Overhead Crane Operator

training

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 Overhead Crane Operator
training
OVERHEAD CRANE
A bridge crane/ overhead crane is a lifting and horizontal
movement device mounted on a "bridge" of one or more
horizontal girders (bridge girders) which are supported at either
end by trucks (end trucks). These trucks are attached at right
angles to the girders and move on runways which are attached to a
building's columns, overhead trusses or frames, or via a free
standing system of columns

Double girder , top running bridge Double girder crane

top running hoist underhung hoist
 OVERHEAD CRANE
A gantry crane is similar to an overhead crane except that the bridge for
carrying the trolley or trolleys is floor supported rather than overhead supported
(wall-mounted). It can be fixed or mobile (a mobile gantry crane stands on
wheels), and are frequently easy to disassemble and reassemble for easy
relocation. is a gantry crane designed to have one "leg" of the crane supporting
an end of the
bridge while the other end of the bridge is supported by an end
truck running on an elevated rail or runway. It is often referred
to as a single leg gantry crane.

Cantilevered gantry crane Semi gantry crane

 OVERHEAD CRANE
A derrick is a lifting device composed of one tower, or guyed mast
such as a pole which is hinged freely at the bottom. It is controlled
by lines (usually four of them) powered by some means such as
man-hauling or motors, so that the pole can move in all four
directions. A line runs up it and over its top with a hook on the end,
like with a crane. It is commonly used in docks and onboard ships.
Some large derricks are mounted on dedicated vessels, and are
often known as "floating derricks".
 OVERHEAD CRANE
A jib crane is a stationary or fixed crane that utilizes a
cantilevered bridge (girder) supported from a stationary vertical
support. A jib crane consists of a hoist attached to a rotating arm
that functions as a manipulator. The arm can rotate 360 degrees
and is mounted on a wall or attached to a floor-mounted support.
Jib cranes can have varying boom styles, including some that
articulate or pivot. Jib cranes may also mount to walls, ceilings
or floors, or may be portable.

Wall mounted Floor mounted/ Pedestal

 OVERHEAD CRANE

Monorail is a hoist system that uses cars that run on a single rail.
Typically the rail is run overhead and the cars are either suspended
from it or run above it. Driving power is transmitted from the cars to
the track by means of wheels that rotate horizontally, making contact
with the rail between its upper and lower flanges. One of the principal
advantages of a monorail is the relative simplicity of its trackage in
comparison with that of a standard railway. Monorails originated and
still function as materials-handling systems, similar to traveling
cranes, for use in large factories.
OVERHEAD CRANE

PARTS OF CRANE
OVERHEAD CRANE
 PROPER PROTECTIVE EQUIPMENT

COVERALL SAFETY GLOVES SAFETY GLASS

PROPER PROTECTIVE EQUIPMENT

HEAD GEARS

SAFETY SHOES

EAR PROTECTOR
SAFETY WARNINGS AND DECALS
 Standard Hand Signals

Hoist: With Lower: With arm Bridge Travel: Arm

forearm vertical, extended downward, extended forward,
forefinger forefinger pointing hand open and slightly
pointing up, move down, move hand in raised, make pushing
hand in small small horizontal motion in direction of
horizontal circle. circles. travel.
 Standard Hand Signals

Trolley Travel: Stop: Arm Emergency Stop:

Palm up, fingers extended, palm Both arms
closed, thumb down, move arm extended, palms
pointing in direction back and forth down, move arms
of motion, jerk hand horizontally. back and forth
horizontally. horizontally.
 Standard Hand Signals

Multiple Trolleys: Move Slowly: Magnet is

Hold up one finger Use one hand to Disconnected:
for block marked give any motion Crane operator
"1" and two signal and place spreads both
fingers for block other hand hands apart--
marked "2." motionless in front palms up.
Regular signals of hand giving
follow. the motion signal.
LIFTING TACKLES

Are slings, shackles, swivels,

hooks or other appliance
which comes in different
shapes and sizes depending
on the job requirements either
in construction or industries,
but their basic functionality is
to grab and hold onto the
goods and materials that are
to be lifted; usually with a
block and pulley system
connected in a lifting machine
or from the hook of a crane
 LIFTING TACKLES
Lifting Hook
A lifting hook is a device for grabbing and lifting loads by means
of a device such as a hoist or crane. A lifting hook is usually
equipped with a safety latch to prevent the disengagement of the
lifting wire rope sling, chain or rope to which the load is attached.

Identification:

Each shackle body shall be legibly and indelibly marked in raised

letters only with, at a minimum, the following information:
•the manufacturers trade mark or logo,
•the working load limit,
•the size, and a traceable identification code for material traceability
 LIFTING TACKLES
SAFE OPERATING PRACTICE
The following practices shall be followed when using hooks:
•Hooks on pedestal cranes shall be painted in a hi-visibility color (e.g.
fluorescent orange).
•Loads shall be centered in the base (bowl saddle) of the hook, to
avoid point loading and shall not be side loaded
•Duplex (“rams-horn”) hooks shall be equally loaded on both sides,
and the pin hole shall not be point loaded, or loaded beyond the rated
load of the hook except for testing.
These inspections shall be performed each day the lifting
equipment is used; Inspect for:
•Distortion, such as bending, twisting, or increased throat opening.
•Latches that are inoperative or fail to fully close the throat opening
because of wear or deformation.
•Wear, deformation, cracks, nicks, and gouges
•Hook attachment and securing means
•The inability to lock (for self-locking hooks)
 LIFTING TACKLES
EVIDENCE OF DAMAGE HOOKS

Spreading is the
widening of the Where is the Bending of the
mouth. Spreading crushing or hook or eye to
should exceed the rubbing of sling or the side;
maximum other lifting tackles Maximum twist
allowable of fifteen on the hook bowl. is not more than
percent from Maximum depths 10 degree.
original wear of ten percent
measurement to the nominal size.
recorded.
 LIFTING TACKLES
Shackles
Are used to connect the slings
to the load and the other end to
the hoist's hook; which are
classified it two types
(1.Anchored 2.Chain or D
Anchored shackle).
Identification:
Each shackle body shall be legibly and
indelibly marked in raised letters only
with, at a minimum, the following
information:
•the manufacturers trade mark or logo,
•the working load limit,
Chain or D shackle
•the size, and a traceable identification
code for material traceability
 LIFTING TACKLES
SAFE OPERATING PRACTICE

Using Shackles
•Do not attempt lifting operations unless you understand the use of the equipment, the slinging
procedures and the mode factors to be applied.
•Do not use defective shackles or unidentified pins.
•Shackles should be fitted so that the body takes the load along its centre line and is not
subjected to side bending loads. When connecting a number of sling legs, and similar
applications, position them so that they do not impose a side load on the shackle jaws. Use
spacers to position them if necessary.
•Ensure the pin is correctly screwed into the shackle eye.
•Tighten by hand; use a small bar to lock the collar to the shackle eye. Check that the thread is
fully engaged with the body but is not too long so that tightening causes the body to deform.
•With bolt and nut pins ensure the nut jams on the inner end of the thread and not on the eye of
the shackle. The bolt should be free to rotate with minimal side float. The split cotter pin must be
fitted before making a lift.
•When using shackles with slings in choke hitch, or in other applications where there may be
movement, place the pin through the eye or link of the sling and never in contact with the bight
of the choke or moving parts which may cause the pin to unscrew.
 LIFTING TACKLES
EVIDENCE OF DAMAGE SHACKLES
Discard: All shackles not fit for use shall be tagged
“Do Not Use”, and destroyed at the earliest
opportunity.
Storage: Shackles should be stored in an area that is
covered, dry or otherwise protected from the
environment. Never return damaged shackles to
storage. Do not alter, modify or repair shackles and
never replace missing pins with unidentified pins,
bolts etc, but refer such matters to a Competent
Person. Never galvanize or subject a shackle to other
plating processes without the approval of the supplier.

This set shall not be used ( out of manufacturer recommendation)

 LIFTING TACKLES
Spreader beam / Lifting beam:

It is a mechanical carrying device used for stabilisation,

attachment or connection. They are frequently used as load
handling equipment for attaching loads; hanging from a
crane hook and fitted with a number of ropes at different
points along its length and used to distribute weight while
lifting wide frames or oversized objects and to control the
sling angle.
 LIFTING TACKLES
SAFE OPERATING PRACTICE

FIXED LENGTH SPREADER BEAM

 LIFTING TACKLES
STORING SPREADER BEAM
 Never return damaged lifting beams to storage. They
should be clean and, where necessary, protected from
corrosion.
 Lifting beams should be stored in a manner that will
provide protection from damage whilst in store.
 Stands or packing should be provided where this is not
built into the beam.
 Ensure the beam is stable and cannot topple over.
 LIFTING TACKLES
TURNBUCKLES

A turnbuckle (also stretching screw) is a device for adjusting

the tension or length of ropes, cables, tie rods, and other
tensioning systems. Its parts are a sleeve with a screwed
connection at one end and a swivel at the other or, more
commonly, a sleeve with screwed connections of opposite
hands (left and right) at each end so that by turning the
sleeve, the connected parts will be drawn together, taking up
slack and producing tension
 LIFTING TACKLES
SWIVEL

A swivel is a connection that allows the connected

object to rotate horizontally and/or vertically. A
common design for a swivel is a cylindrical rod that
can turn freely within a support structure. The rod is
usually prevented from slipping out by a nut, washer
or thickening of the rod.
 LIFTING TACKLES
LIFTING CLAMPS
A lifting device with teeth used for lifting loads that do not
have eyebolts; it is use to join, grip, support, or compress
mechanical or structural parts with opposing tools that often
adjustable sides or parts for bracing objects or holding them
together; the clamping body defines a slot to receive the
article to be lifted with opposed jaws mounted on opposite
sides of the slot, one jaw being mounted for opening and
closing movement relative to the other jaw.
HORIZONTAL CLAMP

UNIVERSAL CLAMP PIPE CLAMP VERTICAL CLAMP

 LIFTING TACKLES
CLIPS and TIMBLES
A clip or wire rope clamp is used to fix the loose end of the
loop back to the wire rope. It usually consists of a u-shaped
bolt, a forged saddle and two nuts Thimbles on the other
hand is a device that is installed inside the wire loops to
preserve the shape of the loop and offer easy loading in case
of heavy lifting. These prevent the wire loops from coming
in direct contact with the material to be lifted.

thimbles

clips
 LIFTING TACKLES
EYE BOLTS

Use plain or regular eye bolts Use shoulder eye bolts Do not pull load over
(non-shoulder) or ring bolts for for vertical or angle the side using lifting
vertical loading only. loading. eye bolts

Do not insert the point of a hook in an eye bolt.

Use a shackle.
 LIFTING TACKLES
SLINGS
It is commonly use to supports a weight by contacting two
or more points using cable, chains or rope to a single point
of lift to evenly distribute weight. Crane lifting slings are
essential for construction and industrial use, and are meant
to carry extremely heavy objects.

Chain sling

Web sling

Wire rope sling Mesh sling

LIFTING TACKLES
Wire rope construction
 LIFTING TACKLES

New slings are marked by the manufacture to show:

•The rated load for the types of hitches, and the
angle upon which they are based,
•The core material, and the diameter or size,
•The cover material if different from core material.
In addition, slings may be marked to show:
•The manufacturer's code or stock number, and
•The name or trademark of the manufacture.
 LIFTING TACKLES
Evidence of damaged sling

1. Inspect the lifting equipment and all the slings before starting any job or work.
Note: Eliminate from service any wire rope having broken wires with:
Max of 6 randomly broken wires in 1 lay and 3 broken wire in 1
strand in 1 lay for running ropes.
2 randomly distributed broken wire in 6 rope diameter and 4
randomly distributed broken wire in 30 rope diameter
 SAFE RIGGING & OPERATING PRACTICE

UNSTABLE UNSTABLE STABLE

UNSTABLE
Hook is not at Load will shift Load will Hook is at the
until center of topple down, center of
center of
gravity of the lifting points is gravity of the
gravity of the
load direct above the load
load
below the hook center of
block gravity of the
load
2. Always ensure that the load is balance.
3. The hook or load block of a crane or hoist must be positioned over
the load to prevent side loading of the crane when the load is hoisted.
 SAFE RIGGING & OPERATING PRACTICE
4. Never stand below the load and always secure the area during
lifting operation.
5. If night lifting jobs are to be done, always have the proper
illuminations.
6. The operator of a crane or hoist must not attempt to move a load if
there is any doubt the load can be safely handled.
7. A load must not contact the crane or hoist and the load must not
contact a structure.
 SAFE RIGGING & OPERATING PRACTICE

8. A load on a crane or hoist load hook must be safely

landed and supported, before being unhooked.
9. Do not engage in any practice that will divert your
attention while operating the crane.
 SAFE RIGGING & OPERATING PRACTICE

10. Ensure fire extinguisher having at least a 10 be rating

must be immediately available for each crane.
 SAFE RIGGING & OPERATING PRACTICE
11. Ensure that the rated load capacity of a crane’s bridge,
individual hoist, or any sling or fitting is not exceeded.
Know the weight of the object being lifted or use a
dynamometer or load cell to determine the weight.
 SAFE RIGGING & OPERATING PRACTICE
12. Make sure the hand signals used by signaler and
operator to control hoisting operations must be heeded
standard signals.
13. Respond to signals only from the person who is directing
the lift, or any appointed signal person.
14. The operator of a crane of hoist must act only on
directions from a designated and competent signaler
whenever the operator does not have a clear and
unobstructed view of the load hook and load throughout the
whole range of the hoisting operation.
15. Obey a stop signal at all times, no matter who gives
it.
 SAFE RIGGING & OPERATING PRACTICE

16. A worker must not remain within range of the run or

swing of the load or equipment whenever the movement of
the load, or any other part of the crane or hoist creates a
hazard, and the operator must not move the equipment when
any worker is so exposed.
17. A worker must not ride on a load, sling, hook or any
other rigging equipment.
 SAFE RIGGING & OPERATING PRACTICE
19. Prevent shock loading, avoid sudden stops or starts.
Shock loading can occur when a suspended load is
accelerated or decelerated, and can overload the crane or
hoist. When completing an upward or downward motion,
ease the load slowly to a stop.
20. Use tagline to prevent and protect the load from swing.
 SAFE RIGGING & OPERATING PRACTICE
21. Hook must be positioned so that no moving part
of the equipment will come within 60 cm (2 ft) of
any obstruction in any area accessible to workers.
22. A load must not be left suspended from the load
hook of a crane or hoist when an operator is not at
the controls.
 SAFE RIGGING & OPERATING PRACTICE
23. Do not move a load over
people. People shall not be
placed in jeopardy by being
under a suspended load. Also, do
not work under a suspended load
unless blocks, jacks, or a solid
footing that will safely support
the entire weight supports the
load. Have a crane or hoist
operator remain at the controls or
lock open and tag the main
electrical disconnect switch.
 SAFE RIGGING & OPERATING PRACTICE

24. Check that all controls are in the off position before
closing the main line disconnect switch.
25. Check for any open wires, cut wires, damage insulation.
26. Operators shall be familiar where is the emergency switch.
 SAFE RIGGING & OPERATING PRACTICE

27. Use rigging protection against cutting or slipping of sling from the load.
SAFE RIGGING & OPERATING PRACTICE
 Sling Hitch Capacity
Determination of bridle hitch sling capacity

 3 legs attached but only 2 legs

carries the load while other use
for balancing.
SWL=SWL(single sling hitch) x H/L x 2

 4 legs attached but only 3

carries the load while other use
for balancing.
SWL=SWL(single sling hitch) x H/L x 3
Sling Hitch Capacity
 Sling Hitch Capacity
Capacity reduction of choker sling

The capacity is reduce as the angle

of use declines

Angle of choke Capacity

%
Over 120o 100
90o to 120o 87
60o to 89o 74
30o to 59o 62
0 to 29o 49
Choke angle
Sling Hitch Capacity
DAILY CHECLIST
Any Question ?