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CRANE SAFETY

1. CORPORATE POLICY, REQUIREMENTS AND PROCEDURES

1.1. Purpose – To establish requirements and procedures for the safe use of cranes and other lifting and hoisting devices.

1.2. Definitions

A. Boom [crane] – A member hinged to the front of the rotating superstructure with the outer end supported by ropes leading to a gantry or A-frame and used for supporting the hoisting tackle.

B. Boom Angle – The angle between the longitudinal centerline of the boom and the horizontal. The boom longitudinal centerline is a straight line between the boom foot pin (heel pin) centerline and boom point sheave pin centerline.

C. Brake – A device used for retarding or stopping motion by friction or power means.

D. Bridge – That part of a crane consisting of girders, trucks, end ties, footwalks and a drive mechanism which carries the trolley or trolleys.

E. Bumper [buffer] – An energy absorbing device for reducing impact when a moving crane or trolley reaches the end of its permitted travel; or when two moving cranes or trolleys come in contact.

F. Cab-Operated Crane – A crane controlled by an operator in a cab located on the bridge or trolley.

G. Clearance – The distance from any part of the crane to a point of the nearest obstruction.

H. Counterweight – A weight used to supplement the weight of the machine in providing stability for lifting working loads.

I. Crane – A machine for lifting and lowering a load and moving it horizontally, with the hoisting mechanism an integral part of the machine. Cranes (whether fixed or mobile) are driven manually or by power.

J. Crawler Crane – A rotating superstructure with power plant, operating machinery and boom, mounted on a base, equipped with crawler treads for travel. Its function is to hoist and swing loads at various radii.

NPCA Guide to Plant Safety 8/20/02

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K. Drum – The cylindrical member around which the ropes are wound for raising or lowering the load.

L. Floor-operated crane – A crane that is pendant or nonconductive rope controlled by an operator on the floor or on an independent platform.

M. Frequent Inspection – A thorough inspection of all critical components of a crane, performed by an operator or other qualified person on a monthly basis.

N. Hoist – A power driven windlass or drum used for raising ore, rock, or other material from a mine and for lowering or raising persons and material.

O. Jib – An extension attached to the boom point to provide added boom length for lifting specified loads. The jib may be in line with the boom or offset to various angles.

P. Load Ratings – Crane ratings in pounds established by the manufacturer.

Q. Overhead Crane – A crane with a movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead fixed runway structure.

R. Outriggers – Extendable or fixed metal arms, attached to the mounting base, which rest on supports at the outer ends.

S. Periodic Inspection – A complete inspection of all critical components of a crane, performed by an independent certified inspector, contracted on an annual basis.

T. Pre-operation Inspection – A visual inspection of a crane, performed by an operator, prior to the use of the crane by that operator.

U. Reeving – A rope system in which the rope travels around drums and sheaves.

V. Rope – Wire rope, unless otherwise specified.

W. Swing – The rotation of the superstructure for movement of loads in a horizontal direction about the axis of rotation.

X. Trolley – The unit that travels on the bridge rails and carries the hoisting mechanism.


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Y. Truck – The unit consisting of a frame, wheels, bearings and axles which supports the bridge girders or trolleys.

Z. Truck Crane – A rotating superstructure with powerplant, operating machinery and boom, which is mounted on an automotive truck equipped with a powerplant for travel. Its function is to hoist and swing loads at various radii.

1.3. General Requirements – Mobile Cranes (truck-mounted and crawler)

A. The use of all cranes and devices designed and used for overhead lifting, including all associated rigging, shall conform to all applicable federal, state, and local statutes, regulations and codes.

B. Inspections shall be documented by the person completing the inspection. Documentation shall include the equipment number or other identifying description of the crane being inspected, the name of the person completing the inspection, the date of the inspection and the results of the inspection and any resulting repairs.

C. Inspections of all wire rope (running or otherwise) shall be made and documented by the crane operator or other designated qualified person. This documentation shall include an identifier for the rope that was inspected, the name of the person completing the inspection, the date of inspection, the signature of the person completing the inspection and the results of the inspection.

D. Prior to the initial use of a new or altered mobile crane (truck-mounted and crawler), the crane shall be tested to ensure compliance with 29 CFR § 1910.180. The following components shall be tested and found to be compliant before the crane shall be placed into service:

Load hoisting and lowering mechanisms. Boom hoisting and lower mechanisms. Swinging mechanism. Travel mechanism. Safety devices.

E. Prior to the initial use of a new or altered mobile crane (truck-mounted and crawler), if manufacturer load tests are not available, the crane shall be load tested. Test loads shall not be more than 110 percent of the rated load at any selected working radius. The


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test reports shall be placed on file and shall be readily available to designated personnel, such as supervisors and crane operators.

F. Pre-operational inspections of mobile cranes (truck-mounted and crawler) shall be completed and documented on the form entitled “Pre-operation Examination Form – Mobile Cranes” (included in this section) by each crane operator, prior to the use of the crane by that operator. An alternative form may be used upon approval of the Safety Department.

G. Pre-operational inspections of mobile cranes (truck-mounted and crawler) used in overhead lifting, shall include the inspection of, but not be limited to, the following:

Fuel, lubricant and fluid levels. Air tanks – proper pressure and relief pressure. Safety devices. Brakes and clutches. Lift, swing and hoisting components. Wire rope, end connections, sheaves, drums, hooks and

rigging hardware. Free rotation of all swivels. Operating mechanisms and instruments. Boom and jib components. Length marks on all boom inserts. Outriggers. Guards – condition and in place. Operator’s cab – clean and free of obstructions. Fire extinguisher – charged and accessible. Tires or crawler tracks.

H. “Frequent” inspections shall be completed and documented on the form entitled “Frequent Examination Form – Mobile/Overhead Cranes” (included in this section) by the crane operator or other competent person on a monthly basis, or more frequently if specified by the manufacturer. An alternative form may be used upon approval of the Safety Department.

I. “Frequent” inspections of mobile cranes (truck-mounted and crawler) shall include the inspection of, but not limited to, the following:

All control mechanisms for excessive wear of components, system leaks and contamination by lubricants or other foreign matter.

All safety devices for malfunction.


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Crane hooks with deformations or cracks (for hooks with cracks or having deformations of more than 15 percent in excess of normal throat opening or more than 10 degrees twist from the plane of the unbent hook).

Rope reeving for noncompliance with manufacturer's recommendations.

Electrical apparatus for malfunction, signs of excessive deterioration, dirt and moisture accumulation.

J. “Periodic” inspections shall be completed and documented on the form entitled “Periodic Examination Form – Mobile Cranes” (included in this section) by a competent person on an annual basis, or more frequently if specified by the manufacturer. An alternative form may be used upon approval of the Safety Department.

K. “Periodic” inspections of mobile cranes (truck-mounted and crawler) shall include a complete inspection of the crane, focusing on, but not limited to, the following:

Deformed, cracked or corroded members in the crane structure and boom.

Loose bolts or rivets. Cracked or worn sheaves and drums. Worn, cracked or distorted parts such as pins, bearings,

shafts, gears, rollers and locking devices. Excessive wear on brake and clutch system parts, linings,

pawls and ratchets. Load, boom angle and other indicators over their full range, for

any significant inaccuracies. Gasoline, diesel, electric or other power plants for improper

performance or non-compliance with safety requirements. Excessive wear of chain-drive sprockets and excessive chain

stretch. Boom cylinders. Travel steering, braking and locking devices, for malfunction. Excessively worn or damaged tires.

L. Daily inspection records and documentation shall be kept with the crane during the day on which the inspection took place. Daily inspection and documentation records for all days other than the current day shall be maintained on site, where the crane is normally based. All other inspection records and documentation, including the documentation of repairs, shall be maintained on site, where the crane is normally based.


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M. All cranes, hoisting and lifting devices and rigging found to have safety defects as a result of an inspection, shall be tagged and taken out of service until such time as qualified personnel can make repairs.

N. Only qualified persons, in accordance with the manufacturer’s recommendations, using manufacturer-specified parts, shall make safety repairs or alterations to cranes or hoisting and lifting devices. All repairs and/or alterations shall be tested and documented by qualified personnel prior to a crane or hoisting and lifting device being placed into service.

O. A certified welder, under the supervision of the crane manufacturer or its designated representative, shall complete welding repairs to crane booms or other structural components.

P. A preventive maintenance program based on the crane manufacturer's recommendations shall be established at each site where cranes are located or based.

Q. The preventative maintenance program established for mobile cranes shall state that before adjustments and repairs are begun, the following precautions shall be taken:

The crane to be repaired shall be moved to a location where it will cause the least interference with other cranes and operations in the area.

All controls shall be at the off position. The power source and controls shall be locked and tagged “Do

Not Operate” as defined in Part III, Lockout Tagout of this manual, including a tag attached to the door or steering wheel of the crane.

R. Upon completion of adjustments and/or repairs to mobile cranes, the crane shall not be operated until all guards have been reinstalled, safety devices reactivated and maintenance equipment removed.

S. Cranes having come into contact with high voltage power lines or lightning, having tipped or otherwise failed under load, or having been involved in an incident resulting in structural damage to the boom or other structural or mechanical components, shall be tagged and taken out of service. The crane shall remain tagged and out of service until such time as a certified crane inspector can complete a thorough inspection, qualified personnel can


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complete all repairs, and a certified crane inspector can verify that all necessary repairs have been completed satisfactorily.

T. No damaged and irreparable rigging shall be used for overhead lifting purposes.

1.4. General Requirements – Overhead Cranes (cab-operated and floor-operated)

A. The use of all cranes and devices designed and used for overhead lifting, including all associated rigging, shall conform to all applicable federal, state, and local statutes, regulations and codes.

B. Inspections shall be documented by the person completing the inspection. Documentation shall include the equipment number or other identifying description of the crane being inspected, the name of the person completing the inspection, the date of the inspection and the results of the inspection and any resulting repairs.

C. Inspections of overhead cranes (cab-operated and floor operated) shall be completed and documented on the form entitled “Examination Form – Overhead Cranes” (included in this section) by the operator or designated competent person. An alternative form may be used upon approval of the Safety Department.

D. Inspections of all wire rope (running or otherwise) shall be made and documented by the crane operator or other designated qualified person. This documentation shall include an identifier for the rope that was inspected, the name of the person completing the inspection, the date of inspection, the signature of the person completing the inspection and the results of the inspection.

E. Prior to the initial use of a new or altered overhead crane (cab-operated and floor operated), the crane shall be tested to ensure compliance with 29 CFR § 1910.179. The following components shall be tested and found to be compliant before the crane shall be placed into service:

Hoisting and lowering. Trolley travel. Bridge travel. Limit switches, locking and safety devices.


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F. Prior to the initial use of a new or altered overhead crane (cab operated and floor operated), if manufacturer load tests are not available, the crane shall be load tested. Test loads shall not be more than 125 percent of the rated load unless otherwise recommended by the manufacturer. The test reports shall be placed on file and shall be readily available to designated personnel, such as supervisors and crane operators.

G. Pre-operational inspections shall be completed and documented by each crane operator, prior to the use of the crane by that operator.

H. Pre-operational inspections of overhead cranes (cab-operated and floor-operated) shall include the inspection of, but not be limited to, the following:

Lubricant and fluid levels. Lines, tanks, valves, drain pumps and other parts of air or

hydraulic systems. Safety devices. Brakes and clutches. Hoisting components. Wire rope, end connections, sheaves, drums, hooks and

rigging hardware. Operating mechanisms, pendants and instruments. Guards – condition and in place. Operator’s cab – clean and free of obstructions.

I. “Frequent” inspections shall be completed and documented on the form entitled “Frequent Examination Form – Mobile/Overhead Cranes” (included in this section) by the crane operator or other competent person on a monthly basis, or more frequently if specified by the manufacturer. An alternative form may be used upon approval of the Safety Department.

J. “Frequent” inspections of overhead cranes (cab-operated and floor- operated) shall include the inspection of, but not limited to, the following:

All control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter.

All safety devices for malfunction. Wire rope, end connections, sheaves, drums, hooks and

rigging hardware. Crane hooks with deformations or cracks (for hooks with

cracks or having deformations of more than 15 percent in


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excess of normal throat opening or more than 10 degrees twist from the plane of the unbent hook).

Rope reeving for noncompliance with manufacturer's recommendations.

Electrical apparatus for malfunction, signs of excessive deterioration, dirt and moisture accumulation.

K. “Periodic” inspections shall be completed and documented on the form entitled “Periodic Examination Form – Overhead Cranes” (included in this section) by a competent person on an annual basis, or more frequently if specified by the manufacturer. An alternative form may be used upon approval of the Safety Department.

L. “Periodic” inspections of overhead cranes (cab-operated and floor-operated) shall include a complete inspection of the crane, focusing on, but not limited to, the following:

Deformed, cracked or corroded members in the crane structure.

Loose bolts or rivets. Cracked or worn sheaves and drums. Worn, cracked or distorted parts such as pins, bearings,

shafts, gears, rollers, and locking and clamping devices. Excessive wear on brake system parts, linings, pawls and

ratchets. Load, wind and other indicators over their full range, for any

significant inaccuracies. Gasoline, diesel, electric or other power plants for improper

performance or non-compliance with safety requirements. Excessive wear of chain-drive sprockets and excessive chain

stretch. Electrical apparatus, for signs of pitting or any deterioration of

controller contactors, limit switches and pushbutton stations.

M. Daily inspection records and documentation shall be kept with the crane during the day on which the inspection took place. Daily inspection and documentation records for all days other than the current day shall be maintained on site. All other inspection records and documentation, including the documentation of repairs shall be maintained on site.

N. All cranes, hoisting and lifting devices and rigging found to have safety defects as a result of an inspection, shall be tagged and taken out of service until such time as qualified personnel can make repairs.


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O. Only qualified persons, in accordance with the manufacturer’s recommendations, using manufacturer-specified parts, shall make safety repairs or alterations to cranes or hoisting and lifting devices. All repairs and/or alterations shall be tested and documented by qualified personnel prior to a crane or hoisting and lifting device being placed into service.

P. A certified welder, under the supervision of the crane manufacturer or its designated representative, shall complete welding repairs to crane booms or other structural components.

Q. A preventive maintenance program based on the crane manufacturer's recommendations shall be established at each site where cranes are located or based.

R. The preventative maintenance program established for overhead cranes shall state that before adjustments and repairs are begun, the following precautions shall be taken:

The crane to be repaired shall be run to a location where it will cause the least interference with other cranes and operations in the area.

All controllers shall be at the off position. The main or emergency switch shall be locked and tagged “Do

Not Operate” as defined in Part III, Lockout Tagout of this manual, including a tag attached to the crane and a sign on the floor beneath or on the hook of the crane where visible from the floor.

Rail stops or other suitable means shall be provided to prevent other cranes that are in operation on the same runway from interfering with the idle crane.

S. Upon completion of adjustments and/or repairs to overhead cranes, the crane shall not be operated until all guards have been reinstalled, safety devices reactivated and maintenance equipment removed.

T. Cranes having come into contact with high voltage power lines or lightning, having failed under load, or having been involved in an incident resulting in structural damage to structural or mechanical components, shall be tagged and taken out of service. The crane shall remain tagged and out of service until such time as a certified crane inspector can complete a thorough inspection, qualified personnel can complete all repairs, and a certified crane inspector can verify that all necessary repairs have been completed satisfactorily.


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U. No damaged and irreparable rigging shall be used for overhead lifting purposes.

1.5. Mandatory Lifting and Hoisting Procedures – Mobile and Overhead Cranes

A. The plant manager or his designee shall plan and discuss all critical lifts with all affected employees and/or contractors working in the adjacent area of the lift, prior to the lift taking place.

B. Only trained and competent operators shall operate cranes or other hoisting or lifting devices.

C. Only trained and competent persons shall rig loads to be lifted by a crane or other hoisting or lifting device.

D. The rated load capacity shall be clearly marked on both sides of all overhead cranes and other hoisting and lifting devices. The block of each overhead crane and other hoisting and lifting device shall be clearly marked with its load rating.

E. A crane-specific load rating chart shall be securely affixed in the cab of all mobile cranes and shall be visible to the operator.

F. The rated load capacity of all rigging shall be clearly marked on all rigging by means of permanently affixed tags. Rigging with missing tags shall not be used unless the rigging is tested, its load capacity determined and another tag is affixed to the rigging.

G. Cranes, hoisting and lifting devices and rigging shall not be loaded in excess of recommended safe working loads.

H. Cranes shall only be used if all safety devices are in place and functional.

I. Employees or other personnel shall not ride loads, crane hooks or other hoisting equipment, except where permitted by OSHA variance.

J. Employees shall only be hoisted by means of a lifting device, which is specifically designed for that purpose.

K. A qualified engineer or a qualified person competent in structural design shall design all personnel platforms and suspension systems.


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L. The design, suspension, rigging and use of personnel platforms shall comply with 29 CFR § 1926.550.g.4.

M. All hoisting and lifting devices used to hoist personnel shall be load tested and equipped with an anti-two-block device and automatic shutdown device that will prevent breaking of the load or the whip line in the event of a two-block condition.

N. All hoisting and lifting devices used to hoist personnel shall be equipped for and operated with controlled load lowering and must not be capable of being operated in free fall.

O. The accessible areas within the swing radius of the crane’s counterweight structure shall be barricaded to prevent access.

P. Hand signals, as prescribed by applicable ANSI standards for mobile cranes, will be posted on all mobile cranes and shall be used for all lifts. (See Example 1.)

Q. Hand signals, as prescribed by applicable ANSI standards for overhead cranes, will be posted in the work areas of overhead cranes and shall be used for all lifts. (See Example 2.)

R. Only one designated and trained signal person shall give hand signals to a crane operator, except in the case of “emergency stop” which can be given by anyone.

S. All personnel shall stay clear of suspended loads.

T. Taglines shall be attached to loads that may require steadying or guidance while suspended.

U. A crane shall not be operated closer than 10 feet of overhead power lines rated 50 kV. or below. For overhead power lines rated over 50 kV., the minimum clearance between the crane and the lines shall be 10 feet plus 0.4 inch for each 1 kV. over 50 kV., or twice the length of the line insulator, but never less than 10 feet.

V. A crane which is in transit with no load and boom lowered shall maintain a minimum clearance from overhead power lines of 4 feet for voltages less than 50 kV., 10 feet for voltages over 50 kV., up to and including 345 kV., and 16 feet for voltages up to and including 750 kV.

W. If cranes must be moved or operated within 10 feet of energized high-voltage power lines, the lines shall be de-energized or other precautionary measures shall be taken.


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X. Mobile cranes shall not be operated without the full amount of counterweight in place as specified by the manufacturer. Truck cranes may be operated temporarily with special care and only for light loads without the full counterweight in place. The counterweight placed on any mobile crane shall not exceed that specified by the manufacturer.

Y. A competent person shall inspect all hoist chains and slings prior to their use on a daily basis. A monthly inspection of all hoist chains and slings that includes a certification record shall be completed by a competent person. This certification record shall include the date of inspection, the signature of the person who performed the inspection and an identifier of the chain that was inspected. (Monthly inspections are recommended, however, OSHA required frequency is based on severity of service conditions, nature of the lift, and experienced gained by utilization of the equipment)

Monthly inspections shall be completed and documented on the form entitled “Monthly Chain Inspection Form” (included in this section). An alternative form may be used upon approval of the Safety Department.

Z. Alloy steel chain slings shall have permanently affixed durable identification stating size, grade, rated capacity, and reach.

1.6. Training

A. The plant manager and employees required to use lifting and hoisting devices will be instructed in the inspection of and proper use of cranes, hoisting and lifting devices, and rigging.

B. Cranes, hoisting and lifting devices, and rigging will be a periodic safety-training topic.

C. Because each piece of equipment, site conditions, product lifting situation is unique, training and general guidelines for operating procedures should include: Responsibility for self and others, Position of Operator, Product / Lift Assessment, Care, Use & Limitations of equipment,

While all safety measures have been taken to prevent accidents, Employees are to assume that all suspended loads may fall.


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Therefore, employees must always maintain an assured clear distance for themselves and others when operating the crane.

1.7. Monitoring and Enforcement – Safety personnel and/or supervisors will monitor and enforce this policy. Employees who refuse to adhere to the requirements of this policy will be subject to disciplinary action.

1.8. Record Keeping

A. The plant manager or his designee shall maintain all records including inspection, maintenance and training records.

B. Training shall be documented by means of “Training Documentation Forms” and/or “Safety Meeting Forms” and a copy shall be placed in each employee’s file (see Part III, Training). Training records shall be retained for a period of three years from the date of the training and shall include the following information:

Employee’s name. Date of training. Outline describing the training material. Signature of trainer documenting that training was provided. Signature of employee documenting that training was

received.

2. STATUTORY REFERENCES

2.1. 29 CFR § 1910.179 – Overhead and Gantry Cranes

2.2. 29 CFR § 1910.180 – Crawler Locomotive and Truck Cranes

2.3. 29 CFR § 1910.184 – Slings

2.4. 29 CFR §1926.550 – Cranes and Derricks

2.5. 29 CFR §1926.552 – Material Hoists, Personnel Hoists, and Elevators

2.6. 29 CFR §1926.554 – Overhead Hoists

2.7. 29 CFR § 1910 Subpart S, Appendix A – Reference Documents

2.8. ASME B30.2-96 – Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist).

2.9. ASME B30.5-94 – Mobile and Locomotive Cranes.

2.10. ASME B30.9-96 – Slings.


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2.11. ASME B30.17-98 – Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoist).


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