Overhead_Crane_Instructors_Notes.pdf

8/20/2019 Overhead_Crane_Instructors_Notes.pdf

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OVERHEAD CRANE

OPERATOR

SAFETY TRAINING

OVERHEAD CRANE

OPERATOR

SAFETY TRAINING


2/67

TYPES OF OVERHEAD CRANESTYPES OF OVERHEAD CRANESTYPES OF OVERHEAD CRANES

Floor Mounted Jib

Bridge Crane

Wall Mounted JibMonorail Crane

Here is an assortment of overhead cranes.

Take pictures of the different types you may have at your facility and put them on

this page. You may also replace other pictures and drawings in this

presentation. To do so:1. Download a picture from a digital camera or scan a picture onto your

computer.

2. Click on the “insert’ button on the toolbar above and select picture>from file

and then go to where the picture is stored on your computer. Click on that file

and it is inserted on the current slide.

3. You may crop it, downsize it, add borders and lighter or darken it. It’s easy

and adds immensely to the presentation.

4. You may also create a hyperlink from a smaller picture to a picture that takes

up the whole slide to see the details better. To do this, a) right click on the

picture, left click on ‘action settings’, select ‘hyperlinks, and then scroll downto the slide where the full size picture is. A good place for it is at the end of

the slide show. Be sure to create a hyperlink back the the original slide to ease

in navigating back and forth between slides.

5. Many of the pictures in this presentation have hyperlinks to a full size picture

at the end of the presentation. Once you have created a hyperlink, it will stay

with that slide no matter what order you put the slides in.


3/67

OVERHEAD CRANE REGULATIONSOVERHEAD CRANE REGULATIONS

• 29 CFR 1910.179 Overhead cranes and gantries

• 29 CFR 1926.554 Overhead hoists

• ASME B30.2 Overhead and gantry cranes (Top

running bridge, single or multiple girder, top

running trolley hoist)

• ASME B30.11 Monorails and underhung cranes

• ASME B30.16 Overhead hoists (underhung)

• ASME B30.17 Overhead and gantry cranes (Top

running bridge, single girder, underhung hoist)

These are the main standards concerning overhead cranes but certainly not all of

them. Many States have additional standards as do some industries such as

Maritime, Mining, Offshore oil platforms, etc.

We have included only the two OSHA standards and the B30.16. This is becausethe are almost identical when it comes to operation and inspections.


4/67

TYPES OF INSPECTIONTYPES OF INSPECTION

FREQUENT: Frequent inspections are visual inspections andexaminations by the operator or other designated personnel.

Records are not required. Inspection intervals are:

• Daily to monthly

PERIODIC: Periodic inspections are visual and audio inspections and

examinations by designated personnel making records of external

conditions to provide the basis for continuing evaluation.

• 1 to 12 month intervals

29 CFR-1910.179(j)(1)(ii)

Inspection procedure for cranes in regular service is divided into two general

classifications based upon the intervals at which inspection should be performed.

The intervals in turn are dependent upon the nature of the critical components of

the crane and the degree of their exposure to wear, deterioration, or malfunction.

The two general classifications are herein designated as "frequent" and

"periodic" with respective intervals between inspections as defined below:

1910.179(j)(1)(ii)(a)

Frequent inspection - Daily to monthly intervals.

1910.179(j)(1)(ii)(b)

Periodic inspection - 1 to 12-month intervals.


5/67

DEFINITIONS OF SERVICEDEFINITIONS OF SERVICE

Normal Service: Involves operations of the crane with randomlydistributed load within the rated load limit or uniform loads of

less than 65% or rated load limi t for no more than 25% of the time

for a normal work shift.

Heavy Service: Involves operation of the crane within the rated loadlimit t hat exceeds normal service.

Severe Service: Involves operation of the crane in normal or heavyservice with abnormal operating conditions.

1. Some cranes are used more than others.

2. The frequency of service is a key factor in determining how often the crane

should be inspected and serviced.

3. Even cranes that are not used need to be inspected, lubricated and maintained.

Especially cranes that are out in the weather all year or in corrosiveenvironments.


6/67

MONTH ___________________

Date Completed: _______ Inspected by: ___________

I NS PE CTION AREA I NS PE CTION RES ULTS

Sat. Unsat. N/A CommentsSupporting Structure

Welds

Bolts

Bridge

Rails & Alignment

Trucks & Wheels

Motor & Drive Train

Brakes

Stops & Limit Controls

Trolley

Wheels

Motor & Drive Train

Brakes

Stops & Limit Controls

Rails & Alignment

Hoist

Wire Rope Condition

Rope Reeving

Chain Condition

Brakes & Ratchets

Equalizer Sheaves

Hoist Limit Control

Functional Operation

Electrical

Control Markings

Control Functions

Warning Alarms

Power Disconnect

Control Pendants

Festoons

Load BlockSheaves

Pins

Swivel

Hook

INSPECTION CHECK LISTINSPECTION CHECK LIST

1. This is a sample of the inspection booklet found on your CD. You can print

one out for every crane. There are two versions, this one, and one that has

check boxes at the bottom of the page for the operator to initial that he has

performed a pre-shift inspection.

2. This is a good time to go out to one of the cranes in your facility and do an

inspection of it.

3. Pre-shift inspections do not have to be lengthy. You are basically looking for

obvious things that might be wrong with the crane.

4. Monthly or yearly inspections, of course, should be thorough and performed

by a competent individual.


7/67

SUPPORTING STRUCTURESUPPORTING STRUCTURE

Note The Accumulation

Of Dirt And/or Paint

CHECKING FOR TIGHTNESS

Cracks In Paint Or Dirt Build up

Often Is Caused By Loose Bolts.

1. Check all fasteners for loose, stretched, missing, or broken fasteners.

2. A good clue is checking for cracked paint around the fastener that shows there

has been movement.

3. Sometimes a build up of dirt or grease can do the same thing.

4. Using a torque wrench to check for tightness does not always work.Corrosion could give you a false reading.

5. Replace a loose or stretched bolt rather than tighten it. It probably has been

damaged.

6. Be sure to replace the bolt with a grade 8 or better.

7. If there are other bolts near by that show signs of looseness, then replace them

all.


8/67

Inspect Welds

For Cracks

CRACKED WELDSCRACKED WELDS

1. Check cracks in the structure and in all welds.

2. A crack in a weld will always start on the end and work itself along the entire

weld until it fails completely.

3. Many times a crack in the paint will be a clue to a weld that is failing.

4. If caught early, the crack many times can be ground out and re-weld.

5. Before welding on any part of the crane, make sure you have a certified

welder and if it is on a structural part of the crane you should get the

manufactures procedure.

6. Also, try to determine why it cracked in the first place. Is the crane being

overloaded or used improperly.


9/67

BRIDGE SYSTEMBRIDGE SYSTEM

Support

System

Bridge

Rails

Span

Structure

Bridge

Trucks

Bridge Drive

Power Panel

1. Climbing up a and checking the bridge system is normally not part of the daily

inspection. Use these slides to familiarize the student with the components of

the bridge crane and how they work together to make a successful lift.

2. Many of these components can be inspected from the ground as the crane is

being operated. If something seems wrong, then a closer look would be

warranted.


10/67 1

BRIDGE TRUCK DRIVEBRIDGE TRUCK DRIVE

Drive

Motor

Motor

Brake

Final

Drive

Shaft

Drive

Wheels






warranted.


11/67 1

DRIVE COUPLINGSDRIVE COUPLINGS

Check Couplings for:

• Loose bolts

• Loose or missing keys

• Cracks






warranted.


12/67 1

DRIVE MOTOR BRAKEDRIVE MOTOR BRAKE

Brake

Solenoid

Brake

Drum

Brake

Shoes






warranted.


13/67 1

WHEELTREAD

WEAR AT AN

ANGLE

WHEEL FLANGE

WEAR

WHEEL ALIGNMENT FOR BRIDGE CRANEWHEEL ALIGNMENT FOR BRIDGE CRANE

HEAVYWEAR






warranted.


14/67 1

TROLLEY SYSTEMTROLLEY SYSTEM

Hoist Machinery

mounted on trolleyTrolley Trucks






warranted.


15/67 1

MONORAIL CRANE TROLLEYMONORAIL CRANE TROLLEY

TROLLEY WHEELS

FUNCTION SMOOTHLY

TROLLEY WHEELSCENTERED ON

BEAM

WHEELS IN

GOOD CONTACT

WITH BEAM FLANGE

1. Climbing up a and checking the monorail system is normally not part of the

daily inspection. Use these slides to familiarize the student with the

components of the bridge crane and how they work together to make a

successful lift.



warranted.


16/67 1

WIRE

STRAND

WIRE ROPE

WIRE ROPE CONSTRUCTIONWIRE ROPE CONSTRUCTION

PROPER WAY TO MEASUREWIRE ROPE DIAMETER

Wire Rope Replacement

Broken Wires: 6 randomly distributed

broken wires in one lay, or three broken

wires in one strand in one lay.

Loss in Diameter: Reduction from

nominal diameter of:

1/64” for dia. up to & including 5/16”

1/32” f or dia. 3/8” t o & includ ing 1/2”

3/64” for dia. 9/16” to & including 3/4”

1. Wire rope comes in various sizes and construction. The most common is the

right regular lay wire rope of the 6X19 class.

2. The strands of a wire rope are made up of several wires twisted together.

3. Several strands are twisted together to form the wire rope.

4. Common wire rope will have either a fiber core or an independent wire ropecore or IWRC. For lifting purposes, IWRC is recommended because it resist

crushing.

5. The designation, 6X19, refers to the basic construction. The ‘6’ stands for the

number of strands, not counting the core, that are used in the rope. The ‘19’ refers

to the number of wire in each strand.

6. When measuring the diameter of wire rope, make sure to measure across the

stands and not the flat area between the strands.

29 CFR 1910.176(h)(2)(i)

In using hoisting ropes, the crane manufacturer's recommendation shall be

followed. The rated load divided by the number of parts of rope shall not exceed

20 percent of the nominal breaking strength of the rope. (or a 5:1 safety ratio)


17/67 1

ABRASION RESISTANCE

Increases with larger wiresDecreases with sm aller wires

FATIGUE RESISTANCE

Decreases with fewer wiresIncreases with more wires

WIRE ROPEWIRE ROPE

STANDARDS FOR SHEAVE

& DRUM RATIOS

D = Diameter of drum or sheave

d = Diameter of wire rope

Ratio = D / d

ASNE/B30.5 “ MOBILE CRANES”Minimum Ratios

Drum Sheave

Load Hoist 18 18

Boom Hoist 15 15

Load Block 16

1. Point out the trade-offs between abrasion and fatigue resistance.

2. Show how sheave size and wire rope diameter relate to each other and the

effects they have on wire rope life.

3. Review how sheaves are dimensioned.


18/67 1

WIRE ROPE INSPECTIONWIRE ROPE INSPECTION

Crossed lines on drum

Heavy loads over small sheaves

Accentuated wi th heavy loads

Improper socketing, kinks

Sudden tension release

Repeated bending, normal loads

KINKED WIRE ROPE

STRAND KNICKING

FATIGUE FAILURE

HIGH STRAND

BIRDCAGE

FATIGUE BREAKS

29 CFR – 1910.179(m)(1) Running ropes. A thorough inspection of allropes shall be made at least once a month and a certification record which

includes the date of inspection, the signature of the person who performed the

inspection and an identifier for the ropes which were inspected shall be kept on

file where readily available to appointed personnel. Any deterioration, resulting in

appreciable loss of original strength, shall be carefully observed and determinationmade as to whether further use of the rope would constitute a safety hazard. Some

of the conditions that could result in an appreciable loss of strength are the

following:

(i) Reduction of rope diameter below nominal diameter due to loss of coresupport, internal or external corrosion, or wear of outside wires.

(ii) A number of broken outside wires and the degree of distribution orconcentration of such broken wires.

(iii) Worn outside wires.

(iv) Corroded or broken wires at end connections.(v) Corroded, cracked, bent, worn, or improperly applied end connections.

(vi) Severe kinking, crushing, cutting, or unstranding.


19/67 1

DRUM INSPECTIONDRUM INSPECTION

1. Check to make sure the wire rope is spooled properly on the drum.

2. On lagged drums, make sure the rope hasn’t jumped a groove which could

damage the rope.

3. Check to make sure the dead end is secured properly.

4. Never hoist down to the point that there would be less than 2 wraps left on thedrum.

5. Check oil often.


20/67 2

HOIST MACHINERYHOIST MACHINERY

CHECK DRUM

GROOVES FOR

WEAR

HOIST

DRIVE

TROLLEY

TRUCK

1. Check to make sure the wire rope is spooled properly on the drum.

2. On lagged drums, make sure the rope hasn’t jumped a groove which could

damage the rope.

3. Check to make sure the dead end is secured properly.

4. Never hoist down to the point that there would be less than 2 wraps left on thedrum.

5. Check oil often.


21/67 2

HOIST MACHINERYHOIST MACHINERY

SINGLE REEVED DRUM DOUBLE REEVED DRUM

VERIFY

FUNCTIONING

LIMIT SWITCH

CHECK

RUNNING

SHEAVE

FOR WEAR

CHECK

EQUALIZING

SHEAVE

FOR WEAR

CHECK

CLEVIS

WEAR

1. Check running and equalizing sheaves for wear and free movement.

2. Check the limit switch to make sure it stops the hook or load if two-blocked.

3. Check the oil often, especially if you detect any leakage.


22/67 2

WORN GROVES PROPER SIZE GROVE

CHECK FLANGES FOR

CHIPS, CRACKS, WEAR

CHECK BEARINGS FOR

WOBBLE, GREASE, EASE

OF ROTATION

MEASURE GROOVE

INSPECTING SHEAVESINSPECTING SHEAVES

CHECK GROOVE

WEAR

150º

CONTACT

1. Check for bearing wear and lubrication.

2. Check the flanges and treads.

3. Show how to use a sheave gauge.

4. Sheaves can only be repaired per manufacture’s procedures.


23/67 2

CHAIN HOISTCHAIN HOIST

Bent Links Stretched Links Worn Links

Chain

Guide

PocketWheel

The chain hoist should be checked for the following:

1. Bent links (Usually a sign that it has been used to wrap around a load and bent

on sharp corners)

2. Stretched links. The links will be sucked in slightly on the sides. Also,measure 5 links and check that measurement during your annual inspection.

3. Chain should not be rusted or brown. If the crane is in a corrosive atmosphere,

be sure to oil it often.


24/67 2

HOOK INSPECTIONHOOK INSPECTION

Wear & Deformatio n

“ Opening Up”

Wear & Cracks

Cracks &

Twisting

[ Wear

[ Deformation[ Cracks & Sharp Nicks

[ Modifications

[ Safety Latches

[ Swivel Wear & Lubrication

[ Hook Shackle Mousing

CHECK FOR:

1. Hooks with threads and nuts need to have threads inspected periodically.

2. Hooks can only be repaired per manufacturer’s procedures.

3. Wear in excess of 5% in the neck of the hook and 10% in other areas including

the bow of the hook is cause for removal.

4. An increase in the hook throat opening of more than 15% is cause for removal.

5. Any twist in the hook of more than 10% is cause for removal.

6. The hook safety latch should be present and function properly.

Accident 014504732 - Employee Killed When Struck By Loose Crane Hook

At approximately 8:15 am on January 29, 1990, employee #1 was working on a

large steel panel weighing approximately 2,608 pounds and measuring 22 feet

long and 6 feet wide. The panel was supported by an overhead crane chain and

hook and was set on metal horses at an angle. The hook slipped off of the

steel panel and struck employee #1 on the head, resulting in his death.


25/67 2

HOOK INSPECTIONHOOK INSPECTION

10o

Throat

Opening

Twisted

Hook

15%

10 percent

Maximum

Al lowab le

Wear

1. Hooks with threads and nuts need to have threads inspected periodically.

2. Hooks can only be repaired per manufacturer’s procedures.

3. Wear in excess of 5% in the neck of the hook and 10% in other areas including

the bow of the hook is cause for removal.

4. An increase in the hook throat opening of more than 15% is cause for removal.

5. Any twist in the hook of more than 10% is cause for removal.

6. The hook safety latch should be present and function properly.


26/67 2

CRANE BLOCKCRANE BLOCK

SIDE PLATE

BOLTS TIGHT

SHEAVE PIN

& BEARING

TIGHT

SAFETY

LATCH

FUNCTIONING

CHECK FOR DISTORTIONS

OR WEAR

SHEAVE GROOVE

NOT WORN, SHEAVES

TURN FREELY

HOOK NUT

TIGHT

& THEADS

INSPECTED

PERIODICALLY

HOOK ROTATION &SWIVEL SMOOTH &

TIGHT

SHEAVE PIN

KEEPER IN PLACE

AND TIGHT

1. The sheaves and bearings need to be inspected as discussed earlier.

2. The side plates and any additional weights attached to the their sides need to be

inspected for loose or missing bolts or other fasteners.

3. The hook should rotate freely on the swivel bearing. Check for excessive

movement.4. The hook shank and nut should be separated periodically and the threads

inspected for corrosion and other damage. The lose of more than 20% of the

treaded area due to corrosion is cause for removal.

5. The safety latch must be in place and functioning properly.


27/67 2

ELECTRICAL CONDUCTORSELECTRICAL CONDUCTORS

Current Collectors

ride on this surface

Check Conductors for:

• Loose fasteners

• Burned surfaces

• Dirt and corrosion• Electrical connections

Always lock out the crane before working around the electrical conductors.


28/67 2

CURRENT COLLECTORSCURRENT COLLECTORS

Current Collectors ride

against conductors

ElectricalConductors

Check Collectors fo r:

• Good spring tension

• Collector surfaces are

not corroded or burned

• Electrical connections

• Ease of movement

Always lock out the crane before working around the electrical conductors.


29/67 2

FESTOON SYSTEMSFESTOON SYSTEMS

CABLE TERMINATION

INSULATORS

IN GOOD

CONDITION

PROPER

CABLETENTION

FREE TROLLEY

MOVEMENT

ELECTRICAL

CONNECTORS

TIGHT

STRAIN RELIEF

ADJUSTED FOR

CORRECT

LENGTH

1. Festoons need to be checked for proper cable tension, free trolley movement

and wire connections.

2. Also, make sure there are no pinch points during bridge or trolley movement.


30/67 3

PENDANT AND CONTROLSPENDANT AND CONTROLS

ALL CONTROL

FUNCTIONS

CLEARLY

LABELED

1. Many times the pendant controls get dropped or banged up during operation.

2. Never use the pendant to pull the crane around.

3. Use a strain relief chain or cable to protect the wires from pulling out.

4. Make sure all controls are marked and legible.

5. Check for buttons that are broken or stick.

6. Always check the emergency stop button on the pendant.


31/67 3

MAX. SWL 10,000 lbs

ACME5 TON ACME5 TON

MAX. SWL 10,000 lbs

Know the SWL of the crane and

never exceed it

Follow all placards, warninglabels and signs on machine

SAFE CRANE OPERATIONSSAFE CRANE OPERATIONS

1. The safe-working-load of the crane should be easily visible to the operator.

2. The safe working load would be the maximum load of the “weakest link” on the

crane. For example: If the maximum SWL of the hoist was 5 tons, then the

SWL, but the beam that it was hung under was good for 7 ½ tons, the SWL of

the crane could not exceed 5 tons and if stenciled on the beam, it should reflect

the 5 ton rating.

3. All warning labels on the crane including crane operation instructions must be

on the crane and legible.

29 CFR 1910.179(b)(5) Rated load marking. The rated load of the craneshall be plainly marked on each side of the crane, and if the crane has more than

one hoisting unit, each hoist shall have its rated load marked on it or its load

block and this marking shall be clearly legible from the ground or floor.


32/67 3

LOCK-OUT TAG-OUTLOCKLOCK--OUT TAGOUT TAG--OUTOUT

NGER

DO NOT

OPERATE

ALWAYS DE-ENERGIZE ELECTRICAL

SYSTEMS BEFORE INSPECTING AND

WORKING ON THEM.

Before adjustments and repairs are started on a crane the following precautions

shall be taken:

29 CFR - 1910.179(l)(2)(i)(a) The crane to be repaired shall be run toa location where it will cause the least interference with other cranes and

operations in the area.

(b) All controllers shall be at the off position.

(c) The main or emergency switch shall be open and locked in the open position.

(d) Warning or "out of order" signs shall be placed on the crane, also on the floor beneath or on the hook where visible from the floor.

(e) Where other cranes are in operation on the same runway, rail stops or othersuitable means shall be provided to prevent interference with the idle crane.

1910.179(l)(2)(ii) After adjustments and repairs have been made the craneshall not be operated until all guards have been reinstalled, safety devices

reactivated and maintenance equipment removed.

1. The emergency shut off musts be visible and accessible.


33/67 3


Acme Bridge Crane

Operation and

Maintenance

Manual

ACME CORPORATION

Read and understand

the operators manual

The Operator and Maintenance Manual should be available and every person that

operates the crane should have read the safe operations section.


34/67 3

Determine the

weight of the load

from accurate

sources

Acceptable methods of determining weight

You may find the weight from:

Data on manufacturing label plates.

Manufacturer documentation.

Blueprints or drawings.

Shipping receipts.

Weigh the item.

Bill of lading (be careful)

Stamped or written on the load

Approved calculations

Never use word of mouth to establish the weight of and item!


1. Knowing the weight of the load is essential to safe overhead crane operations.

With mobile cranes, picking up a load that is too heavy could cause the crane

to tip. Not so with overhead cranes. Severe damage could result in trying to

lift a load that exceeds the SWL.

2. There are many ways to learn the weight of a load. The most accurate is, of

course, weighing it yourself.

3. If you do weigh an item, be sure to mark the weight somewhere on the load

for the next guy that has to lift it.

4. There will be times when you just have to make an a guess. Using the best

calculations that you can, come up with an estimate and then double it. It it is

well within the capacity of the crane, go ahead and make the lift. If by

doubling it, it is within 75% of the capacity of the crane, then you should

weigh it.


35/67 3

Cranes shall not be used

for side pulls except when

specifically author ized by a

responsible person who

has determined that the

stability of the crane is not

thereby endangered and

that various parts of the

crane will not be

overstressed.


MAX. SWL 10,000 lbs MAX. SWL 10,000 lbs

ACME5 TON

5TON

29 CFR - 1910.179(n)(3)(iv)

Cranes shall not be used for side pulls except when specifically authorized by a

responsible person who has determined that the stability of the crane is not

thereby endangered and that various parts of the crane will not be

overstressed.

1. Side pulling on a crane may cause the wire rope on the drum to cross and be

susceptible to kinks and crushing.

2. It could also put stress on the trolley causing damage.


36/67 3


ACME5 TON

5TON

Never hoist a load

over the heads of

employees


29 CFR – 1910.179(n)(3)(vi)

The employer shall require that the operator avoid carrying loads over people.

1. Never allow a rigger to stand under a load as it descends for the purpose of

controlling it.2. Use a tag line instead.


37/67 3


ACME5 TON

5TON


The employer shall

insure that the

operator does not

leave his position at

the controls while

the load is

suspended.

29 CFR – 1910.179(n)(3)(x)

The employer shall insure that the operator does not leave his position at the

controls while the load is suspended.

1. Always put the load down and secure it before leaving the area.


38/67 3

The operator shall test the

brakes each time a load

approaching the rated

load is handled. The

brakes shall be tested by

raising the load a few

inches and applying the

brakes.

MAX. SWL 10,000 lbs

ACME5 TON ACME5 TON

MAX. SWL 10,000 lbs


8,750 lbs

29 CFR - 1910.179(n)(3)(vii)

The operator shall test the brakes each time a load approaching the rated load is

handled. The brakes shall be tested by raising the load a few inches and

applying the brakes.

1. As brakes become worn, they may stop a smaller load, but not one at or nearcapacity.

2. It is good practice to load test your crane at least every 3-4 years.


39/67 3



ACME5 TON

5TON

The load shall not be

lowered below the

point where less than

two full wraps of rope

remain on the hoisting

drum.

29 CFR - 1910.179(n)(3)(viii)

The load shall not be lowered below the point where less than two full wraps of

rope remain on the hoisting drum.

1. You never want to run out of hoist line. Many cranes have automatic stops that

can be set so this will not happen. Still it is good practice to check you line whenlowering loads down close to the limit of your line.


40/67 4

At the beginning of each

operator's shift, the

upper limit switch of

each hoist shall be tried

out under no load.


29 CFR - 1910.179(n)(4)(i)

At the beginning of each operator's shift, the upper limit switch of each hoist shall

be tried out under no load. Extreme care shall be exercised; the block shall be

"inched" into the limit or run in at slow speed. If the switch does not operate

properly, the appointed person shall be immediately notified.

1. The upper limit switch will keep the load or hook from being pulled into to

hoist, possibly parting the line.

2. Never use the limit switch to operate lower your load.


41/67 4


• Read and understand the operators manual• Follow all placards, warning labels and signs on machine

• Know the SWL of the crane and never exceed it

• Determine the weight o f the load from accurate sources

• If an estimate of the load is near the max. capacity of the crane,

then use a dynamometer to measure the exact weigh t

• Use a loud signal, such as a whistle, horn or bell or verbal

warning to alert employees of crane movement

• Never hoist a load over the heads of employees

• Never use limit switches or end stops as operating controls

• Begin each shift by testing the upper limit switches

• Avoid running the crane in to the end stops or l im it switches

• Never walk backward when guid ing a load

Summary of safe crane operations


42/67 4


• Never hoist tw o or more separately rigged loads on a single hook

even if the combined weight is wi thin the capacity of the crane

• Never wrap the hoist line around the load

• Never electrical load and/or hoist -limit swit ches or warning devices

• Start lifts slowly and avoid shock loading

• Always place the hook d irect ly over the center o f g rav ity or the

designated lifting point

• Use taglines to help maneuver the load

• Never use taglines to sw ing the load

• Before hoisting the load, check for loose parts that might shift o r fall

• On cranes with wire rope hoist lines, there should never be less than

two wraps on lagged (grooved) drums and three wraps on unlagged

• When lifting near or at capacity, test the brakes after the load is

raised a few inches

• Suspend and transport loads at a level that allows the operator a

clear view• Never drag slings, cables or chains across the floor



43/67 4


Cab-operated overhead cranes:

• Enter and exit cab only through approved access ways

• Never walk along runway tracks

• Never climb o r jump from one crane to another

• Use both hands to cl imb access ladder

• Keep unnecessary items out of the cab

• Complete the pre-shift inspection checklist before operation

• Know the location of emergency shutoff switches

• Know emergency evacuation routes

• Place all controls in the OFF position before turning the main switch ON

• Maintain a portable fire extinguisher in the cab

• Never move the cab without a signal from the designated signal giver

• Avoid bumping crane and carriage s top b locks

• If a power failure occurs , place all contro ls in the OFF positi on

• Park the cab in an approved, designated posi tion



44/67 4

HAND SIGNALSHAND SIGNALS

Mult iple Trol leys Bridge Direction Trol ley Direction Move Slowly

Emergency StopStopRaise LoadLower Load

1. Hand signal charts should be posted in the work area.

2. Always have one person designated as the signal giver.

3. Use clear precise motions.

4. Review each hand signal and any other hand signals you might be using

5. Anyone can give the emergency stop signal.


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WIRE ROPE SLING INSPECTIONWIRE ROPE SLING INSPECTION

1. Wire rope slings are to be inspected on a regular basis and a record kept of

these inspections. Refer to the inspection card for inspection criteria.

2. As of July 2000 wire rope slings are to have a tag which indicates the lifting

capacities of the sling for vertical, choker, and basket hitches.


46/67 4

COMMON CAUSE FOR REMOVALCOMMON CAUSE FOR REMOVAL

Severe wear, abrasion or scraping

Kinking

1. Kinking in the eyes and other parts of the wire rope sling is nearly always the

result of it going around a pin or pick point that is of a less diameter than the

rope itself.

2. Using slings with thimbles in the eye will prevent this.

3. It is not recommended using a wire rope sling in a tight choker.


47/67 4

FLEMISH EYEFLEMISH EYE

Separate rope into 2 part,

3 adjacent strands and 3

adjacent s trands and co re.

These 2 parts are re-laid

back in opposite directions

to form an eye and the ends

are secured with a pressed

steel sleeve.

1. The Flemish eye is also know as a “Molly Hogan” or a “Farmers” eye.

2. The strength of the eye is in the wrap and not the steel sleeve.

3. They may be used with a thimble also.


48/67 4

PRESSED STEEL SLEEVE

TURNBACK EYETURNBACK EYE

1. Turnback eyes are made by bring the rope back onto itself and crushing a

steel sleeve around it.

2. The strength of the eye is in the sleeve and if not done properly may pull out.

3. Turnback eyes are not recommended for lifting.


49/67 4

TYPES OF TERMINATIONSTYPES OF TERMINATIONS

1. Wedge sockets are very handy if you are changing blocks or hooks often.

2. Slings should not be used that have eyes made with wire rope clips.

3. Eyes made with wire rope clips may be used to terminate the dead end of the

hoist line.


50/67 5

CHAIN SLING INSPECTIONCHAIN SLING INSPECTION

1. Chain slings are to be inspected on a regular basis and a record kept of these

inspections. Refer to the inspection card for inspection criteria.

2. Chain slings are often used to hold steel while it is being welded. Always

check to make sure no heat damage has occurred. Heat damage can be detected

by discolored metal.


51/67 5

SYNTHETIC SLING INSPECTIONSYNTHETIC SLING INSPECTION

1. This slide and the next two show the different types of sling damage that can

occur. Refer to the inspection record of additional inspection criteria.

2. Synthetic slings are required to be inspected on a regular basis and a record kept

of such inspections.

3. Never tie a knot in a flat sling to shorten it.4. Never use synthetic slings around high heat sources or hot work.

5. When taking a sling out of service, cut the eyes in it or destroy it. If you don’t it

may find its way back into service.


52/67 5

SYNTHETIC SLING INSPECTIONSYNTHETIC SLING INSPECTION

1. The manufacturer’s tag should be on the sling and contain the SWL.

2. This tag must also be legible.

3. Nylon slings are also susceptible to damage through ultra-violet light. Always

keep your slings out of the sun when not in use.

4. Wet nylon slings can be used but lose 15% of their strength.


53/67 5

SHACKLESSHACKLES

DEFORMATION BOLT SUBSTITUTION WEAR

1. Shackles must be load rated and have the WLL written on them along with the

manufacturer and country where they were made.

2. Only shackles of the screw pin or bolt type may be used for lifting.

3. If a shackle is used as a permanent part of the hoist line, then it must be

moused closed or use the bolt type with a cotter pin.4. Shackle that only use a cotter pin to keep the pin in are not legal for lifting.

When inspecting them, look for:

• Wear

• Deformation

• Pin or bolt substitution

• Non-rated shackles

• Worn threads on the pin


54/67 5

SHACKLESSHACKLES

IN-LINE45 DEGREES

90 DEGREES

LOAD

Side Loading Reduction Chart

For Screw Pin & Bolt Type Shackles Only†

0° In-Line

45° from In-Line

90° from In-Line

100% of Rated Working Load Limit

70% of Rated Working Load Limit

50% of Rated Working Load L imit

Ang le of Side Load Adj ust ed Wor king L oad L imi t

† DO NOT SIDE LOAD ROUND PIN SHACKLES

1. The working load limit, WLL, shown on the shackle is for vertical loads.

2. Round pin shackles are ones which do not have a nut on the end of the pin and

should not be used for lifting..


55/67 5

EYE BOLTSEYE BOLTS

DO NOT REEVE SLINGS ONE EYE BOLT

TO ANOTHER. L OAD ON BOLT IS ALTERED.

WRONG!

CAUTION!

STRUCTURE MAY BUCKLE FROMCOMPRESSION FORCES.

DIRECTION OF PULL ADJUSTED WORKING LOAD

In-Line

45 Degrees

60 Degrees

Full Rated Working Load

30% of Rated Working Load

60% of Rated Working Load

1. The rated capacity of a eye bolt drops significantly when pulled other than

vertically.

2. Emphasize the dramatic drop to the students.

3. Threading a sling through the eye bolts increases the stress on the eye bolts by

two and should never be done.


56/67 5

BELOW-THE-HOOK LIFTING DEVICESBELOW-THE-HOOK LIFTING DEVICES

BALANCED

“ C” HOOK

BALANCED

PALLET FORKTELESCOPIC

COIL GRAB

COIL

LIFTING

HOOK

1. These are a few of the types of below-the-hook lifting devices. There are

many more.

2. Be careful of home-made lifting devices.

3. Any lifting device must be load rated and have a manufacturer’s nomenclature

plate on it indicating its weight and SWL.4. Add pictures of the different types of lifting devices you have at your facility,

including: spreader and lifting beams, plate clamps, barrel clamps or hooks.


57/67 5

SLING ANGLESSLING ANGLES

Tension in slings

Compression in load

Sling Angle

Stresses in the sli ngs and the load increase as the sli ng angle decreases

1. When slings are brought together and form a hitch arrange as shown above the

stresses in the slings increase and a compression force on the load is created.

2. As the sling angle decrease the stresses in the sling and on the load increase.


58/67 5

1000 lbs

1 0 0 0

l b s

1000 lbs

5 0 0

l b s

5 0 0

l b s

1000 lbs

5 7 5

l b s

5

7 5 l b

s

1000 lbs

7 0 5 l b

s7 0 5 l b

s

1000 lbs

1 0 0 0

l b s 1 0 0 0 l b s

1000 lbs

5 7 3 5 l b s 5 7 3 5 l b s


5°

60°

45° 30°

1. Review each of the different sling angle configurations and point out the increase

in the stresses.

2. Sling angles of 60 degrees are the best to use because of the minimal increase of

stress in the slings. When required to use smaller sling angles, slings need to be

selected based on the increased stress and not on the weight of the load.

3. When the sling angle is 30 degrees for a 1000 lbs load, the compression loads

which are crushing the load will be 866 lbs. Depending on the structural strength of

the load, it may be damaged.


59/67 5

1000 lbs 1000 lbs 1000 lbs

5 0 0

l b s

5 0 0

l b s

A

Factor of Angl e “ A”

Load in each sling

leg = 500 x Load Ang le Factor

H

L

A

Sling Angle Degree (A) Load Angle Factor = L/H

90

60

50

4530

1.000

1.155

1.305

1.4142.000

Load On Each Leg Of Sling = (Load / 2) X Load Angle Factor


1. All that is need to calculate these stress is the weight of the object and a

measuring tape.

2. As shown in the slide above, the length of the sling is divided by the height of

the sling connection to the top of the load.

3. The answer is then multiplied by the portion of the load it is to support and thiswill be the stress in the sling.

Example: If my sling was 8 feet long and the height ‘H’ was 4 feet, 8 divided by 4

equals 2. The portion of the weight the sling is to support is half of 1000 lbs or 500

lbs. 2 X 500 = 1000 lbs which is the stress in the sling.


60/67 6

Acceptable methods of determining weight

You may find the weight from:

Data on manufacturing label plates.

Manufacturer documentation.

Blueprints or drawings.

Shipping receipts.

Weigh the item.

Bill of lading (be careful)

Stamped or written on the load

Approved calculations

Never use word of mouth to establish the weight of and item!

ESTIMATING WEIGHTSESTIMATING WEIGHTS

1. Knowing the weight of the load is critical to a safe lift.

2. Not all information is reliable.

3. The surest way to find the weight is to weigh the load.

4. If the object is solid and made up primarily of one material then you

could calculate the weight.


61/67 6

Calculating the weight

To find the weight of any item you need to know its volume and unit weight.

• Volume x Unit weight = Load weight

• Unit weight is the density of the material

• Unit weight is normally measured by pounds per cubic foot.


1. Anytime you calculate the weight it is really only an estimation. But it will get

you in the “ball park”.

2. Always error on the safe side in your calculations.


62/67 6

34

3634

50

30

53

62

30

30

28

25

50

52

45

64

100

75120

105

TIMBER

Cedar

CherryFir, seasoned

Fir, wet

Hemlock

Maple

Oak

Pine

Poplar

Spruce

White pine

Railroad ties

LIQUIDS

Diesel

Gasoline

Water

EARTH

Earth, wet

Earth, drySand and gravel, wet

Sand and gravel, dry

165

535500

560

480

710

490

460

160

110

140

60

155

110

130

144

150

80

160

METALS

Aluminum

BrassBronze

Copper

Iron

Lead

Steel

Tin

MASONARY

Ashlar masonry

Brick, soft

Brick, pressed

Clay tile

Rubble masonry

Concrete, cinder, haydite

Concrete, slag

Concrete, stone

Concrete, reinforced

MISC.Asphalt

Glass

Here are some examples

of common materials and

their unit weight:

The unit weight is:

pounds per cubic foot


1. It’s wise to have similar “cheat sheets” for materials that you handle frequently.

2. Knowing the unit weight of different materials helps in weight estimation.

3. Knowing the difference between steel (490 lbs), reinforced concrete (150 lbs),

and wood (25-65 lbs) is useful.


63/67 6

If the material was cedar, then all we would have to do to determine

it’s weight would be to multiply the unit weight of cedar x 64.

Unit weight x Volume = Weight

34 lbs. X 64 cubic ft. = 2,176 lbs.

CALCULATING VOLUMECALCULATING VOLUME

Volume of a cube

Length x Width x Height = Volume

8 ft x 4 ft x 2 ft = 64 cubic feet

8 ft long

4 ft wide

2 ft high

1. Cubes are easy to calculate.

2. Finding the weight is as simple as multiplying the volume of the cube by the

unit weight of what it is made of.


64/67 6


Volume of a cylinder

Pi x Radius Squared x Length = Volume

π x Radius² x Length = Volume

3.14 x 1² ft x 10 ft = 31.4 cubic ft

If the material was reinforced concrete, then all we would have

to do to determine it’s weight would be to multiply the unit weight

of reinforced concrete x 31.4.

150 lbs. X 31.4 cubic ft. = 4,710 lbs.

2 ft wide

10 ft long

1. The volume of a cylinder is a little more difficult, but not rocket science.

Having a scientific calculator and knowing how to use it is a good idea.

2. Again, just multiply the volume in cubic feet by the unit weight to find the

weight of the load.


65/67 6

Volume of pipe

Calculating the volume of pipe is a bit trickier but it is

just simply subtracting

the volume of the hole from the volume of the pipe.


If the pipe were one inch thick,

three feet wide and 8 feet long,

then we would figure the volume

of the entire pipe and subtract the

volume of the hole to get the the

volume of the material.

3.14 x (1 ½ ft.)² x 8 feet = total volume of pipe (56.52 ft³)

3.14 x (1ft 5 in.)² x 8 feet = volume of hole (50.41 ft³)

56.52 ft³ – 50.41 ft³ = 6.11 ft³

Volume of material x unit weight = total weight

If this pipe were steel then the unit weight would be 490

lbs.

6.11 x 490 lbs = 2,9994 lbs.

8 ft long

1 in. thick

3 ft wide

1. Finding the volume of a pipe is not too much different than finding the volume

of a cylinder. You just have to do it twice and then subtract the volume of the

hole from the total volume of the pipe.

2. It is helpful to know how to change fractions into decimals. Calculators are a

must for this. To change 1 foot 5 inches (or 17/12ths) into a decimal, simple

divide 12 into 17 which would be 1.4266.


66/67 6

For thin pipe a quick way to *ESTIMATE the volume is to split the pipe

open and calculate the volume like a cube. The formula would be:

π x diameter = width, so:

π x diameter x length x thickness x unit weight = weight of object

3.14 x 3 ft x 8 ft x 1/12 ft (or .08 ft) x 490 lbs = *3,077.2 lbs

8 ft long

3.14 (π) x 3 ft diameter = 9.42 (width)

1/12 ft = 1 in. thick


1. This is only an estimate and should not be used with thick pipe.

2. Simply spit the pipe down the middle and open it up into a thin plate.

3. Then calculate the the volume of the cube that is created.

4. To find the width, multiply pi times the diameter.


67/67

WEIGHT TABLES

Weight tables are an excellent way to calculate load weight.If you are handling certain materials often, then having a chart

that gives you the weight per cubic foot, cubic yard, square foot,

linear foot or per gallon. Here are a few examples:

METAL PLATES

STEEL PLATES weigh approximately 40 lbs per sq. ft. at 1 inch thick.

1/2 inch thick would then be about 20 lbs. per sq. ft.

A steel plate measuring 8 ft. x 10 ft. x 1/2 inch would then weigh about

3,200 lbs. (8 x 10 x 40 lbs = 3,200 lbs.)

BEAMS

Beams come in all kinds of materials and shapes and lengths. STEEL

I-BEAMS weigh approximately 40 lbs a linear ft. at 1/2 inch thick and

8 inches x 8 inches. If it were 1 inch thick then it would be 80 lbs a

linear ft. If it were 20 feet long at 1 inch thick then it would weigh about

1,600 lbs. (20 ft. x 80 lbs. = 1,600lbs.)

WEIGHT TABLESWEIGHT TABLES

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