Associated Training Services, Corp. Crane Facts 2 The exact number of cranes being operated within the United States is unknown The best estimates put the number of mobile and tower cranes used in construction at between 95,000 and 100,000 Source: U.S. Bureau of Labor Statistics, OSHA and The National Institute for Occupational Safety and Health 3 1
The volume of crane accidents can only be estimated because the definition of accident is not universal Some businesses may include only events that result in injury or death. Others report only certain industry segments. Even the definition of crane is not universal Some exclude non-construction cranes such as industrial gantry, bridge and jib cranes Others exclude longshore or mining operations In addition, some loss reports do not include the liability aspects of crane accidents 4 The number of injuries involving cranes are estimated at 900 to 1,100 per year The average annual cost is between $205,000 and $490,000, depending on the severity To date, the most expensive crane-related injury was in Illinois, where the settlement was 29 million dollars for a quadriplegic injury Source: Construction Risk Management, Inc., Craneaccidents.com 5 Claims for damage to the crane are generally not less than $100,000 Claims estimates for crane failure while handling loads is estimated at an average of $48,000 each loss Source: Construction Risk Management, Inc., Craneaccidents.com and American Cranes and Transportation 6 2
On average 89 deaths occur annually from crane accidents 32% are caused by the victim being struck by the crane load 27% are electrocutions from contact with power lines 21% are related to assembly and disassembly of the crane 12% are boom or wire rope failure 11% are from the crane tipping over 3% are struck by the rotating superstructure of the crane 2% are falls from the crane The average cost of each death is 1.1 million dollars Between January 1 and March 31, 2009, there were 49 reported crane-related fatalities Source: Journal of Construction Engineering and Management and craneaccidents.com 7 8 Overloading Side pull Outrigger failure Hoist limitation Two-blocking Killer hooks Boombuckling Upset/overturn Unintentional turntable turning Oversteer/crabbing Control confusion Access/egress Unintentional power line contact Source: MacCollum, D.V.: Crane Hazards and Their Prevention. American Society of Safety Engineers, Des Plaines, IL (1993) 9 3
Improper assembly/dismantling Rigging failure/fall of load or lifting tackle Being struck by a moving load Being struck by the crane Source: MacCollum, D.V.: Crane Hazards and Their Prevention. American Society of Safety Engineers, Des Plaines, IL (1993) 10 Set up Supporting surfaces Power lines Understanding crane capacity Rigging failure Weather Considerations Inspection and maintenance deficiencies Operator error Signaling (communication) problems Management/engineering error 11 12 4
Obtain proper medical attention for those injured How do we stand-up the toppled crane? Obtain second crane for hoisting toppled crane Obtain sand for resetting the base of the toppled crane If our crane operator is injured, where do we get another qualified operator? Evaluate third party liabilities, damage to existing structures, lost productivity from cleanup and impact on project schedule Address the perception of the public 13 Who pays for lost production time? Who pays for the damage to the crane? Who pays for third party liabilities? Numerous studies have shown that on top of the direct costs associated with accidents, there are also many indirect costs that must be considered Research indicates an average ratio of 4:1 indirect vs. direct costs In today s litigious environment, many experts believe this ratio can be as high as 10:1 Source: OSHA, The Direct and Indirect Costs of Accidents Safety Pays 1996 14 15 5
Technical knowledge and safety procedures Regulatory requirements Manufacturer requirements Company/project requirements and procedures Training, certification, installation/removal and inspections Communication and planning Pre-project Pre-task Operational Evaluation 16 Crane safety equipment Anti-current devices Anti-upset devices Operator and rigger protection mechanisms Anti-collision devices Experience and supervision Responsibilities Accountabilities Qualifications 17 Little is said about operator responsibilities and even less is said about management responsibilities This leads to confusion when deciding fault AMERICAN Society of Mechanical Engineers (ASME) subcommittee worked for 6 years to define new responsibilities Does not require new positions Single person could have one or more roles 18 6
Crane operator Site supervisor Lift director Crane owner Crane user 19 Designated person Qualified person 20 Directly controls the crane s functions Operator is not responsible for things beyond direct control If there are doubts about safety, stop in a controlled manner Resume only when the safety issue is addressed or when directed by the lift director 21 7
Understand and apply the operator manual Understand crane s functions, limitations and operating characteristics Know site conditions that could have a negative effect on lifts and consult the lift director Check whether controls are on, off or in neutral prior to starting the crane 22 Confirm that crane configuration is correct to suit the load, site and lift Know and follow assembly/disassembly directions of the manufacturer or a qualified person Personally observe or use a signal person for outrigger setting and retraction (standard) Perform required daily inspections Note: wherever the reference (standard) appears, it is referring to something that has been in the ASME Crane Standards volume for a long time 23 Test crane controls and only use the crane if the controls work properly Report any need for adjustment or repair to designated person Follow lock out/tag out procedures Inform the lift director of any need to make adjustments to the crane capacity 24 8
Review crane requirements with the lift director before operations Ensure that the load and rigging weights have been provided Calculate or determine net capacities for configurations to be used and verify, using the chart, that crane has enough net capacity for the lift 25 Understand basic rigging but is not responsible for rigging the load or ensuring that it is rigged properly Know signals and respond to those of the appointed signal person When signals are not required, the operator is responsible for movement of crane Follow any stop signal (standard) Operate the crane in smooth and controlled manner 26 Must not operate the crane when physically or mentally unfit (standard) Must not allow attention to be diverted while actually operating the crane controls (standard) Refuse to operate crane if crane or load would enter prohibited zone of energized lines Know how to travel the crane 27 9
Enact emergency procedure if power fails during lift (standard) Follow proper procedures before leaving the crane unattended (standard) 28 Exercise supervisory control over the work site on which a crane is being used and over the work which is being performed on that site In some situations, the site supervisor and lift director could be the same person 29 Ensure that the crane meets the requirements of ASME B30.5 chapter 2 before use on site Ensure that a lift director is appointed and meets the definition of a qualified person Determine if additional regulations apply Ensure that crane operators are properly qualified per chapter 3 of ASME B30.5 30 10
Ensure that crane work and travel areas are properly prepared Ensure assembly/disassembly is supervised by a qualified person Only allow crane operation near power lines when ASME B30.5 requirements are met Ensure adverse conditions are addressed (i.e. support, wind, weather, darkness) 31 Ensure that riggers are supervised by a qualified person Ensure coordination between crane operations and other appropriate operations Only allow special lifting operations (i.e. multi-crane lift, lifting people, pick and carry) when the requirements of ASME B30.5, the manufacturer or a qualified person are met Ensure crane maintenance is performed by a designated person 32 Directly oversees the work being performed by a crane and the associated rigging crew 33 11
Must be at the jobsite during a lift Ensure that crane work and travel areas are prepared before use Ensure traffic controls are in place to restrict unauthorized access to crane work area Ensure that people involved understand their responsibilities, duties and the associated hazards 34 Appoint signal persons and inform the operator Ensure signal persons meet ASME B30.5 requirements Inform operator of weight and locations Get operator verification that weight will not exceed crane capacity Ensure that riggers are designated persons 35 Ensure load is properly rigged and balanced Ensure implementation of necessary precautions associated with special lifting operations such as multi-crane lifts, lifting people, pick and carry, barge work, etc. Only allow crane work near power lines when requirements of ASME B30.5 and site supervisor are met 36 12
Stop crane operations if an unsafe condition is discovered Address the safety concerns of the operator and accept complete responsibility if the operator is overruled At no time may the manufacturer of ASME B30.5 requirements be overruled Ensure that ASME B30.23 requirements are followed when lifting people 37 A crane lift is only as good as the communication between the signal person and the operator Most signalers do a poor job Unqualified signal people are unacceptable 38 Occupational Safety and Health Administration (OSHA) Cranes and Derricks Negotiated rulemaking Advisory Committee (C-DAC) American Society of Mechanical Engineers (ASME) 39 13
Continuous Operator concerns Signal person qualifications Testing includes Understanding crane operation and limitations Hand signals when used Voice signals when used 40 Voice signals Agreement between operator, signaler, lift director ID operator and signaler Directions from operator perspective If using voice consider complexity Essential elements for voice Hand signals posted Special signals 41 National commission for the Certification of Crane Operators (NCCCO) certification requirements Written exam Practical exam Training 42 14
Ideal conditions Level crane Static load Like new machine Freely suspended load Little or no wind Proper support Proper assembly Perfect weather Operation normal 43 44 If any conditions are not met, adjust capacity accordingly Manufacturer s specifications Individual operator s judgment How much to reduce 45 15
Wind Conditions on load charts Stronger at elevations 46 Wind=pressure on crane and load Area vs. force 47 Wind on side of boom 48 16
Wind on front of boom 49 Wind on back of boom 50 Wind decision factors Wind speed Surface area of boom and load Boom length Wind direction Manufacturer s instructions 51 17
Those operations repeated over and over High speed operation Capacity must be reduced Follow manufacturer s directions 52 Manufacturer differences Deduct amounts 53 Static vs. dynamic loads All load chart capacities are for static loads Acceleration produces hook load higher than actual weight. 54 18
Every crane movement that causes dynamic load is not accounted for by the load chart % load increase due to stopping a lowering load 55 Dynamic load is determined by mass and acceleration Static load is constant Dynamic load changes Dynamic load adds to static load 56 Factors that increase dynamic load Quick starts and stops Increased weight Operating speed How to minimize dynamic load 57 19
Machine condition categories Privately operated Bare rentals Normal wear and maintenance 58 H:\Curriculum\POWERPOINTS\MASTER POWERPOINTS\CRANE\Understanding the Risks Associated with Cranes.ppt 59 20