CRANES & MOBILE LIFTING EQUIPMENT

Transcription

1 CRANES & MOBILE LIFTING EQUIPMENT Contents Company Policy and Procedure... 1 Mobile Crane Operations and Inspections... 2 Introduction... 2 Safety Training Requirements... 3 Lifting Principles... 5 Operational Considerations... 6 OSHA Requirements for Mobile Cranes... 6 Mobile Crane Inspections... 7 Crane Set-up... 8 Electrical Hazards... 8 Load Charts... 8 Inspection Types... 9 Starting the Inspection Specific Inspection Items and References Rough Terrain 45 ton Hydraulic Crane ton Lattice-Boom Crawler Crane General Terms and Definitions General Load Charts OSHA Cranes and Derricks OSHA Site Plans Site Specific Crane Plan Crane/Boom Truck Inspection Report Hand Signal Charts... 39

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3 Company Policy and Procedure This Company s policy on lifting equipment is adopted from the OSHA Standards for Cranes and Derricks. The following procedures and practices will be enforced at the workplace to ensure no employee is exposed to hazards from the operation of cranes or lifting devices: Only authorized personnel trained in safe operating procedures, and designated to operate overhead or gantry cranes or lifting equipment will be allowed to operate such equipment for the company. A load-rating chart must be permanently mounted in the cab of each crane, easily readable from the operator s normal operating station. Inspection 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 will be made monthly on critical items in use such as brakes, crane hooks, ropes, structural members, & welds. This certification record will be kept readily available with the equipment. Certified production written operational and rated load tests will be obtained from the manufacturer and kept available with the equipment. Equipment will be re-tested after any structural repairs or modifications which may only be made by the manufacturer or technician certified by the manufacturer. A thorough inspection of all wire ropes in use, including running ropes, will be made at least once a month. A record which will include the date of inspection, the signature of the person who performed the inspection, and an identifier for the ropes will be made and kept on file in the office at the company. All inspections will be performed by the job-sit supervisor, who is certified as the company s competent person for operation and inspection of overhead and gantry cranes, hoisting equipment, and derricks. Any deterioration, resulting in appreciable loss of original strength will be kept under observation to determine whether further use of the rope would constitute a safety hazard. Particular care will be taken to inspect ropes at equalizer sheaves or other sheaves where rope travel is limited, or with saddles. 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 will be given a thorough inspection before it is used. The inspection will be for all types of deterioration and will be performed by the job-sit supervisor, whose approval will 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 will be made and kept readily available. A carbon dioxide, dry chemical or equivalent fire extinguisher will be kept in the cab or vicinity of the crane, and the operator and maintenance personnel will be made familiar with the use and care of the fire extinguisher. If crane operations are to be performed in the vicinity of overhead power lines, the lines must be de-energized and grounded, or other protective measures provided before work is started. If the lines are to be de-energized, arrangements will be made with the utility operator involved to de-energize and ground them. If protective measures, such as guarding, isolating, or insulating, are provided, these precautions must prevent employees from contacting lines directly with any part of their body or indirectly through conductive materials, tools, or equipment. Lifting hooks or shackles will be visually inspected before each use, and monthly inspection with a certification record which includes the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, of the hook inspected will be performed by the job-site supervisor. Safety Services Company 1

4 Hooks or shackles with cracks or having more than 15 percent in excess of normal throat opening or more than 10 twist from the plane of the unbent hook will be taken out of service and replaced. Hoist chains, including end connections, will be inspected before each use for excessive wear, twist, distorted links interfering with proper function, or stretch beyond manufacturer's recommendations. Monthly inspection with a certification record which includes the date of inspection, the signature of the person who performed the inspection, and an identifier of the chain which was inspected will be made by the job-sit supervisor. A preventive maintenance program based on the crane manufacturer's recommendations will be established, and performed. Maintenance records will be kept of all repairs or replacements made. Only authorized technicians may perform repairs on lifting equipment. Before any servicing or maintenance of equipment is done, personnel will perform proper applicable lockout/blockout/tagout procedures to ensure the safety of personnel performing these tasks. Mobile Crane Operations and Inspection Introduction Construction sites are often communities within themselves consisting of a variety of activities with numerous pieces of equipment and tools in use simultaneously. An important piece, and one of the most expensive pieces of equipment in use on most construction sites is the crane. Statistics indicate that a significant number of construction injuries and fatalities are crane related accidents that also cost hundreds of thousands of dollars in equipment damage and other related costs. An example of the tremendous loss potential occurred a few years ago when two cranes, working in tandem, while traveling, dropped their load onto a sports stadium under construction and some other construction equipment. Although no personal injuries were experienced, the cost due to equipment damage and the project delays was extremely high. For instance, the cost of one ton mobile crawler crane alone is in excess of $800,000.00, and, depending upon capacity and added components, can sell for more than $1,000, Construction delays and investigative costs can easily run the cost into the millions of dollars. Today, manufacturers design and build stronger and lighter cranes in response to specific industry needs. Speed, utility, capacity, and reach (radius) have been improved to the point that the crane has become an indispensable workhorse for construction. Therefore, a thorough understanding of cranes, their capabilities and limitations is critically important for everyone involved in construction today. The crane can perform safely and economically when operated within the design parameters set by the manufacturer. Due to significant advances in lifting technology, crane operators, site supervisors, and safety professionals need to keep abreast of modern crane technology and changes in operating procedures to help them recognize problems before potentially unsafe conditions lead to accidents that result in injuries and/or fatalities, as well as equipment damages. With these factors in mind, the need for a better understanding of crane operations and the implementation of appropriate maintenance schedules is evident in preventing accidents. A recent study indicates that although mechanical failures represent only 11% of the causes of crane accidents, they usually result in the major accidents involving injuries, fatalities, substantial material costs, and usually spectacular media coverage. 2 Safety Services Company

5 Studies and analyses of crane accidents involving mechanical failure show they are frequently due to a lack of preventive maintenance or adequate training and/or experience on the part of the personnel involved. It is important that not only crane operators but also other personnel working with cranes receive training in crane operations. Cranes and associated rigging equipment must be inspected regularly to identify any existing or potentially unsafe conditions. In addition, preventive maintenance must be performed as required by the crane manufacturer and/or the supplier to ensure safe crane operation. The inspections performed by OSHA compliance officers and/or other safety professionals also can play an important role by identifying hazards as well as safe crane operations. This chapter addresses major issues related to the crane itself and provides some basic information on crane capacities and inspection criteria for OSHA compliance. Since it would be difficult to fully address all types of cranes available in today's market, two types of cranes typically found on construction sites are discussed in this section. Some of the issues encountered during inspections cover the following three areas: Basic Crane Operations Lifting principles/mechanics and some operational criteria. Typical Crane inspection Checklist Listing of critical items and components recommended for periodic inspection. Regulations OSHA regulations and applicable ASME/ANSI and PCSA standards. This section also contains general guidelines for crane inspections, as well as some suggested operational considerations and inspection items recognized by a number of construction companies. Cranes are designed for both general use and for specific purposes. Similar to the vast automobile industry, crane manufacturers produce similar models or types of cranes for the same purpose, often with different sizes of the same model of crane. Each type, model, or size of crane manufactured, may have different operating controls and require specialized operator training, individualized inspection criteria, and different preventive maintenance schedules. Two commonly used cranes, a hydraulic rough terrain crane and a crawler lattice boom friction crane, are used as examples for comparison in this chapter. There are several significant differences between these two cranes, primarily in boom hoist and load line controls. The somewhat smooth operation of the boom control adjustments on the hydraulic cranes may suggest falsely to the novice operator or inspector that it is a simple crane to operate. On the other hand, the lattice boom friction cranes' movement of its boom, or its adjustment in load position tend to be a little jerky requiring more skill and experience to operate smoothly. Another clear difference between the two types of cranes is their load charts. Due to the fixed boom length, the lattice boom friction crane has a somewhat simplified load chart. This requires extensive motion control and an anticipation of boom movement to accurately lift or place loads. Conversely, the hydraulic crane's load charts are more extensive or complicated due to the variations in boom length, thus requiring more training in the multiple charts available. The differences between these two types of cranes are significant enough to require specific training on each type of crane. Crane operators cannot be expected to be totally knowledgeable and proficient in the operation of the many diverse types of cranes available today. They cannot be expected to move from one type of crane to another without adequate education and training on the specifics of each piece of equipment. Safety Services Company 3

6 Training and Safety Requirements Moving large, heavy loads is crucial to today's manufacturing and construction industries. Considerable technology has been developed for these operations, including careful training and extensive workplace precautions. To a crane operator, few experiences can be as frightening as when a crane becomes unbalanced while a load is being lifted or when the crane collapses under the weight of an excessive load. There are significant safety issues to be considered, both for the operators of the diverse "lifting" devices, and for workers in proximity to them. The following references aid in recognizing and evaluating lifting and hoisting hazards in the workplace. Safety measures employers should take regarding cranes Employers must permit only thoroughly trained and competent workers to operate cranes. Operators should know what they are lifting and what it weighs. For example, the rated capacity of mobile cranes varies with the length of the boom and the boom radius. When a crane has a telescoping boom, a load may be safe to lift at a short boom length or a short boom radius, but may overload the crane when the boom is extended and the radius increases. To reduce the hazard of injury, follow these precautions: Equip all cranes that have adjustable booms with boom angle indicators. Provide cranes with telescoping booms with some means to determine boom lengths unless the load rating is independent of the boom length. Post load rating charts in the cab of cab-operated cranes. (All cranes do not have uniform capacities for the same boom length and radius in all directions around the chassis of the vehicle.) Require workers to always check the crane s load chart to ensure that the crane will not be overloaded by operating conditions. Instruct workers to plan lifts before starting them to ensure that they are safe. Tell workers to take additional precautions and exercise extra care when operating around power lines. Teach workers that outriggers on mobile cranes must rest on firm ground, on timbers, or be sufficiently cribbed to spread the weight of the crane and the load over a large enough area. (Some mobile cranes cannot operate with outriggers in the traveling position.) Direct workers to always keep hoisting chains and ropes free of kinks or twists and never wrapped around a load. Train workers to attach loads to the load hook by slings, fixtures, and other devices that have the capacity to support the load on the hook. Instruct workers to pad sharp edges of loads to prevent cutting slings. Teach workers to maintain proper sling angles so that slings are not loaded in excess of their capacity. Ensure that all cranes are inspected frequently by persons thoroughly familiar with the crane, the methods of inspecting the crane, and what can make the crane unserviceable. Crane activity, the severity of use, and environmental conditions should determine inspection schedules. Ensure that the critical parts of a crane such as crane operating mechanisms, hooks, air, or hydraulic system components and other load-carrying components are inspected daily for any maladjustment, deterioration, leakage, deformation, or other damage. 4 Safety Services Company

7 Safe use of slings As an employer, you must designate a competent person to conduct inspections of slings before and during use, especially when service conditions warrant. In addition, you must ensure that workers observe the following precautions when working with slings: Damaged or defective slings must be removed from service immediately. Do not shorten slings with knots or bolts or other makeshift devices. Do not kink sling legs. Do not load slings beyond their rated capacity. Keep suspended loads clear of all obstructions. Remain clear of loads about to be lifted and suspended. Do not engage in shock loading. Avoid sudden crane acceleration and deceleration when moving suspended loads. Mobile Cranes Lifting Principles There are four basic lifting principles that govern a crane's mobility and safety during lifting operations: Center of Gravity The center of gravity of any object is the point in the object where its weight can be assumed to be concentrated or, stated in another way, it is the point in the object around which its weight is evenly distributed. The location of the center of gravity of a mobile crane depends primarily on the weight and location of its heaviest components (boom, carrier, upperworks, and counterweight). Leverage Cranes use the principle of leverage to lift loads. Rotation of the upperworks (cab, boom, counterweight, load) changes the location of the crane's center of gravity, its leverage point or fulcrum. As the upperworks rotates, the leverage of a mobile crane fluctuates. This rotation causes the crane's center of gravity to change and causes the distance between the crane's center of gravity and its tipping axis to also change. Stability can be affected by the fluctuating leverage the crane exerts on the load as it swings. The crane's rated capacity is therefore altered in the load chart to compensate for those changes in leverage. Provided the ground is capable of supporting the load, a crane can be made more stable by moving the tipping axis further away from its center of gravity. The extra stability gained by moving the tipping axis can then be used to carry larger/heavier loads. INCREASED STABILITY = MORE LOAD Stability Is the relationship of the load weight, angle of the boom and its radius (distance from the cranes center of rotation to the center of load) to the center of gravity of the load. The stability of a crane could also be affected by the support on which the crane is resting. A crane's load rating is generally developed for operations under ideal conditions, i.e., a level firm surface. Unlevel surfaces or soft ground therefore must be avoided. In areas where soft ground poses a support problem for stability, mats and or blocking should be used to distribute a crane's load and maintain a level, stable condition. Safety Services Company 5

8 In addition to overturning (stability failure), cranes can fail structurally if overloaded enough. Structural failure may occur before a stability failure. In other words, a mobile crane's structure may fail long before it tips. As loads are added beyond its rated capacity, a crane may fail structurally before there is any sign of tipping. Structural failure is not limited to total fracture; it includes all permanent damage such as overstressing, bending and twisting of any of the components. When a crane is overstressed, the damage may not be apparent. Nevertheless, a structural failure has occurred and overstressed components are then subject to catastrophic failure at some future time. Structural Integrity The crane's main frame, crawler track and/or outrigger supports, boom sections, and attachments are all considered part of the structural integrity of lifting. In addition, all wire ropes, including stationary supports or attachment points, help determine lifting capacity and are part of the overall structural integrity of a crane's lifting capacity. The following elements may also affect structural integrity: The load chart capacity in relationship to stability; The boom angle limitations which affect stability and capacity; and The knowledge of the length of boom and radius in determining capacity. Stability failures are foreseeable, but in structural failure it is almost impossible to predict what component will fail at any given time. No matter what the cause, if the crane is overloaded, structural failure can occur. Operational Considerations Cranes are carefully designed, tested, and manufactured for safe operation. When used properly they can provide safe reliable service to lift or move loads. Because cranes have the ability to lift heavy loads to great heights, they also have an increased potential for catastrophic accidents if safe operating practices are not followed. Crane operators and personnel working with cranes need to be knowledgeable of basic crane capacities, limitations, and specific job site restrictions, such as location of overhead electric power lines, unstable soil, or high wind conditions. Personnel working around crane operations also need to be aware of hoisting activities or any job restrictions imposed by crane operations, and ensure job site coordination of cranes. Crane inspectors therefore should become aware of these issues and, prior to starting an inspection, take time to observe the overall crane operations with respect to load capacity, site coordination, and any job site restrictions in effect. Requirements for Mobile Cranes OSHA Construction Requirements A review of the OSHA crane standards provide a basis for a crane inspection. Construction crane standards requirements are found in Subpart N, 29 CFR Some key requirements state that: (1) The employer shall comply with the manufacturer's specifications and limitations applicable to the operation of any and all cranes and derricks. Where manufacturer's specifications are not available, the limitations assigned to the equipment shall be based on the determinations of a qualified engineer competent in this field and such determinations will be appropriately documented and recorded. Attachments used with cranes shall not exceed the capacity, rating, or scope recommended by the manufacturer. 6 Safety Services Company

9 (2) Rated load capacities, and recommended operating speeds, special hazard warnings, or instruction, shall be conspicuously posted on all equipment. Instructions or warnings shall be visible to the operator while he is at his control station. (5) The employer shall designate a competent person who shall inspect all machinery and equipment prior to each use, and during use, to make sure it is in safe operating condition. Any deficiencies shall be repaired, or defective parts replaced, before continued use. (6) A thorough, annual inspection of the hoisting machinery shall be made by a competent person, or by a government or private agency recognized by the U.S. Department of Labor. The employer shall maintain a record of the dates and results of inspections for each hoisting machine and piece of equipment. (15) Except where electrical distribution and transmission lines have been de-energized and visibly grounded at point of work or where insulating barriers, not a part of or an attachment to the equipment or machinery, have been erected to prevent physical contact with the lines, equipment or machines shall be operated approximate to power lines only in accordance with the following: (i) For lines rated 50 kv or below, minimum clearance between the lines and any part of the crane or load shall be 10 feet; (ii) For lines rated over 50 kv, minimum clearance between the lines and any part of the crane or load shall be 10 feet plus 0.4 inch for each 1 kv over 50 kv, or twice the length of the line insulator, but never less than 10 feet; (iv) A person shall be designated to observe clearance of the equipment and give timely warning for all operations, where it is difficult for the operator to maintain the desired clearance by visual means; (vi) Any overhead wire shall be considered to be an energized line unless and until the person owning such line or the electrical utility authorities indicate that it is not an energized line and it has been visibly grounded. (16) No modifications or additions which affect the capacity or safe operation of the equipment shall be made by the employer without the manufacturer's written approval. In no case shall the original safety factor of the equipment be reduced. To supplement the OSHA standards for Cranes and Derricks, references are made to applicable ASME/ANSI and PCSA standards. The ASME/ANSI "B30" series of standards address: "Cranes", "Cableways", "Derricks", "Hoists", "Hooks", "Jacks" and "Slings". For the purpose of this section ASME/ANSI B30.5, "Mobile and Locomotive Cranes" will be the reference document for the crane inspection criteria. References also are made to the Power Crane Shovel Association (PCSA), Standard No. 2, "Mobile Hydraulic Crane Standards." Mobile Crane Inspections This section on crane inspection is included for the purpose of giving contractors a perspective on what an OSHA Compliance Officer will be looking for to ensure compliance with regulations. Since cranes impact such a large segment of work going on at any job site, crane inspections must include a survey or walk around of the entire operation that questions how the crane will be operating and how other crafts will be effected by working with and around the crane. Observation of crane operations prior to an inspection, or simply asking how cranes have or will be used, can indicate possible problem areas that may need a closer review during the inspection process. Safety Services Company 7

10 Pre-inspection Before the actual inspection begins, the Compliance Officer will gather some general information about the crane operator's qualifications & the crane's certifications, such as: Operator Qualifications The Compliance Officer will observe the operator in action and when the opportunity permits ask a few question concerning the cranes capacity and restrictions imposed, either due to activity involved in or functional limitations. Crane Records The Compliance Officer will ask for inspection and maintenance records and verify that the appropriate operator's manual and load charts are available for that particular crane in use. 8 Safety Services Company

11 Crane Setup In the Compliance Officer s initial survey of crane operations, he or she will look for crane stability, physical obstructions to movement or operation, and proximity of electrical power lines, as well as the following: Leveling Has the crane operator set the crane up level and in a position for safe rotation and operation? Outriggers Are the outriggers, where applicable, extended and being used in accordance with manufacturer's recommendations? Stability The relationship of the load weight, angle of boom, and its radius (the distance from the cranes center of rotation to the center of load) to the center of gravity of the load. Also, the condition of crane loading where the load moment acting to overturn the crane is less than the moment of the crane available to resist overturning. Structural Integrity The crane's main frame, crawler, track and outrigger supports, boom sections, and attachments are all considered part of structural components of lifting. In addition, all wire ropes, including stationary supports, help determine lifting capacity and are part of the structural elements of crane operations. Electrical Hazards Working around or near electrical power lines is one of the most dangerous practices for crane operations. The OSHA requirements limit crane operations to a minimum clearance of 10 feet. Cranes should not be used to handle materials or loads stored under electric power lines. In addition, operation of mobile cranes near de-energized electric power lines is not recommended until the following steps have been taken: Load Charts The power company or owner of the power line has de-energized the lines. The lines are visibly grounded and appropriately marked at jobsite. Durable warning signs are installed at the operator's station and on the outside of the crane identifying the clearance requirements between the crane/load and electrical power lines. A qualified representative of the power company or owner of the electrical power line are on the job site to verify that the power lines have been de-energized or properly grounded. Load Charts are the principle set of instructions and requirements for boom configurations and parts of line which establish crane capacity for safe crane operations. Availability The crane operator must have in his/her possession the appropriate load charts related to the crane in use and for the loads being lifted. Correct Use The crane operator must show adequate understanding and proficient use of the load charts as related to the equipment in use and the loads being lifted. Safety Services Company 9

12 Safe Operating Precautions As stated above, cranes are carefully designed, tested, and manufactured for safe operations. When used properly they can provide safe reliable service to lift or move loads. Because cranes have the ability to lift heavy loads to great heights, they also have an increased potential for catastrophic accidents if safe. operating practices are not followed. Accidents can be avoided by careful job planning. The person in charge must have a clear understanding of the work to be performed and consider all potential dangers at the job site. A safety plan must be developed for the job and must be explained to all personnel involved in the lift. Before operations begin for the day, a walkaround inspection needs to be conducted to ensure that the machine is in proper working condition. Only qualified and properly designated people shall operate the crane. Regular inspections are important, they provide a means of detecting potential hazards or conditions that could contribute to a sequence of events leading to an accident. Safe, reliable, and the economic operation of lifting equipment, cannot be ensured without regular safety inspections and thorough preventive maintenance programs. A thorough inspection program can forecast maintenance needs or potential equipment failures or malfunctions. The lack of such a program could result in serious deterioration of the equipment that might lead to excessive replacement, or repair charges, as well as an increased potential for accidents. Due to the wide variation of conditions under which a crane may operate, it is impossible for the manufacturer to determine inspection intervals appropriate for every situation. Inspection intervals recommended in manufacturer's publications represent minimum intervals for average operating conditions. More frequent inspection intervals should be required if use and site conditions are severe and warrant it. Inspections are also designed as maintenance checks and/or as a verification that proper repairs or modifications of equipment have been completed which, if not checked could affect capacities as well as personnel safety. Since the initial load rating for cranes was determined and set under ideal conditions, inspections are required by manufacturers to guarantee optimal operating efficiency and capacity as determined by the load charts. The American National Standards Institute, ANSI B30.5, 1968, and OSHA both require inspections be divided into two categories: frequent and periodic. In addition to the performance of these regular inspections, equipment is required to be inspected and tested to ensure that it is capable of safe and reliable operation when initially set or placed in service and after any major repairs or any design modification. Inspection Types A. Frequent Inspections (daily to monthly intervals) Frequent inspections are usually performed at the start of each shift by the operator who walks around the crane looking for defects or problem areas. Components that have a direct bearing on the safety of the crane and whose status can change from day to day with use must be inspected daily, and when possible, observed during operation for any defects that could affect safe operation. To help determine when the crane is safe to operate, daily inspections should be made at the start of each shift. Frequent inspections should include, but are not limited to the following: Check that all exposed moving parts are guarded. A removed guard may indicate that a mechanic is still working on part of the crane. Check to make sure any swing area of the cab is barricaded to prevent crush hazards, and that the lift area is barricaded and designated as a controlled access zone. 10 Safety Services Company

13 Visually inspect each component of the crane used in lifting, swinging, or lowering the load or boom for any defects that might result in unsafe operation. Inspect all wire rope (including standing ropes), sheaves, drums rigging, hardware, and attachments. Remember, any hook that is deformed or cracked must be removed from service. Hooks with cracks, excessive throat openings of 15%, or hook twists of 10 degrees or more, must be removed from service. Check for freedom of rotation of all swivels. Visually inspect the boom and jib for straightness and any evidence of physical damage, such as cracking, bending, or any other deformation of the welds. Look for corrosion under any attachments that are connected to the chords and lacing. Watch carefully for cracking or flaking of paint. This may indicate fatigue of the metal which often precedes a failure. On lattice booms, look for bent lacing. If they are kinked or bent, the main chord can lose substantial support in that area. When lacing is bent, the ends also tend to draw together which pulls the main chords out of shape. This precaution is especially important on tubular booms where every component must be straight and free from any dents. Do not attempt to straighten these members by hammering or heating them and drawing them out. They must be cut out and replaced with lacing to the manufacturer's specifications, procedures, and approval. Inspect tires for cuts, tears, breaks, and proper inflation. Visually inspect the crane for fluid leaks, both air and hydraulic. Visually check that the crane is properly lubricated. The fuel, lubricating oil, coolant and hydraulic oil reservoirs should be filled to proper levels. Check that the crane is equipped with a fully charged fire extinguisher and that the operator knows how to use it. Check all functional operating mechanisms such as: sheaves, drums, brakes, locking mechanisms, hooks, the boom, jib, hook rollers brackets, outrigger components, limit switches, safety devices, hydraulic cylinders, instruments, and lights. Check the turntable connections for weld cracks and loose or missing bolts. If they are loose, there is a good chance that they have been stretched. When checking the outriggers be sure that neither the beams nor the cylinders are distorted. Check that the welds are not cracked and that both the beams and cylinders extend and retract smoothly and hold the load. Check the condition of the floats, and check that they are securely attached. Inspect and test all brakes and clutches for proper adjustment and operation. Always inspect boom hoist lockout and other operator aids, such as anti-two-block devices (ATB) and load moment indicators (LMI), for proper operation and calibration. While the engine is running, check all gauges and warning lights for proper readings and operate all controls to see that they are functioning properly. Check for any broken or cracked glass that may affect the view of the operator. B. Periodic Inspections (1 to 12 month intervals) The periodic inspection procedure is intended to determine the need for repair or replacement of components to keep the machine in proper operating condition. It includes those items listed for daily inspections as well as, but not limited to, structural defects, excessive wear, and hydraulic or air leaks. Inspection records of the inspected crane shall be maintained monthly on critical items in use, such as brakes, crane hooks, and ropes. These inspection records should include, the date of inspection, the signature of the person who performed the inspection, and the serial number, or other identifier. This inspection record should be kept readily available for review. The manufacturer's maintenance and inspection records, forms/checklist, or equivalent should be used. Safety Services Company 11

14 Inspect the entire crane for structural damage. Be careful to check for distortion or cracks in main frame, outrigger assemblies, and structural attachments of the upperworks to the carrier. Inspect all welded connections for cracks. Inspect the main chords and lacings and other structural items for paint flaking and cracking which may indicate potential failure, as well as for dents, bends, abrasions, and corrosion. Check hydraulic booms for bending, side sway, or droop. Check for deformed, cracked, or corroded members in the load/stress bearing structure. Magnetic particle or other suitable crack detecting inspection should be performed at least once each year by an inspection agency retained by the owner. Inspection reports should be requested and retained in the crane file. Inspect cracked or worn sheaves and drums. Inspect for worn, cracked, or distorted parts such as: pins, bearings, shafts, gears, rollers, locking devices, hook roller brackets, removable outrigger attachments lugs, and welds. Inspect for excessive wear on brake and clutch system parts, linings, pawls, and ratchets. Inspect all indicators, including load and boom angle indicators, for proper operation and calibration. Inspect all power plants for proper operation. Inspect for excessive wear on drive sprockets and/or chain stretch. Inspect for correct action of steering, braking, and locking devices. Check that the counterweight is secure. Check that the identification number is permanently and legibly marked on jibs, blocks, equalizer beams, and all other accessories. Inspect all hydraulic and pneumatic hoses, fittings, and tubing. Any deterioration of any system component will cause the inspector to question whether further use would constitute a safety hazard. Conditions, such as the following, require replacement of the part in question: Any evidence of oil or air leaks on the surfaces of flexible hoses or at the point at which the hose in question joins the metal end couplings. Any abnormal deformation of the outer covering of hydraulic hose, including any enlargement, local or otherwise. Any leakage at connections which cannot be eliminated by normal tightening. Any evidence of abrasive wear that could have reduced the pressure retaining capabilities of the hose or tube effected. The cause of the rubbing or abrasion must be immediately eliminated. Starting the Inspection Since most crane inspections begin with a general walk-around and observation of the overall crane set up and operation, followed by a specific inspection of items or components, the following guidelines are presented in that order. The first section addresses the general items and operational considerations when inspecting any type of crane, followed by the specific inspection items for two specific types of cranes: Grove Rough Terrain 45 Ton (hydraulic) and Manitowoc Ton Crawler (lattice boom friction) cranes. 12 Safety Services Company

15 In general, the following should be considered when inspecting any crane: Review all inspection and maintenance documents for the crane being inspected, including the crane manufacturer's inspection and maintenance requirements. Conduct a walkaround inspection, paying particular attention to mechanical systems leaks or damage (oil, hydraulic, air) and structural deficiencies. Look at crane cab for properly marked controls, damaged instruments and for properly displayed and legible load charts. Ask the operator, ground crew (riggers), and/or supervisors appropriate questions on load charts, rigging and load weight determinations, and capacities. Request the operator to raise and lower the boom/load line, where practical, and inspect, from the cab position, the running line or rope of the main hoist drum and secondary line or jib line. Check brake action and its ability to stop. If practical, request the operator to lower boom to look at the condition of booms sections, lacing, lifting components, anti-two-block devices, jib back stops, and the condition of the hook. Check crane set up and stability of outriggers on hydraulics and/or the effectiveness of cribbing on crawlers. If possible, request that the crane be rotated to check all clearances and overall stability. Specific Inspection Items and References The following table identifies the specific inspection items for cranes as well as a brief description and purpose to help the inspector to have a better understanding of what and why the item is being inspected. ITEM 1.) Manufacturer's Operating and Maintenance Manuals 2.) Guarding 3.) Swing Clearance Protection 4.) High-Voltage Warning Sign 5.) Boom Stops INSPECTION ITEMS & DESCRIPTION DESCRIPTION / PURPOSE Manufacturer's operating and maintenance manuals shall accompany all mobile hoisting equipment. These manuals set forth specific inspection, operation and maintenance criteria for each mobile crane and lifting capacity. All exposed moving parts such as gears, chains, reciprocating or rotating parts are guarded or isolated. Materials for guarding rear swing area. High-voltage warning signs displaying restrictions and requirements should be installed at the operator's station and at strategic locations on the crane. Shock absorbing or hydraulic type boom stops are installed in a manner to resist boom overturning. 6.) Jib Boom Stops Jib stops are restraints to resist overturning. 7.) Boom Angle Indicator 8.) Boom Hoist Disconnect, Automatic Boom Hoist Shutoff 9.) Two-Blocking Device 10.) Power Controlled Lowering A boom angle indicator readable for the operator station is installed accurately to indicate boom angle. A boom hoist disconnect safety shutoff or hydraulic relief to automatically stops the boom hoist when the boom reaches a predetermined high angle. Cranes with telescoping booms should be equipped with a two-blocking damage prevention feature that has been tested on-site in accordance with manufacturers requirements. All cranes hydraulic and fixed boom used to hoist personnel must be equipped with two-blocking devices on all hoistlines intended to be used in the operation. The anti-two blocking device has automatic capabilities for controlling functions that may cause a two-blocking condition. Cranes for use to hoist personnel must be equipped for power controlled lowering operation on all hoistlines. Check clutch, chains, and sprockets for wear. Safety Services Company 13

16 11.) Leveling Indicating Device 12.) Sheaves 13.) Main Hoist and Auxiliary Drums System 14.) Main Boom, Jib Boom, Boom Extension 15.) Load Hooks and Hook Blocks 16.) Hydraulic Hoses Fittings and Tubing 17.) Outriggers 18.) Load Rating Chart A device or procedure for leveling the crane must be provided. Sheave grooves shall be smooth and free from surface defects, cracks, or worn places that could cause rope damage. Flanges must not be broken, cracked, or chipped. The bottom of the sheave groove must form a close fitting saddle for the rope being used. Lower load blocks must be equipped with close fitting guards. Almost every wire rope installation has one or more sheaves ranging from traveling blocks with complicated reeving patterns to equalizing sheaves where only minimum rope movement is noticed. Drum crushing is a rope condition sometimes observed which indicates deterioration of the rope. Spooling is that characteristic of a rope which affects how it wraps onto and off a drum. Spooling is affected by the care and skill with which the first larger of wraps is applied on the drum. Manufacturer's criteria during inspection usually specify: Minimum number of wraps to remain on the drum. Condition of drum grooves Condition of flanges at the end of drum. Rope end attachment. Spooling characteristics of rope. Rope condition. Boom jibs, or extensions, must not be cracked or corroded. Bolts and rivets must be tight. Certification that repaired boom members meet manufacturers original design standard shall be documented. Non-certified repaired members shall not be used until recertified. Hooks and blocks must be permanently labeled with rated capacity. Hooks and blocks are counterweighted to the weight of the overhaul line from highest hook position. Hooks must not have cracks or throat openings more than 15% of normal or twisted off center more than 10 o from the longitudinal axis. All hooks used to hoist personnel must be equipped with effective positive safety catches especially on hydraulic cranes. Flexible hoses must be sound and show no signs of leaking at the surface or its junction with the metal and couplings. Hoses must not show blistering or abnormal deformation to the outer covering and no leaks at threaded or clamped joints that cannot be eliminated by normal tightening or recommended procedures. There should be no evidence of excessive abrasion or scrubbing on the outer surfaces of hoses, rigid tubing, or hydraulic fittings. Outrigger number, locations, types and type of control are in accordance with manufacturer's specifications. Outriggers are designed and operated to relieve all weight from wheels or tracks within the boundaries of the outriggers. If not, the manufacturer's specifications and operating procedures must be clearly defined. Outriggers must be visible to the operator or a signal person during extension or setting. A durable rating chart(s) with legible letters and figures must be attached to the crane in a location accessible to the operator while at the controls. The rating charts shall contain the following: A full and complete range of manufacturer's crane loading ratings at all stated operating radii. Optional equipment on the crane such as outriggers and extra counterweight which effect ratings. A work area chart for which capacities are listed in the load rating chart, i.e. over side, over rear, over front. Weights of auxiliary equipment, i.e. load block, jibs, boom extensions. A clearly distinguishable list of ratings based on structural, hydraulic or other factors rather than stability. A list of no-load work areas. A description of hoistline reeving requirements on the chart or in operator's manual. 14 Safety Services Company

17 19.) Wire Rope 20.) Cab Main hoist and auxiliary wire rope inspection should include examining for Broken wires. Excess wear. External damage from crushing, kinking, cutting or corrosion. Contains all crane function controls in additional to mechanical boom angle indicators, electric wipers, dash lights, warning lights and buzzers, fire extinguishers, seat belts, horn, and clear unbroken glass. 21.) Braking Systems 22.) Turntable/Crane Body Truck cranes and self-propelled cranes mounted on rubber-tired chassis or frames must be equipped with a service brake system, secondary stopping emergency brake system and a parking brake system. Unless the owner/operator can show written evidence that such systems were not required by the standards or regulations in force at the date of manufacture and are not available from the manufacturer. The braking systems must have been inspected and tested and found to be in conformance with applicable requirements. Crawler cranes are provided with brakes or other locking devices that effectively hold the machine stationary on level grade during the working cycle. The braking system must be capable of stopping and holding the machine on the maximum grade recommended for travel. The brakes or locks are arranged to engage or remain engaged in the event of loss of operating pressure or power. Make sure that the rotation point of a crane gears and rollers are free of damage, wear and properly adjusted and the components are securely locked and free of cracks or damage. The swing locking mechanism must be functional (pawl, pin) and operated in the cab. 23.) Counterweight The counterweight must be approved and installed according to manufacturer's specifications with attachment points secured. The following table shows the items that need to be examined for the Grove Rough Terrain 45 Ton Hydraulic Crane and their corresponding applicable OSHA 1926 and ANSI B30.5 Standards. ROUGH TERRAIN 45 TON HYDRAULIC CRANE STANDARD ( ) 550(a)(8) 550(a)(13)(ii) & (iii) 550(a)(4) INSPECTION ITEMS Outriggers 1. Lubrication 2. Structural Condition 3. Pressure hoses/connections Turntable/Crane Body 1. Ensure Level/Stability 2. Wear/Gear/Teeth/Rollers 3. Cracks 4. Bolts/Ensure securely Attached Counter Weight 1. Proper Size 2. Attachment Connection/Bolts Engine Housing 1. Cleanliness/No Rags/Trash 2. Gear/Machinery Guards 3. Clear Access/Walkways 4. Brakes/Clutch Adjustments 5. Hand Signal Illustration 6. Swing Break ANSI B & & (Fig.16) Safety Services Company 15

18 550(a)(12) 550(a)(14)(i) 550(a)(2) 550(a)(13) & 550(a)(13)(iii) 550(b) 550(a)(7) 550(a)(7)(v) (a)(9) 550(a)(15) Cab 1. Glass/Visibility 2. Instruments and Controls 3. Functioning Horn (warning signal) 4. Fire Extinguisher 5. Appropriate Load Charts and Warning Signs 6. Proper and Adequate Access (steps/walkway) Drum 1. Proper Size and Spoiling of Hoistlines 2. Drum Sides/Shields for cracks 3. Dogs/Pawls/Locking Devices 4. Drum Rotation vs. Control Motion Boom Sections (Boom sections correspond with crane model) Boom Stops Hoist Line Guides/Sheaves Jib Attachment/Backstops/Belly Slings Sheave System 1. Ensure hoist line and sheave size match 2. Worn 3. Lubrication/Move freely Load/Auxiliary Hook and Block System 1. Sheaves Function Smoothly 2. Hook Rotates Freely/Lubricated 3. Proper Becket 4. Properly Reeved Wire Rope/Hoist Line 1. Overall Condition 2. End Connections 3. Lubrication 4. Clips Safety Devices 1. Anti-Two Block Devices 2. Boom Backstop Devices 3. Swing Radius Warning Devices 4. Job or Site Specific Devices/system (near electric power/personnel hoisting platforms) Additional references: 550(a)(1) ---- Crane used in accordance with manufactures specification. 550(a)(5) ---- Inspection: Competent Person. 550(a)(6) ---- Annual Inspection Record. 550(a)(16) ---- No modifications without written approval of manufacturer & & (Fig. 17) The following table shows the items that need to be examined for the Manitowoc Ton Lattice Boom Crawler Crane and their corresponding applicable OSHA 1926 and ANSI B30.5 Standards. 16 Safety Services Company

19 STANDARD ( ) 550(a)(8) 550(a)(13)(ii) & (iii) (a)(4) 550(a)(12) - 550(a)(14)(i) 550(a)(2) 550(a)(13) & 550(a)(13)(iii) 550(b) 150 TON LATTICE BOOM CRAWLER CRANE INSPECTION ITEMS Track Crawler System 1. Lubrication 2. Connection Bolts 3. Drive Chain (slack & wear) Turntable/Crane Body (Upper Works) 1. Assure Level/Stability 2. Wear/Gear/Teeth/Rollers 3. Cracks 4. Bolts/Pins - Assure Securely Attached Counter Weight 1. Proper Size 2. Attachment Connection/Bolts Engine Housing 1. Cleanliness/No Rags/Trash 2. Gear/Machinery Guards 3. Clear Access/Walkways 4. Brakes/Clutch Adjustments 5. Hand Signal Illustration 6. Swing Break Cab 1. Glass/Visibility 2. Instruments and Controls 3. Functioning Horn (warning signal) 4. Fire Extinguisher 5. Appropriate Load Charts and Warning Signs 6. Proper and Adequate Access (steps/walkway) Hoist Drum System 1. Proper Size and Spoiling of Hoistlines 2. Drum Sides/Shields for Cracks 3. Dogs/Pawls/Locking Devices 4. Drum Rotation vs. Control Motion 5. Clutch and Brakes Boom Sections(Boom sections correspond with crane model) 1. Base Section Properly Attached 2. Pin Clearance 3. Boom Lacing/Cord Damage 4. Boom Stops 5. Gantry System A-Frame 6. Hoist Line Guides/Sheaves 7. Boom Section Connection Pins/Keys 8. Boom and Gantry Support System 9. Jib Attachment/Backstops/Belly Slings (Jib Security Device) Sheave System 1. Ensure Hoistline and Sheave Size Match 2. Worn 3. Lubrication/Move freely Load/Auxiliary Hook and Block System 1. Sheaves Function Smoothly 2. Hook Rotates Freely/Lubricated 3. Proper Becket 4. Properly Reeved ANSI B & & (Fig.16) & & Safety Services Company 17

20 550(a)(7) 550(a)(7)(v) (a)(9) 550(a)(15) Additional references: Wire Rope/Hoist Line 1. Overall Condition 2. End Connections 3. Lubrication 4. Clips Safety Devices 1. Anti-Two Block Devices 2. Boom Backstop Devices 3. Swing Radius Warning Devices 4. Job or Site Specific Devices/System/Program for work near electric power and use of personnel hoisting platforms) 550(a)(1) ---- Crane used in accordance with manufactures specification. 550(a)(5) ---- Inspection: Competent Person. 550(a)(6) ---- Annual Inspection Record. 550(a)(16) ---- No modifications without written approval from manufacturers (Fig. 17) GENERAL TERMS & DEFINITIONS Auxiliary Hoist Axis of Rotation Boom Boom Angle Indicator Boom Stops Brake Block Crane Counterweight Deck Drum Gantry Headache Ball Holding Brake Jib Load Load Block Main Hoist A supplemental hoisting unit, usually of lower load rating and higher speed than the main hoist. The vertical axis around which the crane's superstructure rotates. In cranes and derricks usage, an inclined spar, strut, or other long member supporting the hoisting tackle. Also defined as a structural member attached to the revolving superstructure used for guiding and acting as a support for the load. An accessory device that measures the angle of the boom base section centerline to horizontal. A devise used to limit the angle of the boom at its highest position. A device used for retarding or stopping motion by friction or power means. Sheaves or grooved pulleys in a frame provided with hook, eye, and strap. A machine consisting of a rotating superstructure for lifting and lowering a load and moving it horizontally on either rubber tires or crawler treads. Weights used for balancing loads and the weight of the crane in providing stability for lifting. The revolving superstructure or turntable bed. The spool or cylindrical member around which cables are wound for raising and lowering loads. A structural frame work (also known as an A Frame) mounted on the revolving superstructure of the crane to which the boom supporting cables are reeved. A heavy weight attached above the hook on a single line or whip line to provide sufficient weight to lower the hook when unloaded. A brake that automatically sets to prevent motion when power is off. An extension attached to the. boom point to provide added boom length for lifting specified loads. The weight of the object being lifted or lowered, including load block, ropes, slings, shackles, and any other ancillary attachment. The assembly of the hook or shackles, swivel, sheaves, pins, and frame suspended from the boom point. Hoist system or boom used. for raising and lowering loads up to maximum rated capacity. 18 Safety Services Company

21 Mechanical Load Brake Outriggers An automatic type of friction brake used for controlling loads in the lowering direction. This device requires torque from the motor to lower a load but does not impose additional loads on the motor when lifting a load. Support members attached to the crane's carrier frame which are used to the crane and may be blocked up to increase stability. Pawl Pendants Radius Reeving Running Sheave Superstructure Test Load Two-Block Quadrant of Operation Also known as "dog". It is a gear locking device for positively holding the gears against movement. Stationary cables used to support the boom. The horizontal distance from the axis of rotation of the crane's superstructure to the center of the suspended load. The path that a rope takes in adapting itself to all sheaves and drums of a piece of equipment. Sheaves that rotate as the hook is raised or lowered The rotating frame, gantry and boom or other operating equipment. Any load or force, expressed in pounds, used for testing or certifying the limitations within acceptable tolerances of the anticipated load. The condition in which the lower load lock or hook assembly comes in contact with the upper load block or boom point sheave assembly. The area of operation that the lift is being made in. Usually divided into four quadrants, i.e. front, rear and side(s) - left side and right side. General Load Charts and Operational Considerations General Load Chart Manufacturer's operating notes supplied with the machine contain important information concerning proper set-up, operation and additional points that need to be considered when calculating load handling capacities of cranes. Mistakes in calculating capacity can cause accidents. Several factors to be considered when calculating a cranes load capacity, including the following: A. Load Radius: the horizontal distance between the center of the crane rotation to center of the load. B. Boom length: including the jib, swing away extension or any other attachments that may increase length of the boom. C. Parts of line: D. Quadrant of operation: the area of operation that the lift is being made in; note different quadrants usually have lower lifting capacities. E. Boom angle: the angle formed between the horizontal plane of rotation and center line of the boom. F. Weight of any attachments: jib, lattice extension or auxiliary boom point. G. Weight of handling devices: ball, block, and/or any necessary rigging. Operational Considerations: A. When working at boom lengths or radii between the figures shown on the load capacity chart, the next lower capacity rating should be used. It is dangerous to guess the capacity for boom lengths or radii between those listed on the rating plate. B. It is very dangerous to lift a load without knowing whether it is within the rated capacity while expecting the crane to start to tip to warn of an overload. Cranes may suddenly tip over or the boom may collapse if the load is too heavy. Safety Services Company 19

22 C. Always stay within the rated capacity. Operators must reduce the load capacity under adverse field conditions until, it is determined, the machine can safely handle the lift. D. Loads shall not be allowed to exceed rated load capacity and working radius. E. Do not use counterweights heavier than the manufacturer's recommended weight. F. Even a light wind can blow the load out of control, collapse booms, or tip machines. G. Winds aloft can be much stronger than at ground level. H. Proper precautions shall be taken when the velocity of wind exceeds 20-mph. I. Crane capacity can be adversely effected when the machine set is not level. J. Do not lift loads when winds create an unsafe or hazardous condition. Booms should be lowered, if possible, under high wind conditions. K. Foot pedal brake locks are furnished on some cranes to allow the operator to rest his legs when suspending the load for short periods of time. Operators should keep their feet on the pedals while foot pedal brake locks are in use. Brakes may cool allowing the load to fall. L. No one, except the oiler, instructor, or designated person should be allowed on a crane with the operator when the crane is in operation. OSHA CFR Cranes and Derricks (a) General requirements. (1) The employer shall comply with the manufacturer's specifications and limitations applicable to the operation of any and all cranecs and derricks. Where manufacturer's specifications are not available, the limitations assigned to the equipment shall be based on the determinations of a qualified engineer competent in this field and such determinations will be appropriately documented and recorded. Attachments used with cranes shall not exceed the capacity, rating, or scope recommended by the manufacturer. (2) Rated load capacities, and recommended operating speeds, special hazard warnings, or instruction, shall be conspicuously posted on all equipment. Instructions or warnings shall be visible to the operator while he is at his control station. (3) [Reserved] (4) Hand signals to crane and derrick operators shall be those prescribed by the applicable ANSI standard for the type of crane in use. An illustration of the signals shall be posted at the job site. (5) The employer shall designate a competent person who shall inspect all machinery and equipment prior to each use, and during use, to make sure it is in safe operating condition. Any deficiencies shall be repaired, or defective parts replaced, before continued use. (6) A thorough, annual inspection of the hoisting machinery shall be made by a competent person, or by a government or private agency recognized by the U.S. Department of Labor. The employer shall maintain a record of the dates and results of inspections for each hoisting machine and piece of equipment. (7) Wire rope shall be taken out of service when any of the following conditions exist: 20 Safety Services Company

23 (i) In running ropes, six randomly distributed broken wires in one lay or three broken wires in one strand in one lay; (ii) Wear of one-third the original diameter of outside individual wires. Kinking, crushing, bird caging, or any other damage resulting in distortion of the rope structure; (iii) Evidence of any heat damage from any cause; (iv) Reductions from nominal diameter of more than one-sixty-fourth inch for diameters up to and including five-sixteenths inch, one-thirty-second inch for diameters three-eighths inch to and including one-half inch, three-sixty-fourths inch for diameters nine-sixteenths inch to and including three-fourths inch, onesixteenth inch for diameters seven-eighths inch to 1 1/8 inches inclusive, threethirty-seconds inch for diameters 1 1/4 to 1 1/2 inches inclusive; (v) In standing ropes, more than two broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection. (vi) Wire rope safety factors shall be in accordance with American National Standards Institute B or SAE J (8) Belts, gears, shafts, pulleys, sprockets, spindles, drums, fly wheels, chains, or other reciprocating, rotating, or other moving parts or equipment shall be guarded if such parts are exposed to contact by employees, or otherwise create a hazard. Guarding shall meet the requirements of the American National Standards Institute B Rev., Safety Code for Mechanical Power Transmission Apparatus. (9) Accessible areas within the swing radius of the rear of the rotating superstructure of the crane, either permanently or temporarily mounted, shall be barricaded in such a manner as to prevent an employee from being struck or crushed by the crane. (10) All exhaust pipes shall be guarded or insulated in areas where contact by employees is possible in the performance of normal duties. (11) Whenever internal combustion engine powered equipment exhausts in enclosed spaces, tests shall be made and recorded to see that employees are not exposed to unsafe concentrations of toxic gases or oxygen deficient atmospheres. (12) All windows in cabs shall be of safety glass, or equivalent, that introduces no visible distortion that will interfere with the safe operation of the machine. (13) (i) Where necessary for rigging or service requirements, a ladder, or steps, shall be provided to give access to a cab roof. (ii) Guardrails, handholds, and steps shall be provided on cranes for easy access to the car and cab, conforming to American National Standards Institute B30.5. (iii) Platforms and walkways shall have anti-skid surfaces. (14) Fuel tank filler pipe shall be located in such a position, or protected in such manner, as to not allow spill or overflow to run onto the engine, exhaust, or electrical equipment of any machine being fueled. (i) An accessible fire extinguisher of 5BC rating, or higher, shall be available at all operator stations or cabs of equipment. (ii) All fuels shall be transported, stored, and handled to meet the rules of Subpart F of this part. When fuel is transported by vehicles on public highways, Department of Transportation rules contained in 49 CFR Parts 177 and 393 concerning such vehicular transportation are considered applicable. (15) Except where electrical distribution and transmission lines have been deenergized and visibly grounded at point of work or where insulating barriers, not a part of or an attachment to the equipment or machinery, have been erected to Safety Services Company 21

24 prevent physical contact with the lines, equipment or machines shall be operated proximate to power lines only in accordance with the following: (i) For lines rated 50 kv. or below, minimum clearance between the lines and any part of the crane or load shall be 10 feet; (ii) For lines rated over 50 kv., minimum clearance between the lines and any part of the crane or load shall be 10 feet plus 0.4 inch for each 1 kv. over 50 kv., or twice the length of the line insulator, but never less than 10 feet; (iii) In transit with no load and boom lowered, the equipment clearance shall be a minimum of 4 feet for voltages less than 50 kv., and 10 feet for voltages over 50 kv., up to and including 345 kv., and 16 feet for voltages up to and including 750 kv. (iv) A person shall be designated to observe clearance of the equipment and give timely warning for all operations where it is difficult for the operator to maintain the desired clearance by visual means; (v) Cage-type boom guards, insulating links, or proximity warning devices may be used on cranes, but the use of such devices shall not alter the requirements of any other regulation of this part even if such device is required by law or regulation; (vi) Any overhead wire shall be considered to be an energized line unless and until the person owning such line or the electrical utility authorities indicate that it is not an energized line and it has been visibly grounded; (vii) Prior to work near transmitter towers where an electrical charge can be induced in the equipment or materials being handled, the transmitter shall be deenergized or tests shall be made to determine if electrical charge is induced on the crane. The following precautions shall be taken when necessary to dissipate induced voltages: [a] The equipment shall be provided with an electrical ground directly to the upper rotating structure supporting the boom; and [b] Ground jumper cables shall be attached to materials being handled by boom equipment when electrical charge is induced while working near energized transmitters. Crews shall be provided with nonconductive poles having large alligator clips or other similar protection to attach the ground cable to the load. [c] Combustible and flammable materials shall be removed from the immediate area prior to operations. (16) No modifications or additions which affect the capacity or safe operation of the equipment shall be made by the employer without the manufacturer's written approval. If such modifications or changes are made, the capacity, operation, and maintenance instruction plates, tags, or decals, shall be changed accordingly. In no case shall the original safety factor of the equipment be reduced. (17) The employer shall comply with Power Crane and Shovel Association Mobile Hydraulic Crane Standard No. 2. (18) Sideboom cranes mounted on wheel or crawler tractors shall meet the requirements of SAE J743a (19) All employees shall be kept clear of loads about to be lifted and of suspended loads. 22 Safety Services Company

25 (b) Crawler, locomotive, and truck cranes. (1) All jibs shall have positive stops to prevent their movement of more than 5 deg. above the straight line of the jib and boom on conventional type crane booms. The use of cable type belly slings does not constitute compliance with this rule. (2) All crawler, truck, or locomotive cranes in use shall meet the applicable requirements for design, inspection, construction, testing, maintenance and operation as prescribed in the ANSI B , Safety Code for Crawler, Locomotive and Truck Cranes. However, the written, dated, and signed inspection reports and records of the monthly inspection of critical items prescribed in section of the ANSI B standard are not required. Instead, the employer shall prepare a certification record which includes the date the crane items were inspected; the signature of the person who inspected the crane items; and a serial number, or other identifier, for the crane inspected. The most recent certification record shall be maintained on file until a new one is prepared. (c) Hammerhead tower cranes. (1) Adequate clearance shall be maintained between moving and rotating structures of the crane and fixed objects to allow the passage of employees without harm. (2) Each employee required to perform duties on the horizontal boom of hammerhead tower cranes shall be protected against falling by guardrails or by a personal fall arrest system in conformance with Subpart M of this part. (3) Buffers shall be provided at both ends of travel of the trolley. (4) Cranes mounted on rail tracks shall be equipped with limit switches limiting the travel of the crane on the track and stops or buffers at each end of the tracks. (5) All hammerhead tower cranes in use shall meet the applicable requirements for design, construction, installation, testing, maintenance, inspection, and operation as prescribed by the manufacturer. (d) Overhead and gantry cranes. (1) The rated load of the crane shall be plainly marked on each side of the crane, and if the crane has more than one hoisting unit, each hoist shall have its rated load marked on it or its load block, and this marking shall be clearly legible from the ground or floor. (2) Bridge trucks shall be equipped with sweeps which extend below the top of the rail and project in front of the truck wheels. (3) Except for floor-operated cranes, a gong or other effective audible warning signal shall be provided for each crane equipped with a power traveling mechanism. (4) All overhead and gantry cranes in use shall meet the applicable requirements for design, construction, installation, testing, maintenance, inspection, and operation as prescribed in the ANSI B , Safety Code for Overhead and Gantry Cranes. (e) Derricks. All derricks in use shall meet the applicable requirements for design, construction, installation, inspection, testing, maintenance, and operation as prescribed in American National Standards Institute B , Safety Code for Derricks. (f) Floating cranes and derricks. (1) Mobile cranes mounted on barges. (i) When a mobile crane is mounted on a barge, the rated load of the crane shall not exceed the original capacity specified by the manufacturer. Safety Services Company 23

26 (ii) A load rating chart, with clearly legible letters and figures, shall be provided with each crane, and securely fixed at a location easily visible to the operator. (iii) When load ratings are reduced to stay within the limits for list of the barge with a crane mounted on it, a new load rating chart shall be provided. (iv) Mobile cranes on barges shall be positively secured. (2) Permanently mounted floating cranes and derricks. (i) When cranes and derricks are permanently installed on a barge, the capacity and limitations of use shall be based on competent design criteria. (ii) A load rating chart with clearly legible letters and figures shall be provided and securely fixed at a location easily visible to the operator. (iii) Floating cranes and floating derricks in use shall meet the applicable requirements for design, construction, installation, testing, maintenance, and operation as prescribed by the manufacturer. (3) Protection of employees working on barges. The employer shall comply with the applicable requirements for protection of employees working onboard marine vessels specified in (g) Crane or derrick suspended personnel platforms. (1) Scope, application and definitions. (i) Scope and application. This standard applies to the design, construction, testing, use and maintenance of personnel platforms, and the hoisting of personnel platforms on the load lines of cranes or derricks. (ii) Definitions. For the purposes of this paragraph (g), the following definitions apply: [A] Failure means load refusal, breakage, or separation of components. [B] Hoist (or hoisting) means all crane or derrick functions such as lowering, lifting, swinging, booming in and out or up and down, or suspending a personnel platform. [C] Load refusal means the point where the ultimate strength is exceeded. [D] Maximum intended load means the total load of all employees, tools, materials, and other loads reasonably anticipated to be applies to a personnel platform or personnel platform component at any one time. [E] Runway means a firm, level surface designed, prepared and designated as a path of travel for the weight and configuration of the crane being used to lift and travel with the crane suspended platform. An existing surface may be used as long as it meets these criteria. (2) General requirements. The use of a crane or derrick to hoist employees on a personnel platform is prohibited, except when the erection, use, and dismantling of conventional means of reaching the worksite, such as a personnel hoist, ladder, stairway, aerial lift, elevating work platform or scaffold, would be more hazardous or is not possible because of structural design or worksite conditions. (3) Cranes and derricks. (i) Operational criteria. [A] Hoisting of the personnel platform shall be performed in a slow, controlled, cautious manner with no sudden movements of the crane or derrick, or the platform. 24 Safety Services Company

27 [B] Load lines shall be capable of supporting, without failure, at least seven times the maximum intended load, except that where rotation resistant rope is used, the lines shall be capable of supporting without failure, at least ten times the maximum intended load. The required design factor is achieved by taking the current safety factor of 3.5 (required under paragraph (b)(2)) of this section and applying the 50 percent derating of the crane capacity which is required by paragraph (g)(3)(i)[f] of this section. [C] Load and boom hoist drum brakes, swing brakes, and locking devices such as pawls or dogs shall be engaged when the occupied personnel platform is in a stationary working position. [D] The crane shall be uniformly level within one percent of level grade and located on firm footing. Cranes equipped with outriggers shall have them all fully deployed following manufacturer's specifications, insofar as applicable, when hoisting employees. [E] The total weight of the loaded personnel platform and related rigging shall not exceed 50 percent of the rated capacity for the radius and configuration of the crane or derrick. [F] The use of machines having live booms (booms in which lowering is controlled by a brake without aid from other devices which slow the lowering speeds) is prohibited. (ii) Instruments and components. [A] Cranes and derricks with variable angle booms shall be equipped with a boom angle indicator, readily visible to the operator. [B] Cranes with telescoping booms shall be equipped with a device to indicate clearly to the operator, at all times, the boom's extended length or an accurate determination of the load radius to be used during the lift shall be made prior to hoisting personnel. [C] A positive acting device shall be used which prevents contact between the load block or overhaul ball and the boom tip (anti-two-blocking device), or a system shall be used which deactivates the hoisting action before damage occurs in the event of a two-blocking situation (two-block damage prevention feature). [D] The load line hoist drum shall have a system or device on the power train, other than the load hoist brake, which regulates the lowering rate of speed of the hoist mechanism (controlled load lowering.) Free fall is prohibited. (4) Personnel Platforms. (i) Design criteria. [A] The personnel platform and suspension system shall be designed by a qualified engineer or a qualified person competent in structural design. [B] The suspension system shall be designed to minimize tipping of the platform due to movement of employees occupying the platform. [C] The personnel platform itself, except the guardrail system and personnel fall arrest system anchorages, shall be capable of supporting, without failure, its own weight and at least five times the maximum intended load. Criteria for guardrail systems and personal fall arrest system anchorages are contained in Subpart M of this part. Safety Services Company 25

28 (ii) Platform specifications. [A] Each personnel platform shall be equipped with a guardrail system which meets the requirements of Subpart M, and shall be enclosed at least from the toeboard to mid-rail with either solid construction or expanded metal having openings no greater than 1/2 inch (1.27 cm). [B] A grab rail shall be installed inside the entire perimeter of the personnel platform. [C] Access gates, if installed, shall not swing outward during hoisting. [D] Access gates, including sliding or folding gates, shall be equipped with a restraining device to prevent accidental opening. [E] Headroom shall be provided which allows employees to stand upright in the platform. [F] In addition to the use of hard hats, employees shall be protected by overhead protection on the personnel platform when employees are exposed to falling objects. [G] All rough edges exposed to contact by employees shall be surfaced or smoothed in order to prevent injury to employees from punctures or lacerations. [H] All welding of the personnel platform and its components shall be performed by a qualified welder familiar with the weld grades, types and material specified in the platform design. [I] The personnel platform shall be conspicuously posted with a plate or other permanent marking which indicates the weight of the platform, and its rated load capacity or maximum intended load. (iii) Personnel platform loading. [A] The personnel platform shall not be loaded in excess of its rated load capacity, When a personnel platform does not have a rated load capacity then the personnel platform shall not be loaded in excess of its maximum intended load. [B] The number of employees occupying the personnel platform shall not exceed the number required for the work being performed. [C] Personnel platforms shall be used only for employees, their tools and the materials necessary to do their work, and shall not be used to hoist only materials or tools when not hoisting personnel. [D] Materials and tools for use during a personnel lift shall be secured to prevent displacement. [E] Materials and tools for use during a personnel lift shall be evenly distributed within the confines of the platform while the platform is suspended. (iv) Rigging. [A] When a wire rope bridle is used to connect the personnel platform to the load line, each bridle leg shall be connected to a master link or shackle in such a manner to ensure that the load is evenly divided among the bridle legs. [B] Hooks on overhaul ball assemblies, lower load blocks, or other attachment assemblies shall be of a type that can be closed and locked, eliminating the hook throat opening. Alternatively, an alloy anchor type shackle with a bolt, nut and retaining pin may be used. 26 Safety Services Company

29 [C] Wire rope, shackles, rings, master links, and other rigging hardware must be capable of supporting, without failure, at least five times the maximum intended load applied or transmitted to that component. Where rotation resistant rope is used, the slings shall be capable of supporting without failure at least ten times the maximum intended load. [D] All eyes in wire rope slings shall be fabricated with thimbles. [E] Bridles and associated rigging for attaching the personnel platform to the hoist line shall be used only for the platform and the necessary employees, their tools and the materials necessary to do their work and shall not be used for any other purpose when not hoisting personnel. (5) Trial lift, inspection and proof testing. (i) A trial lift with the unoccupied personnel platform loaded at least to the anticipated lift weight shall be made from ground level, or any other location where employees will enter the platform to each location at which the personnel platform is to be hoisted and positioned. This trial lift shall be performed immediately prior to placing personnel on the platform. The operator shall determine that all systems, controls and safety devices are activated and functioning properly; that no interferences exist; and that all configurations necessary to reach those work locations will allow the operator to remain under the 50 percent limit of the hoist's rated capacity. Materials and tools to be used during the actual lift can be loaded in the platform, as provided in paragraphs (g)(4)(iii)[d], and [E] of this section for the trial lift. A single trial lift may be performed at one time for all locations that are to be reached from a single set up position. (ii) The trial lift shall be repeated prior to hoisting employees whenever the crane or derrick is moved and set up in a new location or returned to a previously used location. Additionally, the trial lift shall be repeated when the lift route is changed unless the operator determines that the route change is not significant (i.e. the route change would not affect the safety of hoisted employees.) (iii) After the trial lift, and just prior to hoisting personnel, the platform shall be hoisted a few inches and inspected to ensure that it is secure and properly balanced. Employees shall not be hoisted unless the following conditions are determined to exist: [A] Hoist ropes shall be free of kinks; [B] Multiple part lines shall not be twisted around each other; [C] The primary attachment shall be centered over the platform, and [D] The hoisting system shall be inspected if the load rope is slack to ensure all ropes are properly stated on drums and in sheaves. (iv) A visual inspection of the crane or derrick, rigging, personnel platform, and the crane or derrick base support or ground shall be conducted by a competent person immediately after the trial lift to determine whether the testing has exposed any defect or produced any adverse effect upon any component or structure. (v) Any defects found during inspections which create a safety hazard shall be corrected before hoisting personnel. (vi) At each job site, prior to hoisting employees on the personnel platform, and after any repair or modification, the platform and rigging shall be proof tested to 125 percent of the platform's rated capacity by holding it in a suspended position for five minutes with the test load evenly distributed on the platform (this may be Safety Services Company 27

30 done concurrently with the trial lift). After proof testing, a competent person shall inspect the platform and rigging. Any deficiencies found shall be corrected and another proof test shall be conducted. Personnel hoisting shall not be conducted until the proof testing requirements are satisfied. (6) Work practices. (i) Employees shall keep all parts of the body inside the platform during raising lowering, and positioning. This provision does not apply to an occupant of the platform performing the duties of a signal person. (ii) Before employees exit or enter a hoisted personnel platform that is not landed, the platform shall be secured to the structure where the work is to be performed, unless securing to the structure creates an unsafe situation. (iii) Tag lines shall be used unless their use creates an unsafe condition. (iv) The crane or derrick operator shall remain at the controls at all times when the crane engine is running and the platform is occupied. (v) Hoisting of employees shall be promptly discontinued upon indication of any dangerous weather conditions or other impending danger. (vi) Employees being hoisted shall remain in continuous sight of and in direct communication with the operator or signal person. In those situations where direct visual contact with the operator is not possible, and the use of a signal person would create a greater hazard for the person, direct communication alone such as by radio may be used. (vii) Except over water, employees occupying the personnel platform shall use a body belt/harness system with lanyard appropriately attached to the lower load block or overhaul ball, or to a structural member within the personnel platform capable of supporting a fall impact for employees using the anchorage. When working over water the requirements of shall apply. (viii) No lifts shall be made on another of the crane's or derrick's loadlines while personnel are suspended on a platform. (7) Traveling. (i) Hoisting of employees while the crane is traveling is prohibited, except for portal, tower and locomotive cranes, or where the employer demonstrates that there is no less hazardous way to perform the work. (ii) Under any circumstances where a crane would travel while hoisting personnel, the employer shall implement the following procedures to safeguard employees: [A] Crane travel shall be restricted to a fixed track or runway; [B] Travel shall be limited to the load radius of the boom used during the lift; and [C] The boom must be parallel to the direction of travel. [D] A complete trial run shall be performed to test the route of travel before employees are allowed to occupy the platform. This trial run can be performed at the same time as the trial lift required by paragraph (g)(5)(i) of this section which tests the route of the lift. [E] If travel is done with a rubber tired-carrier, the condition and air pressure of the tires shall be checked. The chart capacity for lifts on rubber shall be used for application of the 50 percent reduction of rated capacity. Notwithstanding paragraph (g)(5)(i)(e) of this section, outriggers may be partially retracted as necessary for travel. 28 Safety Services Company

31 (8) Pre-lift meeting. (i) A meeting attended by the crane or derrick operator, signal person(s) (if necessary for the lift), employee(s) to be lifted, and the person responsible for the task to be performed shall be held to review the appropriate requirements of paragraph (g) of this section and the procedures to be followed. (ii) This meeting shall be held prior to the trial lift at each new work location, and shall be repeated for any employees newly assigned to the operation Selection and use of work practices (c) Working on or near exposed energized parts. (3) Overhead lines. If work is to be performed near overhead lines, the lines shall be deenergized and grounded, or other protective measures shall be provided before work is started. If the lines are to be deenergized, arrangements shall be made with the person or organization that operates or controls the electric circuits involved to deenergize and ground them. If protective measures, such as guarding, isolating, or insulating, are provided, these precautions shall prevent employees from contacting such lines directly with any part of their body or indirectly through conductive materials, tools, or equipment. Note: The work practices used by qualified persons installing insulating devices on overhead power transmission or distribution lines are covered by of this Part, not by through of this Part. Under paragraph (c)(2) of this section, unqualified persons are prohibited from performing this type of work. (i) Unqualified persons. [A] When an unqualified person is working in an elevated position near overhead lines, the location shall be such that the person and the longest conductive object he or she may contact cannot come closer to any unguarded, energized overhead line than the following distances: [1] For voltages to ground 50kV or below feet (305 cm) [2] For voltages to ground over 50kV feet (305 cm) plus 4 inches (10 cm) for every 10kV over 50kV. [B] When an unqualified person is working on the ground in the vicinity of overhead lines, the person may not bring any conductive object closer to unguarded, energized overhead lines than the distances given in paragraph (c)(3)(i)(a) of this section. Note: For voltages normally encountered with overhead power line, objects which do not have an insulating rating for the voltage involved are considered to be conductive. (ii) Qualified persons. When a qualified person is working in the vicinity of overhead lines, whether in an elevated position or on the ground, the person may not approach or take any conductive object without an approved insulating handle closer to exposed energized parts than shown in Table S-5 unless: [A] The person is insulated from the energized part (gloves, with sleeves if necessary, rated for the voltage involved are considered to be insulation of the person from the energized part on which work is performed) or [B] The energized part is insulated both from all other conductive objects at a different potential and from the person or [C] The person is insulated from all conductive objects at a potential different from that of the energized part. Safety Services Company 29

32 Table S-5 - Approach Distances for Qualified Employees - Alternating Currents Voltage range (phase to phase) 300V and less Over 300V, not over 750V Over 750V, not over 2kV Over 2kV, not over 15kV Over 15kV, not over 37kV Over 37kV, not over 87.5kV Over 87.5kV, not over 121kV Over 121kV, not over 140kV (iii) Vehicular and mechanical equipment. Minimum approach distance Avoid Contact 1 ft. 0 in. (30.5 cm) 1 ft. 6 in. (46 cm) 2 ft. 0 in. (61 cm) 3 ft. 0 in. (91 cm) 3 ft. 6 in. (107 cm) 4 ft. 0 in. (122 cm) 4 ft. 6 in. (137 cm) [A] Any vehicle or mechanical equipment capable of having parts of its structure elevated near energized overhead lines shall be operated so that a clearance of 10 ft. (305 cm) is maintained. If the voltage is higher than 50kV, the clearance shall be increased 4 in. (10 cm) for every 10kV over that voltage. However, under any of the following conditions, the clearance may be reduced: [1] If the vehicle is in transit with its structure lowered, the clearance may be reduced to 4 ft. (122 cm). If the voltage is higher than 50kV, the clearance shall be increased 4 in. (10 cm) for every 10 kv over that voltage. [2] If insulating barriers are installed to prevent contact with the lines, and if the barriers are rated for the voltage of the line being guarded and are not a part of or an attachment to the the vehicle or its raised structure, the clearance may be reduced to a distance within the designed working dimensions of the insulating barrier. [3] If the equipment is an aerial lift insulated for the voltage involved, and if the work is performed by a qualified person, the clearance (between the uninsulated portion of the aerial lift and the power line) may be reduced to the distance given in Table S-5. [B] Employees standing on the ground may not contact the vehicle or mechanical equipment or any of its attachments, unless: [1] The employee is using protective equipment rated for the voltage or [2] The equipment is located so that no un-insulated part of its structure (that portion of the structure that provides a conductive path to employees on the ground) can come closer to the line than permitted in paragraph (c)(3)(iii) of this section. [C] If any vehicle or mechanical equipment capable of having parts of its structure elevated near energized overhead lines is intentionally grounded, employees working on the ground near the point of grounding may not stand at the grounding location whenever there is a possibility of overhead line contact. Additional precautions, such as the use of barricades or insulation, shall be taken to protect employees from hazardous ground potentials, depending on earth resistivity and fault currents, which can develop within the first few feet or more outward from the grounding point. 30 Safety Services Company

33 SITE LAYOUT, SITE-SPECIFIC ERECTION PLAN AND CONSTRUCTION SEQUENCE (a) Approval to begin steel erection. Before authorizing the commencement of steel erection, the controlling contractor shall ensure that the steel erector is provided with the following written notifications: (1) The concrete in the footings, piers and walls and the mortar in the masonry piers and walls has attained, on the basis of an appropriate ASTM standard test method of field-cured samples, either 75 percent of the intended minimum compressive design strength or sufficient strength to support the loads imposed during steel erection. (2) Any repairs, replacements and modifications to the anchor bolts were conducted in accordance with (b). (b) Commencement of steel erection. A steel erection contractor shall not erect steel unless it has received written notification that the concrete in the footings, piers and walls or the mortar in the masonry piers and walls has attained, on the basis of an appropriate ASTM standard test method of field-cured samples, either 75 percent of the intended minimum compressive design strength or sufficient strength to support the loads imposed during steel erection. Written notifications. A copy of the written notification(s) required by this section must be maintained on the site by the controlling contractor for review until completion of the project. (c) Site layout. The controlling contractor shall ensure that the following is provided and maintained: (1) Adequate access roads into and through the site for the safe delivery and movement of derricks, cranes, trucks, other necessary equipment, and the material to be erected and means and methods for pedestrian and vehicular control. Exception: this requirement does not apply to roads outside of the construction site. (2) A firm, properly graded, drained area, readily accessible to the work with adequate space for the safe storage of materials and the safe operation of the erector's equipment. (d) Pre-planning of overhead hoisting operations. All hoisting operations in steel erection shall be pre-planned to ensure that the requirements of (d) are met. (e) Site-specific erection plan. Where employers elect, due to conditions specific to the site, to develop alternate means and methods that provide employee protection in accordance with (c)(5), (a)(4) or (e)(4), a site-specific erection plan shall be developed by a qualified person and be available at the work site. Guidelines for establishing a site-specific erection plan are contained in Appendix A to this subpart. Site-Specific Erection Plan. In addition to and not in lieu of the provisions of 29 CFR (e), the steel erection contractor must develop and implement a written sitespecific erection plan. (1) The site-specific erection plan must: (a) Be developed by a qualified person; (b) Identify the site; (c) Be available at the work site; and Qualified person (also defined in ) means one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter, the work, or the project. (d) Be signed by the qualified person responsible for its development and any modification(s). Safety Services Company 31

34 NOTE: The site-specific erection plan does not have to be developed by an engineer, or resemble an engineering report. (2) The site-specific erection plan must contain the following: (a) A description of the procedures that will be used to comply with (a). Consider the dead weight of the structure, the weight and working reactions of all static and dynamic loads placed on it, and all external forces that may be applied such as wind and reactions by erection equipment. NOTE: There is a presumption that some form of temporary guying or bracing is necessary to provide lateral stability to the structural steel framing as it is being erected. Accordingly, the employer has the burden of establishing that the structural steel framing is inherently stable during erection and/or the sequence of erection, plumbing, bolting and decking is such that structural stability is maintained at all times and no temporary guying or bracing is needed. Such determination must be documented in the site-specific erection plan. (b) A description of the procedures and work practices that will be used to protect employees from falls and other hazards where it is necessary to walk/work on suspended loads. Employee(s) are allowed on suspended loads only when a competent person has determined that it is the safest way to accomplish a specific task or there is no other way to do the work. Appendix A to Subpart R Guidelines for Establishing the Components of a Sitespecific Erection Plan: Non-Mandatory Guidelines for Complying with (e) (a) General. This appendix serves as a guideline to assist employers who elect to develop a site-specific erection plan in accordance with (e) with alternate means and methods to provide employee protection in accordance with (e), (c)(5), (a)(4) and (e)(4). (b) Development of a site-specific erection plan. Pre-construction conference(s) and site inspection(s) are held between the erector and the controlling contractor, and others such as the project engineer and fabricator before the start of steel erection. The purpose of such conference(s) is to develop and review the site-specific erection plan that will meet the requirements of this section. (c) Components of a site-specific erection plan. In developing a site-specific erection plan, a steel erector considers the following elements: (1) The sequence of erection activity, developed in coordination with the controlling contractor, which includes the following: (i) Material deliveries: (ii) Material staging and storage; and (iii) Coordination with other trades and construction activities. (2) A description of the crane and derrick selection and placement procedures, including: (i) Site preparation; (ii) Path for overhead loads; and (iii) Critical lifts, including rigging supplies and equipment. (3) A description of steel erection activities and procedures, including the following: (i) Stability considerations requiring temporary bracing and guying; (ii) Erection bridging terminus point; 32 Safety Services Company

35 (iii) Anchor rod (anchor bolt) notifications regarding repair, replacement and modifications; (iv) Columns and beams (including joists and purlins); (v) Connections; (vi) Decking; and (vii) Ornamental and miscellaneous iron. (4) A description of the fall protection procedures that will be used to comply with (5) A description of the procedures that will be used to comply with (6) A description of the special procedures required for hazardous non-routine tasks. (7) A certification for each employee who has received training for performing steel erection operations as required by (8) A list of the qualified and competent persons. (9) A description of the procedures that will be utilized in the event of rescue or emergency response. (d) Other plan information. The plan: (1) Includes the identification of the site and project; and (2) Is signed and dated by the qualified person(s) responsible for its preparation and modification. Safety Services Company 33

36 Company: SITE-SPECIFIC CRANE OPERATION PLAN & CHECKLIST Job Name & Location: Job Supervisor: Project Engineer: Crane Operator: Date(s) on Site: Qualified Person: Qualified Rigger: Scope of Work Roofing Sq. Ft.: Tons: Siding Sq. Ft.: Tons: Decking Sq. Ft.: Tons: General Miscellaneous Sq. Ft.: Tons: General Description of Work: Site Layout 1. Has controlling contractor provided adequate access to site? Yes No 2. Is laydown area firm, properly graded, well drained, and accessible? Yes No Pre-Construction Site Conference Has a Pre-Construction Site Conference been held? Yes No Please list those attending: Sequence of Crane Activity 1. Give a general sequence of Crane activities: 2. Material delivery date: 3. How will activities be coordinated with other trades: Cranes 1. Crane Type: 2. Crane Brand: 3. Crane Capacity: 4. How is the site prepared for the crane? 5. How many different locations will the crane have and where are they? 6. What is the path for overhead loads? 7. How will employees be notified of overhead loads? 8. Are there any critical lifts? (75% of capacity or dual crane) Yes No a. How many? 9. Describe critical lifts: 10. Are lift permits attached for critical lifts? Yes No 11. Are lift permits attached for all lifts over 5,000 lbs. Yes No 34 Safety Services Company

37 Fall Protection Has fall protection training been documented? Is a Competent Person on-site at all times? Were fall protection systems designed by a Qualified Person? Falling Object Protection Method for securing loose items aloft: Yes No Yes No Yes No Are all personnel wearing hard hats? Yes No Are Crane operation areas properly barricaded? Yes No Hazardous Non-Routine Tasks Are Job Hazard Analyses performed on all non-routine tasks? Yes No Attach Job Hazard Analyses. Training Certification Are all personnel properly trained for performing job-related activities? Yes No Are all personnel properly trained for the use of fall protection systems? Yes No Attach documentation of training. List of Qualified and Competent Persons 1. Qualified Person for fall protection system design: 2. Qualified Rigger: 3. Crane Operator: 4. Crane Inspector: 5. Fall Protection Competent Person: Emergency Rescue Procedures Self-Rescue Emergency Response Team Manbasket Stair Tower First Aid Trained Personnel Hoists Aerial Lifts Other Other Considerations Specific to this Site: Comments: Completed By: Reviewed By: Date: Date: Safety Services Company 35

38 CRANE/BOOM INSPECTION REPORT Company Name: Job Site Location: Date: Time: Job Foreman/Supervisor: Person(s) Making Inspection: Subcontractors On-Site (List Name and Trade): Equipment Type: Equipment #s: Manufacturer: Columns: A = Adequate at time of inspection B = Needs consideration C = Needs immediate attention N/A = Not applicable GENERAL JOB SITE INFORMATION: Copy of safety manual on site? OSHA 300 and 301 Forms Posted and Complete? Are required OSHA Posters posted? Phone number to nearest medical center posted? Toolbox talks up-to-date? Copy of HazCom program & MSDS sheets on site? Work areas properly signed and barricaded? CRANE/BOOM Carrier Vehicle: Motor Crank case oil is clean and full Engine coolant is about 2 inches below cap Clutch /Converter Drive Line Transmission fluid at proper level Frame Brakes Differentials Outriggers Cab Steering Lights Tires properly inflated (look on load charts for Manufacturing recommendations) Cuts or bulges in the tires Rims & Bolts Fire Extinguisher Glass Warning Lights Access HYDRAULICS: Relief Valve(s) Restrictor Valves Pipe Lines Hose Lines Outrigger Cylinders A B C N/A Action Taken 36 Safety Services Company

39 HYDRAULICS (Continued): A B C N/A Action Taken Boom Hoist Cylinder Boom Crowd Cylinder Control Valves Swing Motor Hoist Motor Pumps Bearings Check hydraulic oil level Mounting Bolts Swing Gear Swing Pinion Seals - Hydraulic BOOM: Shipper Welds Boom Welds Pins - Boom Pivot Support Roller Boom Pins Bearing Sheave Load Block Sheave Load Block Hook Boom Main Section WEDGE SOCKETS: Wire rope size and wedge socket is a proper match? Dead end of wire rope extends at least 9 inches beyond wedge socket? Dead end of the wire rope is secured properly? SHEAVES: The wire rope is seated properly in the sheaves? The wire rope keepers (keeps cable from coming out of the sheaves) are in good shape? Check the bolts on the sheave plates for tightness? Check for any weld cracks? Signs of bent or buckled panels or parts? OPERATIONAL CHECKS: Crane operators logs up-to-date and on-site? Operators familiar with load charts? Load chart is in cab? Hand signal charts on crane? Handrails leading into crane cab are good condition? Out rigger pads not cracked? Outriggers extended & swing radius barricades in place? Hydraulic hoses in good condition? The drum cable is properly spooled? Boom angle indicator is available and working? Swing through 360 degrees, does boom angle indicator stay the same throughout rotation? Does boom swing break work properly? Back-up alarm is working? Does the horn work? Engine started, gauges are checked & working properly? Out riggers are extended out; working properly? Safety Services Company 37

40 OPERATIONAL CHECKS (Continued): A B C N/A Action Taken Crane is leveled, working properly? Boom up, unlock the swing break, does it swing when level? Extend out the boom, are all sections extending evenly? Brakes & brake systems check out? Safety pressure relief valves check out? Is equipment a safe distance from edge of trench or excavation? MATERIALS HANDLING: Chains and slings inspected and tagged as required? Employees kept from under suspended loads? Materials properly stored or stacked? Employees using proper lifting methods? Tag lines used to guide loads? HOOKS Replace If: If hook throat opening has increased by 15% If load-bearing point (throat) has been worn by 10%, the hook must be replaced. If hook tip is twisted by 10 or more, the hook must be replaced. Check for excessive damage from chemicals and for deformation and cracks. Check for and replace damaged, inoperative, or missing hook latches. Unsafe Conditions, Situations, Acts, or Practices Observed: Comments: Operator s Signature Signature (person(s) performing inspection/evaluation) Signature (person(s) performing inspection/evaluation) Date Date Date 38 Safety Services Company

41 RECOMMENDED HAND SIGNALS for CONTROLLING CRANE OPERATIONS HOIST LOWER STOP BOOM UP SWING BOOM DOWN MAKE MOVEMENT SLOWLY EMERGENCY STOP TRAVEL Safety Services Company 39

42 40 Safety Services Company