1. CRANE OPERATIONS SAFETY

2. Crane usage varies In our facility we use cranes to move materials in the shop and in the yard. However, whether or not it is an overhead crane, all terrain wheeled crane, or a small jib crane certain precautions need to be taken. First analyze the characteristics of the load being moved.

3. Characteristics of the load: Is the load hazardous or toxic Know the weight of the load Know the size and dimensions of the load 1a

4. Typical Steel Plate In BTC Shop Steel Thickness: Wt. per sq. ft. Typical sheet: Wt. per sheet. 3/16” 7.66 96” X240” 1226# ¼” 10.21 96” X 240” 1634# 3/8” 15.32 96” X 240” 2451# ½” 20.42 96” X 240” 3267# ¾” 30.63 96” X 240” 4901# 1” 40.84 96” X 240” 6535#

5. Material Securement As per our Material Handling Policy # 20 & 21: All materials are to be 100% secured by proper rigging before the load is moved, and remain secured until the load is landed and properly secured before the load is released. Only authorized operators are to operate lifting equipment, only authorized personnel should work around lifted loads, and care should be taken with loads that can shift or roll. The operator shall insure that no load is moved over a person, and that non-qualified persons are outside the lifting radius. All loads being moved should be controlled by the use of tag lines if needed.

6. Know Your Rigging : Lift points Methods of attachment Rated capacity Other factors affecting equipment operation. 2a

7. Rigging Fittings, sheaves –Shackles –Blocks –Sockets –Hooks May have safety latch –Eyes –Turnbuckles

8. Rigging Always use rigging to connect the load to the hook Materials –Wire rope –Fabric –Chain Slings –Straight (regular) –Choker –Basket –Double, triple, etc.

9. Rigging Sling angle –Stress on sling legs varies with the angle –Divide the load by the number of sling legs, and divide by sin of the angle For a two-legged sling, 2000 lb load and 60 degree, stress = 1155 lbs on the sling leg

10. Operators –18 years old –Physically Fit –Knowledge (training) Estimating load weight Signals Operation –Skill (demonstration) Controlling Crane Hazards

11. Operating procedures, Handling the load: Load not to exceed crane load rating Step-by-step procedures: OSHA 1910.179(n)(3) Requires that “the load be well secured and properly balanced in the sling or lifting device before it is moved more than a few inches.” Applicable rigging precautions: When using open throated shop bridles; a set of double hooks are to be used between the bridle legs on the two outside (end) bridle legs to insure a good connection of the lifting bridle (clamp) to the load. Safety measures: OSHA 1910.179(n)(3)(ix) Requires that “When two or more cranes are used to lift a load one qualified person shall be in charge of the operation. He shall analyze the operation and instruct all personnel involved in the proper positioning, rigging of the load, and movements to be made.” Never lift a load over people. Emergency procedures: Anyone can signal an emergency stop, however only one signalman should give directions to the operator. 2b

12. Overhead cranes moving loads Load secured in sling or rigging Hoist rope not kinked Lines not twisted Hook position centered Area secured 9a

13. Overhead cranes moving loads Avoid sudden acceleration/deceleration Avoid contact with obstructions No side pulls allowed unless authorized by a responsible person after determining that the stability of the crane is not endangered or crane parts over stressed. The operator is never to leave the crane controls with a load suspended. 9b

14. Overhead crane operator’s duties Inspect crane at start of the shift Insure load is properly rigged Test brakes when load is near capacity Raise load a few inches Apply brakes Keep two wraps of rope on drum when lowering a load 10a

15. Overhead crane operator’s duties Sound a warning when: Starting bridge movement Load nears people Test upper limit switch under no load 10b

16. Controlling Crane Hazards Inspection –Frequent Daily, monthly Hooks, rope, crane operation –Periodic At least annually Complete inspection - wear, damage, deterioration, operation slings Testing Records

17. Overhead crane frequent inspections (Daily to Monthly) Check all functional operating mechanisms for maladjustment, excessive wear, including electrical components, limit switches, and brakes Visually inspect hooks insure that the throat opening is no more than 15% of the normal opening, nor more than a 10% twist & that safety clips are intact. Check wire rope, reeving and slings for excessive wear beyond manufactures’ specs. Check upper limit switch before every shift. 4a

18. Overhead Crane Frequent Inspections Inspect crane hooks Check hoist chains/end connections Look for excessive: –Wear; twisted, distorted or stretched links 4b

19. Overhead crane periodic inspections (1 to 12 Months) Look for members that are deformed/cracked Check for loose bolts or rivets Inspect for cracked/worn sheaves/drums Excessive wear on brake system Excessive wear of chain drive sprockets or excessive chain stretch Electrical apparatus: controller contactor, limit switches, and pushbutton stations 5b

20. Overhead crane inspection Cranes not in regular use Idle for 1 month/less than 6 months; Shall be given an inspection following frequent inspection guidelines. Idle for more than 6 months; Shall be given a through inspection following the criteria for a periodic inspection. Standby cranes; inspect semi-annually 6a

21. Overhead crane wire rope inspection Inspect once a month Prepare certification record Keep record on file Certification record must include: Inspection date Signature Identifier for the ropes 7a

22. Overhead crane wire rope inspection If wire rope is idle for a month or more: Inspect it Prepare certification record Turn it in to the office 7d

23. Maintenance requirements for overhead cranes Based on crane manufacturer’s recommendations Comply with the following precautions 24a

24. Maintenance requirements for overhead cranes Run crane to safe location Set all controllers to “off” position Open & lock the main/emergency switch in open position Place “out of order” signs on crane/floor 24b

25. Maintenance requirements for overhead cranes Prevent interference with idle crane When finished: Reinstall guards Reactivate safety devices Remove maintenance equipment 24c

26. Adjustments & repairs for overhead cranes Correct unsafe conditions found during inspections Done only by designated personnel 25a

27. Adjustments & repairs for overhead cranes Maintain adjustments of components All functional operating mechanisms Limit switches/control systems Brakes, power plants 25b

28. Adjustments & repairs for overhead cranes Promptly provide repairs/replacements Discard defective crane hooks Discard defective chains/rope slings Discard critical parts…cracked, broken, bent, excessively worn Keep pendant control stations clean/legible 25c

29. SAFETY FIRST In everything that we do safety will be considered first above all else. Cutting corners and taking short cuts is not acceptable, it can kill people. Remember it’s not the obvious hazards you see that usually cause accidents; It is the things that you don't see coming that can hurt you, so analyze the task (JSA) and discuss it with everyone involved in order to minimize potential hazards.

30. SAFETY FIRST Written warnings will be issued for safety violations. These will go into your personnel & safety file and are considered during evaluations for pay raises, and safety awards points. Gross negligence for safety rules and policy can result in suspension w/o pay and even termination without prior warning.

31. SAFETY FIRST All near misses as well as accidents will be reported to the safety manager. Near misses are important indicators that something is wrong and the process involved needs to be corrected. Failure to report near misses or accidents will result in disciplinary action. Remember we are our brothers keeper, if you see an unsafe situation stop it, correct it, and report it.