Académique Documents
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Mechanical Advantage
Levers are used to magnify the applied force, they provide positive
mechanical advantages.
A third-class lever provides what is called a fractional mechanical
advantage, this is a mechanical disadvantage. It takes more force
than the force of the load lifted.
In a wheelbarrow, a 50-pound pull actually overcomes a 200-pound
weight. The workers effort is magnified four times, so the mechanical
advantage of the wheelbarrow is 4.
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4
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1
How many levers can you find in the loader?
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2
Mechanical Advantage
Expressing the same idea in mathematical terms: MECHANICAL
ADVANTAGE = RESISTANCE divided by EFFORT
This rulemechanical advantage equals resistance divided by
effort applies to all machines.
Effort
Resistance
M.A.
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3
Mechanical Advantage
The mechanical advantage of a lever may also be found by dividing
the length of the effort arm (A) by the length of resistance arm (a).
Stated as a formula, this reads:
How does this apply to third-class levers?
Your muscle pulls with a force of 1,800 pounds to lift a 100-pound
object. So you have a mechanical advantage of which is fractional-
less than 1.
Arm(a) Resistance
A) EffortArm(
M.A.
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4
Mechanical Advantage
A single fixed block is a first-class
lever with equal arms. The arms
(EF and FR) in the figure are
equal.
The mechanical advantage is 1.
A single fixed block does not
magnify force nor speed.
You have to apply 200 pounds of
force to keep the weight
suspended.
200 lbs
200 lbs
200 lbs
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115
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5
Mechanical Advantage
If you use a single block and fall to
magnify the force you exert.
In the figure the block is not fixed. The
fall is doubled as it supports the 200-
pound load.
When rigged this way, you call the
single block and fall a runner.
Each half of the fall, EF and FR, carries
one-half of the total bad, or 100 pounds.
Thus, with the runner, the man is lifting a
200-pound load with a 100-pound pull.
The mechanical advantage is 2.
100 lbs
Fall
100 lbs
200 lbs
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6
Many combinations of single, double, and triple blocks
can be rigged to give greater advantages.
The number of parts of the fall going to and from the
movable block tells you the approximate mechanical
advantage of the tackle.
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7
The mechanical
advantage of those
obtained from A is
multiplied four times in B.
The overall mechanical
advantage is the product
of the two mechanical
advantages or 12.
100 lbs
100 lbs
100 lbs
100 lbs
400 lbs
400 lbs
400 lbs
400 lbs
1200 lbs
B
A
If the rule is applied by which the parts of the fall going to and from
the movable blocks are counted, you find that block A gives a
mechanical advantage of 3 to 1.
Block B has four parts of fall running to and from it, a mechanical
advantage of 4 to 1.
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8
Summary
Review Objectives
Question and Answer Session
119
CRANES
Basic Crane Types and
Components
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Objectives
Define Cranes and Crane Types
Define typical crane parts
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1
Cranes are classified as weight-handling equipment
and are designed primarily to perform weight-lifting and
excavating operations under varied conditions.
To make the most efficient use of a crane, you must
know their capabilities and limitations.
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2
Definitions
Crane Consists of a rotating structure for lifting and
lowering horizontally on rubber tires or crawler treads
Hoist - Used to lift and lower load.
Boom An inclined spar, strut, or other long member
supporting the hoisting tackle
Boom stops A device used to limit the angle of the
boom at its highest position
Brake To slow or stop motion by friction or power
Block Sheaves or grooved pulleys in a frame with
hook, eye and strap
Jib Extension attached to the boom point to provide
added boom length for lifting specified loads.
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3
Types of Cranes
The following list of cranes described are
just a few of the many different types of
crane application.
Mobile
Gantry
Overhead
Jib
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4
Mobile Crane
The most basic type of
mobile crane consists of a
steel truss or telescopic
boom.
It is mounted on a mobile
platform, which may be rail,
wheeled or caterpillar
tracks.
The boom is hinged at the
bottom, and can be raised
and lowered by cables or
by hydraulic cylinders.
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5
Mobile Crane
A hook is suspended from the top of the boom by wire
rope and sheaves.
To increase the horizontal reach of the hoist, the boom
may be extended by adding a jib to the top. The jib can be
fixed or, in more complex cranes, luffing (that is, able to
be raised and lowered).
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6
Mobile Crane
The wire ropes are operated by whatever prime movers
the designers have available, operating through a variety
of transmissions.
Some examples of this type of crane can be converted to
a demolition crane by adding a demolition ball, or to an
earthmover by adding a clamshell bucket or a dragline
and scoop.
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Mobile Crane Parts
Jib or whip line
Jib hook & headache ball
Jib section
Jib mast (gantry)
Main line
Main block or hook
Gantry
Counterweight
Machine deck
Ring gear, turntable, swing circle
Equalizer or outer ball
Inner ball
Boom tip sheaves
Jib tip
Upperworks or superstructure
refers to entire crane structure
above the swing circle
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CRANE DESCRIPTION
PEDESTAL: a fabricated tubular steel structure
which supports the crane from the deck to the
turntable.
It gives the crane a set height over temporary and
permanent structures.
Allows access to machinery spaces and the cab of
the crane and houses the turntable gears..
TURNTABLE: is mounted on the upper end of the
pedestal.
Serves as a base for crane mast and also houses
machinery spaces.
Allows the crane to rotate in circular motion..
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9
CRANE DESCRIPTION
MAST: an enclosed steel structure which supports
the rigging for the boom.
Provides attachment points for topping lift and
hoist fairlead sheaves
CONTROL CAB: an enclosed structure which
houses and protects all crane operator controls.
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HOOK BLOCK
A hook block on a
crane is the primary
unit for lifting an
objector load,
transferring it to a new
place by swinging or
traveling and then
placing the load.
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1
Sheaves
Sheaves are located in
the hook block boom
tip, boom bridle, gantry,
and boom mast.
Sheaves rotate on
either bearings, or
bushings, and are
installed where wire
rope must turn or bend.
The sheave grooves
must be smooth and
free from surface
defects which could
cause rope damage
Worn sheave groove
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2
Boom Angle Indicators
Boom angle indicators are
normally mounted on the
boom butt, visually
readable by the operator.
On most crane the boom
angle indicator is a metal
plate with degree numbers (0
to 90 degrees) and a freely
swinging arm that reacts as
the boom angle changes
The numbers and arm
should remain clean and
visually readable at all time.
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Clamshell
The clamshell bucket is
two scoops hinged
together in the center
with counterweights
bolted around the hinge.
A clamshell consists of:
hoist drum lagging
(hoist drum diameter)
clamshell bucket
tag line
wire ropes to operate
holding and closing
lines.
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4
Example Clamshell Rigging
Arrangement
The two hoist drum wire
ropes on the crane are
rigged as the holding and
closing lines for controlling
of the bucket.
The tag line winder
controls the tension on the
tag line that helps prevent
the clamshell from twisting
during operations.
Tag line
Winder
Tag line
Cable
Cable guide
roller
Sheave
Closing cable
Holding cable
Cable Drum
Boom point
sheave
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Dragline
The dragline component
consists of a dragline bucket
and fairlead assembly.
The wire rope components
of the dragline are the drag
cable, the bucket hoist, and
the dump.
Once a crane is rigged with
a dragline, the crane is
referred to by the name of
the attachment.
Hoist Socket
Drag and Drag Rope Socket
Dump Cable
Dump Block
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Example Dragline Rigging
Arrangement
The drag cable pulls
the bucket through the
material when digging.
The bucket is raised
by the hoist wire rope
and moved to the
dump point
Dump the bucket by
releasing the tension
on the drag cable.
Fairlead
Drag cable
Cable Drum
Drag cable
Hoist
cable
Boom point
sheave
Dump sheave
Dump cable
3-point
socket
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Improper load rating
Excessive speeds
No hand signals
Inadequate inspection
and maintenance
Unguarded parts
Unguarded swing
radius
Working too close to
power lines
Improper exhaust
system
Shattered windows
No steps/guardrails
walkways
No boom angle
indicator
Not using outriggers
Crane Hazards
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Planning
Level the crane and ensure support surface is firm and
able to support the load
Contact power line owners and determine precautions.
Know the location and voltage of overhead power lines.
Know the basic crane capacities, limitations, and job
site restrictions, such as the location of power lines,
unstable soil, or high winds.
Make other personnel aware of hoisting activities.
Barricade areas within swing radius.
Ensure proper maintenance and inspections.
Determine safe areas to store materials and place
machinery.
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Load Limiting Factors
Not level
Wind
Side loads
On its wheels
Lifting over the side
Use of extensions, jibs and other attachments
Limits of wire rope, slings and lifting devices
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Mobile Cranes Lifting Principles
Center of Gravity
Leverage
Stability
Structural Integrity
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1
Gantry Crane
A gantry crane has a hoist in a which runs horizontally
along gantry rails, usually fitted underneath a beam
spanning between uprights which themselves have
wheels so that the whole crane can move at right angles
to the direction of the gantry rails.
These cranes come in all sizes, and some can move very
heavy loads, particularly the extremely large examples
used in shipyards or industrial installations
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2
Gantry Crane
Trolley
Bridge
Gantry Legs
Hook & Block
Trucks
Rails
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3
Overhead Traveling Crane
Also known as a "suspended crane", this type of crane
works in the same way as a gantry crane but without
uprights.
The hoist is on a which moves in one direction along one
or two beams, which move at right angles to that direction
along elevated tracks, often mounted along the side walls
of an assembly area in a factory.
Some of them can lift very heavy loads.
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4
Overhead Traveling Crane
Trolley
End Truck
Hoist
Bridge
Bridge Drive
Runway
Hook & Block
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5
Jib Crane
A jib crane is a type of crane where a horizontal member
(jib or boom), supporting a moveable hoist, is fixed to a
wall or to a floor-mounted pillar.
Jib cranes are used in industrial premises and on military
vehicles.
The jib may swing through an arc, to give additional
lateral movement, or be fixed.
Similar cranes, often known simply as hoists, were fitted
on the top floor of warehouse buildings to enable goods to
be lifted to all floors.
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6
A jib crane contains a tilted strut (the jib) that supports a
fixed pulley block.
Cables are wrapped multiple times round the fixed block
and round another block attached to the load.
When the free end of the cable is pulled by hand or by a
winding machine, the pulley system delivers a force to the
load that is equal to the applied force multiplied by the
number of lengths of cable passing between the two
blocks. This number is the mechanical advantage.
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7
Jib Crane
Rigid
Support
Rigid
Support
Jib Boom
Column
Trolley
Hoist
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8
Summary
Review Objectives
Question and Answer Session
149
CRANE SAFETY
Basic Handsignals
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0
Cranes
Cranes are classified as weight-handling equipment
and are designed primarily to perform weight-lifting and
excavating operations under varied conditions.
Overhead cranes are a standard fixture in many
industrial, manufacturing and assembly environments.
They are devices that raise and lower a desired load and
move it along a horizontal plane. This plane of movement
is determined by the type of overhead cranes used.
To make the most efficient use of a crane, you must
know their capabilities and limitations.
The most common types are the beam crane, gantry
crane and the jib crane.
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1
Trolley
End Truck
Hoist
Bridge
Bridge Drive
Runway
Hook & Block
Overhead Traveling Crane
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2
Gantry Crane
Trolley
Bridge
Gantry Legs
Hook & Block
Trucks
Rails
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3
Jib Crane
Rigid
Support
Rigid
Support
Jib Boom
Column
Trolley
Hoist
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4
Verbal Communication
Verbal communications vary upon needs.
The most common method is portable radios and are
widely used at construction sites.
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5
Nonverbal Communication
While there is a broad range of non-verbal signals such as
signal flags, buzzers and whistles the most common mode
used in the industry is the ASME B30.5 Consensus Standard
of Hand Signals.
Unless voice communications are used then according to
B30.5 the operator must use standard hand signals.
A hand signal chart must be conspicuously posted at the job
site.
When a crane is traveling or moving, without direction from
the rigger, audible signals must be given from the cranes horn
Stop one signal
Forward two signals
Reverse three signals
Never give signals to a crane operator unless you are the
designated signal giver.
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6
Hand Signals
Hand signal charts
similar to this one
should be posted
conspicuously.
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7
General Rigging Safety
The rigging worker must be aware of the hazards
associated with the trade.
The movement of loads moving around other workers can
be a safety hazard where falling material and equipment
can occur.
It is the personal responsibility of the employee to supply
full participation in an employer's safety program
Safety consciousness is the key to reduction of accidents,
injuries and death on job sites.
Safe work habits can reduce mistakes that lead to
accidents.
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15
8
Personal Protection
Always be aware of your environment when working with
cranes.
Stay alert and know the location of equipment at all times
when moving about the work area.
Use standard personal protective equipment which
includes:
Hard hats
Safety shoes
Gloves
Barricades
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9
Equipment and Supervision
Rigging operations must be planned and supervised to
ensure the following:
Proper equipment is available
Correct load ratings are available for the material and
equipment
The rigging equipment is well maintained and in good
working condition
The supervisor is responsible for the following functions:
Proper load rigging
Crew supervision
Rigged material and equipment meets required
capacity and safe condition
Lifting bolts and other rigging material is installed
correctly
Guaranteeing the safety of crew and personnel
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16
0
Basic Rigging Precautions
Determine the weight of all loads before attempting a lift.
Rig the load so the load is stable and center of gravity is below
hook.
Follow the following safety practices:
Always read manufacturers literature for all equipment which
provides information on checks and inspections.
Determine the weight of loads which includes the rigging and
hardware.
Know the safe working load capacity of the hardware and rigging
Inspect all equipment and rigging before using, discard defective
components
Report defective equipment and hazardous conditions to supervisor
Stop hoist and rigging operations when weather provides hazardous
condition, such has lightning or high winds
Recognize factors that can reduce rigging equipment capacity, such
as side loads
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16
1
Barricades
Barricades should be used to isolate the area of and
overhead lift.
Always follow the site requirements for proper erection of
barricades.
Contact the supervisor for clearance before proceeding
Be sure to account for crane swing radius in barricading,
especially the rear of the crane
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16
2
Load-Handling Safety
Safe and effective control of a load involves stric
observance of safety requirements.
Ensure that the swing path or load path is clear of
personnel and obstructions.
Keep both front and rear swing paths clear during lift.
Be aware of crane movements while observing the
movement of the load.
With the exception of tag line tenders make sure the load
placement area is clear of personnel and ensure the
required blocking and cribbing for the load is in place
before positioning the load.
No one should work under the load
If blocking load after setting load then do not remove load
stress from sling.
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16
3
Load-Handling Safety Contd
Follow these procedures when loads are handled:
Before lifting ensure loads are securely slung and
balanced to prevent shifting
Use tag lines to control the load
Safely land and properly block loads before removing
slings
Only use lifting beams for the purpose they were
designed for. Ensure that the weight and working load for
the beam is visible.
Never wrap hoist ropes around load, only use slings and
other lifting devices.
Do not twist multiple-part lines around each other.
Bring load line over the center of gravity of the load before
beginning the lift.
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16
4
Load-Handling Safety Contd
Make sure rope is properly seated on the drum and in the
sheaves if rope had been in a slack condition.
Load and secure any materials and equipment being
hoisted to prevent movement.
Keep hands and feet away from pinch point as slack is
taken up.
Wear gloves when handling wire rope.
Ensure that all personnel are standing clear of while loads
are lifted and lowered and when slings are removed.
Never ride a load that is being lifted
Never lift a load over other personnel.
Never work under a suspended load
Never leave load suspended when hoisting equipment is
unattended.
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5
Load-Handling Safety Contd
Never make temporary repairs to a sling
Never lift loads with a multi-leg sling unless unused legs
are properly secured.
Ensure all slings are made of the same material when
using two or more slings on a load.
Remove or secure all loose pieces from a load before
moving it.
Lower load onto adequate blocking to prevent damage to
the slings.
Never pull a choker sling from under a load if the load has
been set upon it.
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16
6
Working Around Power Lines
The crane signalman must stationed at times to warn the
operator when the load or crane is approaching the
minimum safe working distance from a power line.
Crane in Operation Crane in Transit
Power Line
(kV)
Boom or Mast
Minimum Clearance
(feet)
Boom or Mast Minimum
Clearance (feet)
0 to .75 10 4
0 to 50 10 6
50 to 200 15 10
200 to 350 20 10
350 to 500 25 16
500 to 750 35 16
750 to 1000 45 20
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7
Method to determine line voltage
One rough method of
determining the line voltage is
to count the number of
insulators suspending the line
Insulators
in a String
Line Voltage
(kV)
2 13.2
2-3 23 to 34.5
4-5 69
5-6 88
6-8 110
8-10 138
9-11 154
12-16 230
18 345
Suspension
Insulators
High
Voltage
Line
Count Insulators Supporting Line to
Determine Line Voltage
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16
8
Crane Improperly Close to Lines
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16
9
Power Line Procedures and Precautions
Ensure that a power line awareness permit (or equal) has
been prepared
Erect non-conductive barricades
Use non-conductive tag lines for controlling load
Qualified signalman shall be in constant contact with
operator
Supervisor shall alert and warn all personnel about
electrocution hazards and how to avoid these hazards
All non-essential personnel shall be removed from crane
work area
No one shall be permitted to touch the crane or load
unless signalman indicates it is safe
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17
0
Guidelines When Crane Contact Power
The operator should stay in the cab unless a fire occurs
Do not allow anyone to touch the crane or load
If at all possible, the operator should reverse the crane
and attempt to break contact with the power line
If the operator cannot stay in the cab he should jump
clear of the cab and attempt to land on both feet at the
same time. He should then walk away using very short
steps.
Call the local power authority or owner of the power line
Have the power lines verified as secure and properly
grounded within view of the operator before allowing
anyone to approach the crane or load.
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17
1
Site Hazards and Restrictions
There are many site hazards and restrictions related to crane
operations.
These hazards include the following:
Underground utilities such as gas, oil, electrical and telephone
lines; sewage and drainage piping; and underground tanks.
Electrical lines or high-frequency transmitters
Structures such as buildings, excavations, bridges and abutments
Operators and riggers should inspect work areas for the following
hazards:
Ensure ground can support the crane and load
Check for a safe path to move the crane around the site
Make sure crane can rotate in the required quadrants for the
planned lift
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17
2
Emergency Response
Operators and riggers need to react quickly and correctly
in response to any crane malfunction or emergency.
They must learn the proper responses to emergency
situations
The first priority of any response is to first prevent injury
or loss of life.
The second priority is to prevent damage to equipments
and structures.
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17
3
Fire
The first response to a fire is to immediately cease crane
operations. If time allows lower the load and secure the
crane.
In all cases of fire, evacuate the area even if the load
cannot be lowered.
Notify emergency services first then make a judgment to
see if the fire can be put out with a fire extinguisher.
Do not become overconfident, the first priority to consider
is the prevention of loss of life or injury to anyone.
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17
4
Malfunctions During Lifting
Operations
If a malfunction or failure causes a crane radius to increase
unexpectedly then the crane can tip over or collapse.
Loads can also be dropped during a malfunction. This could cause a
whiplash effect that could cause the boom or crane to fail.
If a problem or fault occurs the operator should lower the load
immediately.
The operator should then
secure the crane and tag the
controls for out of service.
Report the problem to the
supervisor.
Do not operate until qualified
repairman has cleared the
problem.
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17
5
Hazardous Weather
Most crane operations take place out door.
Extreme hot or cold weather and high winds can make
work uncomfortable and hazardous.
Snow and rain can affect the weight of the load.
Instability can be affected by winter because freezing can
give the false stable feeling to the ground.
Severe rain can cause the ground under the crane to
become unstable due to erosion of softening of the soil.
Major weather hazards that need to be seriously take is
Lightning and High Winds. Cranes, due to height and
construction make them prone to lightning strikes. During
high winds the boom should be lowered to the ground.
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6
Using Cranes to Lift Personnel
Using a crane is not specifically prohibited, but OSHA regulations
discourage it.
The restrictions are such that it is only permitted is special situations.
When it is allowed, certain controls must be in place, including the
following:
The rope design factor is doubled
No more than 50 percent of the crane capacity, including rigging,
may be used
Anti two-blocking devices are required on the crane boom. Anti
two-blocking devices are electrical sensing devices. They are
installed on the crane to prevent the "headache ball" from hitting
the sheave.
Platform must be specifically designed for lifting personnel
Basket must be tested with appropriate weight and then
inspected
Every intended use must undergo a trial run with weights rather
than people
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17
7
Personnel Platform Loading
Must not be loaded in excess of its rated capacity/
Number of employees, including material, occupying the
platform must exceed limit established for platform.
Platforms must be used only for employees, their tools
and material necessary to perform their work.
Materials and tools for use must be secured to prevent
displacement during lift.
The materials and tools must be evenly distributed in the
platform while suspended.
Operators may be required to shut down at a certain wind
speed.
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8
Personnel Platform Rigging
Hooks must be closed
and locked, no mousing
Legs of bridles must be connected
to master link or shackle
Permanent marking for
weight and rated capacity
Eyes in wire rope must be
fabricated with thimbles.
Attachments must be able to lock
Guardrail, midrail and toeboard
system. Requires inner grab rail.
Overhead protection
is required if there is
danger of falling
objects from above
Bridles and rigging for
attaching platform to
hoist must not be used
for any other purpose
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17
9
Lift Planning
Before conducting a lift most construction sites and
companies require a lift plan to be completed and signed.
Lift plans are mandatory for steel erection and multiple-
crane lifts.
The lift plan contains information relative to:
Crane
Loading
Rigging
Special Instructions for lift
Restrictions for lift
A new lift plan is required if there are deviations from
original plan.
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18
0
Summary
Review Objectives
Question and Answer Session
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18
1
Terms
Anti Two Blocking Device
Barricades
Center of gravity (CG)
Cranes
Kilovolts (kV)
Lift Plan
Line voltage
Personnel Platform
Personal protection equipment (PPE)
Weight-handling equipment
182
HAND SIGNALS
Basic Hand signals
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18
3
Objectives
Define a Signalman
Define basic hand signals
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18
4
Signalman
The signalman is part of the crane or lifting crew and is
responsible to the operator to give signals for lifting,
swinging, and lowering loads.
A signalman should also be a qualified seasoned crane
operator.
Not only does the signalman give signals for handling
loads but the signalman can visually observe what the lift
operator cannot.
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18
5
Some Checks for a Signalman
1. The load hook is centered over the center of balance
of the load, as the weight is being lifted by the crane.
2. The boom deflection does not exceed the safe load
radius.
3. All the rigging gear is straight and not causing damage
to itself or the load.
4. During a lift with a boom crane, check the boom
suspension system and boom hoist reeving to
ensure proper operation.
5. Check the hook block and boom tip sheaves reeving
to ensure proper operation.
6. Check the stability of the outriggers especially when
swinging from one quadrant of operation to another.
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18
6
Some Checks for a Signalman
7. Use tag lines and tag line handlers to prevent the load
from swinging or twisting
8. Signal only to lift the load high enough to clear any
obstacles.
9. ALWAYS have eye-to-eye contact with the crane
operator. The crane operator depends on the signalman
to lift, swing, and lower a load safely.
10. The signalman must also know the load weight
being lifted and the radius and capacity of the crane.
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7
Raise
With forearm vertical, forefinger pointing up, move hand in
small horizontal circle
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8
Lower
With arm extended downward, forefinger pointing down,
move hand in small horizontal circles.
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9
Use Main Hoist
Tap fist on head: then use regular signals
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19
0
Use Whip Line
(Auxiliary Hoist). Tap elbow with one hand: then use
regular signals
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19
1
Raise Boom
Arm extended, fingers closed, thumb pointing upward.
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19
2
Lower Boom
Arm extended, fingers closed, thumb pointing downward.
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3
Move Slowly
Use one hand to gave any motion signal and place the
other hand motionless in front of hand giving the motion
signal.
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19
4
Raise Boom and Lower Load
With arm extended, thumb pointing up, flex fingers in and
out as long as load movement is desired
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19
5
Lower Boom and Raise Load
With arm extended, thumb pointing down, flex fingers in
and out as long as load movement is desired.
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19
6
Swing Boom
Arm extended, point with finger in direction of swing of
boom.
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7
Stop
Arm extended, palm down, hold position rigidly
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8
Emergency Stop
Arm extended, palm down, move hand rapidly right and
left
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19
9
Travel
Arm extended forward, hand open and slightly raised,
make pushing motion in direction of travel.
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20
0
Dog Everything
Clasp hands in front of body.
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20
1
Travel Both Tracks
Both fists in front of body, make circular motion about
each other indicating direction of travel-forward or back.
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20
2
Travel One Track
Lock track on one side indicated by raised fist. Travel
opposite track in direction indicated by circular motion of
other fist, rotated vertically in front of body.
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203
20
3
Summary
Review Objectives
Question and Answer Session