“Understanding the Importance of Proper Equipment Inspections”

Jeffrey HammonsVP Risk Management

AmQuip Crane Rental LLC

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The inspection and maintenance of equipment should be managed in the same way as any other business activity is, if not carried out effectively, it can have severe safety, compliance, legal and financial implications for a business.

Introduction

The consequences of improper equipment inspections can be unrecoverable….

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“Crane Inspector May Have Been At Fault”

Accidents

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US Labor Department's OSHA proposes $176,000 in fines against Stowe Woodward LLC for hazards at Concord, NH, plant. Eleven serious violations with $49,000 in fines involve a lack of frequent crane inspections.

OSHA cites Mississippi manufacturer with 40 safety and health violations. The company is being cited for 32 serious safety violations with $54,826 in proposed penalties. The violations are associated with failing to install guardrails along open platforms; failing to train workers on lockout/tagout procedures regarding energy sources; failing to conduct periodic inspections of crane, crane hook and hoist chains;

OSHA cites three Ohio-based companies for failing to protect workers from safety and health hazards. Twelve serious safety violations.…..”conduct annual crane inspections, remove defective web slings from service”….

Regulatory

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Legal

Rigging Contractor Is Acquitted in the Collapse of a Crane

Crane Owner Is Cleared of All Charges in Fatal Collapse

Cranes Today. (December 2000). "Mitsubishi faces $99m damages as court finds it to blame for Big Blue's collapse“

Operator in fatal midtown crane collapse involved in two prior accidents, a crane operator licensed by the city of New York since 1996, was questioned in two previous lawsuits where co-workers were injured while he was at the controls. In both court cases, he described alarming circumstances where cranes were given cursory inspections and computerized safety systems were bypassed.

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Reliability & Asset Longevity To ensure proper credit is given for the next slide please

Note: Dan Snook with MTU/Mercedes and Brian Hill with Manitowoc Crane Care put the slide together I am using them for the purposes of this presentation.

• Decrease cost of operation (Support Billing)

• Avoid downtime

• EPA compliance

• Record keeping

• Approval of fluids, lubricants, filters are Important (Seasonal)

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Maintenance recommendations

Why follow the manufacturer’s maintenance recommendations?

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Reliability & Asset Longevity

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Reliability & Asset Longevity

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Financial Accident Costs;

• Reaction to Accident(Direct and Indirect Costs)• Investigation• Cash $ spent under the organization deductible

Insurability

Legal

Reputation

Reliability/longevity of equipment, increased maintenance costs, Warranty

Prequalification Difficulties

Additional Overhead costs such as, LC professionals, Insurance involvement, Development and Implementation of Policy, Best Practices to eliminate potential for future reoccurrence.

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Types of Inspections

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Types of Inspections

1. Modified Cranes — Anytime a crane is modified, the modification must be inspected by a qualified person. According to 1926.1434 (a), modifications or additions which affect the capacity of a crane or safe operation of the crane are not permitted except when the manufacturer has reviewed and approved the modification. The manufacturer must provide updated load charts, manuals, procedures, or labels as needed. If the manufacturer refuses or fails to review the modification request within 30 days, a registered professional engineer (who is qualified with respect to the crane and modification) can approve the modification, but must provide the same information that the manufacturer would have provided. In addition, cranes can be modified if the original safety factor of the crane is not reduced.

EXAMPLE: adding aluminum walkway to the top of lattice boom

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2. Repaired/Adjusted Cranes —Anytime a crane has had a repair to a component that relates to safe operation, it must be inspected by a qualified person prior to initial use.

EXAMPLE: Repairing damaged lacing

3. Post Assembly —After assembly is completed, the crane must be inspected by a qualified person. Tower cranes must also have a pre-assembly inspection and require a test lift to complete post assembly inspection.

4. Shift inspection —OSHA no longer requires a daily inspection; instead shift inspections must be done by a competent person. This inspection is not required to be documented, recall rope requirements.

5. Monthly Inspection —The monthly inspection is simply a documented shift inspection done by a competent person. The employer is responsible for maintaining the last three monthly inspections, and they must be made available to an inspector.

Types of Inspections

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6. Annual/Comprehensive Inspection —This inspection must be performed by a qualified person and must be documented. Disassembly is required, as necessary, to complete the inspection. In addition, a functional test must be performed. Any deficiencies must be assessed to determine if they represent safety concerns. If so, the crane must be taken out of service until repairs are made.

7. Severe Service - Where the severity of use/conditions is such that there is a reasonable probability of damage or excessive wear. The employer must stop using the equipment and a qualified person must inspect the equipment for structural damage to determine if the equipment can continue to be used safely.

8. Equipment not in regular use inspection —Equipment that has been idle for 3 months or more must be inspected by a qualified person in accordance with the (Monthly) inspection before initial use.

Types of Inspections

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Types of Inspections

Lets look at an Rough Terrain (RT) conclusive checklist for identification of key elements

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What devices if inoperable result in a crane being removed

from service?

Operational Aides and Safety Devices

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Safety DevicesThe following safety devices are required on all equipment covered by this subpart, unless otherwise specified:

1. Crane level indicator2. Boom stops3. Jib stops4. Equipment with foot pedal brakes, must have locks5. Hyd. outrigger jacks/Hyd. stabilizer jacks must have an integral holding device/check

valve6. Equip on rails must have rail clamps and rail stops, exceptions….7. Horn

Proper operation required. Operations must not begin unless all of the devices listed in this section are in proper working order. If a device stops working properly during operations, the operator must safely stop operations. If any of the devices listed in this section are not in proper working order, the equipment must be taken out of service and operations must not resume until the device is again working properly.

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Operational Aides

Operations must not begin unless the listed operational aids are in proper working order, except where an operational aid is being repaired the employer uses the specified temporary alternative measures. Must adhere to the specified time frames for operations and more protective alternative measures specified by the crane/derrick manufacturer, if any, must be followed.

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Category I devices and alternative measures.

1. Boom Hoist Limiting Device -

2. Luffing Jib Limiting Device -

3. Anti Two-Blocking Device -

Temporary Alternative Measures (use at least one). One or more of the following methods must be used:

Use a boom angle indicator, clearly mark boom hoist cable that gives operator time, install mirror/remote cameras

Same but to address movement of the luffing jib

Telescopic boom – Clearly mark the cable to provide operator time to stop the hoist, use a spotter when extending boom

Lattice boom - Clearly mark the cable that will give the operator time to stop the hoist, or use a spotter.

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Category I devices and alternative measures.

Must be repaired no later than 7 calendar days after the deficiency occurs.

Exception: If the employer documents that it has ordered the necessary parts within 7 calendar days of the occurrence of the deficiency, the repair must be completed within 7 calendar days of receipt of the parts.

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Category II devices and alternative measures.

1. Boom angle or radius indicator-

2. Jib angle indicator-

3. Boom length indicator-

Temporary Alternative Measures (use at least one). One or more of the following methods must be used:

Radii or boom angle must be determined by measuring the radii or boom angle with a measuring device.

Radii or jib angle must be determined by ascertaining the main boom angle and then measuring the radii or jib angle with a measuring device.

Mark the boom with measured marks to calculate boom length, Calculate boom length from boom angle and radius measurements, Measure the boom with a measuring device.

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Category II devices and alternative measures.

4. Load weighing/similar devices -

5. Outrigger/stabilizer position -

6. Hoist drum rotation indicator -

Temporary Alternative Measures (use at least one). One or more of the following methods must be used:

load must be determined from a source recognized by the industry (load's manufacturer) or by calculation method recognized by the industry.

The operator must verify that the position of the outriggers or stabilizers is before beginning operations requiring outrigger or stabilizer deployment.

Mark the drum to indicate the rotation of the drum. In addition, install mirrors or remote video cameras and displays if necessary for the operator to see the mark.

Required on Equip. manufactured after 11/8/2011

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Category I devices and alternative measures.

Must be repaired no later than 30 calendar days after the deficiency occurs.

Exception: If the employer documents that it has ordered the necessary parts within 7 calendar days of the occurrence of the deficiency, and the part is not received in time to complete the repair in 30 calendar days, the repair must be completed within 7 calendar days of receipt of the parts.

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In Summary Understand the importance of crane inspections, buying them versus

doing them. Who is at risk? Selection and Prequalification of your 3rd party crane inspection

companies, task specific Insurance certificates Understand OSHA requirements of inspections and when to perform

them How comprehensive should the inspections be? Have a formal process to capture deficiencies and assign corrective

actions, USE IT. Understand what crane systems, devices failure constitutes removal

from service and what your requirements are to continue safely operating the crane are.

Reliability advantages

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In Summary

Questions

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Contact Information

Jeffrey C. Hammons Sr.AmQuip Crane Rental LLCVice President, Risk Management1150 Northbrook Drive, Suite 100Trevose PA 19053Office 215-639-9200 Mobile 215-779-9056jeffrey.hammons@amquip.com