Crane and Hoist Safety

PUBH 3310 November 13, 2009

Objectives
Know hazards associated with cranes Become familiar with common types of industrial and construction cranes Understand rigging basics, including the importance of sling angle Be familiar with methods of controlling crane hazards and preventing accidents
2

Outline
Crane Hazards Crane types
Industrial cranes Construction cranes Rigging (and sling angle)

Controlling hazards
Inspections and training Power lines Equipment failure and crane stability Other
3

Crane Hazards
Over 250,000 cranes in operation
125,000 in construction 80,000 general and maritime

80 fatalities per year One death per thousand crane operators in their working lifetime (45 years) Risk to citizens and other workers
4

Causes of Crane Fatalities

Electrocution Crane assembly/disassembly Crane upset/overturn Rigging failure Overloading Struck by moving load Manlifts Struck by counterweight Two-blocking Hoist limitations Other 39% 12% 7% 7% 4% 4% 4% 2% 2% 2% 6%

A. Suruda,et al, Crane-Related Deaths in the U.S. Construction Industry, 1984-

Crane Types
"Industrial cranes
Overhead Gantry Jib

"Construction cranes
Mobile Tower Derricks
6

Industrial Cranes
Overhead Cranes
Common in industrial facilities Supported by overhead rails Components Bridge Trolley Hoist Often pendant or remote operated Easy to use, little training required, no stability problems

Industrial Cranes
Gantry cranes
Similar to overhead cranes, but supported by a mobile frame which travels on the ground
Small (1000 10,000 pound capacity) gantry crane Large (600 ton capacity) gantry crane
8

Industrial Cranes
Jib cranes
Pivot mounted boom with trolley and hoist

Floor-mounted jib crane Wall-mounted jib crane

9

Industrial Cranes
Power hoist
Usually electric or air operated

Chain hoist (or "chain fall")

Hand operated

10

Construction Cranes
Tower cranes
Variable height climbing cranes Used for building construction
11

Construction Cranes
Mobile cranes
Crawler cranes Truck cranes Hydraulic cranes Boom telescopes May have jib

Equipped with outriggers for stability

12

Hydraulic Cranes

13

Hydraulic Cranes

14

Construction cranes
Derricks
Boom angle changes to adjust horizontal distance Often used in shipyards, building construction, etc.
Gin pole Chicago boom Stiff-leg Etc.

15

Mine-shaft rescue using a gin pole derrick improvised from an extension ladder Stiff-leg construction derrick
16

Hay derrick

17

Rigging
Rigging: The hardware and equipment used to safely attach a load to a lifting device
Wire rope
Usually a "core" member to increase flexibility Fiber Core (FC) Wire Strand Core (WSC) Independent Wire-rope Core (IWRC)

18

Rigging
Fittings, sheaves
Shackles Blocks Sockets Hooks
May have safety latch

Eyes Turnbuckles
19

Rigging
Always use rigging to connect the load to the hook Materials
Wire rope Fabric Chain

Slings

Straight (regular) Choker Basket Double, triple, etc.

20

Rigging
Sling angle
Stress on sling legs varies with the angle Divide the load by the number of sling legs, and divide by sin of 2000 lbs the angle
For a two-legged sling, 2000 lb load and 60 degree, stress = 1155 lbs on the sling leg

2 legs

1 1155 lbs sin 60 leg

2000 lbs 1 2000 lbs 2 legs sin 30 leg 21

Controlling Crane Hazards

Operators
18 years old Physical exam Knowledge (training) Estimating load weight Signals Operation Skill (demonstration)

22

Controlling Crane Hazards

Inspection
Frequent Daily, monthly Hooks, rope, crane operation Periodic At least annually Complete inspection - wear, damage, deterioration, operation slings

Testing Records

23

Preventing Crane Accidents

Contact with energized power lines (45% of accidents)
De-energize overhead lines Maintain minimum distance 10 feet distance for 50 kv Over 50 kv, add 4 inches per 10 kv Use proximity alarms Warn when energized line is near No fatalities in 25 years, according to mfg. Warning signs I-15 construction was a good example

Sigalarm 24

Warning label

25

Preventing Crane Accidents

Under hook lifting device problems
Overturned cranes
Inspect, proper use, etc.

Assure a level and stable base for the crane Comply with load charts Weight Boom angle and extension Only vertical loads Wind can cause a significant side load
26

Load Chart
Load charts inside the cab include Structural capacity and tipping limits for the crane Capacity is highest for short radius over front loads with outriggers extended.
27

Load Chart
Rear Over Radi us
18.8' Boom 24' Boom 29.8' Boom 18.8' Boom

Over Side
24' Boom 29.8' Boom 18.8' Boom

Over Front
24' Boom 29.8' Boom

6 8 10 12 15 18 20

65,600* 57,250* 50,760* 44,970 33,180 25,960 56,510* 49,230* 43,250* 33,290 26,250 22,940 47,060* 41,310* 33,350 26,310 23,010

65,600* 57,250* 50,760* 45,540* 39,370 27,540 56,510* 49,230* 43,250* 37,090 28,370 22,910 47,060* 41,310* 35,080 28,490 23,030

66,720* 61,150* 52,520* 46,390* 39,620 27,540 56,510* 49,230* 43,250* 37,090 32,471 29,820 47,060* 41,310* 35,080 30,730 28,430

25
29

16,910
13,030

15,330
11,870

23,770
16,750

Preventing Crane Accidents

Dropped loads
Operating anti-two block device (upper limit switch) Proper rigging Inspection

Boom collapse
Inspection Stable base No overloading No horizontal loading

Crushing by the counter weight

Stay away from the rear of the crane
29

Preventing Crane Accidents

Proper outrigger use
Level Fully extended Stable base Use cribbing to distribute the load

30

Outrigger Use

Outrigger with cribbing

31

Preventing Crane Accidents

Rigging failure
Inspection Proper use temperature, angles, etc. Fall protection for workers suspended by crane "man basket" or "suspended work platform

Falls

32

Links
Managing Mobile Crane Hazards
http://www.elcosh.org/en/document/96/d 000104/managing-mobile-cranehazards.html

Crane, Derrick, and Hoist Safety

http://www.osha.gov/SLTC/cranehoistsafet y/index.html

33