1. www.engineeredsystemsonline.com Overhead Crane Safety Seminar 2015 Safety School Presentation

2. www.engineeredsystemsonline.com BE A CRANE SAFETY HERO! Train your Operators!

3. www.engineeredsystemsonline.com Who is? www.engineeredsystemsonline.com History We currently have 10 Locations  Duncan, SC  Columbia, SC  Charleston, SC  Atlanta, GA  Northeast GA  Lowell, NC  Archdale, NC  Cartersville, GA  Augusta, GA  Charlotte, NC

4. www.engineeredsystemsonline.com OSHA 1910.179 What is a crane? Defined in section (a) paragraph (1) 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. www.engineeredsystemsonline.com Page 1

5. www.engineeredsystemsonline.com O S H A 1910.179 Incorporated by Reference Cites A S M E B30.2 A W S D1.1 & D14.1 Cites Therefore the ASME and AWS (American Welding Society) regulations become law because they have been incorporated by reference.

6. www.engineeredsystemsonline.com Important Definitions (a15) Appointed – means assigned specific responsibilities by the employer or the employers representative. Page 2 (a35) Designated – means selected or assigned by the employer or the employer’s representative as being qualified to perform specific duties. Page 4

7. www.engineeredsystemsonline.com Important Definitions QUALIFIED as defined by ASME: A person by possession of a recognized degree in an applicable field or a certificate of professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work.

8. www.engineeredsystemsonline.com Designated Personnel OSHA 1910.179 (a)(35) page 4 How do you determine the qualifications of your designated personnel? Where can you get the needed training?... What training do they need? What training do they have? Only designated personnel shall be permitted to operate a crane.

9. www.engineeredsystemsonline.com Important Definitions (a45) Load – the total superimposed weight on the load block or hook. Page 5 (a50) Rated Load – the maximum load for which a crane or individual hoist is designed and built by the manufacturer and shown on the equipment nameplate(s). Page 6

10. www.engineeredsystemsonline.com Rated Load Test 1910.179 (k)(2) Test loads shall not be more than 125% of the rated load unless otherwise recommended by the manufacturer. The test reports shall be placed on file where readily available to appointed personnel. Page 28 Should vs Shall

11. www.engineeredsystemsonline.com Qualifications Crane operation, to be safe and efficient, requires skill, the exercise of extreme care and good judgment, alertness and concentration, and a rigid adherence to proven safety rules and practices as outlined in current CMAA(Crane Manufactures Association of America), ASME, and OSHA safety standards. In general practice, no person should be permitted to operate a crane: (a) Who cannot speak the appropriate language or read and understand the printed instructions (b) Who is not of legal age to operate this type of equipment, as determined by OSHA, State, Federal, and employer guidelines. (c) Whose hearing or eyesight is impaired (unless suitably corrected~with good depth perception) (d) Who may be suffering from heart or other ailments which might interfere with the operator's safe performance (e) Unless the operator has carefully read and studied the operation manual supplied by the Crane Manufacturer, or has been properly instructed to operate the specific equipment. (f) Unless the operator has demonstrated his instructions through practical operation (g) Unless the operator is familiar with the rigging equipment and practices….. www.engineeredsystemsonline.com

12. Other Considerations Your processes Environment Special devices, etc

13. www.engineeredsystemsonline.com Why Inspect and Maintain Your Cranes and Hoists? Safety Efficiency

14. www.engineeredsystemsonline.com Frequency Periodic Two General Classifications of Inspections www.engineeredsystemsonline.com

15. Frequency Inspections Include: Daily, or shift inspection (NOT documented) Monthly inspection (SHALL be documented)* * Hooks, Chains, and Wire Ropes must have signed certification of a monthly inspection.

16. www.engineeredsystemsonline.com Who Performs? Operator performs frequency at beginning of each shift. Frequency inspections must be performed and documented on a monthly basis by a designated person. Designated – means selected or assigned by the employer or the employer’s representative as being qualified to perform specific duties.

17. www.engineeredsystemsonline.com Frequency Inspections Checks: 1910.179 (J)(2) Page 24 Wire Rope or Chain Limit Switches Motor Brake Control (Pushbutton, Radio, Chain, or Cab) Load Block and Hook…

18. www.engineeredsystemsonline.com Periodic Inspections 1910.179 (J)(3) Page 26 Every 1 to 12 months More detailed inspections Should be the time where repairs and lubrication take place 1910.179 (l)(1) Preventive maintenance: A preventive maintenance program based on the crane manufacturers recommendations shall be established…

19. www.engineeredsystemsonline.com DATE OF INSPECTION: Month:____________Day: __________Year:_________Inspected By:________________ HOIST. MFG ;___________________________ S/N:____________________ ­M/N___________________________ ELECTRIC / MECHANICAL / AIR OK 1. [] LUBRICATION 2. [] CABLE/ CHAIN 3. [] DRUM / SPROCKET / POCKET WHEEL 4. [] MOTOR BRAKE 5. [] LIMIT SWITCHES (MECHANICAL/ PADDLE) 6. [] IDLER SHEAVE 7. [] CONTROL PANEL 8. [] DISCONNECT (VISIBLE, ACCESSIBLE ) OK 1. 9. [] LOAD BLOCK & HOOK 2.10. [] CONTROLS (P.B. / RADIO/ CHAIN) 11. [] SEALS 1.12. [] GUARDS 2.13. [] SUPPORT MEMBERS (BOLTED & WELDED) 3.14. [] HOIST MOTOR & GEAR BOX 4.15. [] AIR FILTER & OILER 5.16. [] FESTOON (ELECTRIC/ AIRLINES) TROLLEY MFG ;___________________________ S/N :____________________________ M/N :________________________________ MOTOR / CHAIN / HAND PULLED OK 17. [] LUBRICATION 18. [] WHEELS & BEARINGS 19. [] GEARS & PINIONS 20. [] MOTOR BRAKE/ SLIP CLUTCH 21. [] DRIVE WHEELS / TIRES 22. [] CONTROL PANEL 23. [] SPROCKETS OK 24. [] DRIVE UNIT ( MOTOR, REDUCER, SEALS) 25. [] DRIVE SHAFT, BEARING, COUPLING 26. [] COLLECTORS 27. [] RESISTOR, FLUID COUPLING 28. [] BUMPERS & STOPS 29. [] SUPPORT MEMBERS (BOLTED, WELDED) 30. [] PULL CHAIN BRIDGE / MONORAIL / JIB S/N :____________________________ M/N :________________________________ MOTOR / CHAIN / HAND PULLED OK 31. [] RAIL CONDITION 32. [] WHEELS, BEARINGS 33. [] MOTOR BRAKE 34. [] GEARS & PINIONS 35. [] COLLECTOR SHOES 36. [] DRIVE SHAFT, BEARING & COUPLING 37. [] DRIVE UNIT (MOTOR, REDUCER, SEALS) OK 38. [] LUBRICATION 39. [] END STOPS, BUMPERS 40. [] CONTROL PANEL 41. [] SWAY BRACING, SUPPORTS, BOLTED & WELDED 42. [] FESTOON, (CABLE, TROLLEYS, J BOX ) 43. [] WARNING DEVICE 44. [] FLUID COUPLING, RESISTOR RUNWAY & ELECTRIFICATION HARDBAR / FESTOON OK 45. [] ELECTRIFICATION 46. [] ALLIGNMENT 47. [] END STOPS, BUMPERS 48. [] GROUND OK 49. [] CONDITION OF TRACK OR RAIL 50. [] SUPPORT BOLTS, WELDS 51. [] CONDITION OF INSULATION Abbreviation Key N.A.R – No Action Required R.D.I. – Repaired During Inspection MON – Monitor Typical Inspection Report www.engineeredsystemsonline.com

20. Safe Crane Operation As stated by: www.engineeredsystemsonline.com

21. Who Is Operating Your Crane? www.engineeredsystemsonline.com Look out here comes that Safety Dude again! This is the second time today he’s been through here…….. Shhh Man I ain’t doin nuthin Look out Quick Hide

22. www.engineeredsystemsonline.com EMERGENCY SHUTDOWN PROCEDURES ASME B30 - The power supply to runway conductors shall be controlled by a switch or circuit breaker located on a fixed structure, accessible from the floor, and arranged to be locked in the open position. In the event of an emergency, would you know where to look for the main disconnect? Is it clearly labeled?

23. www.engineeredsystemsonline.com To Do’s of Crane Operation Read the operating manual and OSHA 1910.179 safety standards for cranes. At the beginning of your shift, a daily frequency inspection shall be performed as stated in OSHA 1910.179 (j) page 24 -26 Perform a “Daily Frequency Inspection” Sometimes called “Daily Operator Inspection” “Pre-shift Check” www.engineeredsystemsonline.com

24. Proper Hoisting Guidelines The measure of a good crane operator is the smoothness of the crane operation. Jumpy and jerky operation, flying starts, quick reversals and sudden stops are the "trademarks" of a poor operator. The good operator should know and follow these proven suggestions for safe and efficient crane handling.. www.engineeredsystemsonline.com

25. Proper Hoisting Guidelines How to Minimize Load Swing: 1. Make sure the hook is located over the load’s center of gravity when the load is being lifted 2. Do not start too quickly. Start in slow speed. 3. Do not stop too quickly. Begin to slow down before the final landing spot...

26. www.engineeredsystemsonline.com Shock Loading A leading cause of crane and hoist damage is due to shock loading. Shock loading occurs when loads are hoisted too fast or stopped abruptly. Learn to operate the hoist and controllers in a smooth manner that reduces shock. www.engineeredsystemsonline.com

27. Avoid Shock Loading When taking the slack out of slings, do so slowly. When all slack is removed from wire ropes or chains, start the hoist motion slowly. Only apply faster speeds after the load is off the ground.

28. www.engineeredsystemsonline.com Determine Load Weight ASME B30.2-3.2.1 Load Weight The crane shall not be loaded in excess of its rated load except for test purposes. Knowing the weight of a load is paramount to safe crane operation. If the weight of the load is unknown, it is impossible to determine, with certainty, that your crane, slings, and other rigging are capable of lifting and sustaining the weight of the load. Where can you find the weight of your load? Check shipping papers, drawings, design plans, blueprints, parts manuals, etc. if you are unsure of the load weight.

29. www.engineeredsystemsonline.com ASME B30.2 Section 2-3.2: Handling the load 2-3.2.1: Load Weight (b) The combined load applied to more than one hoisting unit shall not exceed the rated load of the crane when the crane has more than one hoisting unit.

30. www.engineeredsystemsonline.com Reeving 1910.179 (j)(2)(vii) Page 25 Check Crane Manufactures Specifications for Proper Reeving Single Reeving Double Reeving

31. www.engineeredsystemsonline.com Side Pulling 1910.179 (n)(3)(iv) Can Cause Improper Reeving Page 33 What will happen if lift is now made?

32. www.engineeredsystemsonline.com Do’s and Don’ts of Crane Operation Be sure your load is secure so that nothing can slip out and cause damage or injury On two-part reeved hoists, keep the lower block from capsizing. This prevents chain or wire rope damage. Never use the load chain or wire rope for a sling and make sure the load chain or rope is straight… no kinks, bends, or breaks … www.engineeredsystemsonline.com

33. Do’s and Don’ts of Crane Operation Never leave a suspended load unattended. That load is your responsibility.

34. www.engineeredsystemsonline.com Do’s and Don’ts of Crane Operation www.engineeredsystemsonline.com Never carry a load over another person… or be under the load yourself. Always stay on the safe side of your load !

35. www.engineeredsystemsonline.com Do’s and Don’ts of Crane Operation Never lift people with a hoist. When you are moving a load, look where your are going. Push, don’t pull. Never hoist a load into the upper limit switch. The upper limit is provided to stop a block that has inadvertently been raised too high or to stop a load that is out of control. The upper limit switch is not an operational control… www.engineeredsystemsonline.com

36. Load Pathway and Placement Some locations provide a clear and open pathway. Other work areas are crowded and leave little room for error in load control. Crane operators must always know where their load is going so they can review the travel path. Never assume that other workers know where you are going.

37. www.engineeredsystemsonline.com Do’s and Don’ts of Crane Operation You should inform workers in the affected areas of your travel path and intentions Walking the intended path is a good way to check for obstacles that may be in the way. Never assume the environment and obstacles remain the same and do not change. Periodically check during the day for changes to conditions and areas. Make every attempt to keep the load as close to the ground as possible…

38. www.engineeredsystemsonline.com Where To Park The Crane Never park the crane where it will interfere with other cranes on the same runway. Never leave the load block or pendant station where it is a hazard to employees or traffic in the area. Always be aware of forklift traffic…

39. www.engineeredsystemsonline.com Operator Daily Inspection Let’s Look at Items to be checked:

40. www.engineeredsystemsonline.com Control Devices-Pendant OSHA1910.179 (g)(1)(v) page 18 Check the pendant and note any breaks, cracks, or torn covers. Note any mislabeled buttons. Operate each button and note that all directions and speeds are operational. Note any buttons that stick or are not smooth in operation. Check pendant cable for broken insulation, exposed wiring, or pinch marks. Check for missing or damaged strain relief. Check grommets and connections at pendant and junction box. Note any missing or torn connections…

41. www.engineeredsystemsonline.com Brakes 1910.179 (f)(2)(iii) Excessive drift Normal stopping distances Is the stopping distance different for a hoist than a bridge or trolley? (Why?) www.engineeredsystemsonline.com page 15

42. www.engineeredsystemsonline.com 1910.179 (f) (2) (iii) Brakes for Hoist Holding brakes on hoists shall be applied automatically when power is removed. page 15 1910.179 (f) (4) (vii) Brakes for Trolley Brakes for stopping the motion of the trolley or bridge shall be of sufficient size to stop trolley or bridge within a distance in feet equal to 10 percent of the full load speed in feet per minute when traveling at full speed with full load. page 16 Brakes

43. www.engineeredsystemsonline.com Hooks ANSI B30.10-2005 Throat – Safety latch Saddle wear Twist Misc damage www.engineeredsystemsonline.com Look for twist/make sure latch is not sprung 0

44. www.engineeredsystemsonline.com Hooks Remember the loading of the hook is critical to consider during the inspection. www.engineeredsystemsonline.com NO TIP LOADING !

45. www.engineeredsystemsonline.com Examine Lift Medium Examples: Wire Rope Link Chain Roller Chain www.engineeredsystemsonline.com

46. Wire Ropes Crane manufacturer’s recommendations shall be followed. No less than 2 wraps left on the drum at the hooks lowest point. Never Saddle A Dead Horse Replacement Ropes www.engineeredsystemsonline.com Dead end Live end Attached to the load block Saddle U-bolt Number of clamps= 3 x rope dia+1 Space between clamps=6 x rope dia

47. www.engineeredsystemsonline.com Wire Rope 1910.179 (m)(1) Visually inspect entire length of rope and end connections. Check for reduction of rope diameter, kinks, broken wires or strands, corrosion, crushing or cutting, and proper lubrication. Any of the deficiencies listed above are to be noted. Certification record must include: date of inspection, signature of inspector, and wire rope identifier… (This is for a monthly inspection only.) www.engineeredsystemsonline.com page 30

48. www.engineeredsystemsonline.com Conditions for Wire Rope Replacement

49. www.engineeredsystemsonline.com Chain 1910.179 (j)(2)(iv) page 25 Visually inspect entire length of chain including end connections. Check for excessive wear, twist, distorted links interfering with proper function or stretch beyond manufacturer’s recommendations. Any of the deficiencies listed above are to be noted. Certification record must include: date of inspection, signature of inspector, and chain identifier … (This is for a Monthly Inspection only.) www.engineeredsystemsonline.com

50. Inspecting Chain Visually inspect each link of the chain for cuts, gouges, excessive wear, proper lubrication, and proper reeving. Check for any twist in the chain and verify proper weld orientation. If the chain is showing wear, check for stretching by comparing 12 links of chain at the dead end of the chain with 12 near the hook. Any difference greater than 1-1/2% if electric or 2-1/2% if manual requires replacement of the chain. www.engineeredsystemsonline.com

51. Sprocket or Pocket Wheel If chain sprocket is visible, inspect sprocket for wear or cracks and note wear on chain. Check for wear around the entrance to the sprocket. Bottom View of hoist www.engineeredsystemsonline.com Looking up where the chain goes through the host Best indicator is unusual noise

52. www.engineeredsystemsonline.com Rigging equipment Inspect rigging equipment: Before each shift As necessary during use Remove rigging equipment from area: If defective When not in use… 2a

53. www.engineeredsystemsonline.com Safe Working Load Do not load rigging equipment in excess of its recommended safe working load. Mark custom lifting accessories (such as hooks, clamps, custom grabs and other lifting accessories) these pieces must be proof tested to 125 percent of their rated load 2b

54. www.engineeredsystemsonline.com Competent Person and Inspection Inspect before each shift (include all fastenings and attachments) Additional inspections (when service conditions warrant) Remove from service any damaged or defective rigging equipment 3a

55. www.engineeredsystemsonline.com Slings General Requirements 7a  Do not shorten slings with knots or bolts or other makeshift devices.  Prevent sling legs from getting kinked  Slings used in basket hitch must have the loads balanced to prevent slippage  Slings must be padded or protected from the sharp edges of their loads  Do not place hands or fingers between the sling and the load  Shock loading is prohibited  Do not pull a sling from under a load when the load is resting on it…

56. www.engineeredsystemsonline.com In what ways have you seen slings being misused? Acid Damage Missing Tag Sling Cuts Punctures or Snags

57. www.engineeredsystemsonline.com Reviewing Good Sling Safety Inspect slings before each use Protect slings from sharp corners Use slings with adequate capacity Keep slings in good condition Never use a damaged sling Never rely on Red. Red is Dead! Stay clear of the load…

58. www.engineeredsystemsonline.com Limit Devices 1910.179 (n)(4)(i) page 34 Upper – required Lower –if provided NO LESS THAN 2 WRAPS AT THE HOOKS LOWEST POINT Limit switches are never to be used as operational stops. www.engineeredsystemsonline.com

59. Final Inspections Visual Inspections Auditory Inspections Any unusual sounds Oil or Grease Leakage Capacity labels Warning devices www.engineeredsystemsonline.com

60. Maintenance 1910.179 (L)(1) page 28 A preventative maintenance program based on the crane manufacturers recommendations shall be established. Maintenance Procedure Adjustments and repairs Any unsafe conditions disclosed by the inspection requirements of paragraph (j) of this section shall be corrected before operation of the crane is resumed. Adjustments and repairs shall be done only by designated personnel. www.engineeredsystemsonline.com

61. Maintenance Program 1910.179 (I) (1) What constitutes a good maintenance program? Routine inspection program Preventative maintenance program Trained and Competent personnel… www.engineeredsystemsonline.com

62. Important Factors in Safe and Efficient Crane Operation Trained Operator Schedule Inspection Program Preventative Maintenance Program Quality Equipment… www.engineeredsystemsonline.com

63. The Most Overlooked Aspect of Crane and Hoist Safety! www.engineeredsystemsonline.com

64. Responsibility The company that USES the crane is responsible for finding safety issues and training someone to do inspections and repairs! www.engineeredsystemsonline.com

65. We would like to thank you for allowing us the privilege of presenting this program. If you have questions or concerns about your crane & hoist, please do not hesitate to contact us. On behalf of our entire organization, we look forward to working with you again in the future. Stay safe out there. www.engineeredsystemsonline.com