c)(3). 2014 Crane Institute America, LLC. All rights reserved. 78
OSHA 1926 Subpart CC Cranes and Derricks 1926.1400 Scope (a) This standard applies to power-operated equipment, when used in construction, that can hoist, lower and horizontally move a suspended load. Such equipment includes, but is not limited to: articulating cranes (such as knuckle-boom cranes); crawler cranes; floating cranes; cranes on barges; locomotive cranes; mobile cranes (such as wheelmounted, rough-terrain, all-terrain, commercial truck-mounted, and boom truck cranes); multi-purpose machines when configured to hoist and lower (by means of a winch or hook) and horizontally move a suspended load; industrial cranes (such as carry-deck cranes); dedicated pile drivers; service/ mechanic trucks with a hoisting device; a crane on a monorail; tower cranes (such as a fixed jib, i.e., hammerhead boom ), luffing boom and self-erecting); pedestal cranes; portal cranes; overhead and gantry cranes; straddle cranes; sideboom cranes; derricks; and variations of such equipment. However, items listed in paragraph (c) of this section are excluded from the scope of this standard. (b) Attachments. This standard applies to equipment included in paragraph (a) of this section when used with attachments. Such attachments, whether crane-attached or suspended include, but are not limited to: hooks, magnets, grapples, clamshell buckets, orange peel buckets, concrete buckets, drag lines, personnel platforms, augers or drills and pile driving equipment. (c) Exclusions. This subpart does not cover: (1) Machinery included in paragraph (a) of this section while it has been converted or adapted for a non-hoisting/lifting use. Such conversions/adaptations include, but are not limited to, power shovels, excavators and concrete pumps. (2) Power shovels, excavators, wheel loaders, backhoes, loader backhoes, track loaders. This machinery is also excluded when used with chains, slings or other rigging to lift suspended loads. (3) Automotive wreckers and tow trucks when used to clear wrecks and haul vehicles. (4) Digger derricks when used for augering holes for poles carrying electric and telecommunication lines, placing and removing the poles, and for handling associated materials to be installed on or removed from the poles. Digger derricks used in work subject to 29 CFR part 1926, subpart V, must comply with 29 CFR 1910.269. Digger derricks used in construction work for telecommunication service (as defined at 29 CFR 1910.268(s) (40)) must comply with 29 CFR 1910.268. (5) Machinery originally designed as vehiclemounted aerial devices (for lifting personnel) and selfpropelled elevating work platforms. (6) Telescopic/hydraulic gantry systems. (7) Stacker cranes. (8) Powered industrial trucks (forklifts), except when configured to hoist and lower (by means of a winch or hook) and horizontally move a suspended load. (9) Mechanic s truck with a hoisting device when used in activities related to equipment maintenance and repair. (10) Machinery that hoists by using a come-along or chainfall. (11) Dedicated drilling rigs. (12) Gin poles when used for the erection of communication towers. (13) Tree trimming and tree removal work. (14) Anchor handling or dredge-related operations with a vessel or barge using an affixed A-frame. (15) Roustabouts. (16) Helicopter cranes. (17) Material Delivery (i) Articulating/knuckle-boom truck cranes that deliver material to a construction site when used to transfer materials from the truck crane to the ground, without arranging the materials in a particular sequence for hoisting. 2014 Crane Institute America, LLC. All rights reserved. 79