SAFE CRANE/HOIST AND

RIGGING OPERATIONS
PRESENTATION

By : DELIUS M. CUEVA
Safety Consultant
 INTRODUCTION

Accidents with cranes and lifting equipment can

be both costly and spectacular. Cranes cannot create
accidents by themselves. They are inanimate objects,
designed and operated to raise and lower loads
efficiently and safely within their stated capacities.
Accidents with cranes can be caused by man’s actions
or inactions. Therefore, it is essential that all personnel
involved in crane operations be familiar with the
general characteristics and capabilities of cranes and
related rigging equipment.
MAJOR TYPES OF ACCIDENTS INVOLVING
CRANES
Contact with power lines Overturns

Falls Mechanical failures

 How Do Crane Accidents Occur?

Instability Lack of
communication
unsecured load, the point of operation
load capacity is a distance from the
exceeded, or crane operator or not in
ground not level or full view of the
too soft operator

Inadequate
Lack
maintenance or
of training
inspection
SOME COMMON TYPES OF CRANES
Overhead Telescopic Boom (Rough Terrain)

Tower Lattice Boom (Crawler)

UNSAFE ACTS / CONDITIONS THAT CAN LED
TO CRANE ACCIDENTS

Improper loading/lifting Working too close to power

Excessive speeds lines
No hand signals Improper exhaust system
Inadequate inspection and No steps/guardrails
maintenance walkways
Unguarded parts No boom angle indicator
Unguarded swing radius Not using outriggers
 CRANE OPERATOR’S QUALIFICATIONS
AND RESPONSIBILITIES

1. He must be a certified crane operator as to what type of crane.

2. He must know and comply with the standard lifting hand signals.

3. He must know the technical operations and precautions

of the crane he operates.

4. He must immediately report to his superior any unusual

malfunction or defects in the unit.
 RULES TO FOLLOW PRIOR TO LIFTING

1. Don’t allow the crane to operate not in perfect mechanical condition.

2. Before starting operations, inspect, test and maintain the crane in

accordance to the manufacturer’s recommendations and maintenance.

3. The operator should remain alert to possible malfunctioning

of the machine while operating.

4. Never use the crane or allow to use when weather conditions such that
hazards to personnel, property or public are created.
5. If the visibility of the operator is impaired by dust, darkness,
fog, rain or thick smoke, strict supervision of the crane must be exercised.

6. Never operate or allow anyone to operate any crane until that person
is thoroughly familiar with the machine, its operation and proper care.

7. Before putting the crane into operation, check and ensure

that it has not moved and that it remains level.

8. If there are any warning signs on the switch or engine starting control,
do not start the engine until they have been verified
 9. Before starting the engine, make sure that all personnel are well
cleared of the machine.

10. Let the engine warms-up for a few minutes to give the oil in the pumps a
chance to circulate and the hydraulic oil to warm up to the minimum
operating temperature.

11. When starting the engine it is necessary to reduce the starter load by
disengaging the clutch before starting. After starting the engine
throttle down to idle speed before engaging the clutch to reduce
shock load in the pump shaft.
12. Know the location and use of all emergency shutdowns.

13. Never back up the machine without first making certain that no one
will be endangered at the back. Use signal man if possible, use
horn and backing horn.

14. Never operate and work alone - use the buddy - system.

15. Never jump from the machine except during emergencies.

16. Don’t leave the crane with suspended load. Lower it down, lock or
support the boom and stop the engine.

17. No one is allowed to ride or permitted to get in while the equipment is

in motion or in operation.

18. The operator must always pay attention to the signal of the rigger.

19. Always use the shortest boom possible.

20. Position the crane as close to the load as possible and in such a way
as to minimize the swing.

21. Fence or barricade areas around the crane adjacent to fixed structure
or objects in which personnel could be trapped and crushed.
22. Regardless of the size or the weight of load to be lifted, always use
the crane’s outrigger with full extended beam and wheels off the
ground.

23. Ensure that the swing lock is disengaged before starting to operate.

24. Make a dry run, especially in areas which are really tight. Go
through all the motions without a load, anticipating what actions
you will take to make a safe lift, and a smooth operation.

25. Most important precaution is to determine the total weight of all

loads before rigging them or attempting to lift them. Total weight
includes the hook block, slings or rigging devices to be used and
the load to be lifted.
 FACTORS AFFECTING CAPACITY
Before the machine is put into operation, the operator
must know the capacity under all conditions and
configurations. Load chart capacities are based on almost
ideal conditions seldom achieved under actual working
conditions, and as such it is extremely important to not
only know how to determine the capacity from the chart
but also to recognize the factors which can reduce the
capacity below what the chart says.
The rated capacities of mobile cranes are based on
both strength and stability. It is extremely important to
know the difference, for in one case one of the structural
components of the crane will break and in the other case
the crane will tip over. Do not use stability to determine
lifting capacity, use the load chart.
 The manufacturer accounts for these variable factors
by providing a load chart that limits the maximum allowable
loads to values below the critical loads. If the operator
exceeds these limits, he could be in trouble.

The operators of all cranes must be guided solely by the

rating plate recommendations concerning loads, boom
length, boom radius, lifting quadrants and other factors listed
on the rating plate such as outrigger position and terrain.

The ability of a mobile crane to lift is also affected by the

quadrant in which it is working. Lifting quadrants are defined
as the, “over the front, over the side, or over the rear”. The
load which can be safety lifted will vary considerably from
quadrant to quadrant. It is the operator’s responsibility to
see to it that plate ratings are not exceeded, regardless of
the quadrant in which he is operating.
 LEGAL REQUIREMENT
DOLE Department Order No. 13, Series of 1998

Section 10. Safety on Construction Heavy Equipment

10.1 a) All heavy equipment operators assigned at the project site must be tested
and certified in accordance with a standard trade test prescribed by Tech -
nical Education and Skills Development Authority (TESDA) in coordination
with its accredited organization/s.

b) All heavy equipment must be tested and certified in accordance with the
standards prepared by DOLE or its recognized organization/s prior to
commissioning of said equipment.
 RIGGING THE LOAD

The importance of rigging the load properly is as

great as determining the weight of the load and the quality
of these operations depends to a large extent, with the
crane operator even though he may not actually rig the
load. He is in a position to provide guidance and control
for the rigging crews and as such should ensure that the
following procedures are observed by not only himself but
all others concerned with the operation.

1. Know the safe working load of the rigging equipment

being used and never exceed this limit.
2. Determine the load weight before rigging it.

3. Wear gloves when working and handling with wire

ropes.

4. Examine all hardware, equipment, tackle and slings

before using them and report defective ones for
replacement.

5. All slings should be identified or tagged with an

identification number and their maximum capacity
permanently attached to the sling.
6. Do not use kinked or damaged slings.

7. Never allow wire rope to lie on ground for any length of

time, or to wet surfaces, rusty steel or near corrosive
substances.

8. Lifting beams should be marked with their weights and

safe lifting load.
Job Site Considerations

The person authorized

and qualified to do rigging
must always pay close
attention to details. One
careless moment or act can
result in serious injury or
death and tremendous
property damage. Proper
rigging is an art and should
never be left to the
inexperienced. If you don’t
know how to do it properly,
then don’t attempt it.
 HANDLING THE LOAD

1. Before making a lift ensure that :

a. The crane is rigged with sufficient parts of line to

make the lift.

b. The load has been properly rigged and well

secured to prevent the movement or
dislodgement of any part. All loose objects must
be removed from the load and the machine .
c. Taglines must be used to control the load.

d. Ensure the load is free before lifting (i.e. it is not

bolted, tied or fastened to the ground or another
object).
e. The load line is over the center of gravity of the
load and the hoist line is vertical.

f. Multiple part lines are not twisted around each other.

g. The rope is properly seated on the drum and in the

sheaves.
Suitable taglines shall be used to control all loads.
2. Avoid impact loading caused by sudden jerking when
lifting or lowering. Raise the hoist line gradually until the
slack is eliminated.

3. Keep hands away from pinch points as the slack is

being taken up.

4. Respond to signals only from the appointed signal man

but OBEY A STOP SIGNAL AT ANY TIME no matter
who gives it.

5. If the load does not ride properly, lower the load and have
it re-adjusted.
 6. Never allow anyone to ride on a load that is being lifted.

7. Never allow anyone to work or pass under a suspended

load.

8. Avoid multiple lifting at one time.

9. Never use a crane boom to drag a load sideways.

Make vertical lifts only.

10. Neither the boom nor the load be lowered to a point

where less than two full wraps of rope remained on the
drum.
11. Allow the maximum clearance between the hook
block and the head sheaves.

12. The operator must never leave his position at the

controls while a load is suspended.

13. Loads must be properly blocked before unhooking or

unslinging.
 1

Be alert and keep out from all overhead

loads.
 ELECTRICAL HAZARDS

Electrocutions are among the most frequently

repeated of all construction accidents and most of them
are caused by cranes contacting overhead power lines.

There is an area surrounding every live power

line that is called or referred to as the absolute limit of
approach. It is strictly forbidden to move any crane
boom or load line or load into this area unless the line
has been de-energized or insulated. There are no other
exceptions.
The absolute limit of approach are as follows :

Line Voltage Absolute limit of approach

1. Up to 125,000 volts --- 10 ft. / 3.0 m.

2. 125,001 to 250,000 volts--- 20 ft. / 6.0 m.

3. over 250,000 volts --- 25 ft. / 7.5 m.

The second requirement is the need to have a

signalman whose whole sole duty is to observe from the
best vantage point and to warn the operator whenever
the boom, the load, or load lines are approaching the
“limit of approach”.
 MORE THAN ONE CRANE OPERATING IN
THE SAME AREA
Whenever two or more cranes are operating in the
same area, there is always a possibility of collision or of the
hoisting ropes or loads falling each other or the structure of
the other crane even when the booms are of different
lengths. To minimize the probability of this occurrence, the
cranes should always be situated in such a way that the
operators have a clear view of the other cranes operating in
the collision danger area. The operators should also have
direct communication with each other so that any operator
may alert or warn the other to impending danger. It is also
recommended that their overall lifting program be set out
and controlled by one man who is in contact with all
operators and riggers and assigns priority of operation for
the cranes.
 LIFTING WITH MORE THAN ONE CRANE
(Tandem Lift)

These are extremely complex operations that need

a great deal of planning before actually doing them for it
is possible to lose not only the load but also all the cranes
that are involved.

One qualified person should be made responsible

for the operation. He should analyze the operation and
instruct all personnel involved in the proper positioning,
rigging of the load, and the movements to be made.
Precautions to be observed when doing tandem lift.

1. Use only the best rigging equipment and cranes.

2. Make all movements as slowly as possible.

3. Keep engine speeds at maximum governed speeds to

avoid stalling.

4. Match the line and swing speeds of all cranes.

5. Do not apply clutches or brakes suddenly.

6. Use only one signalman and ensure that he is in radio
contact with the operators.

7. Know how much of the load is to be carried by each

crane and be absolutely sure that the slings are
arranged to divide the load as planned.

8. Bear in mind that machine capacities are based on

freely suspended and balanced loads, with the boom tip
directly over the center of gravity of the load.
KINDS OF KNOTS
 SIGNALLING

Whoever is in-charge of any operation (contractor,

foreman, superintendent) using any crane must ensure
that a fully competent signalman is assigned to work with
the crane for as long as it is working within his area of
responsibility.

The procedure requires that a signalman be present at all

times whenever :

1. The crane is working within a boom’s length of power

lines.
2. The operator can not clearly see the hook and load at all
times.

3. The machine is being backed up or moved and the

operator cannot see all parts of the machine and its path
of travel.

Hand signals should be used only when the distance

between the operator and the signalman is not great and
atmospheric conditions allow for clear visibility. It is
recommended that the signalman wear high visibility gloves
(day-glo orange) to distinguish him from the other men and
make the signals more clear.
It is strongly recommended that 2 - way radios be used
on all crane operations where signalling is required.
There are too many accidents that result from
misunderstood or misinterpreted hand signals and all
would be prevented by voice communication.

Adequate lighting arrangements and radio communication

must be provided for night operations.

In cases of operations where the operator cannot see the

load due to obstructions, two signalmen are needed.
The signalman must :

1. Position himself in full view of the operator and if using

hand signals close enough for the signals to be seen
clearly.

2. Be fully qualified by experience with the operation.

3. Be responsible for keeping the public outside of the

operation area.
4. Direct the load so that it never passes over anyone
working beneath, if can’t be avoided, let them vacate
the area.

5. Be in constant communication with the operator at all

times with either the hand signals or the two-way radio.
STANDARD CRANE SIGNALS

STOP. ARM EXTENDED, PALM DOWN,

MOVE HAND RIGHT AND LEFT.
DOG EVERYTHING. Clasp hands in front of
body.
MOVE SLOWLY/HOIST UP SLOWLY. Use one hand to
give any motion signal and place other hand motionless in
front of hand giving the motion signal.
HOIST UP. With forearm vertical forefinger pointing up,move
hand in small horizontal circles.
HOIST DOWN/LOWER LOAD. With arm extended
downward forefinger pointing down move hand in small
horizontal circles.
USE MAIN HOIST. Tap fist on head, then use regular
signals.
USE WHIPLINE.(AUXILIARY HOIST). Tap elbow with
one hand then use regular signals.
LOWER BOOM. Arm extended, fingers closed thumb
pointing downward.
RAISE BOOM. Arm extended, fingers closed, thumb pointing
upward.
SWING. Arm extended point with finger in direction of
swing of boom.
RAISE THE BOOM AND LOWER THE LOAD. With arm
extended thumb pointing up, flex fingers in and out as long as load
movement is desired.
LOWER THE BOOM AND RAISE THE LOAD. With arm
extended, thumb pointing down, flex fingers in and out as long as
load movement is desired.
TRAVEL.(Rail Mount or Crawler). Arm extended forward
hand open and slightly raised making pushing motion in
direction of travel.
EXTEND BOOM (Telescopic Booms). Both fists in front of
body with thumbs pointing outward.
RETRACT BOOM (Telescopic booms). Both fists in
front of body with thumbs pointing toward each other.
 KINDS OF HITCHES

Single Choker Hitch Double wrap Choker Hitch

Double Basket Hitch Double Choker Hitch
Single Basket Hitch Double wrap Basket Hitch
Single Vertical Hitch Two Leg Bridle Hitch
Three Leg Bridle Hitch Four Leg Bridle Hitch
KINDS OF RIGGING EQUIPMENT
 Shackles
Types of Shackles

Straight Bow Roller

DIFFERENT TYPES OF
DAMAGES DUE TO
IMPROPER USE &
IMPROVISED RIGGING
GEARS
 Bended Welded eye Corroded

Bended due to tension Substandard Substandard Equipment

Three Leg Bridle Hitch Kinked Bird Caging

Strands Cuts Corroded Severe Cuts

Three Leg Bridle Hitch Corroded Corroded

Un secure pin Improper handling Corroded

CRITERIA FOR REJECTING WIRE ROPE
SLINGS
 For strand laid and single part slings; ten
randomly distributed broken wires in one rope lay
or five broken wires in one strand in one rope lay.
 Wire rope diameter is smaller than the nominal
diameter by more than 7 percent.
 Evidence of rope deterioration from corrosion.
 Kinking, crushing or other damage that results in
detrimental distortion of the rope structure.
THE RIGGING TRIANGLE
Increasing the sling angle (included angle) increases the stress on each leg
of the sling, even though the load remains constant. The stress on each leg
can be calculated by dividing the load weight by the cosine of the angle.
COMPUTATION OF SAFE WORKING LOADS
(Rule of Thumb)
WIRE ROPES :
SWL = rope diameter x rope diameter x 5
(Japanese standard, F.S. = 6)

Note : Diameter is in inches.

1 inch. = 25.4 mm.

Examples :

1.) ½” diameter wire rope :

SWL = ½” x ½ x 5 = 1.25 tons
2.) 5/8” diameter wire rope :
SWL = 5/8 x 5/8 x 5 = 1.953 tons

3.) 1” diameter wire rope :

SWL = 1 x 1 x 5 = 5 tons
SHACKLE : Safe load in tons is diameter of pin in
one-fourth inches (1/4”) squared and divided by three (3).

Example : ½” pin diameter = 2 quarters

SWL = 2 x 2 = 4 = 11/3 tons or
3 3
2,667 lbs.
CHAINS : Safe load in tons is 6 times the diameter of chain
stock in inches squared.
Example : ½” diameter chain stock
SWL = ½ x ½ x 6 = 1 ½ tons or 3000 pounds
MANILA ROPE : Change the rope diameter into eights of an
inch. Square the numerator and multiply by 20.
Example : 1) ½” diameter manila rope = 4/8 in diameter
SWL = 4 x 4 x 20 = 320 pounds
2) 5/8” diameter manila rope = 5/8 in diameter
SWL = 5 x 5 x 20 = 500 pounds
3) 1” diameter manila rope = 8/8 in diameter
SWL = 8 x 8 x 20 = 1,280 pounds
NYLON ROPE : Change the rope diameter into eights of an
inch. Square the numerator and multiply by 60.
Example : ½” diameter nylon rope = 4/8 inch diameter
SWL = 4 x 4 x 60 = 960 pounds
POLYPROPYLENE ROPE : Change the rope diameter into
eights of an inch. Square the numerator and multiply by 40.
Example : ½” diameter = 4/8 inch diameter
SWL = 4 x 4 x 40 = 640 pounds
POLYESTER ROPE : Change the rope diameter into eights of
an inch. Square the numerator and multiply by 60.
Example : ½” diameter = 4/8 inch diameter
SWL = 4 x 4 x 60 = 960 pounds
POLYETHYLENE ROPE : Change the rope diameter into
eights of an inch. Square the numerator and multiply by 35.
Example : 1” diameter polyethylene rope = 8/8 inch diameter
SWL = 8 x 8 x 35 = 2240 pounds
WIRE ROPE CLIPS = Install u-bolt over short end (u-dead
principle)
3/16” - 7/16” dia. = 2 clips
½” - 5/8” dia. = 3 clips
¾” - 1” dia. = 4 clips
1 1/8” - 1 ¼” dia. = 5 clips
1 3/8” - 1 5/8” dia. = 6 clips
LOAD CHART
(Tadano Mobile Crane, TS-75M)
RANGE DIAGRAM
(Tadano Mobile Crane, TS-75M)
RIGGING PROBLEM
 THERE IS ONLY
ONE WAY TO
OPERATE A CRANE
AND THAT IS

SAFELY

THANK YOU !