CHAPTER 16: FORKLIFT TRAINING, CRANES & RIGGING, AERIAL LIFTS

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FORKLIFT TRAINING AND CERTIFICATION

REQUIREMENTS

Only workers trained and certified by JTT-approved forklift operators are allowed to operate this equipment. The JTT worker must be able to demonstrate to the trainer’s satisfaction that they understand and can perform the classroom training criteria. They must then operate the forklift in a safe and professional manner.

OBJECTIVES

After completing this program, students will be able to successfully do the following:

• Describe the general categories of materials and equipment.

• Define commonly used operating terms for rated capacity, lift the load, tilt the load, stacking and un-stacking loads, lower mast, pivot point, daily squawk sheets, and safety precautions.

Rated Capacity One of the most important things to know about a forklift is its rated capacity; NEVER exceed this capacity. Look for the manufacturer's ID plate stating the rated capacity under normal conditions and with special attachments. Know how much a load weighs before you try to move it. Always check the load charts. Never add unauthorized counterweight. Only operate the vehicle in the manner it was designed and never operate the vehicle beyond it’s established limits. Pre-Operation / Pre-Shift inspections At the beginning of each shift, the operator shall inspect and check the assigned equipment, reporting immediately to his/her supervisor any malfunction of the clutch or of the braking system, steering, lighting, or control system and locking/tagging out the equipment if necessary. Check the following areas daily before starting a forklift:

• Tires for cuts, bulges and correct pressure.

• Wheel lugs.

• Parking brake for proper operation.

• Brakes.

• Engine oil.

• Hydraulic oil.

• Coolant level.

• Fuel Level.

• Look for leaks.

• Battery.

• Back-up alarm and horn in proper working condition.

• Hose/Belts/Cables.

• Mast/Forks/Chains.

• Seat Belt.

• Steering.

• Gauges/Controls.

• Never modify the machine unless authorized.

• Check forks for welds, cracks and misalignment.

• Inspect work to ensure there are no overhead energized electrical lines.

• Insure proper lock out / tag out procedures as necessary are followed.

WARNING: Do not operate a machine whose forks have been repaired by welding, unless the welding has been specifically authorized by the manufacturer. Report any item in need of repairs to your supervisor. If repairs are needed the supervisor will advise steps to be taken including if necessary tagging the equipment and removing it from service.

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Operation To operate a forklift you must be qualified. You must read and understand the operators’ manual and the applicable safety rules for forklifts, and be able to perform the daily inspection. In addition, you must complete the training for forklifts. NEVER take it upon yourself to start using this equipment, even if you think that you are qualified, or if the use is just for a short time. Never allow passengers unless the lift is provided with proper seating and safety belts. You will not use, or attempt to use any forklift in any manner or for any purpose other than for which it is designated.

Know all the Federal, State and local rules that apply to this equipment and the job site. There are also rules governing its operation and maintenance. Before starting work, check with your superintendent for these rules and any site-specific rules that apply.

If you are taking prescription drugs, are experiencing dizziness, or are in any way limited in mental or physical capacity, do not operate this equipment.

� Mount with three-point contact. � Understand all operational controls. � Wear the seat belt, put it in place and properly adjust it prior to starting the lift. � Start the engine from the operators’ seat only. � Keep you arms and legs inside the cage. � Never operate controls from outside the cab. � Wear all protective clothing and safety devices issued to you or called for by the job site, including your seat belt.

DO NOT wear loose clothing, floppy cuffs, dangling belts–anything that can get caught in machinery. � Never allow anyone to ride on the forklift. � Always give pedestrians the right-of-way. � Check the work areas for hazards. � Always check for overhead obstructions. Always ensure there is sufficient overhead clearance and never operate

in the vicinity of electrical power lines. � Operate the controls smoothly. � Always shut off the ignition while fueling. Fuel in designated areas only. � Never allow anyone under the load or on the load. Never use the machine as a personnel lift–workers must only

use a designated personnel carrier. � Know where the fire extinguishers and first aid kits are located and know how to use them. � Wear proper PPE for plant. If the cab is not enclosed, proper safety glasses are always to be used. � Use the forklift for its intended use only � Do not lift a load that is over the capacity of the lift and make sure load is centered. � Do not load the forklift beyond its established load limit. � Do not move loads which because of the length, width, or height that have not been centered and secured for safe

transportation. � Use good common sense.

Lift the Load

� Square up on the center of the load, and approach it straight on with forks in traveling position. Always pick up the load at its center of gravity.

� Stop when the tips of your forks are about a foot away from the load. � Level the forks and slowly drive forward until the load is resting against the backrest. � Ensure that the load is stable, then lift the load high enough to clear whatever is under it, and lift the load safely. � For side shift equipped machines, center the forks and carriage before lifting. � Carefully tilt the mast back to stabilize the load. � Look over both shoulders to make sure you are clear. Back out about a foot. � When you back out of an aisle, remember to allow enough room for forks to clear the sides before starting the turn. � Think of the drive wheels as a pivot point. When you turn, the back of the forklift makes a circle around the front. � Never lift a load using one fork.

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Driving with a Load Safely

� Always travel with a load tilted slightly back for added stability. � Travel with the forks as low as possible. � Travel with the load at the proper height. Drive slowly and carry the load no higher than eye level. A stable

clearance height is four to six inches at the tips and two inches at the heels to clear most uneven surfaces and avoid debris.

� If you can't see over the load, drive in reverse. Never try to look around it. � Watch for obstacles while traveling. � Always be aware of load width. � Never raise a load while traveling. Stop before you raise mast. � Never speed or use excessive maneuvering. � Avoid steep slopes or unstable surfaces. � Use frame leveling when necessary. � Keep the load low. � Travel up and back down inclines when loaded. � Slow down for turns, ramps, dips, or slippery surfaces. � Avoid crossing ditches or railroad tracks. � Avoid sudden starts, stops, or turns, and apply brakes smoothly.

Safe Steering Turning a forklift requires a little more concentration than driving a car. Because it steers from the rear, the forklift handles very differently from cars and other roadway vehicles.

� Think of the drive wheels as a pivot point. When you turn, the back of the forklift makes a circle around the front. The

back end of the forklift swings wide and can injure co-workers or damage products or equipment. � Never make a turn at normal traveling speed. Always slow down to maintain balance. � When turning into an aisle, stay wide. This helps the load clear the side and gives you the chance to square up

with your destination. � When you back out of an aisle, remember to allow enough room for forks to clear the sides before starting the

turn. Putting the Load Down

� Drive safely to the location. If possible, plan to load, unload, and turn on flat level ground. � Use extreme caution when placing load overhead or around other people. � Use stabilizers when setting loads high, doing long reaches or gaining capacity when retracted. � Come as close to the landing point as possible, square up, and stop about a foot away. � Level the forks and then drive the rest of the way, using the transverse to set or lift the load. � Use the frame tilt to level the machine. � Lower the load to the floor. � To make sure you won't hook the load when you back out, tilt the fork slightly forward. � Look over both shoulders and back straight out until the forks have cleared the pallet. � Never place loads that exceed the scaffold capacity. � Never attempt to discharge a load off the forks by stopping the machine.

Stacking & Un-stacking Loads

� Approach the load slowly and squarely. � Stop about a foot from the load and raise the mast high enough so the forks are at the correct height. � Slowly move forward until the load is square over the top. � Be sure that load sits squarely on stack, or it could tip over. � Look over both shoulders and slowly back straight out. � Once you've cleared the top of the stack, stop and lower the mast to traveling position. � Tilt the forks back and you are ready to go. � Never stack a load on uneven ground.

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o If loads have to be re-handled several times, place stacking blocks under them. � Level the forks and lower the mast, until the load is no longer supported by the forks.

Stopping and Parking the Forklift

� Avoid sudden stops. � Never leave the operator’s seat without first lowering the load to the ground, setting the service brake, and placing

the controls in neutral or park. � Always stop the engine, turn the key off, and set the parking brake at the end of shift, or if unauthorized people will

have access to the machine. � Avoid parking on slopes. If necessary set brake and chock the wheels. � Only park in designated areas. � If you leave your forklift unattended for any reason, always lower the mast completely, turn off the engine and set

the brake.

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GENERAL HEALTH AND SAFETY STANDARDS

NOTE: At no time are J.T. Thorpe & Son workers to operate cranes on any project. We are not qualified to operate, inspect, or ensure that the cranes are maintained in proper working order or have capacity to make any lift. JTT shall obtain the assistance of qualified crane companies and operators if needed on the project. 1. If you cannot see or are more than 25 feet from the forklift:

a. The forks must be lowered. b. The controls must be neutralized. c. The power must be shut off. d. The brakes must be set. e. The wheels must be chocked if on a slope.

2. If you can see and are within 25 feet of the forklift:

a. The forks must be lowered. b. The controls must be neutralized. c. The brakes must be set.

3. Before leaving the forklift, check:

a. The forklift is parked safely and away from traffic. b. The brakes are set and functional. c. The forks are lowered completely. d. The ignition key is removed (after the shift or around non-workers).

4. When the forklift is used as an elevated work platform:

a. An operator must be at the workstation when workers are on the platform. b. Keep forklift in normal operating position when raising or lowering. c. Do not move the forklift with workers on the platform, unless inching in. d. Use an approved platform securely attached to the forklift. e. The area between the workers and moving parts of the forklift must be guarded. f. The hydraulic system cannot allow a descent greater than 135 feet per minute. g. A safety device must be installed to prevent tilting of the mast.

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BASIC PRINCIPLES A forklift works on the cantilever principle. As long as the weight on each side of the fulcrum is equal and the distance from the fulcrum is equal, the load is stable. COUNTERWEIGHT FULCRUM However, if the load is increased, or the distance from the fulcrum becomes greater on one side, the load becomes unstable.

COUNTERWEIGHT LOAD FULCRUM On a forklift, the front drive axle is the fulcrum. The forks, mast, and load are located on one side...with the frame, engine, and counterweight, etc., on the other side. The forklift can lift and raise its maximum capacity easily because this load is located approximately twice as close to the fulcrum as the counterweight is. The maximum capacity is based on a load with a 24-inch center of gravity (on a load that is 48 inches long.) The center of gravity is the balancing point of any mass. When the center of gravity is no longer centered over the base, the mass will simply tip over. There are three centers of gravity with a forklift. One is for the forklift and one for the load and the combined center known as the centroid. As the load is raised or lowered, the centroid moves and varies the stability by changing the center of gravity of the unit. Remember that when the centroid is raised it may not affect front to rear stability, but it will definitely affect the side-to-side stability.

LOAD

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POWER LIFT TRUCK SAFE OPERATING RULES

These rules and instructions must be posted as per CAL/OSHA TITLE 8, SECTION 3664

1. Only drivers authorized by the employer and trained in the safe operations of industrial trucks or industrial tow

tractors shall be permitted to operate such vehicles. Training in safe operation of powered industrial trucks will be developed.

2. Stunt driving and horseplay are prohibited. 3. No riders shall be permitted on vehicles unless provided with adequate riding facilities. 4. Employees shall not ride on the forks or lift trucks. 5. Employees shall not place any parts of their bodies outside the running lines of an industrial truck, or between mast

uprights or other parts of the truck where shearing or crushing hazards exist. 6. Employees shall not be allowed to stand, pass, or work under the elevated portion of any industrial truck, loaded or

empty, unless effectively blocked to prevent it from falling. 7. Drivers shall check the vehicle at least once per shift, and if found to be unsafe, the matter shall be reported

immediately to a foreman or mechanic, and the vehicle shall not be put in service again until it has been made safe. Attention shall be given to the proper functioning of tires, horn, lights, battery, controller, brakes, steering mechanism, cooling system, and the lift system for fork lifts (forks, chains, cable, and limit switches).

8. No truck shall be operated with a leak in the fuel system. 9. Vehicles shall not exceed the authorized or safe speed. Drivers must maintain a safe distance from other vehicles,

keep the truck under positive control, and observe all established traffic regulations at all times. For trucks traveling in the same direction, a safe distance is approximately 3 truck lengths, or preferably a time lapse–3 seconds–passing the same point.

10. Trucks traveling in the same direction shall not be passed at intersections, blind spots, or dangerous locations. 11. The driver shall slow down and sound the horn at cross aisles and other locations where vision is obstructed. If the

load being carried obstructs forward view, the driver is required to travel with the load trailing. 12. Operators shall look in the direction of travel and not move a vehicle until certain all persons are in the clear. 13. Trucks shall not be driven up to anyone standing in front of a bench or other fixed object large enough to trap the

person between it and the truck.

14. Grades shall be ascended or descended slowly. a. When ascending or descending grades in excess of 10 percent, loaded trucks shall be driven with the

load upgrade. b. On all grades, the load and load engaging means shall be tilted back, if applicable, and raised only as far

as necessary to clear the road surface. c. Motorized hand and hand/rider trucks shall be operated on all grades with the load engaging means

downgraded.

15. The forks shall always be carried as low as possible, consistent with safe operations. 16. When leaving a vehicle unattended, either:

a. The power shall be shut off, brakes set, the mast brought to the vertical position, and forks left in the down position. When left on an incline, the wheel shall be blocked.

b. The power may remain on, provided the brakes are set, the mast is brought to the vertical position, forks left in the down position, and the wheels blocked, both front and rear.

17. When the operator of an industrial truck is dismounted and within 25 feet of the truck (which remains in the

operator’s view), the load-engaging means shall be fully lowered, controls neutralized, and the brakes set to prevent

movement.

18. Vehicles shall not be run onto any elevator unless the driver is specifically authorized to do so. Before entering an elevator, the driver shall determine that the capacity of the elevator will not be exceeded. Once on the elevator, the power must be shut off and the brakes set.

19. Motorized hand trucks must enter elevators or other confined areas with the load end forward. 20. Vehicles shall not be operated on floors, sidewalk doors, or platforms that will not safely support the loaded vehicle.

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21. Prior to driving onto trucks, trailers and railroad cars, their flooring shall be checked for breaks and other structural weaknesses.

22. Vehicles shall not be driven in and out of highway trucks and trailers at loading docks until such trucks or trailers are securely blocked or restrained and the brakes set.

23. To prevent railroad cars from moving during loading and unloading operation, the car brakes shall be set, wheel chocks or other recognized positive stops used, and blue flags or lights displayed in accordance with applicable regulations promulgated by the Public Utilities Commission.

24. The width of one tire on the powered industrial truck shall be the minimum distance maintained from the edge by the truck while it is on any elevated dock, platform, freight car or truck.

25. Railroad tracks shall be crossed diagonally, whenever possible. Parking closer than 8-1/2 feet from the centerline of railroad tracks is prohibited.

26. Trucks shall not be loaded in excess of their rated capacity. 27. A loaded vehicle shall not be moved until the load is safe and secure. 28. Extreme care shall be taken when tilting loads. Tilting forward with the load engaging means elevated shall be

prohibited, except when picking up a load. Elevated loads shall not be tilted forward except when the load is being deposited onto a storage rack or equivalent. When stacking or tiering, backward tilt shall be limited to what is necessary for stabilizing the load.

29. The load-engaging device shall be placed in so that the load is securely held or supported. 30. Take special precautions in the securing and handling of load by trucks equipped with attachments, and during the

operation of these trucks after the loads have been removed. 31. If a hook is used, employers must make monthly inspection and keep a record of the hooks with deformations or

cracks. The certification records must include 1) date of inspection; 2) signature of person performing inspection; and 3) the serial number or other identifier of hook inspected.

32. When powered industrial trucks are used to open and close doors, comply with the following provisions:

a. A device specifically designed for opening or closing doors shall be attached to the truck. b. The force applied by the device to the door shall be applied parallel to the direction of travel of the door. c. The entire door opening operation shall be in full view of the operator. d. The truck operator and other employees shall be clear of the area where the door might fall while being

opened.

33. If loads are lifted by two or more trucks working in unison, the total weight of the load shall not exceed the combined rated lifting capacity of all trucks involved.

34. Maintenance records per OSHA standard including testing of capacity of forklift shall be kept current and on file. 35. Once a month, employers shall perform rope inspection and certify the date, and the signature of the person performing

inspection for any ropes used during forklift operations. 36. A CO2 or dry chemical fire extinguisher shall be kept in the crane cab or vicinity of the forklift.

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JTT FORKLIFT OPERATOR QUALIFICATION TEST

NAME: SIGNATURE:

SSN (last 4 #) DATE:

Select the MOST correct answer.

1. Powered industrial trucks should be operated by:

A. All employees B. Persons you know C. Only authorized and trained drivers

2. As an industrial truck operator, it is:

A. Your responsibility to watch for pedestrians B. Management's responsibility to keep them out of your work area C. A pedestrian’s responsibility to watch for you

3. Operator should check their vehicles at least:

A. Once a week B. At the beginning of each shift C. Monthly

4. In checking your vehicle, you find the power steering system squeals as soon

as you turn it. You should: A. Tell another employee B. Notify your supervisor C. Ignore it until the end of the shift

5. When parking your vehicle, be sure to leave the forks:

A. At least five feet above the floor area B. Three feet above the floor level C. Flat on the floor and shut off the power

6. You must use your horn when:

A. Trying to catch your supervisor’s attention B. Racing another vehicle C. At blind intersections

7. When driving on a slippery or wet surface you must:

A. Drive slowly B. Place foot on brake pedal

C. Drive at a high speed

8. When transporting a load, carry the load:

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A. In a raised position B. As close to the floor as possible C. Halfway up the mast

9. In operating a vehicle, it is most important to:

A. Listen for unusual noises B. Keep it clean C. Keep it waxed

10. When changing from forward to reverse:

A. Always stop B. Slow down C. Don't worry about speed, industrial vehicles are built to take the shock

11. When transporting a load that is too wide or too high:

A. Look around the mast B. Raise load higher C. Drive backwards

12. Never exceed the rated load capacity of your vehicle:

A. Unless you add additional counter weighing B. Unless your lift is under 84 Inches high C. Never exceed the rate load capacity

13. The GREATEST cause of accidents among new vehicle operators is:

A. Driving on the wrong side of the aisle B. Driving backwards C. Forgetting to watch overhead obstruction when lifting

14. The primary hazards in the operation of lift trucks are:

A. Collision and overturning of the truck B. Movement or collapse of bridge plates, dock boards, etc. C. All of the above

15. If you have to park on an incline: A. Leave the machine in gear B. Set brakes and block the wheels C. Turn off motor only

16. When taking a load clown a ramp:

A. Reduce speed by zigzagging B. Drive frontward C. Drive backwards

17. When operating an Industrial vehicle, the driver should face

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A. The front of the vehicle B. Any direction C. The direction of travel

18.When entering or leaving a building, you should:

A. Stop and drive out B. Slow down C. Stop, sound horn, and go out slowly

19. Railroad tracks should be crossed:

A. Straight ahead B. On a slant C. Turn and then back up across

20. Another person may ride the forks of a forklift truck:

A. If absolutely necessary B. In no case whatsoever C. If the operator approves

21. When lifting, lowering, or carrying load:

A. Keep mast tilted slightly forward B. Keep mast tilted slightly backward C. Keep mast vertical

22. T F Vehicles should not exceed the authorized or safe speed, should always maintain a

safe distance from vehicles, and should keep the truck under positive control at all times.

23. T F Vehicles should not be used on passenger or freight elevators unless specifically

authorized to do so. 24. T F You must make sure that the capacity of the elevator will not be exceeded before you

drive your vehicle. 25. T F Vehicles shall not be driven in and out of highway trucks and trailers at loading and unloading docks until such trucks are securely blocked and brakes set. 26. T F Loaded vehicles shall not be moved until the load is safe and

secure. 27. T F If you take special care, it's okay to let bystanders stand beneath the loads when high-stacking. 28. T F Lift trucks can be refueled or recharged anywhere. Trained by:_________________ Date Trained:_________________________

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FORKLIFT SAFETY TRAINING

PRESENTED BY: Date: SIGNATURE: ______________________ Trained by:_________________

NAME (print) SIGNATURE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

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FORKLIFT TRUCK OPERATOR PERFORMANCE TEST

Provided at initial training and updated every two years OPERATOR’S NAME: DATE:

FORKLIFT TYPE:

All Terrain - Grade All - Standard Counter Balance - OTHER

1. Operator’s ability to perform check-off sheet inspection for safe operation of truck prior to use. Uses check off-sheet satisfactorily. □ Failed to check off safety items □ 2. Proper use of Controls (understands proper technique and movement of control to get desired direction).

a. Clutch operation Yes No b. Inching control (auto transmissions) Yes No c. Tilt control Yes No d. Lift control Yes No e. Attachment control Yes No f. Steering techniques for type of machine being used by operator Yes No g. Proper positioning of all controls, switches, and parking brakes when leaving machine unattended Yes No h. Service brake Yes No i. Parking brake Yes No

3. Maneuvering Skills a. Smooth starting and stopping. Acceptable □ Needs Practice □ Poor Control □ b. Sharp turns forward and reverse. 1. Proper speed. Yes No 2. Looks in direction of travel. Yes No 3. Carries forks low. Yes No 4. Clears obstacles by safe distance. Yes No

4. Selecting loads.

a. Proper capacity for truck used. Yes No

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b. Proper size load for visibility and safety of handling. Yes No

c. Load tilted back against backrest. Yes No d. Carries load low, but high enough to clear floor obstacles

Yes No

5. Driving with load.

a. Smooth starting and stopping Yes No

b. Proper speed. Yes No

c. Sound horn at intersections and corners. Yes No

d. Keeps to the right in aisles used for two-way traffic. Yes No

e. Travels at least three lengths behind other vehicles. Yes No

f. Handles load in manner to prevent product damage. Yes No

6. Stacking.

a. Approaches loads squarely. Yes No

b. Stacks straight and squarely. Yes No

c. Does not tier too high. Yes No d. Deposits load safely, does not use excessive tilt action. Yes No e. When selecting top load for pickup, uses proper fork spread for load. Yes No f. Removes load and lowers to safe level before turning.and proceeding in direction of travel Yes No

(Drivers License #) (SSN#)

Last 4 numbers

(Signature) (Date)

(Examiner Name)

(Examiner Signature) (Date)

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CRANE OPERATION PURPOSE J.T Thorpe & Son (JTT) does not operate cranes on their projects. JTT will hire a qualified subcontractor for crane work. If for some unforeseen reason a crane is needed and JTT cannot hire a sub contractor, JTT will require that the crane meet the following criteria and the operator will be trained on this data every four (4) years). In order to maintain a safe workplace for its employees, only qualified individuals shall operate these devices. This program outlines the procedures for safe operations and the training requirements regarding overhead cranes, hoists and rigging equipment. SCOPE Applies to all JTT employees who operate overhead cranes, hoists, and rigging equipment in the scope of their job duties and assignments. When work is performed on a non-owned or operated site, the operator’s program shall take precedence, however, this document covers JTT employees and shall be used on owned premises, or when an operator’s program doesn’t exist or is less stringent. DEFINITIONS ANSI - the American National Standards Institute. Appointed - assigned specific responsibilities by the employer or the employer's representative. Auxiliary hoist - a supplemental hoisting unit of lighter capacity and usually higher speed than provided for the main hoist. Brake - a device used for retarding or stopping motion by friction or power means. Bridge - that part of a crane consisting of girders, trucks, end ties, foot-walks, and drive mechanism that carries the trolley or trolleys. Bridge travel - the crane movement in a direction parallel to the crane runway. Bumper [buffer] - an energy absorbing device for reducing impact when a moving crane or trolley reaches the end of its permitted travel; or when two moving cranes or trolleys come in contact. Crane - a machine for lifting and lowering a load and moving it horizontally, with the hoisting mechanism an integral part of the machine. Cranes, whether fixed or mobile, are driven manually or by power. Designated - selected or assigned by the employer or the employer's representative as being qualified to perform specific duties. Drum - the cylindrical member around which the ropes are wound for raising or lowering the load. Emergency stop switch - a manually or automatically operated electric switch to cut off electric power independently of the regular operating controls. Floor-operated crane - a crane which is pendant or nonconductive rope controlled by an operator on the floor or an independent platform. Hoist - an apparatus that may be a part of a crane, exerting a force for lifting or lowering. Holding brake - a brake that automatically prevents motion when power is off. Limit switch - a switch that is operated by some part or motion of a power-driven machine or equipment to alter the electric circuit associated with the machine or equipment.

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Load - the total superimposed weight on the load block or hook. Load block - the assembly of hook or shackle, swivel, bearing, sheaves, pins, and frame suspended by the hoisting rope. Main hoist - the hoist mechanism provided for lifting the maximum rated load. Main switch - a switch controlling the entire power supply to the crane. Overhead crane - a crane with a movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead fixed runway structure. Rated load - the maximum load for which a crane or individual hoist is designed and built by the manufacturer and shown on the equipment nameplate(s). Rope - refers to wire rope, unless otherwise specified. Runway - an assembly of rails, beams, girders, brackets, and framework on which the crane or trolley travels. Side pull - that portion of the hoist pull acting horizontally when the hoist lines are not operated vertically. Span - the horizontal distance center to center of runway rails. Standby crane - a crane which is not in regular service but which is used occasionally or intermittently as required. Stop - a device to limit travel of a trolley or crane bridge. This device normally is attached to a fixed structure and normally does not have energy absorbing ability. Trolley - the unit that travels on the bridge rails and carries the hoisting mechanism. Trolley travel - the trolley movement at right angles to the crane runway. Wall crane - a crane having a jib with or without trolley and supported from a sidewall or line of columns of a building. It is a traveling type and operates on a runway attached to the sidewall or columns. OPERATIONS

1. The crane must supply a substantial and durable chart with clearly legible letters. Figures shall be securely fixed to the crane cab in a location easily visible to the operator while seated at this control station. All other safety devises must be supplyed and in prope working order. These include boom stops, foot pedals, horns etc. Manufactures safety requirements will be followed.

2. Critical items such as the crane brakes, hooks, and ropes must be inspected monthly, with records

maintained.

3. All manufacturer procedures applicable to the operational functions of the equipment, including its use with attachments, must be complied with by the operator at all times..

4. There must be available, updated, written reports on rated load tests showing the test procedures and

confirming the adequacy of any repairs or alterations.

5. All ropes will be thoroughly inspected before crane is used. They must be certified by record of date of inspection, ID of the rope inspected, and signature of the person performing inspection.

6. The work zone shall be identified by demarcating boundaries such as flag and range limiting devices, or

defining the work zone as 360 degrees around the equipment up to the maximum working radius. The hazard assessment must determine if any part of the equipment could get closer than 20 feet to a power line.

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7. Electrical lines shall be deenergized or grounded, or other protective measures shall be taken before work is started if equipment could get within 20 feet of the power line.

8. A preventive maintenance program for the crane based upon the crane manufacturer's recommendations will

be implemented.

9. JTT will make a monthly inspection and keep a record of hoist chains (including end connections) for (A) excessive wear, (B) twist, (C) distorted links interfering with proper function, and (D) stretch beyond manufacturer's recommendation. The certification records must include (1) Date of inspection, (2) Signature of person performing inspection, and (3) Identifier of chain inspected.

10. JTT does not operate cranes in areas that are enclosed, in order to keep employees from exposure to unsafe

concentrations of toxic gases or materials.

11. Cranes will not be assembled or used unless ground conditions are firm, drained, and graded to a sufficient extent so that, in conjunction (if necessary) with the use of supporting materials, the equipment manufacturer’s specifications for adequate support and degree of level of the equipment are met. The manufacturer's procedures and prohibitions must be complied with when assembling and disassembling equipment.

12. A competent person will conduct a visual inspection of equipment prior to each shift. The inspection must

consist of observation for apparent deficiencies. Some inspection items shall include control mechanisms, pressurized lines, hooks and latches, wire rope, electrical apparatus, tires (when used), and ground conditions.

13. It is pointed out once more that JTT employees will not operate cranes, but in the event a qualified operator

was employed by JTT and the equipment when used had the potential to strike and injure an employee or pinch/crush an employee against any other object. A site specific safety program will be developed that will identify the safety measures to be used to control this exposure. All persons will be trained on these procedures prior to the start of the job.

14. Signal persons will be provided in the event of the following situations:

(A) The point of operation is not in full view of the operator (B) The view is obstructed when the equipment is traveling (C) The operator or the person handling the load determines it is necessary due to site specific concerns

15. Equipment will be inspected monthly by a competent person and documented. Documentation must include

the following: items checked, results of inspection, and name and signature of the inspector. Documentation must be retained for 3 months. (Documented monthly inspection not required if the daily inspection is documented and

16. The assembly/disassembly of equipment must be directed by a competent and qualified person

17. All workers not specifically involved with operation to the crane are to clear the area to prevent the potential to

strike and injure an employee or pinch/crush an employee against any other object.

18. It is pointed out once more that JTT employees will not operate cranes, but if a JTT worker was assigned to operate the crane, the operator shall have access to procedures applicable to the operation of the equipment. Procedures include rated capacities (load charts), recommended operating speeds, special hazard warnings, instructions and operator's manual.

19. It is pointed out once more that JTT employees will not operate cranes, but if a JTT worker was assigned to

operate the crane only those workers qualified by training or experience shall be allowed to operate equipment and machinery. Within 4 years of November 8th 2010, employers must ensure operators be qualified/certified by one of the following methods:

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A. Certification by an accredited crane operator testing organization B. Qualification by an audited employer program C. Qualification by the U.S. military D. Licensing by a government entity

20. Modifications or additions that may affect the capacity or safe operation of the crane will not be made without

written approval from the manufacturer or approval from a registered professional engineer

21. Safety devices are required to be on all equipment and must be in proper working order before operations begin. If any of the devices are not in proper working order the equipment must be taken our of service and operations must not resume until the device is working properly again. Examples of safety devices may include: crane level indicator, boom stops, jib stops, foot pedal brake locks, horns.

If repairs are identified as needed, a qualified person will make the repairs. Warning cards will be placed on the crane indicating the crane is “Out of Order” until all repairs are made. Whenever there is a safety concern, the operator has the authority to stop and refuse to handle loads until a qualified person has determined that safety has been assured. NOTE: JTT workers will not modify any crane at any time. Inspection of cranes will follow the guideline listed below.

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DAILY GUIDE FOR OVERHEAD CRANE INSPECTIONS

Yes No All functional operating mechanisms for maladjustment interfering with proper operation

Yes No Leakage in lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems

Yes No Hooks for deformation, chemical damage, or cracks. Hooks having more than 15% in excess of normal throat opening or more than 10 degrees twist from the plane of the unbent hook.

Yes No Hooks. Dye penetrant, magnetic particle, or other suitable crack-detecting inspection performed at least once a year.

Yes No All functional operating mechanisms for excessive wear of components

Yes No Rope reeving for noncompliance with manufacturer's recommendations

Yes No Condition of wire rope.

Yes No Deformed, cracked, or corroded members

Yes No Cracked or worn sheaves or drums.

Yes No Loose bolts, nuts, or rivets

Yes No Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers, locking and clamping devices

Yes No Excessive wear in brake system parts, linings, pawls, and ratchets

Yes No Load, wind and other indicators over their full range, for any significant inaccuracies

Yes No Gasoline, diesel, electric, or other power plants for improper performance or noncompliance with applicable safety requirements.

Yes No Electrical apparatus, for signs of pitting or any deterioration of controller, master-switches, and push button stations.

Yes No Required warning labels absent or illegible.

Yes No Supporting structure, trolley and bridge for alignment and continued ability to support the imposed loads.

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RIGGING OPERATIONS JTT will also implement the following procedures for the ropes and slings and rigging under the control of JTT and used for the crane operations:

1. A certification record–including the date of inspection and the signature of the person who performed inspection–will be maintained. The same records will also be kept on inspections of all other ropes. Only trained qualified riggers will be allowed to rig loads for JTT crane operators.

2. Whenever slings are used, the following practices will be observed:

A. Slings that are damaged or defective will not be used. B. Slings shall not be shortened with knots, bolts, or other makeshift devices. C. Sling legs shall not be kinked. D. Slings shall not be loaded in excess of their rated capacities. E. Slings used in a basket hitch shall have the loads balanced to prevent slippage. F. Slings shall be securely attached to their loads. G. Slings shall be padded or protected from the sharp edges of their loads. H. Suspended loads shall be kept clear of all obstructions. I. All employees shall be kept clear of loads about to be lifted and suspended loads. J. Hands or fingers shall not be placed between the sling and its load while the sling is being tightened

around the load. K. Shock loading is prohibited. L. A sling shall not be pulled from under a load when the load is resting on the sling. M. The JTT designated competent person will inspect all slings and attachments prior to use.

If alloy steel chain slings are used, they shall have permanently affixed, durable identification, stating size, grade, rated capacity, and reach. The following procedures for these slings and hooks shall be implemented:

1. Hooks, rings, oblong links, pear-shaped links, welded or mechanical coupling links, or other attachments shall have a rated capacity at least equal to that of the alloy steel chain with which they are used. Otherwise, the sling shall not be used in excess of the rated capacity at the weakest component.

2. Makeshift links or fasteners formed from bolts, rods, or other such attachments, shall not be used.

3. A thorough periodic inspection of alloy steel chain slings in use will be made on a regular basis, to be

determined on the basis of (A) frequency of sling use, (B) severity of service conditions, (C) nature of lifts being made, and (D) experience gained on the service life of slings used in similar circumstances. Such inspections will take place at least once every 12 months.

4. JTT will make and maintain a record of the most recent month in which each alloy steel chain sling was

thoroughly inspected, and shall make such record available for examination.

5. The inspection of alloy steel chain slings will be performed by a competent person designated by JTT management, and shall include a thorough inspection for wear, defective welds, deformation, and increase in length. Where such defects or deterioration are present, the sling shall be immediately removed from service.

6. JTT will ensure that before use, each new, repaired, or reconditioned alloy steel chain sling, including all welded

components in the sling assembly, shall be proof tested by the sling manufacturer or equivalent entity. JTT will retain a certificate of the proof test and make it available for examination.

7. Alloy steel chain slings shall not be used with loads in excess of the rated capacities. Slings will be used only in

accordance with the manufacturer's recommendations.

8. Fire extinguisher training as outlined in Training Section 3 of this manual will be provided to the operator. Rigging and Sling Inspections and Safety Requirements

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1. Only select rigging equipment that is in good condition. 2. Each sling shall be inspected before being used. Each sling, fastenings and all attachments shall be inspected

by a designated competent person by COMPANY. 3. All rigging equipment shall also be inspected annually. 4. Defective equipment is to be removed from service and destroyed to prevent inadvertent reuse. 5. The load capacity limits shall be stamped or affixed to all rigging components. 6. All devices shall be visually inspected prior to use and removed from service for any of the following conditions

and to ensure the proper use and care:

a. Synthetic slings with: i. Abnormal wear. ii. Torn stitching. iii. Broken or cut fibers. iv. Discoloration or deterioration.

b. Wire rope slings with:

i. Kinking, crushing, bird caging, or other distortions. ii. Evidence of heat damage. iii. Cracks, deformation, or worn end attachments. iv. Six randomly broken wires in a single rope lay. v. Three broken wires in one strand of rope. vi. Hooks opened more than 15% at the throat.

� Hooks twisted sideways more than 10 degrees from the plane of the unbent hook.

c. Alloy steel chain slings with: i. Cracked, bent, or elongated links or components. ii. Cracked hooks. iii. Shackles, eye bolts, turnbuckles, or other components that are damaged or deformed.

Rigging a Load

1. Whenever any sling is used specific safety practices shall be observed. 2. Determine the weight of the load - do not guess. 3. Determine the proper size for slings and components. 4. Do not use manila rope for rigging. 5. Ensure that shackle pins and shouldered eyebolts are installed in accordance with the manufacturer's

recommendations. 6. Ensure that ordinary (shoulderless) eyebolts are threaded in at least 1.5 times the bolt diameter. 7. Use safety hoist rings (swivel eyes) as a preferred substitute for eye bolts wherever possible. 8. Pad sharp edges to protect slings. 9. Remember that machinery foundations or angle-iron edges may not feel sharp to the touch but could cut into

rigging when under several tons of load. 10. Wood, tire rubber, or other pliable materials may be suitable for padding. 11. Do not use slings, eyebolts, shackles, or hooks that have been cut, welded, or brazed. 12. Install wire-rope clips with the base only on the live end and the U-bolt only on the dead end. 13. Follow the manufacturer's recommendations for the spacing for each specific wire size. 14. Determine the center of gravity and balance the load before moving it. 15. Initially lift the load only a few inches to test the rigging and balance.

Moving a Load

1. Center the hook over the load to keep the cables from slipping out of the drum grooves and overlapping, and to prevent the load from swinging when it is lifted.

2. Inspect the drum to verify that the cable is in the grooves. 3. Use a tag line when loads must traverse long distances or must otherwise be controlled. 4. Manila rope may be used for tag lines. 5. Plan and check the travel path to avoid personnel and obstructions. 6. Lift the load only high enough to clear the tallest obstruction in the travel path.

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7. Start and stop slowly. 8. Land the load when the move is finished. 9. Choose a safe landing area. 10. Never leave suspended loads unattended 11. In an emergency where the crane or hoist has become inoperative, if a load must be left suspended, barricade

and post signs in the surrounding area, under the load, and on all four sides. 12. Lock open and tag the crane or hoist's main electrical disconnect switch.

Whenever the operators view is obstructed, site specific safety concerns require it, or if the operator determines it is necessary, a signal person must be provided. Signals to the operator shall be in accordance with the standard hand signals prescribed by the applicable ANSI standard for the type of crane in use unless voice communications equipment (telephone, radio, or equivalent) is used.

1. Signals shall be discernible or audible at all times. 2. Some special operations may require addition to or modification of the basic signals. 3. For all such cases, these special signals shall be agreed upon and thoroughly understood by both the person

giving the signals and the operator, and shall not be in conflict with the standard signals.

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SIGNALS FOR CONTROLLING CRANE OPERATIONS:

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AERIAL LIFT OPERATION

1. Aerial lifts used by JTT will be designed and constructed per the applicable requirements of the American National Standards for "Vehicle Mounted Elevating and Rotating Work Platforms," ANSI A92.2-1969, including appendix. Aerial lifts acquired before January 22, 1973, which do not meet the requirements of ANSI A92.2-1969, may not be used.

2. Only authorized persons who are trained and designated as an operator by JTT shall operate an aerial lift.

3. Aerial lifts will not be "field modified" by JTT personal or others.

4. Lift controls shall be tested daily by the operator prior to use, in order to determine that controls are in safe working

condition. If more than one shift is being worked, tests shall be made at the beginning of each shift, during which the equipment must be used to determine that the brakes and operating systems are in proper working order.

5. The JTT operator will know the weight of the materials and people to be placed in the basked prior to starting

work. Boom and basket load limits specified by the manufacturer shall not be exceeded.

6. The vehicle will have a reverse signal alarm, audible above the surrounding noise level. If it does not have this alarm, the lift will be backed up by the operator only when an observer signals that it is safe to do so.

7. The JTT operator and any other worker inside the work basket shall always stand firmly on the floor of the basket,

and not sit or climb on the edge of the basket, or use planks, ladders, or other devices for a work position.

8. All JTT workers shall wear approved fall protection whenever inside the basket of an aerial lift, and a lanyard will be attached to the boom or basket.

9. Proper clearance will be maintained between the equipment and electrical lines. For lines rated 50 kV. or below,

minimum clearance between the lines and any part of the equipment or load shall be 10 feet.