Crane Operations

A "crane" is 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.

References

1. DOE-STD-1090-2007
2. 29 CFR 1910.179


Lifting equipment come in all shapes and sizes to
make your lifting job easier. However, using the
equipment improperly can cause breakdowns and
damage. Personnel can be seriously be seriously
injured if improperly used.

Your Safety is the #1 Priority on any job.

This program is to be used to ensure a safe
working environment during lifting operations
utilizing proper equipment.


How Do Accidents Occur?


Instability unsecured load, load capacity
exceeded, or ground not level or too soft

Lack of communication - the point of
operation is a distance from the hoist
operator or not in full view of the operator

Lack of training

Inadequate maintenance or inspection
Requirements
General Requirements
Inspection Requirements
Operational Procedure Requirements
Training requirements

General Requirements
Each crane shall have the load rating plainly
marked on each side of the crane.
If the crane has more than one hoisting unit,
each hoist shall have its load rating marked on it
or its load block and this marking shall be clearly
legible from the ground floor.
All cranes shall be locked and tagged out while
repairs are in progress to them or any other
equipment or building structure that may have
personnel or equipment in their path.

Inspections
General Inspections
Initial Inspections
Frequent Inspections
Periodic Inspections

General Inspections:
Cranes and hoists that have been
overloaded shall have a General
Inspection performed prior to being
returned to service.
Initial Inspection:

Prior to initial use, any and all new and altered
cranes shall be inspected and tested to ensure
compliance with the provisions of 29 CFR1910.179
and ABSI B30.2. Only after determining, by this
inspection, testing and proper documentation, that
the crane is in safe operating condition shall it be
put into service.

Initial Inspection (Cont)

Items to be Inspected:

Hoisting and lowering
Trolley travel
Bridge travel
Limit switches, locking and safety devices
Trip setting of hoist limit switches
Load test of not more than 125% of rated load

Frequent Inspections:
Operating mechanisms for maladjustment: Daily
Deterioration or leakage in pneumatic and hydraulic
parts: Daily
Hooks with deformation or cracks (visual): Daily
Hooks with deformation or cracks (written record
with signature of inspector and date): Monthly
Hoist chains and end connections for wear, twist or
distortion (visual): Daily
Hoist chains and end connections for wear, twist or
distortion (written record with signature of inspector
and date): Monthly
Frequent Inspections:
Running Rope and end connections for wear, broken
strands, etc. (written record with signature of
inspector, rope identity and date): Monthly
Functional operating mechanisms for excessive
wear: As needed
Rope reeving according to manufacturers'
recommendations: As recommended
Periodic Inspections:
A qualified inspector shall perform a
complete inspection at the following
intervals:
1. Normal service yearly.
2. Heavy service semiannually.
3. Severe service - quarterly
Periodic Inspections (Continued)
Deformed, cracked or corroded members
Loose bolts or rivets
Cracked or worn sheaves and drums
Worn, cracked or distorted parts, such as pins, bearings,
gears, rollers, etc.
Excessive wear on brake-system parts
Inaccuracies in load, wind and other indicators
Electric or fossil fuel motors
Excessive wear of chain drive sprockets and chain
Deteriorated electrical components, such as pushbuttons,
limit switches or contactors
Periodic Inspections (Continued)
1. Bolts, rivets, nuts, and pins for being loose or
absent.
2. Check for suspect/counterfeit parts (see
Terminology and Definitions, Chapter 1).
3. Cracked or worn drums or sheaves.
4. Worn, corroded, cracked, or distorted parts such
as pins, bearings, shafts, gears, rollers locking,
and clamping devices.
5. Excessive wear on motor or load brakes.
Periodic Inspections (Continued)
6. Excessive wear of chains, ropes, synthetic web
strap, load sprockets, drums, sheaves, and chain
stretch.
7. Deterioration or damage of end connections and
terminations of wire rope, load chains, and
synthetic web.
Periodic Inspections (Continued)
8. Hooks damaged from chemicals, cracks,
any visibly apparent bend or twist from the
plane of the unbent hook, or any distortion
causing an increase in throat opening of 5%
not to exceed 14 inch unless otherwise
recommended by the manufacturer. See
Chapter 13 for additional hook requirements.
9. Hook-retaining nuts or collars and pins,
welds, or riveting used to secure the
retaining members.
Periodic Inspections (Continued)
10. Suitable crack-detecting inspections for
hooks, such as dye-penetrant or magnetic-
particle inspections (performed when
required by the inspector).
11. Electrical apparatus for signs of pitting or
any deterioration of controller contactors,
limit switches, and pushbutton switches.
12. Supporting structures and trolleys, if
used, for continued ability to support the
imposed loads.

Periodic Inspections (Continued)
13. Warning labels for illegibility or absence.
Inspections
Inspections are to be completed and
documented.
Documentation is to be filed at the local or
regional office.
If the inspection has not been documented
then it never happened.


Retention of Inspections:
All inspection records shall be retained at
the facility where each crane, hoist or
other equipment covered by this program
is located.
All maintenance and repair records shall
be retained for the life of the equipment.

Operational Procedures:
Only qualified personnel or trainees, under
the direct supervision of qualified personnel,
who meet the following requirements shall
be allowed to rig, operate, inspect, or
perform maintenance on cranes, hoists, or
powered forklift trucks
Operational Procedures:
Only qualified personnel or trainees, under
the direct supervision of qualified personnel,
who meet the following requirements shall
be allowed to rig, operate, inspect, or
perform maintenance on cranes, hoists, or
powered forklift trucks
Operational Procedures (cont)
a. Do not engage in any practice that will
divert your attention while engaged in
operating the hoist.
b. Do not operate equipment if you are
physically or mentally unfit.
Operational Procedures (cont)
c. Familiarize yourself with the equipment
and its proper care. If adjustments or repairs
are necessary, or any damage is known or
suspected, report it promptly to the
appointed person. Notify the next operator of
the problem upon changing shifts.
Correct deficiencies before resuming normal
operation.
Operational Procedures (cont)
d. Test all controls before beginning a shift.
If any controls do not operate properly,
adjust or repair them before beginning
operations.
e. Operators are responsible for those
operations under their direct control.
Whenever there is doubt as to safety,
consult with responsible management
before handling the load.
Operational Procedures (cont)
f. Do not operate a hoist that bears an out-of order
sign or is otherwise tagged out-of service.
g. If there is a tag, sign, or lock on electric- or air-
powered equipment, do not energize the
equipment until the tag, sign, or lock is removed by
the person who placed it there or by an authorized
person.
h. Do not close the main line disconnect device on
powered equipment until you are certain that no
one is on or adjacent to the hoist or carrier.
Attaching the Load
a. The supporting structure or anchoring means
shall have a load rating at least equal to that of the
hoist.
b. Use hoists only in areas that will allow you to be
clear of the load.
c. Do not wrap the hoist rope or chain around the
load.
d. Attach the load to the hook using slings or other
approved devices.
Attaching the Load
g. Operate hand-chain-operated hoists with hand
power only and with no more than one operator
per hand chain.
h. Do not use a lever extension (cheater) on
manual-lever-operated hoists.
i. Properly seat the slings or other approved
devices in the saddle of the hook before carrying
out hoisting operations.
Moving the Load
A. Take care in hoisting to be certain that:
1. Hoist ropes or chains are not kinked or twisted.
2. The load does not contact any obstructions.
3. Multiple-part ropes or chains are not twisted
around each other.
B. Before starting to hoist, ensure that the rope or
chain is properly seated on the drum, sheaves, or
sprockets.
C. Before starting the hoist, be certain that all
personnel are clear of the equipment.
Moving the Load
D. Do not operate hoists until the hook is
positioned above the center of gravity of the load,
except when specifically authorized by an
appointed person who has determined that the
components of the hoist and its mounting will not
be overstressed.
E. Do not move or lift a load more than a few
inches until it is well balanced in a sling or lifting
device.
Moving the Load (cont.)
D. Do not operate hoists until the hook is
positioned above the center of gravity of the load,
except when specifically authorized by an
appointed person who has determined that the
components of the hoist and its mounting will not
be overstressed.
E. Do not move or lift a load more than a few
inches until it is well balanced in a sling or lifting
device.
Moving the Load (cont.)
F. Do not lift, lower, or travel the hoist while
anyone is on the load or hook.
G. Avoid carrying loads above personnel.
H. Test the brakes each time a load approaching
the rated capacity is handled by raising the load
just enough to clear the floor or supports and
checking for brake action. Continue the lift only
after you are sure that the braking system is
operating properly.
I. Inch the hoist into engagement with a load, and
avoid unnecessary stops and starts.
Moving the Load (cont.)
J. Do not perform side pulls with hoists except as
specifically authorized by a qualified person.
K. If power goes off during operation of cab
operated equipment, immediately place all
controllers in the OFF position. Before reuse,
check operating motions for proper direction.
L. Do not leave a suspended load unattended
unless specific precautions have been instituted
and are in place.
M. Tag lines should be used as required to guide,
snub, or otherwise control the load.
Moving the Load (cont.)
N. Take signals from only one person using the
standard hand signals shown in Chapter 7,

Overhead and Gantry Cranes. Obey a STOP
signal regardless of who gives it.

O. Lift the hoist load block above head level for
storage when the equipment is not in use.
Ordinary Lifts
Hoisting and rigging operations for ordinary lifts
require a designated leader. The designated
leader shall be present at the lift site during the
entire lifting operation. If the lift is being made by
only one person, that person assumes all
responsibilities of the designated leader.

Leadership designation may be by written
instructions, specific verbal instructions for the
particular job, or clearly defined responsibilities
within the crews organizational structure.
Ordinary Lifts
The designated leaders responsibility shall
include the following:
1. Ensure that personnel involved understand how
the lift is to be made.
2. Ensure that the weight of the load is
determined, that proper equipment and
accessories are selected, and that rated capacity
is not exceeded.
3. Survey the lift site for hazardous/unsafe
conditions.
4. Ensure that equipment is properly set up and
positioned.
Ordinary Lifts
5. Ensure that a signaler is assigned, if required,
and is identified to the operator.
6. Direct the lifting operation to ensure that the job
is done safely and efficiently.
7. Stop the job when any potentially unsafe
condition is recognized.
8. Direct operations if an accident or injury occurs.

The operator or other designated person shall
visually examine the hoist in accordance with
the requirements for a daily inspection
Commonly asked questions
Q. Where are the standard crane signals located?

A. The signals are located in ANSI/ASME B30.2-2011.
These are standard signals recommended by ANSI;
however, OSHA does not require the signal system in its
29 CFR 1910.179, overhead and gantry crane regulation.
The manufacturers of overhead cranes may also provide
their own version of crane signals.
Commonly asked questions
Q. Do standards exist for other types of cranes?

A. Yes, several. Here are just a few: OSHA 29 CFR
1910.180 regulates the operation of crawler locomotive and
truck cranes; 29 CFR 1910.181 covers derricks; 29 CFR
1910.183 covers helicopter cranes; and 29 CFR 1910.178
covers powered industrial trucks. The ANSI/ASME B30.2
covers portal tower and pillar cranes; ANSI/ASME B30.5-
2007 covers mobile and locomotive cranes; and
ANSI/ASME B30.11-2010 covers monorails and underhung
cranes.

Standard Hand Signals for Controlling
Overhead and Gantry Cranes
HOIST








With forearm vertical, forefinger pointing up, move hand in
small horizontal circles

Standard Hand Signals for Controlling
Overhead and Gantry Cranes
LOWER







With arm extended downward, forefinger pointing down,
move hand in small horizontal circles.

Standard Hand Signals for Controlling
Overhead and Gantry Cranes
STOP








Arm extended, palm down, move arm back and forth
horizontally

Standard Hand Signals for Controlling
Overhead and Gantry Cranes
Emergency STOP








Both arms extended, palms down, move arms back and
forth horizontally.

Standard Hand Signals for Controlling
Overhead and Gantry Cranes
Bridge Travel








Arm extended forward, hand open and slightly raised,
make pushing motion in direction of travel.

Standard Hand Signals for Controlling
Overhead and Gantry Cranes
Trolley Travel








Palm up, fingers closed, thumb pointing in direction of
motion, jerk hand horizontally.

Standard Hand Signals for Controlling
Overhead and Gantry Cranes
Move Slowly








Use one hand to give any motion signal and place other
hand motionless in front of hand giving the motion signal.