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1 Cranes, Derricks, Hoists, Elevators, and Conveyors 30-Hour Construction Industry OSHA Outreach Training Program Cranes, Derricks, Hoists, Elevators, and Conveyors Topics Common Causes of Accidents Work Area/Operational Preparedness Employer Requirements Worker Roles Case Study Cranes, Derricks, Hoists, Elevators, and Conveyors Four Major Types of Crane Accidents Contact with power lines Overturns Mechanical Failures Falls Common Causes of Accidents

Cranes, Derricks, Hoists, Elevators, and Conveyors Cranes...Cranes, Derricks, Hoists, Elevators, and Conveyors 1926 Subpart CC – Cranes and Derricks in Construction Work Area/Operational

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Page 1: Cranes, Derricks, Hoists, Elevators, and Conveyors Cranes...Cranes, Derricks, Hoists, Elevators, and Conveyors 1926 Subpart CC – Cranes and Derricks in Construction Work Area/Operational

1

Cranes, Derricks, Hoists, Elevators, and Conveyors

30-Hour Construction Industry OSHA Outreach Training Program

Cranes, Derricks, Hoists, Elevators, and Conveyors

Topics

• Common Causes of Accidents

• Work Area/Operational Preparedness

• Employer Requirements

• Worker Roles

• Case Study

Cranes, Derricks, Hoists, Elevators, and Conveyors

Four Major Types of Crane Accidents

• Contact with power lines

• Overturns

• Mechanical Failures

• Falls

Common Causes of Accidents

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Reasons Accidents Occur

• Poor Load Planning/Instability

• Lack of communication

• Lack of training

• Inadequate maintenance or inspection of equipment

Common Causes of Accidents

Cranes, Derricks, Hoists, Elevators, and Conveyors

1. Improper loading rating

2. Excessive speeds

3. No hand signals

4. Inadequate inspection and maintenance

5. Unguarded parts

6. Unguarded swinging radius

7. Working too close to power lines

8. Improper exhaust systems

9. Shattered windows

10. No steps or guardrails on walkways

11. No boom angle indicator

12. Not using outriggers

Hazardous Environments for Crane Operations

Common Causes of Accidents

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Cranes, Derricks, Hoists, Elevators, and Conveyors

1926 Subpart CC –Cranes and Derricks in Construction

Work Area/Operational Preparedness

Cranes, Derricks, Hoists, Elevators, and Conveyors

Crane Use1. Capacities and limitations

of the crane and job site restrictions.

2. Operators, signal persons, and riggers –qualifications/certifications

3. Level the crane and check the support surface

4. Check for power line precautions

5. Communicate hoisting activities in work area

6. Barricade swing area

7. Maintenance and inspection

8. Identify safe store and pick up/put down area for materials and machinery

Work Area/Operational Preparedness

Cranes, Derricks, Hoists, Elevators, and Conveyors

Load Capacity: Speed - Warnings

Make sure the crane operator can see the:

• Rated Load Capacities

• Operating Speeds

• Special Hazard Warning

• Instructions

• Operator’s manual

Work Area/Operational Preparedness

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Hand Signals

Work Area/Operational Preparedness

Cranes, Derricks, Hoists, Elevators, and Conveyors

Guard Moving Parts

Work Area/Operational Preparedness

Cranes, Derricks, Hoists, Elevators, and Conveyors

Swing Radius

• Stay out of the swing radius of the crane.

• Make sure there are barrier guards showing the swing radius.

Work Area/Operational Preparedness

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Operator Visibility

Make sure broken windows or other obstructions do not prevent the operator from seeing.

Work Area/Operational Preparedness

Cranes, Derricks, Hoists, Elevators, and Conveyors

Guardrails

Runways and steps need to have guardrails, handholds and slip resistant surfaces.

Work Area/Operational Preparedness

Cranes, Derricks, Hoists, Elevators, and Conveyors

Guardrails

Use ladders to get to the upper portion of the cab.

Work Area/Operational Preparedness

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Crane Use Near Power Lines

Boom or crane contact with energized power lines accounts for nearly 45% of crane accidents.

Work Area/Operational Preparedness

Cranes, Derricks, Hoists, Elevators, and Conveyors

Identify Work Zone

Work Zone = Marking Boundaries

Or

360 degrees around crane up to maximum working radius

POWER LINES

Work Area/Operational Preparedness

Cranes, Derricks, Hoists, Elevators, and Conveyors

Crane Use Near Power LinesPre-operational requirements:

1. Identify work zone

2. Determine proximity to power lines, if closer than 20 feet, if so, must do one of the following three:

a. De-energize and ground

b. Ensure no part of equipment, load line, or load gets closer than 20 feet to power line

c. Determine line’s voltage and minimum approach distance permitted under Table A.

Work Area/Operational Preparedness

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Could you get within 20 feet of power line?

YES NO

Option #1

Deenergize &

Ground

Encroachment

Prevention Measures(Equipment Operations)

Option #3

Ask Utility for

Voltage and

Use Table A

(with minimum

clearance distance)

Option #2

20-foot

clearance

No further

action

• Planning meeting

• If tag lines used Non-conductive

•Elevated warning lines, barricade

or line of signs

PLUS (Choose one):

Proximity alarm, spotter, warning device,

range limiter, or insulating link

Work Area/Operational Preparedness

Cranes, Derricks, Hoists, Elevators, and Conveyors

Table A – Minimum Clearance Distances

Voltage (nominal, kV, alternating

current)

Minimum clearance distance (feet)

up to 50 10

over 50 to 200 15

over 200 to 350 20

over 350 to 500 25

over 500 to 750 35

over 750 to 1000 45

over 1000 (as established by the power line

owner/operator or registered professional

engineer who is a qualified person with

respect to electrical power transmission and

distribution)

Work Area/Operational Preparedness

Cranes, Derricks, Hoists, Elevators, and Conveyors

Must Show:

• Staying outside zoneis infeasible

• Infeasible to deenergize and ground

Intentionally Working Closer Than Table A Zone

All of the following are required:

1. Power line owner – sets minimum

approach distance

2. Planning meeting – minimum procedures

- Dedicated spotter

- Elevated warning line or barricade

- Insulating link/device

- Nonconductive rigging

- Range limiter (if equipped)

- Nonconductive tag line (if used)

- Barricades - 10 feet from equipment

- Limit access to essential workers

- Prohibit non-operator workers from touching

above insulating link

- Properly ground crane

- Deactivate automatic re-energizer

- Insulating line cover-up installed

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Cranes, Derricks, Hoists, Elevators, and Conveyors

• Comply with all applicable employer requirements.

• Designate a competent person to inspect all machinery and equipment prior to each use.

Employer Requirements

Cranes, Derricks, Hoists, Elevators, and Conveyors

GROUND CONDITIONS

Controlling Entity: Provide Adequate Conditions

Employer Requirements

• Firm, drained and graded

• Sufficient to support crane (in conjunction with blocking, mats, etc.)

Cranes, Derricks, Hoists, Elevators, and Conveyors

Controlling Entity must Inform

equipment user & operator of known

underground hazards (voids, utilities, etc.)

GROUND CONDITIONS

Employer Requirements

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Cranes, Derricks, Hoists, Elevators, and Conveyors

ASSEMBLY / DISASSEMBLY

Two options:

Manufacturer procedures

or

Employer procedures

(criteria requirements)

Employer Requirements

Cranes, Derricks, Hoists, Elevators, and Conveyors

General requirements, such as:

– A/D Director = “competent & qualified person”

– A/D Director must:

• Understand procedures

• Review procedures (unless A/D Director has used them before)

• Check that crew members understand their tasks, hazards

–Follow manufacturer’s prohibitions

–All rigging work is done by a Qualified Rigger

–When using outriggers - fully extend or deploy as per the load chart

ASSEMBLY / DISASSEMBLY

Employer Requirements

Cranes, Derricks, Hoists, Elevators, and Conveyors

• Qualified Rigger – adds requirements that employers must use a qualified rigger for rigging operations during assembly/disassembly and other activities when workers must be in the fall zone to handle a load. (§1926.1404 and § 1926.1425)

• Synthetic Slings – adds requirements (i.e., padding) for use of synthetic slings in rigging. (§ 1926.1404(r))

Employer Requirements

Special Note

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Training Requirements

1. Employer must provide training

2. Training administration

Employer Requirements

Cranes, Derricks, Hoists, Elevators, and Conveyors

Safety Devices• Safety devices are required and must be

operational at all times

• Include:

– Crane level indicator

– Boom/Jib stops (except derricks)

– Integral holding device/check valve for outrigger and stabilizer jacks

Employer Requirements

Cranes, Derricks, Hoists, Elevators, and Conveyors

Operational Aids

Employer Requirements

Operational aids are required but temporary alternative measures are also allowed while operational aids are being repaired.

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Operational AidsCategory 1: Boom hoist limiting device, luffing jib limiting

device, and anti two-blocking device

Must be repaired within 7 days of discovery of deficiency

Category 2: Boom angle or radius indicator, boom length indicator, load weighing devices, jib angle indicator, outrigger/stabilizer position sensor/monitor, and hoist drum rotation indicator

Must be repaired within 30 days of discovery of deficiency

Employer Requirements

Exception: employer has documented that it ordered the part and then repaired the equipment within 7 days of receipt of the replacement part.

Cranes, Derricks, Hoists, Elevators, and Conveyors

Supplemental Tower Crane Requirements• Foundations & structural supports

– Design & Inspection

• Plumb tolerance– Specification & verification

• Climbing procedures– Host structure strength verification

– Wind

• Post-erection load test

• Monthly Inspection: tower mast bolts, upper-most tie-in, braces, floor supports, floor wedges

Employer Requirements

Cranes, Derricks, Hoists, Elevators, and Conveyors

Required Documentation Includes

• Monthly & annual inspection reports for the equipment and wire rope

• Modifications that affect the safe use of the equipment

• Operator and signal person qualifications

• Tower crane foundation/support design

• When repairs or adjustments of the equipment are needed

Employer Requirements

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Cranes, Derricks, Hoists, Elevators, and Conveyors

• Employer-developed procedures (i.e., assembly/disassembly, operational, and other procedures related to the safe operation of the equipment)

• Power line encroachment procedures/plan

Employer Requirements

Required Documentation Includes

Cranes, Derricks, Hoists, Elevators, and Conveyors

Comprehensive

State Plan

State Plan

Public Sector Only

Federal OSHA

Puerto Rico-

Comprehensive

Virgin Islands-

Public Sector

Only

Source: Establishments County Business Patterns, 2005; Employment Current Employment Statistics (CES), 2007

AK

WASH

OREG

CALIF

NEV

N. DAK

IDAHO

WYO

ARIZN. MEX

UTAH

COLO

TEXAS

OKLA

KANSAS

NEBR

HI

S. DAK

MINN

IOWA

MO

ARK

LA

MISSALA GA

FLA

SC

NC

TENN

KY

IND

WISMI

OH

WV

PA

NY

VA

ME

MONTVT

NH

MD

NJ

DE

CT

RI

MA

ILL

Federal:

District of Columbia

Guam

American Samoa

Trust territories

Revised April 2010

STATE PLAN STATES

Employer Requirements

Cranes, Derricks, Hoists, Elevators, and Conveyors

• States must set job safety and health standards that are “at least as effective as” comparable federal standards.

• Although most states adopt standards identical to federal ones, there is some flexibility. Therefore, cranes and derricks standards may differ in states operating their own plans.

• Some states already have their own cranes and derricks standards in place. Their regulations must be “at least as effective as” the federal standard.

• Go to www.osha.gov/dcsp/osp for more information on state plan states.

Employer Requirements

STATE PLAN STATES

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Training RequirementsHazard Recognition

Employer Requirements

• Fall Hazards• Struck-by Hazards• Crushing Hazards• Electrical Hazards

Cranes, Derricks, Hoists, Elevators, and Conveyors

Employer Requirements

Training RequirementsHazard Recognition

Cranes, Derricks, Hoists, Elevators, and Conveyors

Training RequirementsHazard Recognition

Employer Requirements

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Training RequirementsHazard Recognition

Employer Requirements

Cranes, Derricks, Hoists, Elevators, and Conveyors

Training RequirementsHazard Recognition

Employer Requirements

Cranes, Derricks, Hoists, Elevators, and Conveyors

Employer Requirements

• Workers must be trained to recognize and avoid hazards.

• Workers must understand this training

‐ Provided in a manner they understand◦ Oral/written training

‐ Provided in a language they understand◦ Some Spanish language materials are

already available through OSHA

Training

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Cranes, Derricks, Hoists, Elevators, and Conveyors

• The participation of workers is a vital component of any workplace injury and illness prevention program; workers are the best eyes and ears for identifying hazards.

• Workers must be trained on the hazards they face and ways to prevent the hazards.

Worker Roles

Worker Participation

Cranes, Derricks, Hoists, Elevators, and Conveyors

• OPTION 1:

Accredited testing organization

• OPTION 2:

Audited employer program

• OPTION 3:

U.S. military

• OPTION 4:

State/local gov’t license

Worker Roles

OPERATOR QUALIFICATION / CERTIFICATION

Cranes, Derricks, Hoists, Elevators, and Conveyors

• Knowledge (written test):

– Controls/performance characteristics

– Calculate capacity

– Preventing power line contact

– Ground conditions & equipment support

– Use and locate info in operating manual

– Appendix C subjects

• Practical test

• OPTION 1:

Accredited testing organization

• OPTION 2:

Audited employer program

• OPTION 3:

U.S. military

• OPTION 4:

State/local license

Testing Criteria

Worker Roles

OPERATOR QUALIFICATION / CERTIFICATION

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Develops and administers the tests (written & practical)

to certify operators

Accredited Testing Organization

Nationally Recognized Accrediting Agency

Option 1: Accredited Testing Organization

Determines compliance

with testing & testadministration

criteria

Different tests forDifferent capacity/type of equipment

Worker Roles

Cranes, Derricks, Hoists, Elevators, and Conveyors

Accredited testing organization

Option 2: Audited Employer Program

Auditor

Audited EmployerProgram

Compliancewith testing & test

administration criteria

Certifies

Employer-administered

written & practical

tests

Worker Roles

Cranes, Derricks, Hoists, Elevators, and Conveyors

Option 3: U.S. Military

U.S. Military

Issues Operator Qualification

Worker Roles

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Option 4: State/local government license

State/local government license

office

Determines license office complies with testing/test administration

criteria

State/local government authority that oversees licensing office

Issues operator license

Worker Roles

Cranes, Derricks, Hoists, Elevators, and Conveyors

Certification Costs for Operators – employers must pay for certification or qualification of their currently uncertified or unqualified operators.

Worker Roles

Special Note

Cranes, Derricks, Hoists, Elevators, and Conveyors

OPERATOR QUALIFICATION / CERTIFICATION

Accredited testing organization

YES * 5 years

Audited Employer Program

NO 5 years

U.S. Military license NO * Set by issuing entity

State/local license

NO *

Valid only in jurisdiction

Set by issuing entity, not > 5 years

Portable Valid

* Subject to State & Local requirements and whether or not the military/state training meets accredited requirements.

Worker Roles

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Cranes, Derricks, Hoists, Elevators, and Conveyors

November 8, 2010: State or local license required if (1) working within a state or locality that has licensing requirements and (2) the licensing program meets the licensing and certification criteria listed in subpart CC.

November 8, 2010-November 10, 2014: Employer must ensure that all operators are competent to operate the equipment safely and are trained and evaluated on that training before operating the equipment.

November 10, 2014: All operators must be certified or qualified.

OPERATOR QUALIFICATION / CERTIFICATION

Worker Roles

Cranes, Derricks, Hoists, Elevators, and Conveyors

• Signal Person – when required:

– Point of operation not in full view of operator

– View of direction of travel is obstructed

– Site-specific safety concerns

• Signal Types:

– Hand, voice, audible or “new”

– Only time an operator can use a cell phone while lifting (but must be hands free)

Signals

Worker Roles

Cranes, Derricks, Hoists, Elevators, and Conveyors

Qualification Requirements:

– Know & understand signals

– Competent in using signals

– Basic understanding of crane operation

– Verbal or written test plus practical test

Signal Person

Worker Roles

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Third party qualified evaluator

Yes Yes

Employer qualified evaluator

Yes No

Qualified How Documentation Portable

Signal Person Qualifications

Worker Roles

Cranes, Derricks, Hoists, Elevators, and Conveyors

Modified or repaired/adjusted

Qualified person

Post-assembly Qualified person

Shift Competent person

Monthly Competent person

Annual Qualified person

Type of Inspection:

Worker Roles

INSPECTIONS

Who Inspects:

Cranes, Derricks, Hoists, Elevators, and Conveyors

• Inspections – all documentation required by the inspection provisions must be available to all inspectors performing required inspections (including wire rope inspections). (§§ 1926.1412 & 1926.1413)

• Pre-Erection Inspection for Tower Cranes – adds a requirement to include inspection of crane components after transportation to the work site and prior to erection of the crane. (§ 1926.1435)

Worker Roles

Special Note

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Cranes, Derricks, Hoists, Elevators, and Conveyors

• Operations procedures must be developed by a qualified person when the manufacturer’s procedures are unavailable.

• Procedures related to the capacity of the equipment must be developed by a registered professional engineer (familiar with the equipment) when the manufacturer’s procedures are unavailable.

• This information must be readily available in the cab of the crane.

Worker Roles

Operations

Cranes, Derricks, Hoists, Elevators, and Conveyors

Operators cannot be engaged in activities that distract her or his attention while operating the equipment (for

example, no cellular phone use unless used for signaling).

Worker Roles

Operations

Cranes, Derricks, Hoists, Elevators, and Conveyors

When workers must be in the fall zone to handle a load, the load must be rigged by a qualified rigger.

Worker Roles

KEEPING CLEAR OF THE LOAD

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Worker Roles

Fall Protection• Fall protection requirements are

specified in the final rule.

• Training is required regarding the criteria and use of fall protection systems that is consistent with 29 CFR 1926 subpart M.

• Anchor points for fall protection systems must meet subpart M requirements and criteria.

Cranes, Derricks, Hoists, Elevators, and Conveyors

Case Study

Miller Park Stadium

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Case Study

Miller Park Stadium

Cranes, Derricks, Hoists, Elevators, and Conveyors

Case Study

Miller Park Stadium

Cranes, Derricks, Hoists, Elevators, and Conveyors

This did not start this way…

• Prior to April of 1999 the Miller Park project was at 27% of premium dollars for injuries at the site.

• As the need to accelerate the production to make the opening day deadline, a dispute over site arose and the then safety director left.

• In the next few months there were serious falls, dropped loads and the death of three workers.

Case Study

Miller Park Stadium

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Cranes, Derricks, Hoists, Elevators, and Conveyors

Original budget: $ 322M

Final Cost: $ 850M+?

➢ $413.9M (construction)

➢ $100M (repairs)

➢ $27-99M (jury awards)

➢ $330.8M (interest on bonds)

Litigation is ongoing with over a Hundred Million Dollars in claims still unresolved.

Case Study

Miller Park Stadium

Cranes, Derricks, Hoists, Elevators, and Conveyors

Knowledge Check

1. Nearly 45% of crane accidents are the result of the boom or crane making contact with ____.

a. other cranesb. work zone barricadesc. energized power linesd. workers on the ground

Cranes, Derricks, Hoists, Elevators, and Conveyors

2. Before beginning equipment operations, the employer must ___.

a. identify the work zone and determine proximity to power lines

b. notify utility company of lift and estimate voltage of power lines

c. locate the fall zone and test load by lifting it at least 20 feet off the ground

d. remove hazard area barriers and observe weather conditions

Knowledge Check

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Cranes, Derricks, Hoists, Elevators, and Conveyors

3. A broken window that distorts the operator’s visibility of the task is acceptable for operation.

a. True

b. False

Knowledge Check

Cranes, Derricks, Hoists, Elevators, and Conveyors

4. Which of the following must be readily available to the crane operator for use at all times?

a. Load charts and recommended operating speeds

b. Special hazard warnings

c. Instructions and operator’s manual

d. All of the above

Knowledge Check

Cranes, Derricks, Hoists, Elevators, and Conveyors

5. Who is responsible for inspecting all machinery and equipment prior to each use and during use, to make sure it is in safe operating condition?

a. Certified person

b. Qualified person

c. Proficient person

d. Competent person

Knowledge Check