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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
2
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
3
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
4
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
5
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
6
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
7
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
8
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
9
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
10
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.
11
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
12
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
13
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
14
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
15
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
16
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
17
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
18
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
19
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
20
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
21
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
22
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
23
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
24
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